DEVELOPMENT OF THE 7S-3000 STRESSED SKIN PANEL BUILDING SYSTEM

(DETAILED REPORT)

by

Seven S Structures Inc. 1

May, 1988

This is a joint publication of the Canadian Forestry Service and the Alberta Forest

Service pursuant to the Canada-Alberta Forest Resource Development Agreement

1Grande Prairie, Alberta

DISCLAIMER

The study on which this report is based was funded in part under the Canada/Alberta Forest Resource Development Agreement.

The views, conclusions and recommendations are those of the authors. The exclusion of certain manufactured products does not necessarily imply disapproval nor does the mention of other products necessarily imply endorsement by the Canadian Forestry Service or the Alberta Forest Service.

(c) Minister of Supply and Services Canada 198.8 Catalogue No.: FO 42-91/59-1988E

ISBN: 0-662-16608-6

Additional copies for this publication are available at no charge from:

Regional Development Canadian Forestry Service

5320 - 122nd Street Edmonton, Alberta

T6H 3S5 Telephone: (403) 435-721

or

Innovative Housing Grants Program Alberta Municipal Affairs 2nd Floor, Jarvis Building

9925 - 107th Street Edmonton, Alberta

T5K 2H9 Telephone: (403) 427-8150

FOREWORD

This study was made possible with funding provided under the Innovative Housing Grants Program (IHGP) of Alberta Municipal Affairs and through the Canada/Alberta Forest Resource Development Agreement Subprogram B~ (FRDA). The Innovative Housing Grants Program is intended to encourage and assist housing research and development which will reduce housing costs, improve the quality and performance of dwelling units and subdivisions, or increase the long term viability and competitiveness of Alberta's housing industry. At this time, priority areas for investigation include building design, construction technology, energy conservation, site and subdivision design, site servicing technology, residential building product development or improvement and information technology. The Forest Resource Development Agreement program is intended:

1) to ensure the security of timber supplies and industry viability over the long term;

2) to promote the efficient utilization of forest resources and especially hardwood resources; and

3) to increase economic diversity and employment opportunities in the forest section.

The aim of this subprogram (B~) research funding is to provide a higher level of utilization of Alberta's aspen forests through improved methods and techniques of aspen management 8S well 8S product and market development.

ACKNOWLEDGMENTS

The author would like to thank and individuals who assisted in resources and information to testing program and to apply for

Dan Anderson, P. Eng., CMHC

the following agencies providing the necessary complete the required the various approvals.

Walter Cool, P. Eng., Alberta Municipal Affairs

John Harms, Pelican Spruce Mills Ltd.

D.J. (Don) Standards

Martin, P. Eng. , Alberta Bui ldi ng

Farid Mawani, Warnock Hersey Professional Services Ltd.

Carl Mitton, Universal Foam Systems Ltd.

D.O. (David) Monsen, MRAIC

Pat Sloan, Alberta Economic Development and Trade

Ted Szabo, P. Eng., Alberta Forestry, Lands and Wildlife

TABLE OF CONTENTS

List of Tables

List of Figures

Executive Summary

1.0 INTRODUCTION 1.1 Project Overview 1.2 Company Background 1.3 7S-3000 Building System 1.4 Other Similar Systems

2.0 PRODUCT DEVELOPMENT 2.1 Stressed Skin Panel Concept 2.2 7S-3000 Wall System 2.3 7S-3000 Roof System 2.4 7S-3000 Floor System 2.5 Engineering Design Criterion 2.6 System Features

3.0 CERTIFICATION REQUIREMENTS 3.1 Certification Procedures 3.2 CMHC Requirements 3.3 ICBO Requirements 3.4 CSA Requirements 3.5 Alberta Building Standards Requirements 3.6 Production Environment 3.7 Certified Testing Agencies 3.8 Certification Costs and Funding

4.0 TESTING PROGRAM 4.1 Structural Tests 4.2 Thermal Tests 4.3 Other Tests 4.4 Modification and Retests 4.5 Summary of Test Results

5.0 PANEL PRODUCTION 5.1 Manufacturing Methods 5.2 Facility and Equipment Requirements

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PAGE NO.

iii

iii

iv

1. 1 1 2 3

5 5 5 7 8 9

13

14 14 15 16 17 18 18 19 20

21 22 22 23 23 23

25 25 25

TABLE OF CONTENTS (Cont'd)

6.0 MARKETING AND PRODUCT DISTRIBUTION 6.1 Potential Market 6.2 Export Potential 6.3 Franchise Distribution Network 6.4 Present Marketing Status

7.0 CONCLUSIONS AND PRODUCT STATUS

APPENDIX A: Panel Components

APPENDIX B: Panel Joint Detail

APPENDIX C: Span Rati ngs

APPENDIX D: Structural Test Results

APPENDIX E: Thermal/Fire Test Results

APPENDIX F: CMHC Building Evaluation Report Technical Requirements

APPENDIX G: ICBO Acceptance Criteria for Sandwich Panels

APPENDIX H: Quality Control Ma nua 1 (Avail abl e Upon Request)

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PAGE NO.

