JEC 2000

Focus Construction

Four separate forums concerning the construction industry presented industrial answers, taking fully into account the end-consumer's expectations and the builder's constraints. (1) Local government: urban living. (2) Rehabilitation: the second life of the housing. (3) Building service industries: necessary performance. (4) The single-family dwelling: living modernity.

A lot of sheets have been presented

House

Chomarat (France) presents composite solutions (glass fiber) integrated within the single-family dwelling.

1) Reinforcements for Rotaflex and Rotaflam bitumen felts. The composite reinforcements give the bitumen felt an outstanding mechanical resistance. The material's fire properties meet the requirements of the building sector.

2) Reinforcements for Rotatex plasters. Thanks to the composite reinforcements, the plaster exhibits high strength while retaining the necessary flexibility.

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Dome

BFG International (Bahrein) specialises in the manufacture of structural FRP (Fibre Reinforced Product) domes meeting high load parameters while offering clients a virtually zero maintenance product and substantial weight savings.These architectural components utilise multi-axial fabrics (Chomarat) in conjunction with high grade gelcoats (Reichold) and resins (Reichold). Decorative effects are incorporated through a number of surface treatment technologies. In 1998, when BFG International approched Singapore's Islamic Council to introduce the concept of GRP (Glass Reinforced Product) domes, the company encountered an initial degree of resistance from Council officials. But they were quickly persuaded of the vast benefits of using GRP. In 1999, BFG International, building on the company's experience in designing and manufacturing over 400 domes world-wide, completed the installation of a stunning double-skin blue dome measuring 8 meters in diameter, and constructed in 12 segments.

FRP Architectural Components offer clients: light weight construction, leak-proof construction, high durability, virtually nil maintenace requirements, tremendous colour and decorative finish choice.

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Insulating panel

Powerdeck RF 43.3 is made of Taufoam enhanced polyisocyanurate foam. This expanded, CFC-free, pentane-free, integrally flame retardant foam contains no carcinogenic fibres. The panel produced by Recticel (France) has two 0.05 mm-thick aluminium skins.

Powerdeck is a high-performance, thermal insulating cellular system with thermal conductivity 0.021 W/sqm.K, low weight 32 kg/cubicmeter, good mechanical strength, integral flame retardant properties with a flame resistance for 30 minutes a self-extinguishing and non-drip behaviour. The product is used for: thermal insulation in structural steelwork buildings, for both new construction and renovation; thermal improvement of fibre-cement roofing systems; interior thermal insulation in farm buildings and industrial premises.

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Floor supporting structure

TMS is a CFC-free polyurethane foam panel inserted between two multilayer skins - kraft and polyethylene scrim. It is produced by Efisol (France). The product is an insulating panel for radiant floors having high thermal resistance (2.05 sqm.K/W), low thickness allows it to be used in renovation, large size for fast installation and optimum material utilisation.

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Sun lab

Presentation of a "sun lab" with reflective blinds by Hexcel Fabric (France).Fabric made and blinds assembled by Franciaflex, Ates, Soliso, Criesser.

PVC-coated glass yarn fabric, made by continuous weaving.Application in architectural reflective blinds.The composite material used for the fabric confers a number of specific characteristics:

- Durability.

- Long-lasting performance, minimum of dirtying, easy cleaning.

- Colour fastness.

- Dimensional stability of the fabric.

- High mechanical resistance, tear resistance and good wind behaviour.

It is used in buildings for the service industry, community living, museums, wherever it is necessary to manage natural light, or wherever the light contributes to the thermal performance of the premises.

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Facade facing

Exteriel by Mermet Industries (France) is a façade cladding system that has been specially designed for durability. It comprises an engineered fibreglass reinforcement in the form of a patented composite fabric (specifically developed by Mermet), a resin that serves both as adhesive and paint, and a set of angle sections. The product in place makes it possible to enliven the façade with raised designs and to absorb potential non-active microcraking. It may be used on most masonry surfaces.

The façade cladding has a number of properties needed to satisfy building requirements, thanks to the system's composite reinforcement:

- The exceptional dimensional stability of the fibreglass fabric gives the façade cladding flexibility and mechanical strength.

