A new lightweight floor system based on sandwich panel

Abstract

A new lightweight floor system was developed to tackle the sustainability issue in the construction sector. The proposed flooring system is suited for rehabilitation of degraded timber floors in existing building. Despite the great potential that sandwich construction shows as load bearing elements their use has been hindered by the high initial cost. Three alternative architecture, all including steel face sheets, were envisaged, namely i) steel webs and polyurethane (PUR) foam core system, ii) glass fiber reinforced polymer (GFRP) webs and PUR foam system and iii) outer steel webs and balsa wood core. The structural, thermal, acoustic and fire resistance requirements were identified in the Portuguese national codes. Particular attention is given to the description of the materials adopted for the different components with respect to the driving factors of the design of the panel, namely weight, cost, environmental impact, load bearing capacity, rigidity, thermal and acoustic properties and fire resistance. The preliminary design of the three sandwich panels is carried out considering the value of the actions established in the Eurocode standards. The final layout and cost estimate are the results of a parametric study aimed at retrieving the lightest and most economical solutions.