A

B

C

D

E

F

G

26 26 26 27 27

29

1-5

1-2

1-3

1-30

1-49

1-8

1-7

Table 1:

Table 2:

Table 3:

Figure 1 :

Figure 2 :

Figure 3 :

Figure 4 :

Figure 5 :

LIST OF TABLES

Span Ratings, 7S-3000 Wall System

Span Ratings, 7S-3000 Roof System

Load and Span Capacities, 7S-3000 Floor Panel

LIST OF FIGURES

Basic Panel Components, 7S-3000 Building System

Lap Joint, 7S-3000 Wall System

Wall EKxpander, S-3000 Wall Sys tem

Securing of Floor Panels, 7S-3000 Floor System

General Design Sequence, 7S-3000 Stressed Skin Panels

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PAGE NO.

9

9

10

3

6

7

8

11

EXECUTIVE SUMMARY

Thi s report outl i nes a test program undertaken to qual i fy 7S-3000 Stressed Skin Panel System to Canada Mortgage and Housing Corpora­tion (CMHC) and Alberta Building Standards (ABC) requirements.

The report also gives some of the background of the development of the 7S-3000 stressed skin panels for structural components includ­ing walls, floors, and roofs, and discusses the potential uses for the panel s. Structural, thermal and various other tests have demonstrated that 7S-3000 stressed skin panels may be used in resi­dential and light commercial construction. Applications for product approval have been made to CMHC, the International Conference of' Building Officials (ICBO) in the US, and various other agencies. It appears that formal approvals allowing general use of the 7S-3000 panels will be forthcoming. Various prototype structures including three residences, three farm buildings, and one light commercial project have been completed to date. Invalu­able experience has been gained with these prototypes regarding improved fabrication and field erection procedures. A pilot plant located in Grande Prairie is the only production facility in place to date, and is capable of producing 90 m (300 lin. ft.) of wall panels per shift. This plant1s production procedures and quality control program are being audited by Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. is establishing a business and marketing plan to place manufacturing facilities in various locations, and to gain wide market acceptability for the 7S-3000 building system.

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1.0 INTRODUCTION

1.1 Project Overview

This report descr ibes the development of the 7S-3000 Stressed Skin Panel S~stem, the certification requirements for this building product, the test program wi th test results, the panel production methods, and preliminar~ marketing and product distribution.

Grant funding from Alberta Municipal Affairs - Innova­tive Housing Grants Program and Canada/Alberta Forest Resource Development Agreement (Alberta Forestr~, Lands and Wildlife) were made available to Seven S Structures Inc. so that certification testing which would lead to regulator~ approval of the building system could be performed. The scope of the project covered by the funding is confined to: the identification of the tests required for approval b~ Canada Mortgage and Housing Corporation (CMHC) and Alberta Building Standards; the performance of these tests at a certified laboratory i and the submission to CMHC for evaluation.

The report contains information on the s~stem and the company, which is not specificall~ within the scope of the project but which is provided to give the reader a better understanding of the 7S System.

1.2 Comp8n~ Background

The company was incorporated on November 26, 198~ under the name of CANUS Industries Ltd. Due to a challenge b~ the Alberta Companies Branch, it was decided to el im­inate an~ future problems by changing the name to Seven S Structures Inc. The Seven S name was derived from the following statement:

"a Stressed Skin Structure that is Safe, Simple and of Superior Strength."

The compan~ was incorporated to research and subsequentl~ develop a modular factory manufactured system of stressed skin panels which incorporates a foamed in-place insulating core between oriented strand board skins.

This type of construction deviates significantly from the standard wood frame construction presently in use. A stressed skin panel uses less framing material and produces less conductance of heat or cold transfer through the wall/roof. The stressed skin panel concept

that was developed seemed to have potential and the company decided to test the idea further. Some panels constructed in-house indicated that the development of a stressed skin panel building system using the proposed design seemed practical and realistic.

