General Description of the System 0

3D - Construction - System

General Description of the System

Copyright (c) , 2008

3D CONSTRUCTION SYSTEM GENERAL DESCRIPTION

 General Description of the System 1

General Description
1 Introduction
3D CROSS SECTION

COVER MESH

SHOTCRETE
(OR GYPSUM FOR
DIAGONAL NON-BEARING
WALLS)

EPS CORE

Figure 1 Section of an EVG-3D wall

The EVG-3D Construction System is a cost-efficient construction system that bases on

industrially prefabricated EVG-3D panels. EVG-3D panels consist of an EPS core with a
thickness ranging from 40 to 100 mm sandwiched between two plane-parallel welded wire
mesh sheets (cover meshes) and inclined diagonal wires in between that go through the EPS
core and that are welded to the cover mesh’s line wires.
This results in a light-weight, three-dimensional truss system with a high inherent stiffness.
The clear spacing between the EPS core and the cover mesh lies between 11 and 19 mm.
EVG-3D panels are high-precision elements produced by fully-automatic EVG Wire Mesh
Welders, type 3D/48. The standard width of EVG-3D panels is 1.20 m while the element’s
length is variable (in steps of 10 cm) and depends on the corresponding field of application.
EVG-3D panels are delivered as positioned elements to the site where they are connected
easily to wall and slab structures. Splice meshes serve to seal the joints between the EVG-
3D panels. This brings about a continuous mesh structure (reinforcement) over the entire
construction.
Afterwards an approx. 40 to 60 mm thick cement-mortar layer (concrete layer) is applied
either manually or, preferably, mechanically onto both sides of the panels. Additionally,
concrete can be applied in a pre-cast concrete factory. In case of non-loadbearing elements,
gypsum can be used instead of concrete. During the process of shotcreting the EPS core of
the EVG-3D panels serves as a shuttering and plaster base. As soon as the concrete has
hardened the EVG-3D construction achieves its structural and functional strength. The result
is a composite sandwich system in which the two reinforced concrete shells are connected
by the wire diagonals arranged in a truss-like pattern with sufficient shear strength.

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2 Application
The EVG 3D Construction System is used for one- or multi-storey residential buildings as
well as for schools, offices and industrial buildings.
Photo 1
Residential building;
duplex house with 2 stories
(Kaposvar, Hungary)

Photo 2 Group of 148

residential buildings made of
EVG-3D panels (Al Ain,
United Arab Emirates)

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Photo 3 4-storey buildings (Valencia, Venezuela)

Photo 4 Multi-purpose hall with non-loadbearing EVG-3D structure (Bogotá, Colombia)

3D CONSTRUCTION SYSTEM GENERAL DESCRIPTION

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Photo 5 2-storey school with 10 class rooms (Phnom Penh, Cambodia)

3 Foundations
Walls of a 3D building start from the upper edge of the foundation, preferably a load bearing
slab, or foundation strips as well. Starter bars with a diameter of 10 mm set at a distance of
approx. 50 cm are necessary on one side of the wall (for outside walls mostly inside) in order
to put up the wall. On account of the exactness it is recommended to drill the holes for the
starter bars later. Then fill up the holes with cement slurry. These starter bars mainly serve
for an easy erection of the panel. For special structural needs only (e. g. wind loads on
cantilever walls) these rebars have to be inserted on both sides at smaller distances
according to the structural requirements. Then it is recommended to fill up the drilling holes
with chemical binding agents epoxy resin). It is only in case of considerable loads (e.g. earth
quake loads) that this connecting reinforcement has to be placed with the foundation slab
already.
Foundations without connecting reinforcement are practicable as well. This may be, for
instance, U-channels of the width of the EPS core that are fixed on the foundation slab. In
this case, the use of small pieces of splice mesh (e.g. 30 × 30 cm) in the wall corners is
recommended. This splice mesh is L-shaped and is clamped below the U-channel. Then the
wall panels can be tied to them.