- Because glass fibre is not sensitive to heat, cold, or moisture, the cladding is weatherproof.

- The stability of the fibreglass reinforcement contributes to the system's overall "stabilising" strength, which constitutes a real advantage in renovation work.

- The reinforcement is chemically resistant, which means that it can be associated with other materials.

- The reinforcement is rot-resistant, which contributes significantly to make the cladding and its properties durable.

- Evaluating the overall cost of works is very favourable to this type of solution because it has a very good quality to price ratio, due to the multi-functionality of the composite solution.

- Exteriel is also very resistant to ultra-violet rays and to dirt of all kinds.

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Phenolic panel

The whole system is embedded in phenolic resin during the injection process and coated with glass fibre.

- 2 composites faces - glass fibre-reinforced phenolic resin and roving fabric, two-component, textured polyurethane paint finish.

- Extruded, MI-rated polystyrene insulating core, injected into a stainless steel thermoregulated mould under controlled vacuum (programmable injection machine).

- Metal inserts for panel mounting onto the frame-structure, and marine-grade plywood trimmer joist for window frame mounting.

Phenolic panels are a promising solution, for both new construction and renovation. The performance level of UNIJECT panels meets the requirements of the construction sector:

- Good flame resistance, MI rating.

- Adjustable thermal and acoustic insulation - depending on the insulating material thickness.

- Low weight (8 kg/sqm), easy to handle panels, exerting lower pressure on the structures, no need for lifting equipment on the construction site.

- High rigidity thanks to the sandwich structure.

- Ease of processing - the finished panels are delivered with the mounting system in place, ready for use on the site.

- The finishing stages take place in the workshop.

- Variety of shapes and finishes offering a wide freedom of choice to designers, architects and contractors.

- Durable properties.

- Good resistance to outdoor aggressions (weathering, pollution).

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Balsa-glass elements

- The table top: balsa sandwich, glass or flax fibre (using an enzyme process), epoxy and linden resin (reinforcement of the tabletop edges).

- Table leg assembly and bars: stainless steel tubing (diameter 35 mm) shaped and assembled with TIG (Tungsten Inert Gas) welding.

- Assembly of leg-tabletop mounting brackets: bonded with 3M VHP double face tape.

- Opening and storing away elements: leg assembly folds by means of a cabled structure designed by specialist Patrick Moreau.

This is only a prototype. The ideal technique would be to use vacuum moulding, both from an aesthetic point of view and to save on resin.

The material is lightweight and aesthetically pleasing in an original way when it is developed in this way.

The composite makes the table top very rigid and keeps the table top from warping.

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Instant bathroom

"Instant" washrooms by Baudet Composites (France)

Materials used to manufacture the washroom unit structures:

- Surface coating: ISO NPG polyester gel-coat, airless internal mixing process.

- Composite structure: glass yarn (roving) and flame retarding orthophtalic polyester resin, spray-up process.

- Processing method: open-mould contact moulding.

Using composite materials for our washroom units satisfies three basic criteria for bathroom construction:

- The units are perfectly watertight, so no water can infiltrate into the building's concrete structures.

- The lightweight structure makes it possible to install the units even for renovation purposes.

- The easy, rapid installation requires only a limited number of workers.

The design is innovative and gracious; the moulding techniques used offer the possibility for unusual shapes and aspect.

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Doors

Gimm (France) doors is a sandwich structure:

- Central core: P.U. foam coating a wooden or metal grid.

- External coating: made of composites polyester resins with glass fibre enforcement.

The gelcoat has a wooden style appearance.

- The composite door offers the advantage of having a wooden surface without the inconvenience of the natural product.

- The composite solution offers a dimensional and geometrical stability.

- No degradation and maintenance free.

- Excellent thermal and acoustical performances.

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Composites framework structure

The JAD (France) structure is produced without a mould, using filament-winding techniques with glass or carbon fibre reinforced epoxy resin.

Two different techniques are used:

- A specific JAD machine (patent pending) that allows shaping the composite components with double triangulation i

- A filament winding machine that uses double cross winding.

- Because the JAD structure is created without a mould, production costs are cut in half.

- The JAD structure is extremely lightweight: its specific weight varies from 1,5 kg/m2 for carbon fibre reinforcement to 8 kg/m2 for glass fibre reinforcement.