In 1986, a Pilot Plant was established in Grande Prairie, Alberta, to produce panels for testing and for some prototype projects including residential, commercial and farm buildings. A company head office and pilot plant were subsequently built in Grande Prairie. A subsidiary business office has been set up in Edmonton.

Financing to date has been provided by various sources, including the founding shareholders, provincial government grant program and investors in a private placement share offering.

The company has identified its human and financial resource requirements and has developed a marketing strategy to enter the commercial phase of its operation.

1.3 75-3000 Bulldlng 5~stem

The 75-3000 bui ldi ng system provides a fast, precise method of building energy-efficient houses and small commercial and farm buildings. The basic system is a stressed skin load-bearing panel having a continuous header, base, and top and bottom plates. The panel is very stiff and can be used vertically, horizontally, or on a slope (for roof appl ications) . Panels are filled with polyurethane foam to provide an RSI ~.9 (R-28) insulation value using a 100 mm (~") thick panel. The conti nuous header permits the installation of windows and doors in almost any location without having to install additional headers. Figure 1 on the following page illustrates the basic panel components. (See also Appendix A, Panel Components.)

The 75-3000 building system offers the following advantages:

1) ease and speed of installation; 2) precise sizing with no shrinking, warping or

twisting; 3) high insulation value per inch of panel thickness; ~) easily sealed JOints, minimizing air infiltration; 5) greater strength than conventional framed walls; 6) ease of transportation; and 7) sturdiness during moving and handling.

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FIGURE 1: BASIC PANEL COMPONENTS - 75-3000 BUILDING SYSTEM

c.l(flfTEO ST .... 1iIIO tGUO ,UrnED , ...

TYI'ICAL ,. AHE\. seCTION

Panels can be manufactured in various sizes up to 7.32 m x 2.~~ m (2~'x8') in size offering versatility of use. Moreover, their manufacture and assembly require little training.

The 75-3000 building system incorporates common products which have been successfully utilized for many years in simi lar appl ications. Currently, or iented strand board (OSB) is used for skins, spacers, reinforcing headers and baseplates. aSB is available locally and is manufactured from plentiful Alberta aspen. OSB is strong and stiff due to the oriented fibers and it can be produced at lower costs than conventional plywood. The polyurethane foam insulation is manufactured from derivatives of natural gas. It has excellent insulating qualities and provides additional strength to the panel.

l.~ Other Similar S~stems

One of the first undertakings made on completion of the prel imi nary 75-3000 panel design was a thorough investigation of the "state of the art" of insulated building panels. Information was obtained from numerous panel manufacturers in Europe, Canada and the US. Panel systems were investigated and studied:

- Nielsen Winter Insulated Panel systems of Mass, USA - Nascor System by Cano Structures Ltd. of Calgary,

Alberta - Lenap Panel System by I.C.P. Inc. of Mass USA - Chase Panel System of Wisconsin, USA - Tups Panel System by Homasote Inc. of New Jersey, USA

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- J-Deck Panels by J-Deck Inc. of Ohio, USA - Foam Laminates of Vermont, USA - Makro Building System of Helsinki, Finland - Nailboard by N.R.G. Barriers Inc. of Maine, USA - Futurebilt Panel Building System of Texas, USA - Enercept Building System of Minnesota, USA - Thermapan Roof/Wall System of Fonthill, Ontario - Foam Home Building System of Texas, USA

As well as a thorough review of the above product lines, Seven S Structures Inc. also proceeded wi th a patent appl ication for its panel system. As a resul t of this appl ication, it became necessary to review all other existing patents for Slmll.ar applications, and to compare these inventions with the 7S-3000 building system. In all cases reviewed to date, no Slmllar building system was found to be identical to the 7S bui ldi ng system, al though some of the 7S detai 1 shave been used by other manufacturers. Compared to other competitive systems, the 7S-3000 building system appears to be unique and in our opinion superior to a 11 other existing systems.

The system's integral header system and C-stud, and its method of assembly, were sufficiently distinctive to warrant patent status, which has been granted in the US. Patent applications have been made in Canada, Australia, and some European and Asian countries.

