Name and Address of Certificate Performance

Holder: M/s Schnell Home, s.r.l. Appraisal Certificate

Unipersonale Via Borghetto, 2B-
zona Ind. San Liberio - 61030 PAC No.1031-S/2017
Montemagglore al Metauro (PU)
Issue No. 01
Italia Tel 39 0721 878711
Email: schnellhome@schnell.it Date of Issue:
13.01.2017

Concrewall
System

Building Materials & Technology Promotion Council

Ministry of Housing & Urban Poverty Alleviation
User should check the
Government of India
validity of the Core 5A, First Floor, India Habitat Centre,
Certificate by contacting Lodhi Road, New Delhi 110 003
Member Secretary,
BMBA at BMTPC or the Tel: +91-11-2463 8096, 2463 8097; Fax: +91-11-2464 2849
Holder of this Certificate. E-mail: bmtpc@del2.vsnl.net.in Web Site: http://www.bmtpc.org
 CONTENTS

PART 1 CERTIFICATION.. 3
1.1 Certificate Holder . 3
1.2 Description of System .. 3
1.3 Panel Types 4
1.4 Assessment ... 7
1.5 Uses of the System . . 8
1.6 Conditions of Certification . 9
1-7 Certification . 9
PART 2 CERTIFICATE HOLDERS TECHNICAL SPECIFICATION ..... 9
2.1 General ....... 9
2.2 Specifications for the System ...... 10
2.3 Design Consideration .... 10
2.4 Machinery Involved 11
2.5 Production Process 12
2.6 Installation Process 12
2.7 Inspection & Testing... 14
2.8 Handling & Storage and Marking & Identification . 15
2.9 Good Practices for Selection and Installation 15
2.10 Maintenance requirements . 15
2.11 Skills/ training needed for installation .. 15
2.12 Guarantees/Warranties provided by the PAC holder . 16
2.13 Service provided by the PAC holder to the customer 16
2.14 Manuals . 16
2.15 Responsibility 16
PART 3 BASIS OF ASSESSMENT AND BRIEF DESCRIPTION OF ASSESSMENT
PROCEDURE 16
3.1 Assessment ................... 16
3.2 Laboratory tests done for assessment ....... 17
3.3 Usage of the System.. 21
PART 4 STANDARD CONDITIONS ............ 22
PART 5 LIST OF STANDARDS AND CODES USED IN ASSESSMENT.. 24
CERTIFICATION ..... 25
PART 6 ABBREVIATIONS 26
PERFORMANCE APPRAISAL CERTIFICATION SCHEME A BRIEF... 27
ANNEX A QAP.. 28
ANNEX B Diagrams ... 30
ANNEX C Test Results.. 39

2
 PART 1 CERTIFICATION

1.1 Certificate Holder: M/s Schnell Home, s.r.l. Unipersonale

Via Borghetto, 2B-zona Ind. San Liberio
61030 Montemagglore al Metauro (PU) -Italia
Tel 39 0721 878711
Email: schnellhome@schnell.it

1.2 Description of System

1.2.1 Name of the System Concrewall System

1.2.2 Brand Name Concrewall

1.2.3 Brief Description The Concrewall System is an industrial system for the
construction of structural walls of reinforced concrete for building in single
panel up to G+3.
The system is composed of a factory produced panel of undulated (wave
shape) polystyrene covered on both sides by an electro-welded zinc
coated square mesh of galvanized steel and linked by 40 connectors per
sq m made of high-elastic-limit 3mm dia wires realizing a 3 dimensional
hyper-static reinforced steel. (Figs 1 & 2)
The panels are assembled on site and in-situ concrete (double panels,
floors, stairs) and shotcreted concrete poured (single panel) to realize the
following different elements of the system:
Vertical structural walls
Horizontal structural elements
Cladding element
Internal walls.

Figure 2. Cross-section
3
1.3 Panel Types

1.3.1 Single Bearing Panel

Used as Load Bearing Wall

Fig. 3
Mesh

Width : 1235 mm
Longitudinal wires : 2.5/3.0 mm @ 80 mm c/c (max)
Transverse wires : 2.5/3.0 mm @ 75 mm c/c (max)
Connectors & cross wire : 3.0 mm @ 150 mm c/c

EPS

Density : 15 kg/m3
Thickness : 40 mm to 240 mm
Wave Depth : 15 mm

4
1.3.2 Single Non Load Bearing Panel

Fig. 4

Mesh

Width : 1235 mm
Longitudinal wires : 2.5/3.0 mm @ 80 mm c/c (max)
Transverse wires : 2.5/3.0 mm @ 75 /150 mm c/c (max)
Connectors & cross wire - : 3.0 mm @150 mm c/c

EPS

Density - : 15 kg/m3
Thickness - : 40 mm to 280 mm
Wave Depth - : 5 /15 mm

5
1.3.3 Single Floor Panel

Used as floors or roofs span upto 5 m x 5m and supported by the walls in

all the sides. The panels are finished on site by 50 mm of casted
concrete in upper side and 30 mm of projected plaster in the lower side.

Fig. 5

EPS
Width : 1200 mm
Thickness : 80 to 200 mm
Density : 15Kg/m3

Mesh

Width : 1235 mm
Longitudinal wires : 2.5 / 3.0 mm @ 80 mm c/c
Transverse wires : 2.5 / 3.0 mm @ 75 mm c/c
Connectors & cross wire : 3.0 mm @ 150 mm c/c

6
 1.3.4 Floor Panel with Joists

Fig. 6

Galvanized steel wire mesh

Longitudinal wires: 2.5 mm dia. every 70 mm
Transversal wires: 2.5 mm dia. every 70 mm
Cross steel wire: 3.0 mm dia.(approx. 68 per m2)

Polystyrene slab density: 15 kg/m3

This panel is used for the floor and the roof system and it is reinforced in
the joists with concrete casting on the site.
The reinforcement of the panel is integrated during the panel assembly
by additional reinforcing bars inside the joists as per the design.
These are suitable for slabs having spans up to 8 m and with live loads
up to 4 kN/m2.

1.4 Assessment

1.4.1 Scope of Assessment

1. 4.1.1 Scope of assessment included suitability of manufactured panel to the
specified requirements for use in building construction as:
Load bearing wall panel
Non-load bearing wall panel
Shear Wall
Floor/ roof slab
The structural and water tightness design for each specific structure is
the responsibility of the building designer.

