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Related Experiment Video

Updated: Jun 29, 2025

Determination of the Mechanical Properties of Flexible Connectors for Use in Insulated Concrete Wall Panels

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Published on: October 19, 2022

Optimized Building Envelope: Lightweight Concrete with Integrated Steel Framework.

Timo Haller¹, Nancy Beuntner¹, Karl-Christian Thienel¹

¹Institut für Werkstoffe des Bauwesens, Fakultät für Bauingenieurwesen und Umweltwissenschaften, Universität der Bundeswehr München, Werner-Heisenberg-Weg 39, 85579 Neubiberg, Germany.

Materials (Basel, Switzerland)

|March 28, 2024

Summary

This study introduces a new prefabricated wall system using steel profiles within lightweight aggregate concrete (LAC). This innovative design enhances thermal insulation and structural stability, meeting energy requirements without extra insulation.

Keywords:

building envelope integrated sheet steel framework lightweight aggregate concrete sustained load

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Area of Science:

Construction Engineering
Materials Science
Building Physics

Background:

Traditional building envelopes often require separate insulation layers to meet energy efficiency standards.
Prefabricated wall elements offer potential for faster construction and improved quality control.
Lightweight Aggregate Concrete (LAC) provides thermal insulation but often lacks sufficient structural capacity on its own.

Purpose of the Study:

To develop and validate a novel construction method for prefabricated wall elements.
To integrate a steel profile framework within an optimized LAC building envelope.
To enhance thermal performance and structural stability of wall elements, reducing material density.

Main Methods:

Integration of cold-formed Sigma-profiles (load-bearing) and U-profiles (non-load-bearing) into a steel framework.
Utilizing LAC to shape the wall, stabilize steel profiles against buckling, and reduce concrete's required compressive strength and density.
Fabrication and testing of tailored composite specimens to verify stabilization and load-bearing capacity.
Production and evaluation of two full-sized wall prototypes in distinct precast plants.

Main Results:

The LAC effectively stabilizes the thin-walled steel profiles, preventing buckling and increasing the overall system's load-bearing capacity.
The optimized LAC achieved superior strength and density values, surpassing existing standards.
The integrated system demonstrated highly competitive thermal conductivity, meeting energy requirements without additional insulation.
Successful validation of the construction method through prototype production in industrial precast plants.

Conclusions:

The novel construction method offers a high-performance, energy-efficient prefabricated wall element.
The synergy between the steel framework and optimized LAC enhances structural integrity and thermal insulation.
This approach presents a viable and innovative solution for modern sustainable construction practices.