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baupanel FAQ

baupanel frequently asked questions

1) How does BAUPANEL compare to a concrete panel system, a traditional system and other fast build solutions in cost and execution?

1) How does BAUPANEL compare to a concrete panel system, a traditional system and other fast build solutions in cost and execution?

BAUPANEL compares favourably in costs and execution given that it is about the process and delivery. BAUPANEL has one solution fulfilling two tasks, being high load resistance walls, as well as thermo-acoustic insulation. This coupled with lightweight panels and quick installation negates the need for cranes and heavy plant and machinery and as a consequence less manpower, which contributes to substantial cost savings when compared the execution of other building solutions.

2) What materials are BAUPANEL® System made of?

2) What materials are BAUPANEL® System made of?

The central core of the panel is made up of expanded polystyrene with a density of 15 kg/m3 – 25 kg/m3 that is cut in a rippled manner to improve the compliance of the concrete when discharged.

The EPS core is edged with mesh of straight and/or corrugated steel, depending on the kind of panel, which are linked together by a series of connectors that go through the EPS core.

Once the micro-concrete has been shotcreted, the panel performs like a compound section because of the connection of the two concrete layers by way of the steel connectors.

3) Can the BAUPANEL® System be used as a structural system?

3) Can the BAUPANEL® System be used as a structural system?

BAUPANEL® System can be used in building as a structural or non-structural (closing) system.
It can be a structural system due to the fact that the system fulfills the requirements of the building codes: it´s used a micro-concrete with the compression strength required by the building codes as well as panels include reinforced steel bars.
If this system was just used as a closing for buildings, we could use sprayed mortar of lesser compression strength, as well as panels without corrugated steel rebars, instead using galvanized steel electro-welded mesh.

4) Are the buildings made with BAUPANEL® System resistant and sound?

4) Are the buildings made with BAUPANEL® System resistant and sound?

It has to be taken into account that the structures are made of reinforced concrete, although they are lighter thanks to the EPS elements. From a structural point of view, BAUPANEL® System is as resistant and sound as any reinforced concrete structure.
We design the structure with  the right covering in external facings to guarantee the buildings durability, as it is standard by international concrete standards.

5) Which thicknesses are more often used in walls and frameworks and how are those thicknesses defined?

5) Which thicknesses are more often used in walls and frameworks and how are those thicknesses defined?

Generally speaking, for external closings we use panels with a minimum EPS core of 10 cm thickness that together with the shotcreted concrete, we end up with a wall section of 17.5 cm thickness, considering a moderate environmental exposure.
By request and due to design criteria a greater wall thickness could be used.
If the panel works as a retaining wall the thickness will be established by calculation in order to bear the earth pressure. In the case of the frameworks, it will be based upon the pre-dimensioning of the thickness according to the main span of the building.
The section will be later checked by calculation. The maximum section of framework elements type BPF is 28 cm thickness (5cm thickness of compression layer, EPS core of 20 cm thickness and lower concrete layer of 3 cm thickness).
 

6) Is BAUPANEL® a prefabricated system?

6) Is BAUPANEL® a prefabricated system?

BAUPANEL® is not a prefabricated system. It is defined as an industrialised or semi-prefabricated system, because the panel is made in the factory and delivered with the exact length according to its position in the building design. The micro-concrete is shotcreted on site.
The main advantages of the above are:
• Greater flexibility in the building works if it is necessary to amend the project.
• The setting out can be done with lower accuracy than in prefabricated system.
• Since the micro-concrete is shotcreted on site, there is no need for joints (except for expansion or construction joints)
 

7) Do the panel assemblers need a special knowledge?

7) Do the panel assemblers need a special knowledge?

The assembly does not demand any special knowledge of bricklaying, as it is a very simple and methodical system. However the micro-concrete shotcreting needs some specialist training to use the mixing pumps.
Our team of technicians will do the training on site and, after checking the results of the training, can approve authorized assemblers of BAUPANEL®.

8) How can we hang a picture up of a wall made with BAUPANEL®?

8) How can we hang a picture up of a wall made with BAUPANEL®?

Unlike other systems, such as, for example, Pladur, BAUPANEL® does not need any special fitting and there is not any weight limit to hang objects up on the walls or ceilings.
Since the facings are of reinforced concrete, the only precautionary measure is to use specific bits for this material.

9) How are the broken installations repaired?

9) How are the broken installations repaired?