1.4.2 Basis of Assessment

The system is assessed for use with framed door and window joinery
installed with vertical jambs. Assessment of the suitability of panels
manufactured as load bearing wall, shear wall, floor/ roof slab etc. is
based on:
Tests on construction materials including individual roof
panel, tensile test of galvanized wire, expanded polystyrene
and cement mortar vis--vis requirements contained in the
specifications;
Determination of Compressive, Flexural and Axial Strength of
Expanded Polystyrene Core Panel by IIT Roorkee
Evaluation Report of the Characterization Tests carried out

7
 by Department of Architecture, Buildings & Structures,
University Polytechnic of Marche
Fire Performance of a Load Bearing Assembly and Fire
Resistance Testing of Floor/Ceiling Assembly by Western
Fire Center, INC, Washington, USA
Finite Element Modelling and Analysis of a G+3 EPS Building
by IIT Roorkee
Durability and Serviceability Assessment of Concrete
Sandwich Expanded Polystyrene Core Panels
Structural Stability Assessment and Development of Design
Guidelines for Expanded Polystyrene Core Panel System
towards Safe & Affordable Housing.
Quality Assurance Scheme followed by the Certificate holder
for process control as per the Quality Assurance Plan
attached at Annex A.

1.5 Use of the Concrewall Panel System

1.5.1 The panel may be used generally in the following ways:

1) As load bearing walling in buildings
2) As high capacity vertical and shear load bearing structural walling
in multi-storey construction.
3) Non Load bearing wall panels
4) As partition infill wall in multi-storey framed building:
5) As floor/ roof slabs
6) As cladding for industrial building

1.5.2 Special Aspects of use:

The building to be constructed using Concrewall panel shall

be manufactured in accordance with the specifications
prescribed in Technical Manual of Schnell Home and
designed by competent structural Engineers.
Plumbing and Electrical services shall be governed by the
provisions and details given by the manufacturer. Good
practices of plumbing services should be followed,
Concrewall System should be constructed only with technical
support or supervision by qualified engineers and builders,
based on structural designs complying with prevailing
standards and specifications; this is applicable even for low-
rise and affordable mass housing to provide safety of
structures.
It is strongly recommended that structural engineers and
building designers associated with Concrewall panel
construction should be thoroughly familiar with the various
structural aspects. It is also recommended that architects and
construction Engineers who undertake Concrewall building
design and construction gain familiarity with the properties of
material, characteristics of Concrewall panels, and its
application and construction system.

8
1.6 Conditions of Certification

1.6.1 Technical Conditions

1. The production capability and quality of the panels vis--vis requirements

specified and competence of the technical persons for design and
proper erection of the panels at site shall need verification for each
plant/ establishment engaged in the production and execution of the
system.
2. The Certificate holder shall inform BMTPC as and when any plant is set
up in India. Schnell Home shall provide full details of design,
manufacture and erection of the panels to the agency who may be
engaged for production and construction.
3. Schnell Home shall also provide necessary training to the technical
persons of the agency engaged for production, design and construction.
4. The Certificate holder shall provide a detailed Quality Assurance System
for production and execution of the system in the field.

1.6.2 Quality Assurance

The Certificate holder shall implement and maintain a quality assurance

system in accordance with Scheme of Quality Assurance (SQA) given in
Annex A attached with this Certificate

1.6.3 Handling of User Complaints

1.6.3.1 The Certificate holder shall provide quick redressal to consumer/user

complaints proved reasonable & genuine and within the conditions of
warranty provided by it to customer/purchaser.

1.6.3.2 The Certificate holder shall implement the procedure included in the SQA.
As part of PACS Certification he shall maintain data on such complaints
with a view to assess the complaint satisfaction and suitable preventive
measures taken.

1.7 Certification

1.7.1 On the basis of assessment given in Part 3 of this Certificate & subject to
the conditions of certification, use & limitations set out in this Certificate
and if selected, installed & maintained as set out in Parts 1 & 2 of this
Certificate, the panels covered by this Certificate are fit for use set out in
the Scope of Assessment.

PART 2 CERTIFICATE HOLDERS TECHNICAL SPECIFICATIONS

2.1 General

2.1.1 The PAC holder shall manufacture the panels in accordance with the
requirements specified in the PAC. In addition it shall follow the
requirements of various materials used in the manufacture of these
panels given in PAC.
9
2.2 Specifications of The System

2.2.1 Specifications

Specification for the raw materials and finished product shall be as per
performance criteria when tested in accordance with the relevant Indian
Standards listed in Part 5 of this Certificate.

2.2.2 Technical Specifications

2.2.2.1 Raw materials

1 Steel for both wire mesh and connectors

1.1 Zinc Coating The zinc covering is variable with the diameter of the
wire mesh. Standard wire mesh shall be of 2.5/3.0 mm dia and zinc
coating galvanizing shall be of 60/90 gm/m2 with a tolerance of 5
gm/m2

1.2 Mechanical characteristics

Tensile strength (2.5mm dia): 750 N/mm2
Yield strength (2.5mm dia): 680 N/mm2
Tensile strength (3.0mm dia): 700 N/mm2

Yield strength (3.0mm dia): 600 N/mm2

Elongation: > 8%

1.3 Chemical characteristics

%C : < 0.24
%P : < 0.055
%S : < 0.055
% Ceq : < 0.52

2. Expanded Polystyrene Self-extinguishing type EPS in accordance

with IS 4671:1984 (UNI EN 13163:2013) having density not less
than 15 kg/m3.

2.3 Design Consideration

2.3.1 General
(i) The Concrewall panels may be designed using the appropriate design
software. The buildings constructed with these panels shall be studied
and designed reinforced concrete structure since the parameters
required for their design are the same as needed for traditional
reinforced concrete. In the calculation model, the building shall be
designed as a structure composed of load bearing walls with a box- like
structure.

(ii) The system is intended for use where Architectural drawings are
available and satisfy the various requirements. The Architect and
Engineer designer team of the concerned developer (client) is
responsible for the drawings and overall building design to comply with
10
 the various regulatory requirements applicable to the area.

(iii)The design engineer shall liase with the engineer of the developer and
provide the necessary loading information for the design of the
foundation.