- The JAD structure has a familiar design, so does not constitute a break with cultural tradition in the building and construction industry.

- Its shape gives it the necessary strength for building insulated roof panels.

- Its hollow structure makes it possible to accommodate all networks (water, wiring, etc.).

- All types of linings may be used with it.

In principle, the JAD structure should be up to earthquake-proof construction standards.

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Composite wall

The JAD (France) structure is produced without a mould, using filament-winding technigues with glass or carbon fibre reinforced epoxy resin.

Two different techniques are used:

- A specific JAD machine (patent pending) that allows shaping the composite components with double triangulation.

- A filament winding machine that uses double cross winding.

With the JAD Façades solution, it is possible to industrialise façade solutions, thus eliminating some of the major constraints at the construction site (bad weather conditions, in particular).

- Because the JAD structure is created without a mould, production costs are cut in half.

- The JAD structure is extremely lightweight its specific weight varies from 1,5 kg/sqm for carbon fibre reinforcement to 8 kg/sqm for glass fibre reinforcement, which is a considerable advanta for all types of structures.

- The JAD structure has a familiar design, so does not constitute a break with cultural tradition in the building and construction industry.

- Its shape gives it the necessary strength for building self-supporting façade elements.

- Its hollow structure makes it possible to accomodate all networks (water, wiring, etc.) and insulating material.

- All types of linings may be used with it, including plaster for in-factory dip coating.

In principle, the JAD structure should be up to earthquake-proof construction standards.

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Shower tub

Bathtub-showertub manufactured by the Duscholux company (Luxembourg).

Application of the Baytec RS process to reinforce a thermoformed methacrylate sheet. The thermoformed acrylic elements are reinforced by a 2-component PUR system sprayed onto the sheet. The system replaces the usual glass/polyester laminates, which are not easily recycled and involve styrene emissions during manuhcture. It offers:

- Solvent-free process.

- Shorter production cycle.

- Outstanding flexural modulus without added glass fibre.

- Environmentally-friendly, cost-effective reinforcement system (recyclable).

The manufacturing process developed by Bayer and Duscholux offers a number of advantages:

- Wide freedom of shape, while ensuring the required engineering properties including water tightness.

- Industrial production helps optimise costs and reduce prices.

- End-of-life product recycling: components are easily dismantled and reused in manufacturing cycles.

- Fire rating meeting the construction sector's requirements.

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Airport canopy
Tettoia per aeroporto

The canopy was construct by BFG International (Bahrein) out of single skin FRP laminates clad on a steel frame.

Due to frequent hurricanes and typhoons, in addition to a harsh and humid environment, a wall designed FRP structure was the natural choice of materials for construction.

The cladding panels were constructed using mat and woven roving construction. An NPG-based gelcoat with excellent weathering properties was utilised for protecting the visible surface.

Special care was taken in the design to allow the thermal expansion of the steel structure in relation to the FRP cladding.

The new Manila International Airport Viaduct Canopy was designed by ADP (Aeroport de Paris) as a show piece for the airport which was opened late 1999.

- It allowed the creation of a complex curved shape without a tremendous cost disadvantage.

- FRP construction guarantees very high durability and minimal maintenance.

- Unlike metallic or concrete alternative, the FRP claddings don't require any type of re-coating, painting or other periodic and expensive maintenance work.

- The panels are light weight and flexible enough to withstand hurricane force winds prevalent in Philippines.

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French window

Acoglass French window in pultruded glass-fibre reinforced polyester resin.The French window is made of composite materials. This type of material confers:

- Exceptional stiffness and mechanical strength to the window.

- Excellent and lasting thermal properties to the frame.

- Corrosion and insect resistance, as well as resistance to most chemicals.

The Acoglass French window can be lacquered ex works or painted once it is in place.

The composite profiles are assembled mechanically in the same way as aluminium profile; therefore, their use does not break with standard techniques commonly practised by assemblers and carpenters.

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Window

Pultruded profiles in glass fibre reinforced composite material, to be used as a substitute for steel reinforcements for PVC profiles used in windows and French windows.
Profilati pultrusi in composito rinforzato con fibre di vetro si possono usare in sostituzione dei rinforzi di acciaio per i profilati in PVC usati nelle finestre e nei portafinestre.