Installations are set up inside the EPS core before shotcreting the structural micro-concrete; therefore they are enclosed between the two layers of concrete. It may happen that during the useful life of a building some installations suffer some damage that needs to be repaired.
There is no problem, but it should be done with the usual care and attention.
With a radial machine, we can make a clean cut to the concrete layer to reach the damage and, after repairing it, restore the removed concrete. If the affected area is not very big, it could even be done without restoring the removed mesh.
If the channels are vertical, this is no problem, but in cases where they are horizontal, we would take the precaution of working on the wall in a different way, especially if it is a load bearing wall.

10) In a building made with BAUPANEL® System, is it possible to open windows or doors later on?

10) In a building made with BAUPANEL® System, is it possible to open windows or doors later on?

There is no problem to open hollows (windows or doors) in non-bearing walls already concreted. It would be also possible to do it in bearing walls as long as a lintel is planned between the hollow and the ceiling so the stress can be distributed. The hollows must be opened with a radial machine.

11) As it is a system working with bearing walls, which kind of buildings can be made with BAUPANEL®?

11) As it is a system working with bearing walls, which kind of buildings can be made with BAUPANEL®?

BAUPANEL® has many applications. It is a wall bearing system, but it is also compatible with clear floors using auxiliary structures of concrete or metal perfectly integrated in our system.
A good example would be a building with many rooms on all the floors but with an open basement where there is no place for bearing walls. The solution would be to rest the structure on bearing frames. Our Technical Department has developed several building specific details for these cases, which can be individually studied.
Another possibility of our System is to use it as façade closing for buildings with a conventional structure. This special use has given a very good performance as well as an excellent thermal and acoustic insulation, together with the benefit of extra useful space.

12) How does a building made with BAUPANEL® act from a thermal and acoustic point of view?

12) How does a building made with BAUPANEL® act from a thermal and acoustic point of view?

From the thermal point of view, it increases very much the value of the closings usually used, which implies a great energy and financial saving during the life of the building. In addition, there is an increase of useful space because the walls, with less thickness, have nearly twice the effectiveness than the traditional ones.
From an acoustic point of view, it satisfactorily fulfills the acoustic standards, such as CTE DB-HR, without being necessary, in most cases, without the need to add any sheeting or other materials.

13) Can BAUPANEL® System be used as retention of land?

13) Can BAUPANEL® System be used as retention of land?

Yes. Simple panels can be used as retaining walls up to 3 metres in height, according to international standards. The panels would be of the kind BPR (with integrated corrugated reinforced bars).
For greater height, we can use the Double Panel type BPD (with a central core of reinforced concrete).

14) Is this a resistant system to seismic tremors?

14) Is this a resistant system to seismic tremors?

Yes. In fact, one of the main advantages of this System is the excellent performance before seismic stress.
The acting seismic stress on buildings is proportional to its mass. Buildings made with BAUPANEL® System practically weigh 35% less than a conventional building, the acting seismic stress on our buildings is lower than that rate.
In addition, the joints between the panels are reinforced with galvanized plain meshes that give extra strength to the structure.
They have certain capacity to become distorted during the earth tremor and, afterward, to recover its previous state.

15) How many people are needed to erect a building with BAUPANEL® System?

15) How many people are needed to erect a building with BAUPANEL® System?

Very few people and machinery is necessary to build with BAUPANEL®.
Two people are enough to erect a detached house of 100 m2 with one floor in just nearly 4 weeks. Furthermore, the building works can be carried out without expensive fixed cranes and two people can easily move one panel.

16) What can I save if I use BAUPANEL®?

16) What can I save if I use BAUPANEL®?

• Time saving (above all the repetitive elements).
• Cost saving (we work do without most heavy machinery traditionally used in building works. Time saving is equal to cost saving).
• Personnel saving (very few people are needed to erect buildings).
• Energy saving (during the life of the building there is an important energy saving thanks to the insulation capacity of the system)

17) Does the BAUPANEL® System require any kind of special foundation?

17) Does the BAUPANEL® System require any kind of special foundation?

BAUPANEL® System is compatible with any kind of foundation usually used.
Depending on the soil, it is likely that slab foundation is used in buildings with an irregular load line layout, and continuous footings in those buildings with a more uniform layout.

18) Does BAUPANEL® System require any kind of special pre-frame?

18) Does BAUPANEL® System require any kind of special pre-frame?

No. We can use the usual ones in the market. It uses metal pre-frames for metal windows and doors, and wooden pre-frames for wooden windows and doors.