(iv)The system shall be designed to provide the required performance

against the loads to be taken into account in accordance with IS 875
(Parts 1-5):1987 and the data given by manufacturer for various panels. It
shall also provide the required bearing resistance for earthquake and
wind forces as per IS 875 (Part 3):1987 and IS 1893 (Part 1):2002,
wherever applicable.

(v)Foundation shall be specifically designed in accordance with provision

given in IS 1904:1986. Both single and double panels should have starter
bars from either foundation or ground floor slab. All foundations should
be designed by experienced engineer with appropriate reference.

(vi)The design assumptions, detailed calculations, references to

necessary and detailed design drawings shall be made available on
demand, if required. The structural design calculations should clearly
demonstrate structural integrity and stability including connection details.

(vii)In addition, any other requirement regarding safety against

earthquake need to be ensured by the designer as per prevailing codal
requirements.

2.3.2 Structure

The Concrewall System receives its outer plane strength by its own
geometrical configuration. Every longitudinal wire is in correspondence of
the wave, so once the plaster is applied, the wire is well covered and the
panel acts as a series of micro-column.

2.3.3 Wind Uplift

The design of roof to wall connections shall be to a specific design to

ensure that the roof structure is properly restrained against uplift.

2.3.4 In-fill Wall

When used as in-fill wall in framed RCC structure, the structure shall be
designed in accordance with IS 456:2000. The fixing of the panels shall
be done in accordance with the details provided by the manufacturer.

2.4 Machinery Involved

(i) Electronic Polystyrene cutting machine

(ii) Wire straightening machine
(iii) Automatic welding mesh machine
(iv) Automatic welding and Panel assembling machine
(v) Automatic mesh cutting machine
(vi) Automatic mesh binding machine
11
2.5 Production Process

Concrewall Panels of different dimensions shall be produced with two

raw materials namely steel wire in coils and polystyrene blocks.

2.5.1 Galvanized wire: It shall include the following phases:

Perfect straightening and cutting of the required wires
Assembly by electrical welding of the wires of different dia to make
mesh of pre-established lengths

2.5.2 Polystyrene blocks EPS: The most complete hypothesis shall include the
following phases:
Shape the dried blocks and cut sheets of a specific form and dimension
according to the final type of product. The possible scraps shall be
grounded and recycled, within certain limits, in the production of EPS
blocks on the condition that these are first cleaned and are without any
foreign substance, with particular attention to the presence of dust.

2.5.3 Assembly:

Assembly of the Concrewall panel shall be made by electro welding no.6

wires (in transversal and perpendicular position with respect to the panel
surface) with two meshes, forming a sandwich including the EPS sheet
between these, which has been previously inserted.

2.5.4 Operations out of line:

The production line is complete after cutting and bending of the external
overlapping meshes.

2.6 Installation Procedure

2.6.1 Foundations

Where Foundations for the Concrewall System are used, they should be
levelled and stepped as this makes panel positioning easier.
For concrewall panels, parallel sided timber or metal template of the
width of panel shall be required to mark the position of the wall panels on
the foundation and the spacing of the starter bar holes.

2.6.2 Wall start up

Line wall positions shall be marked and profiled.

A timber or metal template of the exact width of panel (from
wire to wire) shall be used to mark the position of the panels
with chalk or pencil lines.
On the panel lines positions shall be marked to drill the
starter bar holes. These should be in a zig zag pattern at 600
mm centres on each side of the panels. Starter bars should
be at all panel joints and on the opposite side in mid panel
plus at all wall corner joints.
Starter bars should be either 6mm or 8 mm dia, 500 mm long

12
 with 100 mm drilled into the foundations and 400 mm above.
Drill bits shall be used to give a tight fit with the starter bars.
Once starter bars are in position, place the Concrewall panels
between the starter bars starting from a corner. Starter bars
shall be wire-tied to the panel mesh and the panels to each
other on the overlapping mesh.

2.6.3 Wall construction

All corners and wall joints should be reinforced with right

angled wire mesh to the full height of the walls.
To cut panels to fit for door & window openings, wire should
be cut with a wire cutter or angle grinder. Measure and mark
the cut lines before starting to cut.
After the wire mesh has been cut, EPS shall be cut with a
hacksaw blade or stiff blade hand saw.
Added steel mesh reinforcement shall be required around
door and window openings to ensure that no plaster cracks
form in these areas. Mesh reinforcement strips shall be tied
diagonally at every corner of openings before plastering.
Once wall panels are in place and tied together, bracing shall
be required to hold them vertical before plastering. This shall
be done only on one side of the panels.
Once the panels are plastered on one side, the wall bracing
shall be removed after 24 hours. The panels are now
sufficiently stiff so that plastering on other side can be done
without bracing.

2.6.4 Door and Window fittings

Before plastering metal cliscoe type window and door

frames (which should be sized to the width of the panels)
may be fitted into the pre-cut panels.
Metal cliscoe type window frame fitted into future house
panel before plastering.
Metal lugs from the back of metal frames shall be wire tied to
the panel mesh to keep the frames in position.
For any other kind of frames, suitable method in accordance with the
manufacturers specifications may be used.

2.6.5 Plastering

Plastering shall be done by machine or hand. The indicative

quantity of each material per cum. should be as follows:
Cement: 350 kg
Sand with mixed granulometry: 1600kg. Sand should be
without clay or any organic substance and totally washed.
Water 160 litres. The quantity of water may be different
according to the natural sand humidity. The parameters that
should be constant are: W/C = 0.52 and I/C = 4.50.
Any problem of workability should be solved without adding
water. The retraction cracks formation may be avoided by
13
 adding Polypropylene fibers in the mix (1kg/m3).
In order to control the final plaster thickness, some guides
should be used. These shall be removed as soon as the
plaster sets up and the spaces are filled and are smoother
before the plaster gets dry.
Spray application should be done in two steps with a first
layer covering the mesh applied on both the sides of the wall
and the finishing layer as soon as the first layer gets dry.

2.6.6 Roof/floor panel

After the vertical panels are assembled, verticality of the walls

should be checked and the bending meshes positioned on all
the corners. Thereafter, horizontal bending meshes shall be
placed to connect the floor/roof to the vertical panels. The
bending meshes should be fixed throughout the perimeter of
the floor/roof, at the level of intrados.
When the horizontal bending meshes are fixed and checked,
floor / roof panel shall be placed on these. The lower mesh of
the panel shall be fixed by steel wire to the bending meshes.
Between the edges of floor/roof panel and vertical panel, gap
of 3.5 cm should be left to ensure structural continuity. The
plaster applied on the walls shall be continued from one level
to another level.
Placing of the Concrewall elements for the floor and/or roof should be
done before the application of the external layer of plaster on the walls.
Casting of concrete on the floor/roof panels (after placing the additional
reinforcing bars, if required) should be done after the walls are plastered
and a number of props shall be put to limit the deformation of the panel.

