Standard for Testing Laminated Sandwich Panels (Structural Insulated Panels
National Sunroom Association
Standard for Testing Structural Insulated Panels for use in Sunrooms and Patio Covers
1.0 Introduction
1.1 Purpose: The purpose of this Standard is to establish requirements for verifying laminated sandwich panels conform to the requirements of the 2003 International Building Code (IBC), the 2003 International Residential Code (IRC), and he 1997 Uniform Building Code (UBC). Basis for conformance recognition are IBC Section 104.1, IRC Section R104.11 and UBC Section 104.2.4.
1.2 Scope
This Standard provides a basis for evaluating laminated sandwich panels used for roof and non-bearing wall elements in Sunrooms and Patio Covers as defined in Section ______fill in Code Sections for IBC, IRC and UBC_____
1.3 Referenced Documents
1.3.1 2003 International Building Code (IBC), International Code Council
1.3.2 2003 International Residential Code (IRC), International Code Council
1.3.3 1997 Uniform Building Code
1.3.4 ASTM C 271, Test Method for Density of Core Materials for Structural Sandwich Constructions, ASTM International.
1.3.5 ASTM C 297, Method for Tension Test of Flat Sandwich Constructions in Flatwise Plane, ASTM International.
1.3.6 ASTM C 365, Test Methods for Flatwise Compressive Strength of Sandwich Cores, ASTM International.
1.3.7 ASTM C 393, Method for Flexural Test of Flat Sandwich Constructions, ASTM International.
1.3.8 ASTM C 481, Test Method for Laboratory Aging of Sandwich Constructions, ASTM International.
1.3.9 ASTM D 1037, Method for Evaluating the Properties of Wood-Base Fiber and Particle Panel Materials, ASTM International.
1.3.10 ASTM E 72, Method of Conducting Strength Tests of Panels for Building Construction, ASTM International.
1.3.11 ASTM E 84, Test Method for Surface Burning Characteristics of Building Materials, ASTM International.
1.4 Definitions
1.4.1 Category I Sunroom
A roof or a covering of an outdoor space. The openings shall be permitted to be enclosed with insect screening or 0.5 mm (20 mil) maximum thickness plastic film. The space is defined as non-habitable and unconditioned.
1.4.2 Category II Sunroom
A roof or a covering of an outdoor space with enclosed walls. The openings are permitted to be enclosed with translucent or transparent plastic or glass. The space is defined as non-habitable and unconditioned.
1.4.3 Category III Sunroom
A roof or a covering of an outdoor space with enclosed walls. The openings are permitted to be enclosed with translucent or transparent plastic or glass. The sunroom complies with additional requirements for forced entry resistance, air leakage resistance and water penetration resistance. The space is defined as non-habitable and unconditioned.
1.4.4 Category IV Sunroom
A roof or a covering of an outdoor space with enclosed walls. The sunroom is designed to be heated and/or cooled by a separate temperature control or system and is thermally isolated from the primary structure. The sunroom complies with additional requirements for forced entry resistance, water penetration resistance, air leakage resistance, and thermal performance. The space is defined as habitable and conditioned.
1.4.5 Category V Sunroom
A roof or a covering of an outdoor space with enclosed walls. The sunroom is designed to be heated and/or cooled and is open to the main structure. The sunroom complies with additional requirements for forced entry resistance, water penetration resistance, air leakage resistance, and thermal performance. The space is defines as habitable and conditioned.
1.5 Notation
…
2.0 Basic Information
2.1 General
The following information shall be included within the test report and/or engineering package for the subject laminated sandwich panel.
2.1.1 Product Description
Complete information concerning material specifications, panel thickness and size, and manufacturing process. Material specifications shall include, facing material, backer material for bonding adhesive to facing, adhesive, and core formulation and density. Information shall also include dimensioned scale drawings of the panel including splines, perimeter elements and shape of facing edges.
2.1.1.1 Panel-facing Material
Panel facing material shall be acceptable under a current ICC-ES evaluation report, a recognized product standard, or the IBC, IRC, or UBC. The material shall be clearly identified to determine compliance.
Exterior panel facings that remain exposed on weather-exposed surfaces, as defined in UBC Section 224, IBC Section 2502 and IRC Section R703, shall be justified to the satisfaction of ICC-ES for this use.
