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 < back to summary 4.7 Attractively priced residential building with sandwich panels and steel structure
Based on optimal heat insulation of the sandwich panels used and an effective fresh-air heater with integrated heat pump and controlled ventilation, the annual energy costs are around EUR 700 to 900 (for an area of 240 m2 of floor space). After an experimental period of two years, the critical building owner described the indoor temperature both in the winter and in the summer as “very pleasant”. A great deal of emphasis was placed on high quality and durability of the building materials and parts despite the low construction costs both of the building construction and the interior fittings. The short construction time is also remarkable. Due to the high level of prefabrication, the inside of the residential building is completed within 15 working days. The steel construction was erected technically and optically to the highest satisfaction of the building owner by an authorised installation company. The manufacturer says the building can be turnkey ready in six to eight weeks. The house type shown here is flexible in every respect as regards size, in its outlines, the choice of supporting structure and architectural design. With this convincing overall concept of price and performance, the dream of one’s own home can also come true for many building owners with limited investment possibilities.
Objective of the planning concept The manufacturer of the steel construction with sandwich panels assumed in the planning concept that many families and particularly building owners could finance this house without a home allowance or home-builder’s child allowance. The maximum price of turnkey completion of the building with a full basement was marked down at EUR 199,000 with an overall surface area of 240 m2, and EUR 33,000 less, or EUR 166,000, if no basement is required. In order to justify the various financial possibilities, one can, instead of a turnkey construction, choose a prefabricated house with interior fittings by building owners themselves. Without a basement, the costs of a building with a surface area of 175 m2 will come to EUR 89,000. Despite the low price level, the manufacturer lays a great deal of emphasis on quality branded products that have durably proven their functional efficiency over several decades. The outlines are flexible due to the supporting structure. The figures 4.7.2a-c show exemplary solutions for arrangement of the basement, ground floor and first floor.
As far-reaching freedom as possible to carry out repairs and maintenance and low energy costs were also required in order to reduce operating costs to a minimum. The plans were therefore based on optimal heat insulation and a high level of waterproofing of the building case and controlled low level ventilation. The heating installation should on the one hand be very effective but also very cost-efficient in the purchase price. As well as an effective shadow technique, a central vacuum cleaner installation should be fitted to facilitate the maintenance of the house. A wellness area with sauna was arranged in the basement to increase the quality of life. The freedom of design of the façades and the outlines had to be guaranteed in order to justify the individual expectations of the architects and building owners. A subsequent conversion or extension should also be possible without too much complexity or costs. The planners demanded the simplest assembly criteria for the supporting structure and the casing of the building, in particular for roof construction. A self-supporting roof construction was also required with no effect on the division of the inner rooms and which offers as much space as possible on the first floor and additional storage space. A second important objective was that the overall construction and drying-up times were to be very short. The construction time of 15 days was only increased by about one month due to the drying-out time for the floor pavement.
The base consists of a reinforced concrete slab, 20 cm thick, on an underlayer of gravel with 40 mm of heat insulation and PE foil as a humidity barrier. The walls of the basement were built from prefabricated reinforced concrete components, 20 mm thick, with underground heat insulation, 50 mm thick. Supporting structure A steel framework was chosen as the supporting structure for this house type with its full basement. The light building with sandwich panels however permits other supporting constructions such as wooden structures. Outside walls, façade Horizontally laid corrugated sandwich panels, 104 mm thick, in RAL 9006 metallic silver (isowelle 104 with an overall width of 1,000 mm) were used for the façade. The panels with the steel substructure are fitted using stainless steel self-drilling screws in the longitudinal joint and covered using the special joint geometry. The inside of the outer walls includes a lagging construction with 2 x 12.5 mm rigid panels and mineral fibre insulation, 160 mm thick, without PE foil in the columns.
The synthetic windows with a U-value of 1.1 sit in a square pipe frame with an 80/80 mm profile (column pipe level). The colour RAL 5013 was chosen in coordination with the colour of the façade.
Roof construction The roof construction, which was self-supporting over the full width of the house, was dismantled using a Hoesch cambered roof. The assembly is double cased with the HP 41 profile for the inner and outer cases. This profile was bent kink-free using a patented production process, thus achieving the bearing capacity for the one 40 mm profile. The arch takes on an attractive shape with its radius of 8,640 mm and vault height of 1,160 mm. There is a layer of heat insulation consisting of non-flammable mineral wool, type W, between the inner and outer casings. Power-activated cover profiles form the distance construction. The cover casings are band galvanised and also coated with a high quality stove enamel finish. The cambered roof is resistant to flying sparks and radiant heat (according to DIN 4102-7) and satisfies the hard roof requirements according to the rating guidelines of the Deutsche Versicherungs-wirtschaft e.V. (GDV - German insurance association). The outside was finished in RAL 9006 silver metallic to match the façade and RAL 9002 was chosen for the inside.
Heating system The heating system continually feeds in fresh, dust-filtered and heated air from outside. The air in each room can be individually adjusted as air flows through each room individually. Special purge valves ensure used air containing smells, humidity and house dust are extracted and fed to the fresh-air heater ventilation system. The central heating unit is small and the space it takes up is really quite minimal. About 95% of thermal recovery takes place via a cross flow heat exchanger. The air fed in needs no additional heating. The energy gain is 10 to 15 times higher than the energy used by the devices due to energy-saving mechanical technology. Infinitely variable valves are available for inlet and outlet air. An air filter cleans the outside air. Inlet and outlet air can be invisibly transported to the intermediate covers and the light dividing walls via folded spiral pipes, flat channels and KN surfaces to be subsequently heated. The heating system is low-maintenance and is characterised by very low energy consumption. It operates extremely quietly, is easy to install and is service-friendly as the filter covers can be removed without tools. Heat recovery from used air can deliver energy savings of over 40% compared with conventional heating techniques. The continually checked and filtered fresh air inlet air contributes to a healthy and comfortable room temperature.
Living and useful floor areas according to DIN 283 It has already been mentioned that there is a lot of flexibility available with the ground plan layout based on the supporting structure and self-supporting cambered roof. With this type of house, building owners opt for the following programme.
Side door closing
Side window closing
Upper and lower window closing
Base
As with the design of the ground plans, the interior design permits the maximum possible licence. Figures 4.7.20 to 4.7.25 show in exemplary manner what sort of interior design is possible in a lightweight building.
Rolf Koschade Pictures Andreas Müller Stahlhausvertrieb Thyssen Krupp Hoesch Bausysteme Wolf GmbH – Wolf-Heiztechnik Koschade, Rolf: Die Sandwichbauweise [Sandwich Panel Construction]
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