2.6.7 Plumbing and electrical fittings

Plumbing and electrical conduits shall be behind the panel

wire mesh before plastering.
The space behind the wire mesh shall be opened up by using
a blow torch to partially melt the EPS along the lines of the
conduits.
As the EPS used in the panels is fire retardant, it will melt
under the flame but not burn.
The wire mesh shall be cut with wire clippers to make space
for DB boards, switches and plug boxes.

Figures 7 to 15 showing typical details of single panel including door &

window details are given at Annex B for guidance.

2.7 Inspections & Testing

Inspections & testing shall be done at appropriate stages of

manufacturing process. The inspected panels shall be stored & packed to
ensure that no damage occurs during transportation. As part of quality
assurance, regular in-process inspections shall be carried out by the
trained personnel of the PAC holder.
14
2.8 Handling , Storage, Marking & Identification

(i) The panels should be stored on a clean, flat hard surface area on the
site. The panels should not be laid down directly on the ground to prevent
them from getting dirty, which could lead to problems of plaster adhesion.
Preferably, panels should be stored on timber battens approx. 2 m apart.

(ii) The panels should not be exposed to sunlight for not more than 1
month either in storage or during construction in order to prevent
changing the polystyrene appearance. The panels should be bound
carefully to make sure these are not accidentally blown by the wind.

(iii) Long term storage of the panels shall be done in a covered,

protected, dry environment so that corrosion of the reinforcement does
not occur and the panels do not get damaged.

(iv) Panels shall be stored and transported to site in a manner that

prevents damage, buckling or sprawling of the polystyrene or bending of
the mesh reinforcement. Operatives should place the panels in position
and tie them down to starter bars of adjoining panels and slabs in the
manner described in the Operational Manual.

(v) Panels should be properly braced to provide rigid temporary support

to the walls during erection and concrete spraying and placing of
concrete in slabs. Propping of walls and slabs should be in accordance
with Schnell Operational Manual.

(vi) The panels shall be delivered to the site with an identification issued
by the manufacturer that reports the element height.

(vii) The panel layout shall provide instructions for laying the components
correctly.

2.9 Good Practices for Installation & Maintenance

Good practices as per requirement of working with Concrewall System of

the manufacturer shall be followed for installation and maintenance of the
system.

2.10 Maintenance Requirements

A proper maintenance guide shall be given by the PAC holder to the

client. When building is to be repainted with fresh coat of paint after
scraping existing paint, check for joint sealant, pipe joint, sun shade etc.
and carry out required maintenance and apply primer before paint is
applied.

2.11 Skills /Training Needed for Installation

Workers shall be trained/ oriented on handling of panel and its erection,

support system, clamping system, infilling of reinforcement and concrete
15
 etc. with all required safety measures taken including heavy hats,
protective shoes etc.

2.12 Guarantees/Warranties Provided by the PAC Holder

PAC holder shall provide necessary guarantees/ warranties. A brochure

giving relevant details of the Schnell Home shall be made available to the
client.

I 2.13 Services Provided by the PAC Holder to the Customer

In-house testing of panels at regular intervals as per the Quality Control

Assurance requirement shall be ensured by PAC Holder.

2.14 Manuals

A site Erection Manual and a Manual for Health & Safety shall be
provided for each project incorporating the Concrewall System.

2.15 Responsibility

Specific design using Concrewall System is the responsibility

of the designer with the instructions, supervision and
guidance of Schnell Home.
Quality of installation of the system on site is the
responsibility of the trade persons engaged by the agency
Quality of maintenance of the building is the responsibility of
the building owner.
Providing necessary facilities and space for movement of
cranes and vehicles is the responsibility of the building
developer.

PART 3 BASIS OF ASSESSMENT AND BRIEF DESCRIPTION OF

ASSESSMENT PROCEDURE

3.1 Assessment

3.1.1 The assessment of the system is based on the panels manufactured,

used, installed and maintained as per statement given in the PAC.

3.2 Laboratory tests performed for assessment

3.2.1 Testing of samples by Foreign Laboratories/ Institutes

The following tests have been performed by various foreign institutes

as per the specifications given by the manufacturer:

3.2.1.2 By Western Fire Center, INC, Washington, USA

1. Fire Performance Evaluation of a Symmetric, Load-Bearing Wall

Assembly

16
 The Symmetric, load-bearing wall assembly consisting of panels of 80
mm undulated EPS foam core with wire mesh on each side of the
foam with 6 mm standoff and concrete layers totaling a nominal 45
mm thickness on each side of the foam core, passed all requirements
of the 1-hr fire endurance test according to ASTM E119. The fire
resistance wall had a finish rating of 61 min. The wall assembly did not
allow flames to pass through the wall assembly for the 1-hr test, nor
did the average unexposed temperature supersede 139C + ambient
or a single-point temperature supersede 181C + ambient.

2. Fire Resistance Testing of Floor/Ceiling assembly

Panels consisted of 160 mm thick undulated undulated EPS foam core

with wire mesh on each side of the foam with 6 mm standoff and
concrete layers totaling a nominal 50 mm thickness were applied to
top of the foam core and 45 mm thickness to bottom of the foam core
as well as around perimeter to complete the 450 mm x 350 mm
assembly. The floor/ceiling assembly passed all the requirements of
the 1-hr fire endurance test according to ASTM E119. The wall
assembly did not allow flames to pass through the assembly for 60
min based on when the test was terminated. There was no unexposed
temperature failure for average or single-point thresholds (139C +
ambient, 181C + ambient) during the 60 min. test. Therefore, this
assembly can be certified for a 60 min resistance line.