19) Does BAUPANEL® System require any kind of special finishing?

19) Does BAUPANEL® System require any kind of special finishing?

Any kind of finishing, even facings with metal substructures can be used.

20) How many floors can be erected with BAUPANEL® System?

20) How many floors can be erected with BAUPANEL® System?

BAUPANEL® System can be built to reach up to 6 stories. However, it would be possible to increase the height because the limit is the loading capacity of the walls and that can be checked by calculation.

21) Does BAUPANEL® observe the international codes in force?

21) Does BAUPANEL® observe the international codes in force?

Our Technical Department has all the necessary specific information to fulfil those standards and will inform and help the architects to draw their projects to observe the basic regulation.

22) Can I obtain the Ten Year Insurance for a building made with BAUPANEL®?

22) Can I obtain the Ten Year Insurance for a building made with BAUPANEL®?

Currently, there are already several insurance companies contracting the Ten Year Insurance for buildings made with BAUPANEL® System.

23) How many years has BAUPANEL® System been in the market?

23) How many years has BAUPANEL® System been in the market?

Buildings using this system have been erected all over the world since the 1970s.

24) Is the  BAUPANEL® System resistant to gunfire?

24) Is the  BAUPANEL® System resistant to gunfire?

There is a ballistic test proving the great resistance of the system to gunfire.

25) Is it true that there is an increase of useful space with the BAUPANEL® System?

25) Is it true that there is an increase of useful space with the BAUPANEL® System?

We made our façade walls fulfilling the CTE thermal & acoustic requirements with only 17.50 cm compared to the 25 cm, as minimum, of the traditional building methods. Thanks to our experience, we can affirm that in a dwelling of 100 m2 of building space we got a benefit of 3m2 of additional space.

26) What tests on BAUPANEL® System have to be done on site?

26) What tests on BAUPANEL® System have to be done on site?

For the concrete and steel tests it follows the International Standards. The concrete is tested in test-tubes on site with the concrete already manufactured or in the laboratory by adding water to the dry mortar.
The corrugated steel is tested taking samples from the panels.

27) How are the BAUPANEL® System shared walls settled?

27) How are the BAUPANEL® System shared walls settled?

BAUPANEL® has a special panel for dilatation joints or shared walls. The side facing the joint or the shared wall has a double mesh and the concrete is poured in touch with it. The side facing the inside of the building will be of shotcreted concrete.
The acoustic insulation rate of this panel is 51.30 dBA.
Previously, it was necessary to put a sheet of EPS with a thickness to be defined in the project in order to formalize the very same joint.
 

28) How is a building made with BAUPANEL® System calculated?

28) How is a building made with BAUPANEL® System calculated?

Calculations are similar to the traditional building methods. Please, keep in mind that reinforced concrete used through the well known methods of strength of material in the technical field.
The bearing walls work by simple compression because the frameworks do not transfer movement to the walls. It has been checked that in the most frequent bearing lines of the point of the building, the permissible stress of the reinforced concrete is not comes well within its agreed standards.
The framework elements work by simple deflection. The maximum movement is calculated in the midspan of the building and it is compared with the resistant stress of the panel chosen for that purpose. If the maximum stress of the panel doesn´t surpass the allowable resistant stress of the panel, then it is not necessary to use reinforcement. If the maximum stress in the midspan surpasses the allowable resistant stress of the panel, it will be necessary to add reinforced bars.
It is necessary to calculate the longest span of the framework to obtain the maximum length that does not need reinforcement.
 

29) Why do the framework panels not touch the walls during the assembly of the BAUPANEL® System?

29) Why do the framework panels not touch the walls during the assembly of the BAUPANEL® System?

In the assembly phase, the frameworks are supported by angular meshes and they are separated by a few centimetres from the bearing walls in order not to interrupt the concrete sections of the walls along its height; otherwise, the walls would have to be cut causing a weakening line on them along its vertical course.

30) Whats the weight of a wall and framework made with BAUPANEL®?

30) Whats the weight of a wall and framework made with BAUPANEL®?

The mass of a BAUPANEL® wall is approximately 180 Kp/m2 and the framework is approximately 215 Kp/m2.

31) What kind of concrete is used?

31) What kind of concrete is used?