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2.0 PRODUCT DEVELOPMENT

2.1 St~essed Skin Panel Concept

Stressed skin panels consists of webs (longitudinal framing members) covered on one or both sides with flanges (skins). The 75-3000 panels consist of OSB webs and OSB skins, assembled in such a way that the skins are mechanically secured and glued to the webs to form an efficient structural unit. As a result of this form of construction, it is possible to reduce the size of the framing members in comparison to those of a similar unit in which the sheathing acts only as a surface covering. The resulting panel is specifically tailored to make the most efficient use of material. As the name implies, the loads and stresses are transmitted mainly through the ski ns, wi th the webs acting as spacers to separate the skins and to keep the skins parallel. The resultant structural component is similar to a box beam or plate girder. This stressed skin concept is used to produce the 75-3000 wall, roof and floor panels.

2.2 75-3000 Wall S~stem

The 75-3000 wall system consists of 89 mm (3-1/2") wide OSB webs spaced at 610 mm (2Lf") o/c. Both skins con­sisting of 9.5 mm (3/8") OSB, are glued to the web.

The panel core consists of a polyurethane foam insulation which is foamed in place after panel assembly is complete. Polyurethane foam is a thermoset cellular plastic consisting of a solid mass of unconnected small closed cells with densities ranging from ls-LfO kg/cubic metre (1-2 Ibs./cubic ft.). The 75-3000 panel foam core has a density of approximately 30 kg/cubic metre C1. 8 lbs. /cubic ft.). I n this density range, rigid urethane foam is an excellent thermal insulator; in fact, urethane foams are the most efficient insulating materials available today, with an insulation value of approximately RSI Lf. 9 per 100 mm of thickness (R7 per inch of thickness). The combination of small, uncon­nected, closed cells, and light weight enables rigid urethane foam to out-perform all other insulating materials. Other advantageous physical properties of urethane foam are its high strength-to-weight ratio, durability, lack of odour and dimensional stability. However, the foam has its limitations since during combustion it emits high levels of toxic smoke; and it deter iorates when exposed to temperatures greater than 80·C.

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The wall panels are joined to each other using a spline or a lap joint as shown in Figure 2 below. CSee also Appendix 8, Sheet Panel Joint Detail). This lap is mechanically secured in the field to produce a continuous wall.

FIGURE 2: LAP JOINT, 75-3000 WALL SYSTEM

i Wall Panel (typ. )

J T , , ,'f· . ,- ., . " . ',' " .. , : ' .... ' .' .

1 I.' "

I '1 I ..

, 'I

t ... · : ' . . -- ..... t. , .. ". " ., 'oP •• " . ... ,.,'.

1 Fastener at 6" o. c. (typ.)

Vertical roof or floor poi nt loads are transmitted to the wall by applying a field-installed top plate which transfers point loads into distributed loads. The application of this field-installed top plate is a requirement whenever roof trusses, roof joists or floor JOists are applied to the top of the wall.

The wall panel is equipped with a continuous top header which allows the installation of windows and doors simply by cutting out the rough openings as required. Span limitations for opening widths must be adhered to as determined by the standard test results.

The panel sizes expected to be manufactured are as follows~

2LfLfO mm high x 1220 mm wide C8'xLf') 2LfLfO mm high x 2LfLfO mm wide C8'x8') 2LfLfO mm high x 3660 mm wide C8'x12') 2LfLfO mm high x LfS80 mm wide C8'x16') 2LfLfO mm high x 6096 mm wide C8'x20') 2LfLfO mm high x 7315 mm wide C8'x2Lf')

Any wall length can be produced by field cutting special" 1220 mm CLf') wide wall expanders. The installed wall

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expander is similar to the wall panel except that it has a double skin. The outer skin is field installed. A wall expander may be considered as a wide spline which requires an additional skin on each side to match the regular wall panel width. The wall expander is illustrated in Figure 3.

FIGURE 3 WALL EXPANDER, 75-3000 WALL SYSTEM

CI·=========.:E.t-I -- 0.5.8. skin (typ.)

~ " ..

I . I

'-- Wall panel

Wall expander, cut to fit.

2.3 75-3000 Roof 5~stem

The 75-3000 roof system panels are similar to the wall panels but consist of 1'"±0 mm (5-1/2") wide aSB webs spaced at 610 mm (2,"±H) olc with a 9.5 mm (3/8") aSB skin on either side glued to the spacers to produce a panel with an overall thickness of 159 mm (6-1/'"±"). The panel sizes will vary according to the roof span or the spacing of the supporting frames which support the panels. The design snow load will also affect the limitation of the total span.