3.2.1.3 By Giordano Institute, Italy -- Thermal Insulation Tests:

Single Panel Concrewall (PCS) 80 mm thick Thermal

transmittance Up = 0.557 W/m2K

3.2.1.4 By CSI (MI), Italy Acoustic Tests

Single Panel Concrewall (PCS) 80 mm thick -- Traditional plaster
Rw= 37 dB

Single Panel Concrewall (PCS) 80 mm thick Acoustic plaster

Rw= 37 dB

3.2.1.5 By CSI (MI), Italy Fire Resistance Test:

Single Panel Concrewall (PCS) 80 mm thick

3.2.1.6 By LAPI (PO), Italy Resistance to Impact with soft body

Single Panel Concrewall (PCS) 80 mm thick 50kg with impacts
of 900 &1200J No cracks were observed

3.2.1.7 By LAPI (PO) Water Penetration Test

Single Panel Concrewall (PCS) 80 mm thick No Penetration was
observed after three hours

17
3.2.2 By Wind Science & Engineering Research Center, Texas Tech
University

Missile Test was conducted by Wind Science & Engineering Research

Center, Texas Tech University on 130 mm and 150 mm thick panels:
Missile test according to Florida Building Code, International Code
Council Texas Deptt. of Insurance windstorm Resistance Construction
Guide. The following results were obtained:

Single Panel Bearing Wall (PCSP) 80 mm thick are resistant to

the Florida Building Code & Dade County Hurricane Envelope
resistance = 55 km/h missile & 225 km/h hurricane.
Single Panel Bearing Wall (PCSP) 80 mm thick threshold of
perforation = 142 km/h missile & 354 km/h hurricane impact
resistance. Since two of the panels were tested to the highest
standard for hurricanes 177 km/h & 355 km/h hurricane and were
reasonably resistant, the 150 mm panel can be rated to 146 km/h &
362 km/h hurricane impact resistance, which is the highest rating
per ICC-5r00 Standard.

3.2.3 Evaluation Report of the Characterization Tests carried out by

Department of Architecture, Buildings & Structures, University
Polytechnic of Marche

The following tests were carried out forming part of this report:

1. Characterization tests on materials

Tests on sprayed structure plaster: Two types of tests were
carried outthe first on 40x40x160 mm samples made
during the panel completion phase and the second on cores
taken from the panel side edging after the tests. The results
of the tests are shown in Table 1 & 2 of Annex C. Table 1
gives the average break load, bending tensile strength &
average and Table 2 shows the compression & puling
strength results.

Tests on the electro-welded mesh: The electro-welded

mesh was put through pulling tests. Two of the six tested
samples had a fragile behavior by the joint welding before
yielding while the other four reached the yield point but
showed very low ductility 9 (Lower than 2). The pulling
strength results and the percentage of extension obtained
besides the break modality observed is shown in Table 3 of
Annex C.

Tests on the core layer: In order to know the mechanical

features of the panel core layer, creep tests were performed
on samples made of three layers of sprayed structural
plaster and two connecting layers. The tests were repeated
on identical samples but without the polystyrene inner
layers. The results are shown in Table 4 of Annex C.

18
2. Bending test on floor panels -- Six tests were carried out on the
following panels:

Two tests on Single Panel Floor (PCSS) 80 mm thick (total

thickness 160 mm) with a 3.3 m clear span;
Two tests on Single Panel Floor (PCSS) 120 mm thick
(total thickness 200 mm) with a 4.3 m clear span;
Two tests on Single Panel Floor (PCSS) 160 mm thick 16
panels (total thickness 240 mm) with a 5.3 m clear span

The difference in length of the panels is due to the different length of

the inner core while the sprayed structural plaster layers have all the
same thickness. The ultimate loads, corresponding greatest moment
by the centre line and the equivalent uniformly loads resulting in the
same greatest moment by the centre line for each panel category is
shown in Table 5, Table 6 shows the Reduced elastic modulus, Table
7 shows the Crack moments by the centre line and Table 8 of Annex
C shows the Break moments by the centre line for each category of
panel.

3. Compression tests on wall panels -- A total of 16 tests were carried

out as detailed brlow:

Two centred compression tests on Single Panel Bearing

Wall (PCSP) 80 mm thick
Two centred compression tests on Single Panel Bearing
Wall (PCSP) 120 mm thick
Two eccentric compression test on Single Panel Bearing
Wall (PCSP) 160 mm thick
One centred compression test on Single Panel Evolution
Wall (PCSE) 80 mm thick
One centred compression test on Single Panel Partition
Wall (PCST) 80 mm thick
Two eccentric compression tests on Single Panel Bearing
Wall (PCSP) 80 mm thick
Two eccentric compression tests on Single Panel Bearing
Wall (PCSP) 120 mm thick
Two eccentric compression tests on Single Panel Bearing
Wall (PCSP) 160 mm thick
One eccentric compression test on Single Panel Evolution
Wall (PCSE) 80 mm thick
One eccentric compression test on Single Panel Evolution
Wall (PCSE) 120 mm thick

PCSP panels are single bearing panels made of a core layer of

variable thickness 80 mm, 120 mm or 160 mm as indicated by the
acronym of each panel) and two outer layers of 35 mm thickness.

PCSE panels are an evolution of the previous ones and are

different from standard panels as the core layer of polystyrene is

19
 not waved and the electro-welded mesh is separated by suitable
spacers.

PCST partition panels are similar to single bearing panels but they
have half the number of spacers connecting the two electro-
welded meshes.

All the panels have a reinforced sprayed structural plaster edging.

The data used for analysis of the panels is shown in Table 9 and
the ultimate load values for each type of panel is shown in Table
10 of Annex C.

4. Diagonal Compression tests on wall panels -- The following tests

were carried out:

Two diagonal compression tests on PCSP08 single panels

(panels 5.1 & 5.2)
Two diagonal compression tests on PCSP08 transversely
pre-stressed single panels
Two diagonal compression tests on PCSP08 single panels
stiffened along their perimeter

The test results are shown in Table 11 of Annex C.

5. Tests on wall-floor joints Each sample is formed by PSCP08 wall

panels and PCSS08 floor panels. The following tests were carried
out:

One test on a joint where the floor panel upper face was tied
to the wall panel outer face (joint 1)
One test on a joint where the floor panel faces were tied to
the wall panel inner face (joint 2)

The test results are shown in Table 12 of Annex C.

6. Static test on a floor built with wall panels -- The floor under testing
was made of single floor panel PCSS12 and the prototype vertical
walls made of single bearing panels PCSP08.
The static test was carried out progressively until the floor
collapsed with a nominal load uniformly distributed acting on the
loaded floor portion of 2000 kgf/m2 as shown in Table 13 of Annex
C.