3D CONSTRUCTION SYSTEM GENERAL DESCRIPTION

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Connection for canteliver-walls

or walls in earthquake areas splice mesh in the corner
according to the structural calculation (below the U-Channel)

50 - 100 cm

U-Channel
Starter bars
ø 10 mm, min. 50 cm
approx. 20 mm U-Channel
50cm
reinforcement
EPS thickness
foundation slab screw
30mm
10-15cm
splice mesh in the corner
Figure 2 Connection to the foundation

Connection Foundation - Outside Wall

EPS-50 OR EPS-100

ø10/50
WALL PANEL

40 STARTERBARS
DRILLED IN PLACE

3 or 5.5 10-15

Figure 3 Connection between foundation and outside wall with starter bars (strip foundation)

The axis of the starter bars is at a distance of 3 cm (EPS-50) or 5.5 cm (EPS-100) from
the wall’s axis. The drilling depth is 10 - 15 cm. The outer edge of the finished wall is flush
with the outer edge of the foundation.

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Connection Foundation Slab - Inside Wall

EPS-50 OR EPS-100

ø10/50
WALL PANEL

40
STARTERBARS
DRILLED IN PLACE

3 or 5.5 10-15

REINFORCED FOUNDATION SLAB

Figure 4 Connection between foundation slab and inside wall with starter bars

The axis of the starter bars is at a distance of 3 cm (EPS-50) or 5.5 cm (EPS-100) from
the wall’s axis. The drilling depth is 10 - 15 cm.

Connection to Foundation with U-Channels

STANDARD DETAIL CORNER DETAIL

U-CHANNEL
PANEL PANEL

SPLICE MESH 0.6 - 0.8 mm

(30/30 CM) 30

EPS-thickness

SCREW U-CHANNEL SCREW U-CHANNEL

WALL AXIS = AXIS OF THE U-CHANNEL

Figure 5 Connection between foundation and inside wall with U-channels

Non-loadbearing walls do not require connection by means of rebars. One possible

option is shown in the sketch above. The U-channel keeps the panel in the correct
location without providing a structural connection between wall and slab.
Other connections which are standard practice in the field of pre-cast concrete elements
are possible, as well.

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4 Walls
In general, walls made of EVG-3D panels and concrete (shotcrete) can be considered as
load-bearing walls. EVG-3D components are thin-walled reinforced concrete sandwich
elements which can mainly transfer compression- and shear forces in the plane of wall. The
flexural resistance perpendicular to the plane of wall is limited. Therefore buildings erected as
3D constructions are composed in a “box-like” way where 3D elements are connected with
each other. Thereby the joints between slab and wall or wall and wall in general do not
transfer any or only minor bending moments.
Forces acting horizontally on 3D buildings such as wind- or earth quake forces are absorbed
most effectively by the 3D shear walls. The respective “box-like” infilling with 3D panel walls
in X- and Y direction of 3D buildings has to be provided. For dimensioning, 3D slabs and 3D
walls can be considered independently from each other. A frame-like design of 3D buildings
is possible to a limited extent only and is not recommended.

held by the slab immovable slab

(diaphragm effect)

LATERAL LOADS
cross wall
(shear wall)
anchored in the foundation
possibly boundary elements compression force

shear forces in the

tension force foundation anchors
Figure 6 Box-like structure

All connections between walls and walls, and walls and slabs take into consideration this
box-like behaviour.

Straight Panel Splice

SPLICE MESH
30

Figure 7 Straight panel splice

The length of splice mesh in straight panel splices is 30 cm.

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Connection Wall - Cross Wall

15

15

CORNER MESH

Figure 8 Inside panel splice

Splice mesh is fixed on both sides. Its length is 2 × 15 = 30 cm.