Intratherm by Koemmerling France (France)is a system of PVC windows where standard steel reinforcement has been replaced by reinforcement made of composite materials. The substitution brings about some substantial improvements:
Intratherm di Koemmerling France (Francia) è un sistema di finestre in PVC dove i normali rinforzi di acciaio sono stati sostituiti con rinforzi in composito. Si ottengono alcuni vantaggi importanti:

- Improved thermal behaviour: K = 1.1 - 1.2 W/sqm.K, or 25% better than a steel reinforcement profile.

- Does away with risk of condensation.

- Greater machining flexibility (close to that of wood).

- An excellent corrosion-proof mounting support.

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Acoustic wall

QuietZone Acoustic Wall Framing by Owens Corning (USA) is an acoustic partitioning system for indoor use. The system is made of a wood frame with facings, and mineral wool. Mineral wool is a sound absorbing material that reduces reverberation times. The special bonds reduce vibrations and direct noise transmission.

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Balneotherapy bath

Acrylic resins, glass fibre. Thermoformed parts.

- This material allows shapes that cannot be produced at acceptable costs with other materials.

- The composite material can be repaired.

- The acrylic composite keeps the bath warm for a longer period.

- Pleasant, warm touch: no "cold wall" effect.

- Lightweight material, despite the additional technical equipment.

- Non-skid material.

Composite floor tile

The JAD structure is produced without a mould, using filament-winding techniques with glass or carbon fibre reinforced epoxy resin.

Two different techniques are used:

- A specific JAD machine (patent pending) that allows shaping the composite components with double triangulation.

- A filament winding machine that uses double cross winding.

With the JAD solution, it is possible to industrialise composite floor tile, thus eliminating some of the major constraints at the construction site (bad weather conditions, in particular).

- Because the JAD structure is created without a mould, production costs are cut in half.

- The JAD structure is extremely lightweight its specific weight varies from 1,5 kg/sqm for carbon fibre reinforcement to 8 kg/sqm for glass fibre reinforcement.

- The JAD structure has a familiar design, so does not constitute a break with cultural tradition in the building and construction industry.

- Its hollow structure makes it possible to accomodate all networks (water, wiring, etc.) and insulating material.

- All types of linings may be used with it.

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Slate shingles

Mira Vista Slate is a range of small roofing elements made of Owens Corning composites.

Aspect: slate

Dimensions: the complete unit - representing several pieces of slate - is 3 sqm. Max. thickness: 3 cm.

Manufacturing process: moulding method similar to automotive BMC (Bulk Moulding Compound).

Composite materials offer a number of advantages, meeting the construction sector's requirements:

- Lightweight panels: can be used for renovation purposes with no need to dismantle the existing roof.

- Weight savings in new construction.

- The low weight facilitates logistics, transport and storage.

- Good flame behaviour (glass fibre).

- Durability.

- Long-lasting properties.

- Durable, uniform colours and aspect.

- Low impact sound transmission (rain, hail).

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Sound proofing system

Presentation of a "tunnel of silence": 2.5 m long, 2 m high, and 1.2 m wide; lined with soundproofing tiles by Chromoroc (France); accessible from either end. Outside the tunnel, a presentation of coloured sand and gravel.

Raw materials: quartz gravel, quartz sand, marble gravel, two-component epoxy resins, two-component polyurethane resins, PVC-coated glass fibre scrim, stiff glass-wool mat, organic and mineral pigments.

Equipment: kneaders, mixers, cross-linking chambers for resin-based products, drying units, polishing equipment, drilling equipment, moulds for the manufacture of soundproofing tiles.

Sand and gravel: semi-automated production. Soundproofing tiles: hand production. Chromoroc patented processes.

The 60cm x 60cm tiles are 16 mm or 24 mm thick.

- The composite concept contributes to the product's acoustic performance: it helps to bind aggregate and resin into a dimensionally stable microporous mortar.

- It gives adequate stiffness to tiles of any size.

- The use of composites makes the tiles rotproof, waterproof, frostproof, and vapour-proof.

Chromoroc products are rated MI.

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This article is published on NT New Textiles, see the contents.