3.2.4 Testing of samples by IIT Roorkee

IIT Roorkee has conducted various tests on the sandwich panels.

20
3.3 Usage of the System

The manufacturer has constructed various housing projects from one

storey to six stories and factories in India and several countries listed
below:

3.3.1 Projects carried out in India (As reported)

I. Buildings
Mass Housing G+3 buildings at Vasai, Maharashtra
Industrial Township at Angul, Orissa
Hostel and Hospital Buildings in Punjab and Himachal Pradesh
Angadwadi Buildings across India by Vedanta group
In-fill Wall use in Multi storey buildings across India

II. Plants
Maad Constructions Co. Ltd., Pune, Maharashtra
Jindal Steel & Power Ltd., Angul, Orissa
Synergy Thrislington, Mohali, Punjab

III. Use with other Systems

In-fill walls for Steel-frame and Floor buildings
Aluminium/Plastic formwork

3.3.2 Projects carried out in Other Countries (As reported)

I. Housing Projects

Several housing projects from one storey to six stories at

various places in Italy
Several housing projects from one storey to six stories at
various places in Spain with the Concrewall Panel system
assembled in Italy
Several housing projects from one storey to six stories in
Hungary, Russia, Saudi Arabia, Oman, Libya, Mexico,
France, Venezuela, Brazil and Argentina etc.

21
PART 4 STANDARD CONDITIONS

This certificate holder shall satisfy the following conditions:

4.1 The certificate holder shall continue to have the product reviewed by BMBA.

4.2 The product shall be continued to be manufactured according to and in

compliance with the manufacturing specifications and quality assurance
measures which applied at the time of issue or revalidation of this certificate.
The Scheme of Quality Assurance separately approved shall be followed.

4.3 The quality of the product shall be maintained by the certificate holder.
Complete testing facilities shall be installed for in-process control.

4.4 The product user should install, use and maintain the product in accordance with
the provisions in this Certificate.

4.5 This certificate does not cover uses of the product outside the scope of this
appraisal.

4.6 The product is appraised against performance provisions contained in the

standards listed in Part-V. Provisions of any subsequent revisions or provisions
introduced after the date of the certificate do not apply.

4.7 Where reference is made in this Certificate to any Act of Parliament of India,
Rules and Regulations made there under, statutes, specifications, codes of
practice, standards etc. of the Bureau of Indian Standards or any other national
standards body and the International Organization for Standardization (ISO),
manufacturers company standards, instruction/manual etc., it shall be
construed as reference to such publications in the form in which they were in
force on the date of grant of this Certificate (and indicated in Part V to this
Certificate)

4.8 The certificate holder agrees to inform BMBA of their clients with details of
construction on six monthly basis.

4.9 The certificate holder agrees to provide to BMBA feedback on the complaints
received, the redressal provided, and the time taken to provide redressal on
complaint to complaint basis as soon as redressal is provided. BMBA agrees to
provide the certificate holder the user feedback received by it, if any.

4.10 If at any time during the validity period, PACH is unable to fulfill the conditions
in his PAC, he should on his own initiative suspend using the PAC and notify
Chairman, TAC the date from which he has suspended its use, the reason for
suspension and the period by which he will be able to resume. He shall not
resume without the prior permission of BMBA. He shall also inform,
simultaneously, his agents, licensees, distributors, institutional, government,
public sector buyers, other buyers and all those whom he has informed about
his holding the PAC. He shall also inform all those who buy his product(s)
during the period of suspension. He shall provide to BMBA at the earliest the
list of who have been so informed by him.

22
PART 5 LIST OF STANDARDS & CODES USED IN ASSESSMENT

5.1 Standards - These Standards are referred for carrying out particular tests
only and do not specify the requirement for the whole product as such.

5.1.1 IS 456:2000 -- Code of practice for plain and reinforced concrete

5.1.2 IS 875:1987 -- Code of practice for design loads for buildings and
Structures

5.1.3 IS 1893 (Part 1):2002 Criteria for Earthquake Resistant Design of

Structures

5.1.4 IS 4671:1984 Specifications for expanded polystyrene for thermal

insulation purposes

5.1.5 IS 4326:1993 Code of Practice for Earthquake Resistant Design and

Construction of Buildings

5.1.6 BS 476(Part 22):1987 Fire resistance

5.1.7 ASTM E 1886-04 Standard Test Method for Performance of Curtain

walls, Doors, Windows and Impact protection systems impacted by Missiles
exposed to cyclic pressure differentials

5.1.8 ASTM E90-90 Sound Proofing

5.1.9 UNI EN ISO 10211(Part 1& 2):1996 Thermal insulation

5.1.10 UNI EN ISO 140(Part 3):2006 Acoustic Insulation

5.1.11 MIP 058:2008 Test method for Impact with a soft body Impermeability
to water jet

5.1.12 FEMA 320/361/The ICC 500 Standard for the Design & construction of
Storm shelters (Debris impact)

5.2 Company Standards of the PAC holder The branded design &
specifications of the raw materials and finished product are as submitted by the
manufacturer. The PAC holder has to make available the company standards to the
consumers according to which testing have been done.

24
PART 6 ABBREVIATIONS

Abbreviations

BMBA Board of Agreement of BMTPC

BMTPC Building Materials and Technology Promotion Council

CPWD Central Public Works Department

ED Executive Director of BMTPC

IO Inspecting Officer

MS Member Secretary of BBA

PAC Performance Appraisal Certificate

PACH PAC Holder

PACS Performance Appraisal Certification Scheme

SQA Scheme of Quality Assurance

TAC Technical Assessment Committee (of BMBA)

26
 Performance Appraisal Certification Scheme - A Brief

Building Materials & Technology Promotion Council (BMTPC) was set up by the
Government of India as a body under the Ministry of Housing &Urban Poverty
Alleviation to serve as an apex body to provide inter-disciplinary platform to promote
development and use of innovative building materials and technologies laying
special emphasis on sustainable growth, environmental friendliness and protection,
use of industrial, agricultural, mining and mineral wastes, cost saving, energy saving
etc. without diminishing needs of safety, durability and comfort to the occupants of
buildings using newly developed materials and technologies.

During the years government, public and private sector organizations independently
or under the aegis of BMTPC have developed several new materials and
technologies. With liberalization of the economy several such materials and
technologies are being imported.