We use micro-concrete with compression strength of 25 N/mm2.
The maximum size of the aggregate is between 0 and 6 mm and it has a special formula based on plasticisers that makes the application and adherence of Baupanel panels easier. It is supplied dry, in sacks or in silos. Its composition includes fibers that help to avoid the cracks by surface shrinkage.

32) Are straining beams used in the building process of the frameworks?

32) Are straining beams used in the building process of the frameworks?

Yes. It is necessary to use straining beams that have a gap between each other of 1.0 and 1.40 metres and parallel to the bearing walls defining the span.
It is advisable to use metal sleeper beams of short section so the shotcreting on the framework lower side can be easier.

33) How long have the frameworks to be shored up?

33) How long have the frameworks to be shored up?

It must follow the instructions of the codes where this matter is defined. It also depends very much on the weather.
Usually, the frameworks are left shored up for approximately 15 days, although it depends on the project and faculty management of the project.

34) What is the thermal resistance and transmittance of the BAUPANEL® System walls?

34) What is the thermal resistance and transmittance of the BAUPANEL® System walls?

Thermal resistance goes between 2,767 m2K/W for the panel with a 10 cm EPS core and 5,331 m2K/W for the panel with a 20 cm EPS core. Thermal transmittance goes between 0,361 W/m2ºK for a panel with a 10 cm EPS core and 0,188 W/m2ºK for a panel with 20 cm EPS core.
The above data implies an improvement of thermal resistance between a 175% and 430% compared to a 25 cm brick wall. The improvement for the thermal transmittance is between 64% and 81%.
The thermal transmittance data of our range of panels enables us to use them all over the world since they surpass the maximum thermal transmittance requested by the codes.

35) What is the acoustic resistance of BAUPANEL® System walls?

35) What is the acoustic resistance of BAUPANEL® System walls?

The range of simple panels, with the concrete thickness defined in each side (3.5 cm) have an average acoustic insulation of 43,50 dBA.
In the case of the shared walls and dividing elements between the different units of use, we could increase the thickness of the walls up to 5.5 cm per side (2 more cm in each side) with a result of 50,6 dBA of acoustic insulation.
In case of the walls that divide installation or activity rooms where it is required 55 dBA acoustic insulation according to CTE, it would be necessary to add some sheeting element on the wall to get the requested acoustic insulation.

36) What kind of material can be used for the plumbing?

36) What kind of material can be used for the plumbing?

In order to carry out the plumbing installations (cold and hot water) inside the BAUPANEL® walls, we must use pipes of plastic material (polybutylene or polypropylene) because due to its flexibility they are easier to be set up.
Copper pipes are not suitable due to their rigidity.

37) How can I get a budget?

37) How can I get a budget?

We need the dimensioned floor and elevation drawings of the dwellings to be budgeted, if possible in AutoCAD file or similar.

38) How do I get involved with BAUPANEL?

38) How do I get involved with BAUPANEL?

Please call us on +41 44 226 99 66 or email us via our general enquiry form on our contact page. We look forward to speaking to you soon.

top 3 questions answered

What materials are BAUPANEL® System made of?

The central core of the panel is made up of expanded polystyrene with a density of 15 kg/m3 – 25 kg/m3 that is cut in a rippled manner to improve the compliance of the concrete when discharged.

The EPS core is edged with mesh of straight and/or corrugated steel, depending on the kind of panel, which are linked together by a series of connectors that go through the EPS core.

Once the micro-concrete has been shotcreted, the panel performs like a compound section because of the connection of the two concrete layers by way of the steel connectors.

 

Is BAUPANEL® a prefabricated system?

BAUPANEL® is not a prefabricated system. It is defined as an industrialised or semi-prefabricated system, because the panel is made in the factory and delivered with the exact length according to its position in the building design. The micro-concrete is shotcreted on site.

The main advantages of the above are:

  • Greater flexibility in the building works if it is necessary to amend the project.
  • The setting out can be done with lower accuracy than in prefabricated system.
  • Since the micro-concrete is shotcreted on site, there is no need for joints (except for expansion or construction joints)

 

Is this a resistant system to seismic tremors?

Yes. In fact, one of the main advantages of this system is the excellent performance before seismic stress.

The acting seismic stress on buildings is proportional to its mass. Buildings made with BAUPANEL® System practically weigh 35% less than a conventional building, the acting seismic stress on our buildings is lower than that rate.

In addition, the joints between the panels are reinforced with galvanized plain meshes that give extra strength to the structure.

They have certain capacity to become distorted during the earth tremor and, afterward, to recover its previous state.

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