Panel facings exposed to the building interior shall have flame-spread and smoke-density ratings as specified in IBC Section 803.1, IRC Section R319 and UBC Section 802.2. Plastic materials shall be approved plastics as set forth in IBC Sections 2602.1 and 2606.4 for use under the IBC or IRC; and UBC Section 217 for use under the UBC. When these characteristics are affected by the core material of the panel, the combined section shall be tested when deemed necessary by the ICC-ES. CHANGE THIS LINE
2.1.1.2 Panel Cores
Honeycomb specifications are to include a detailed description or illustration noting the thickness, cell size, kraft paper weight or metal thickness, direction of the paper or metal ribbon, percent impregnation of materials, etc.
Foam plastic specifications are to include the density, thickness, whether it is preformed slab, frothed or expanded, foam manufacturer and the type, catalog number, etc. The position of the panel during the frothing or pouring operation is to be specified.
Other core materials with specifications and descriptions will be considered.
When the core material does not completely fill the portion between panel facings, voids shall be detailed or properly described. Voids formed by honeycomb cells are not regulated by this subsection. The method used to maintain voids during foaming or bonding shall be described.
Core materials classified as noncombustible shall be justified under IBC Section 703.4, IRC Section R202, and UBC Section 215, as applicable. Combustible core materials, except foam plastic, shall have a minimum Class Ill flame-spread classification not exceeding 200 and smoke-density rating not exceeding 450 when tested under ASTM E 84 for use under the IBC, IRC, and UBC Standard 8-1 for use under the UBC; in the thickness intended for use. Foam plastic cores shall comply with IBC Sections 2602.1 and 2603 and IRC Section R318 and the ICC-ES Acceptance Criteria for Foam Plastic Insulation (AC12).
2.1.1.3 Adhesives
Adhesives shall comply with the ICC-ES Acceptance Criteria for Sandwich Panel Adhesives (ACO5). Adhesive specifications are to include the type, class, thickness of application, number of coats and assembly instructions, etc.
2.1.1.4 Backer Material
Back Material shall be suitable for use with adhesive and facing material. Backer material shall be tested as part of the qualification under AC05.
2.1.1.5 Connections
Connections shall be detailed or adequately described. Fasteners shall be properly specified, including size, length and location.
2.1.2 Installation Instructions
Installation details and limitations, fastening methods, joint treatments and face treatments, and locations of fasteners.
2.1.3 Packaging and Field Identification
Description of packaging and method of identifying components in the field.
2.1.4 Field Preparation
Method for field cutting, trimming, and treatment of cut edges and cut ends.
2.2 Testing Laboratories
Testing Laboratories shall be accredited with..
2.3 Test Report
Test reports shall include….
2.4 Product Sampling
Sampling of test specimens shall… Specimens shall be representative of standard manufacture in conformance with the minimum requirements of the quality control manual addressed in Section 8 of this criteria. The specimens shall be sampled in accordance with Section 3.1 of AC85.
2.5 Panel Justification Options
Panels may be justified by load tests as described in Section 4. Justification by this method limits their use to sizes and materials used in the tests. Allowable loads determined may be used for shorter spans or heights but extrapolation is not permitted.
3.0 Verification Requirements
3.1 General
Laminated sandwich panels may be justified by load tests defined within Section 3.0 and 4.0 of this standard. Justification by this method limits their use to sizes and materials used during testing. Allowable loads shall be determined in accordance with Section 3.3 (???) and may be used for shorter spans but extrapolation to longer spans is not permitted.
3.1.1 Duration of Load Increase
Allowable values developed under Section 3.3 are not subject to increase due to duration of loading. This includes wind and seismic.
3.1.2 Combination of Loads
Where loading conditions result in several modes of superimposed stressing, the sum of the ratios of actual loads over allowable loads shall not exceed one
3.1.3 Substitutions
Substitutions of material shall not be allowed unless compliance with Section ___ of this standard has been demonstrated by ______Test lab? Engineer?
3.1.4 Openings in Panels
Openings in panels shall not be allowed unless such openings were included in the test program.
3.1.5 Internal Elements and Mating Elements
...
3.1.6 Factors of Safety
Factors of safety are dependent on the consistency of materials, the range of test results and the load deformation characteristics of the panel. Generally a minimum factor of safety of 2.5 is applied to the ultimate load based on the average of three tests.
For Patio Cover roof panels limited to recognition under IBC Appendix Chapter I, or IRC Appendix Chapter H, or Division Ill of UBC Appendix Chapter 31, and consisting of metal facings and factory-adhered foam plastic cores, the following factors of safety are applicable to uniform transverse loads:
F.S. = 2.0, ultimate load determined by bending (facing buckling) failure for allowable live loads up to 20 psf (958 Pa) and wind loads
3.1.7 Alternate Materials
[Zach McCartney to evaluate parameters that are important 1 month turnaround for circulation Monday April 2, 2007.