However, benefits of such developments have not been realized in full measure as
understandably the ultimate users are reluctant to put them to full use for want of
information and data to enable them to make informed choice.

In order to help the user in this regard and derive the envisaged social and
economic benefits the Ministry of Housing &Urban Poverty Alleviation has instituted
a scheme called Performance Appraisal Certification Scheme (PACS) under which
a Performance Appraisal Certificate (PAC) is issued covering new materials and
technologies. PAC provides after due investigation, tests and assessments,
amongst other things information to the user to make informed choice.

To make the PACS transparent and authentic it is administered through a Technical

Assessment Committee
(TAC) and the BMTPC Board of Agreement (BMBA) in which scientific,
technological, academic, professional organizations and industry interests are
represented.

The Government of India has vested the authority for the operation of the Scheme
with BMTPC through Gazette Notification No. 1-16011/5/99 H-II in the Gazette of
India No. 49 dated 4th December, 1999.

Builders and construction agencies in the Government, public and private sectors
can help serve the economic, development and environmental causes for which the
people and Government stand committed by giving preference to materials and
technologies which have earned Performance Appraisal Certificates.

Further information on PACS can be obtained from the website: www.bmtpc.org

27
 ANNEX A
(Clause 1.4.2)

QUALITY ASSURANCE PLAN FOR CONCREWALL SYSTEM

S. Parameters to be Requirement specified Test Method Frequency

No. inspected of Testing
A. Raw Materials
1. Zinc Coated Drawn Steel Steel mesh 2.5/3.0 mm As per Every Lot
Wire Mesh @ 65/70 mm/cc Company
Standards
2. Expanded Polystyrene Density shall not be less As per Every Lot
(ESP) than 15 kg/mm3, Company
Standards
3. Cement PPC, OPC 43 IS 8112:1989 Every Batch
& 53 Grade As specified IS12269:1987
i) Compressive strength
ii) Setting time
4. Fly Ash Grade I As specified IS 3812 (Part Every Batch
Fineness, Lime reactivity, 1):2003
Compressive strength,
Drying shrinkage and
Soundness
5. Coarse Aggregate (Metal) As specified IS 383:1970 Every Batch
Grading, Fineness
Modulus, Specific gravity,
Water absorption,
Moisture content,
Flakiness index,
Elongation, Deleterious
substance, Soundness,
Aggregate impact &
crushing value and
Abrasion value
6. Fine Aggregate (Sand) -- As specified IS 383:1970 Every Batch
Grading, Specific gravity,
Water absorption,
Moisture content,
Deleterious substance,
Soundness
7. Water As specified IS 456:2000 Every Batch

8. Concrete As specified IS 456:2000 Every Batch

9. Reinforcement -- Mild As specified IS 1786: 2008 Every Batch

steel Grade I, Fe 415 &
Fe 500 Grade
B. Welded Mesh / Concrewall System

1. Acceptance of the raw Quantity, Appearance & Visual,

materials i) Steel Mesh completeness/ Brand, Vernier
ii) Polystyrene (EPS) Compliance of material Caliper and Every Lot
Amount of material, and Dimensions as per Tape

28
 Visual inspection, manufacturer measure
Specifications verification Specifications
and Dimensional controls
2. Straightening and Dimensions and Visual and
cutting wire Condition of material as Tape Every
Coil steel wire per manufacturer measure Length
straightening and cutting Specifications
in the right size of the
longitudinal and
transversal wires
3. Electro welding Dimensions and Tape Every
Steel wires welding to Orthogonally as per measure dimension of
obtain a mesh manufacturer the panels
Specifications
4. Shaping polystyrene Dimensions as per Tape Every
Cutting the polystyrene manufacturer measure and dimension of
panels from the blocks in Specifications Vernier the panels
right dimensions caliper
5. Welding/Assembling Dimensions and Tape Every
panels Orthogonally as per measure and dimension of
Assembling electro manufacturer Vernier the panels
welded mesh and Specifications caliper
polystyrene panels

29
 ANNEX B
(Clause 2.6.7)

DRAWINGS

Figure 7. Building Details for Single Panel -- Elevation

30
Figure 8. Building Details for Single Panel -- Sections

31
Figure 9. Building Details for Single Panel -- Sections

32
Figure 10. Building Details for Single Panel -- Sections

33
Figure 11. Building Details for Single Panel Door Detail

34
Figure 12. Building Details for Single Panel Window Detail

35
Figure 13. Building Details for Single Panel Fisher & Plaster Detail

36
Figure 14. Sheet Concrewall Double Panel

37
Figure 15. Sheet Reinforcement Mesh

38
 ANNEX C
(Clause 3.2.3)
TEST RESULTS*

Table 1. Test of 40x40x160mm Samples

Break Average Break Bending Average

Sample load Load tensile Compression
(Bending) (Compression) Strength Strength
(kN) (N/mm2) (N/mm2)
(kN)
P.1.1 3.48 35.10 6.80 21.14
P.1.2 -- 36.54 -- 22.01
P.1.3 2.85 35.10 5.64 20.90
P.2.1 2.86 32.13 5.65 19.13
P.2.2 2.23 35.18 4.52 21.45
P.2.3 2.61 32.02 5.10 19.29
B1 2.40 40.38 5.16 24.93
B2 2.34 32.60 4.97 20.97
B3 2.57 36.64 5.27 22.07
A1 2.98 36.71 6.41 22.66
A2 2.52 35.90 5.35 21.89
A3 2.48 36.55 5.53 22.84
C1 3.11 38.48 6.45 22.37
C2 2.83 38.94 5.80 23.46
C3 2.46 38.87 5.23 23.70
C4 2.39 37.72 4.96 23.00
Average 2.67 36.18 5.52 21.95

Table 2. Tests on cores

Sample Test type Diameter Thickness Strength C Fc Fct

(cm) h (cm) Max(kN) (h/d) (N/mm2) (N/mm2)
1c Compression 9.4 9.4 214.90 30.9 --
1.00
1t Indirect 9.4 6.8 22.30 -- -- 2.22
pulling
2c Compression 9.4 9.2 160.20 25.0 --
0.99
2t Indirect 9.4 7.2 25.80 -- -- 2.43
pulling
3c Compression 9.4 9.4 142.70 20.5 --
1.00
3t Indirect 9.4 6.9 23.70 -- -- 2.33
pulling
4c Compression 9.4 9.3 163.40 24.0 --
1.00
4t Indirect 9.4 7.2 27.80 -- -- 2.62
pulling
Average 25.1 2.40
39
 Table 3. Tests on the Electro-welded mesh

