Design and fabrication of sandwich composite panels for emergency sheltering

We are using sandwich panels to build high performance light-weight structures which are cost effective. Pre-fabricated sandwich composite panels could be widely used in emergency situation as an alternate to housing structures. Our main focus is on design and fabrication of sandwich composite panel

Project Title

Design and fabrication of sandwich composite panels for emergency sheltering

Project Area of Specialization

Shared Economy

Project Summary

We are using sandwich panels to build high performance light-weight structures which are cost effective. Pre-fabricated sandwich composite panels could be widely used in emergency situation as an alternate to housing structures. Our main focus is on design and fabrication of sandwich composite panels which have good temperature insulating properties and have high compressive and bending strength.

There are some major design constraint which needs to be considered while material selection are as follows:

• High compressive and bending strength.
• Good Thermal insulation.
• Water resistance and low moisture absorption.
• Good dielectric properties.
• Resistance to ageing in harsh environment.
• Inflammability

The materials selected after a detailed literature review are extruded polystyrene(XPS), balsa wood and glass fiber sheets. Different types of testings are to be performed using a specific ASTM standard for each testing. These materials will be joined by epoxy and other layup equipment in a vacuum infused system. The facilities in Air university would be utilized for testing and fabrication purpose as well as the testing which is not available in Air university would be done from other private labs or universities.

Project Objectives

Our aim is to fabricate high performance light-weight sandwich composite panels which are cost effective and easy to install in emergency situation. We are providing an alternate to conventional homes which are constructed using bricks, cement, sand and concrete. In addition, sandwich panels are being designed in such a way that it will have better thermal insulation properties which will result in increased thermal comfort and cost saving in terms of low energy utilization for air conditioning and heating purposes. Furthermore, these will be pre-fabricated sandwich panels which will be portable and easy to install in emergency situations.

 There are some major design constraint which needs to be considered while material selection are as follows:

• High compressive and bending strength.
• Good Thermal insulation.
• Water resistance and low moisture absorption.
• Good dielectric properties.
• Resistance to ageing in harsh environment.
• Inflammability

Project Implementation Method

The first and the most important part of our project was the selection of materials. For this reason, a comprehensive literature review was done to come up with the materials having enormously good heat insulating properties and the cost effectiviness of those materials was also kept in mind while selecting those materials. Apart from this, weight of materials was also taken in to account as our sandwich panel should be light weight fro easy installation in emergency situations. Three materials were selected from the literature review; Glass fiber sheets, balsa wood and the core will be of extruded polystyrene (XPS).  A detailed analysis was performed on ANSYS to check out the mechanical strength of our panel and they came out to be amazingly great. Many calculations were performed to calculate the heat transfer rate of our sandwich panel. Now comes the fabrication part, where we need to buy the material for at least eight to ten panels because different types of testing is required and each testing requires a specific ASTM standard and for that specific dimensions for specific testing are required. After the procurement of all the finalized materials there comes the fabrication stage where we will fabricate the sandwich panel with the materials procured from the market. For the fabrication purpose curing oven, vacuum pump and other layup equipment will be used. Epoxy will be used to join different layers of sandwich panel. ASTM standards will be kept in consideration while doing the fabrication part. The fabrication process will be followed by a comprehensive testing regime, where the materials will be tested. The compressive and bending strength will be measured. The fabricated panel will be tested in accordance with ASTM standards.  

Benefits of the Project

• These pre-fabricated sandwich panels will either insulate or preserve heat in hot and cold weathers respectively. 
• In emegency situations, the making of the houses from these pre-fabricated panels will take only one to two days depending on the area of the house as these panels are easy to install.
• These light weight panels are very easy for transportation.  
• These pre-fabricated sandwich panels are 100% eco friendly.
• From these panels we can save a lot of energy as they will insulate most of the heat so the excessive energy which we use on heating/cooling devices will be saved.
• These light weight panels have enough mechanical strength to withstand any kind of harsh weather. The ANSYS analysis showed that even if a person of 80 kgs is standing on this panel, it will give the maximum deformation of 0.3 mm which is almost negligible.
• These panels are water proof and water resistant to withstand heavy rains.
• The panels are also fire resistant.

Technical Details of Final Deliverable

The expected thickness of our sandwich composite panel will be around 2.5 inches. It will have a core of extruded polystyrene(XPS), balsa wood will be attached on both sides of XPS to provide extra added strength and glass fiber sheets will be at the faces. These materials will be joined by epoxy and other layup equipment in a vacuum infused system.

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Core Technology

Others

Other Technologies

Sustainable Development Goals

Good Health and Well-Being for People, Affordable and Clean Energy, Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Sustainable Cities and Communities, Climate Action

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com