Outside Wall Corner

30

15

OUTSIDE
15

INSIDE 15

Figure 9 Outside wall corner

For wall panels of 50 mm EPS each, splice mesh with a width of 10 + 20 = 30 cm can be
used at the outer side of outside corners.

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Wall Opening
ADD. REINFORCEMENT
50 50
(ACC. TO CALCULATION)

30 30

PANEL CONCRETE PANEL

30
30

50 OPENING
50
SPLICE MESH
15
14 U-MESH
16
PANEL 5 PANEL
FOAM

CONCRETE REVEAL WOODEN FRAME

Figure 10 Wall opening

The splice mesh has to be fixed in all corners of the opening and has to have a length of
at least 50 cm. The opening can be made with or without concrete reveal.

5 Slabs
3D slabs are always designed as simply supported or continuous one way slabs. A slab
acting in two ways cannot be recommended to be made with 3D panels.

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one-way slab two-way slab flat slab

(preferred with 3D) (not recommended with 3D)
Figure 11 Slab systems

Therefore, slabs made from 3D elements require always continuous supports. In an area
where continuous supports are interrupted flush beam strips have to form a support, e.g.
above doors having the same height as the room.
Another field of application are inclined roof slabs. The two roof halves often are constructed
in such a way that they support each other like in a three-hinged arch. The occurring
horizontal forces are transferred via the cross walls (y-direction in figure 12) to the
foundation. The roof acts also as a diaphragm and possibly has to be provided with
additional reinforcement in transverse direction.
The reaction force in the support of the roof slab generated by the diaphragm action is
transferred to the cross walls (gable walls and internal walls) via the panel joint.

horizontal force Figure 12 Load transfer

mechanism in a roof slab

transfer of shear force

direction of roof span x
to the cross wall

Connection Slab - Outside Wall

ø 8 MM/20 CM

50
CONNECTING
14 REINFORCEMENT
ø 10 MM
50
2 ø 8 MM

6
10 45
100
5 SPLICE MESH

EPS FLUSH WITH THE

SURFACE OF THE WALL
RING BEAM

5 10 5

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Figure 13 Connection slab - outside wall

The area of steel in the ring beam has to be at least 1.0 cm² (= 2 ø 8 mm). The distance of
the stirrups at the support can be extended at the cross edge to up to 40 cm. The EPS of
the slab panel has to be flush with the surface of the wall.

Connection Slab - Load-bearing Inside Wall

CONNECTING
REINFORCEMENT
EPS FLUSH WITH THE ø 10 MM
SURFACE OF THE WALL
4 ø 8 MM

6
10
100
5
REINFORCEMENT ACCORD.
ø 10 MM/25 CM TO STRUCT. CALCULATION

5 5 5

ø 10 MM/25 CM (CONNECTING BAR)

100
Figure 14 Connection slab - load-bearing inside wall

As an alternative the connecting bar at the support can be replaced by two U-shaped
stirrups (see figure 13). The EPS of the slab has to be flush with the surface of the wall. A
reinforced ring beam is not absolutely necessary.

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Ridge Detail

ø 8 MM/20 CM 2 ø 8 MM

60 60

REMOVE EPS

ø 8 MM/20 CM

30
70

Figure 15 Ridge with connection reinforcement

In the area of the connection reinforcement, the EPS has to be removed to ensure the
concrete cover.

Eaves Detail

U-MESH
20

25 REMOVE EPS

Figure 16 Design of the eave

In the area of the support, the EPS has to be removed or the length of wall panels
has to be chosen correspondingly shorter.

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Overhang at Cross Edge

ROOF

15 15
CORNER MESH 15
U MESH 14

16
CORNER MESH ACC. TO
REMOVE EPS OR
STRUCTURAL REQUIREMENT
CUT THE PANEL

WALL
Figure 17 Roof overhang at cross edge

The thickness of the bottom concrete layer must be kept the same also in the area of the
wall panels.

3D CONSTRUCTION SYSTEM GENERAL DESCRIPTION