Sample Test Dia Max. Max. tensile Length A10 Break

(mm) S strength (mm/3cm) (%)
(kN) 2
(N/mm )
1.1 Pulling 3 5.60 792.64 32.40 8.00 On the wire
1.2 Pulling 3 4.60 651.10 31.14 3.80 On the link
2.1 Pulling 3 4.75 814.42 32.50 8.33 On the wire
2.2 Pulling 3 5.80 820.95 31.96 6.53 On the link
3.1 Pulling 3 4.66 659.81 31.01 3.37 On the wire
3.2 Pulling 3 6.17 673.21 -- -- On the link

Table 4. Tests on links

Sample Test Diameter Max.Strength Break

(mm) (kN)
1.1 Detachment 3 2.17 Joint detachment
1.2 Detachment 3 3.03 Joint detachment
2.1 Detachment 3 2.86 Joint detachment
2.2 Detachment 3 2.90 Joint detachment
3.1 Detachment 3 1.92 Wire yield
3.2 Detachment 3 2.88 Joint detachment

Table 5. Bending Test

Panel Ultimate Greatest Eq.uniformly Crack Crack Crack

load moment dist. load load moment qeq
(kN) (kN/m) (kN/m2) (kN) (kNm) (kN/m2)
6.1 18.3 10.52 6.90 -- -- --
6.2 18.5 10.64 6.98 3.0 1.73 1.13
7.1 14.9 8.57 5.62 2.6 2.15 0.83
7.2 14.4 8.28 5.43 3.0 2.48 0.96
8.1 13.7 7.88 5.17 1.0 1.08 0.27
8.2 13.0 7.48 4.90 1.2 1.29 0.33

Table 6. Reduced elastic module

Panel B* (m) H* (m) * fess*

6.2 1.12 0.16 0.30 0.06
7.1 1.12 0.21 0.24 0.05
8.2 1.12 0.25 0.21 0.05

where
B = breadth of panel
H = thickness of panel
= reduction factor of the section
fess = reduction factor in the cracking phase
40
 Table 7. Crack moments by the centre line

Panel Pfess * Mfess * p.p * Mp.p* Mfess.tot * *

(kN) (kN/m) (kN) (kNm) (kNm)
6.2 3.0 1.73 1.84 2.5 4.23 0.34
7.1 2.6 2.15 2.07 4.8 6.95 0.36
8.2 1.2 1.29 2.02 7.1 8.39 0.45

where
Pfess = panel cracking weight
Mfess = moment due to panel cracking weight
p.p = panel own weight
Mp.p = moment due to Panel cracking weight
Mfess.tot = total cracking moment
= reduction factor of tensile strength

Table 8. Break moments by the centre line

Panel Pu * Mu * p.p * Mp.p* Mu.tot * Mres*

(kN) (kN/m) (kN) (kNm) (kNm) (kNm)
6.2 18.4 10.6 1.84 2.5 13.1 12.2
7.1 14.6 12.1 2.07 4.8 16.9 16.6
8.2 13.3 14.4 2.02 7.1 21.5 21.1
Where:
Pu = ultimate load,
Mu = related moment by the centre line
p.p = panel own weight,
Mp.p = moment due to panel own weight
Mu.tot = total ultimate moment
Mres = plastic moment

Table 9. Compression Test Results

Panel Ultimate Average Distributed

Load ultimate ultimate
(kN) load (kN) load (kN/m)

2a.1 701 742 662.5

2a.2 783
3a.1 806 825 736.6
3a.2 844
4a.1 855 881 786.6
4a.2 907
X.2 736 --- 657.1
Y.2 765 --- 683.0
2b.1 375 388 346.4
2b.2 401
3b.1 460 503 448.7
41
 3b.2 545
4b.1 524 577 515.2
4b.2 630
X.1 461 --- 411.6
Y.1 591 --- 527.7

Table 10. Ultimate loads (centred compression)

Panel Average ultimate Pcr1* Pcr2* Pcr3* *

load (kN) (kN) (kN) (kN)
PCSS08 742 82.8 3653.0 931 0.25
PCSS12 825 92.8 7424.0 1082 0.15
PCSS16 881 92.8 13169.2 1221 0.10
Where:
Pcr1 = ultimate load for the first case
Pcr2 = ultimate load for the second case
Pcr3 = actual ultimate load
= ratio between Pcr3 & Pcr2

Table 11. Diagonal compression test results

Panel Test type 1st crack Break Break modality

load (kN) load (kN)
5.1 Diagonal compression 144 302 Break due to local
without pre-compression crushing preceded by
diagonal cracking
5.2 Diagonal compression 129 342 Break due to local
without pre-compression crushing preceded by
diagonal cracking
5.3 Diagonal compression 118 332 Break due to local
with 30 kN pre- crushing preceded by
compression diagonal cracking
5.4 Diagonal compression 168 306 Break due to local
with 90 kN pre- crushing preceded by
compression diagonal cracking
C.1 Diagonal compression 103 341 Break due to diagonal
without pre-compression stress
C.2 Diagonal compression 137 225 Break due to diagonal
without pre-compression stress

Table 12. Results of the tests on joints

Joint Crack Crack Ultimate Ultimate Break modality

load (kN) moment load (kN) moment
(kNm) (kNm)
1. 1.54 -1.06 4.89 3.37 Break of the vertical panel
-1.90 -1.31 -5.80 -4.00 outer face
2. 1.60 1.01 3.02 2.08 Break by the connecting
-1.23 -0.86 -3.40 -2.34 point between floor panel
and vertical panel
42
 Table 13. Static test on floor

Increase Nominal load uniformly Increase Nominal load uniformly

No. distributed on the loaded No. distributed on the loaded
floor (kgf/m2) floor (kgf/m2)
0. 80 11. 1120
1. 160 12. 1220
2. 240 13. 1320
3. 320 14. 1420
4. 420 15. 1520
5. 520 16. 1620
6. 620 17. 1720
7. 720 18. 1820
8. 820 19. 1920
9. 920 20. 2000
10. 1020

*The above tables should be read in conjunction with the Test reports available with
the PAC Holder/BMTPC

43