3.1.8 Sealants
… Unassigned
3.1.9 Alternate Manufacturing Locations
[Zach McCartney]
3.1.10 Deflection Limits
Deflection limits for laminated sandwich panels…
3.2 Test Data Required
Test data shall be provided which verifies the physical characteristics of the laminated sandwich panel.
3.2.1 Foam Plastic
Data verifying conformance with ASTM C578 shall be submitted …
3.2.2 Weather Protection
For exterior walls consisting of the laminated sandwich panels, data verifying compliance with IBC Section 1403.2 and IRC Section 703.1 shall be provided.
3.2.3 Surface Burning Characteristics
See Section 3.4 of AC 214 for additional information.
3.2.4 Thermal Barrier Requirements
The factory-assembled panels shall be separated fro the interior of the building with an approved thermal barrier set forth in IBC Section 2603 or IRC Section R318.1.2, whichever code is applicable. (Add something for UBC) For use without a thermal barrier as required by the codes, the factory-assembled panels shall be tested in accordance with IBC Section 2603.7 or IRC Section R318.3, whichever code is applicable.
This is a section out of AC214. It might be helpful to the group creating a fire standard.
3.2.4 Wall Panel Transverse Load Tests
…
3.2.5 Roof and Floor Panels
…
3.2.6 Concentrated Load Tests
… Terry Cavanagh
3.2.7 Density Tests-Preformed Foamed Plastic Core Material
…
3.2.8 Coefficient of Expansion for Core and Facings
[Craig to perform a sensitivity analysis after the group agrees to the methodology] This issue needs to be addressed but should be something different than what is currently in AC04. … Craig Joss
3.2.9 Temperature Differentials on Panel Facings
Martin to provide verbiage – ASCE 7-05 Appendix C (C.4) & ASCE 7-05 Section 1.3.3]. The deformation of panels that have skins with high coefficients of expansion or that have interior and exterior skins with different coefficients of expansion shall be determined per section 3.3.6 using the coefficients of thermal expansion determined in section 3.2.8 and meteorological data for the locality.
The differential in the interior and exterior skin temperatures (DT) shall be as follows:
(1) Non-Habitable Patio Rooms:
DT =10°F
(2) Habitable Sunrooms
(a) Winter time:
DT =70°F minus the average minimum temperature; but need not exceed 50°F???
(b) Summer time:
DT =70°F for metal skin panels
DT =???°F for osb skin panels
3.2.10 Long Term Creep Performance
… Terry Cavanagh
3.2.11 Diaphragm Performance
Verification of the end use diaphragm performance of SIP/sandwich panels. Factory assembled panels shall be tested to determine the maximum static shear capacity of the assembled diaphragm panel. Permissible deflection shall be that deflection up to which the diaphragm and any attached distributing or resisting element will maintain its structural integrity under design load conditions, such that the resisting element will continue to support design loads without danger to occupants of the structure.
4.13 - ASTM E445-98 (needs to be modified for use with SIP/sandwich panel construction)
[Sub-sections to be defined if E445 is deemed appropriate]
Key issues with ASTM E445-98 standard:
1 – This standard addresses frame construction with diaphragm attached. SIP’s are composite construction and therefore do not have a separate frame. E445 requires a baseline test of the supporting frame structure prior to the application of the diaphragm sheathing. E445 could be modified to include load point bearing supports so that no additional framing is needed, otherwise the test framing would need to be accounted for to develop appropriate test results.
3.2.12 Connection Performance
… Craig Joss
3.2.11 Bearing Capacity (Optional)
At a minimum, bearing capacity shall be determined for the smallest bearing plate intended for use in the field. This test is considered optional if it is deemed necessary to test more than the minimum bearing plate size. It may be desirable to test all bearing plate configurations intended for use in the field if panel is used in different configurations.
Testing shall include load to failure (or highest load desired) of the minimum bearing surface intended for field use. Testing shall include end bearing and mid-span bearing to simulate field use header and wall supports respectively. At a minimum the following must be determined:
· Fastener pull-out and shear failure due to (potential) bending moment.
· Sandwich panel shear failure
· Face bending and buckling failure
· Sandwich panel core crushing failure (need to determine maximum allowable crushing of core material – suggest that this is best determined through testing. I did not find any reliable source for reference to determine a reasonable limit)
· Deflection due to local compression at bearing plate
Test data results shall indicate:
· Mode of failure
· Ultimate load at failure