Like the wall panels, the roof panels have a framed-in­place polyurethane foam insulation core, which is foamed in place after panel assembly is complete, and they are also connected together with splines or lap joints. The R-value produced is approximately R51 7.0 (R-'"±O), depending on the foam type and density being used. 75-3000 roof panels result in sloped interior ceilings. A finish can be applied directly to the inner side of the panels and exterior roofing can be applied directly to the outside. Since the panel is in fact the roof structure, attic spaces are eliminated. Vented over­hangs are no longer necessary and condensation problems should be eliminated.

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2.~ 15-3000 Floor 5~st.m

The 75-3000 floor system consists of PiO mm (5-1/2") wide OSS webs spaced at ~OO mm (16") olc wi th a 15.5 mm (5/8") OSS top skin and a 9.5 mm (3/8") OSS bottom skin. At the option of the Client, these panels may be urethane filled or may· remain empty. These floor panels are also joined together with a lap splice or a spline connector, in the direction parallel to the web, and they are butted together over the support members in the direction perpendicular to the webs. These panels are standardized in 1220 mm (~') wide or 2~~0 mm (8') wide sections, with spans ranging from 1.2 m to ~.3 m (~' to 1~'), depending on the loads for which they are designed.

The floor panels are supported on the perimeter foundation walls and intermediate wood or steel beams similar to a conventional Joist floor system. They are secured to these members with screws or long shank nails, as specified in the construction detail drawing, figure ~ below.

fIGURE ~: SECURING Of fLOOR PANELS, 7S-3000 fLOOR SYSTEM

,.,.,...--'11,,-

--.­

-.'1---

Wall panel

-I:'"

,..---i+-f"=-----+Tii+-- Toe screw L . '~'f---I~"

h-.,...,.., ...... J:f~=.;:. =~_~-- Nailer plate (typ.)

I'

-+-1-+-- Floor panel

. ," ' .. •. 't: . . ~ . t'\ - Level strip

..• ·.·~'L " . \. .. .. ..... ," "...... ,

• '.. 'f.. ~"." , '. , ... , .'. ,.. ..... • :l "

'"' . .', , .

s: V.

A

FOundation liall

NOTE: Siailar detail used for other types of floor construction.

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It is recommended that a final plywood or composite board overlay be installed before a finished flooring is applied to the panels.

2.5 Engineering Design Criteria

Span ratings for the 75-3000 wall panels are indicated in Table 1 below and in Appendix C, Span Ratings.

TABLE 1: SPAN RATINGS, 75-3000 WALL SYSTEM

WALL PANELS Load 1.92 kPa (LfO psf)

Wall Thickness Deflectionl Max. Wall Height

108 (Lf-1/Lf") 108 (Lf-1/Lf") 108 (Lf-1/Lf") 159 (6-1/Lf")

L/180 L/2LfO L/2LfO L/360

Lf270 (1 Lf ' ) 3890 (12'-9") 3380 (11'-1") '1Lf90 (1'1'-9")

Span ratings for the 75-3000 roof panels are as shown in Table 2 below and in Appendix C, Span Ratings.

TABLE 2: SPAN RATINGS, 75-3000 ROOF SYSTEM

ROOF PANELS WVE Load 1.92 kPa ('10 l2§f.2.

i)

ii)

iii)

For deflection1 limitation of:

Span/360, allowable maximum span Span/2LfO, allowable maximum span Span/180, allowable maximum span

3200 3500 3500

(10'-6") (11'-6") (11'-6")

i. Deflection in this case refers to the maximum allow­able deflection under the design live load (as op­posed to the permanent weight of the structure). The desired allowable deflection depends on the buildings use.

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The load and span capacities of the floor panels are limited to those indicated on the span table shown in Table 3 below and Appendix C, Span Ratings.

TABLE 3: LOAD AND SPAN CAPACITIES, 75-3000 FLOOR PANELS

FLOOR PANELS Load 1.S2 kPa (~O psf) LIVING AREAS

For deflection limitation of:

i) Span/3601, allowable maximum span ii) Span/2~0, allowable maximum span

38S0 mm (12'-S") ~O~O mm (13'-3")

Load 1.~~ kPa (30 Q§f2 BEDROOM AREAS

i) Span/360, allowable maximum span ii) Span/2~0, allowable maximum span

~160 mm (13'-8") ~3S0 mm (1~'-5")

A general design method::.~ for stressed skin panels is summarized in the sequence chart shown in Figure 5 on the following page. Depending on the designer's experience, steps may be combined or rearranged in sequence, but all basic operations must be carried out in the design process.

1. Span/360 refers to the allowable amount of deflection when the maximum live load is applied.

=. This design method is based upon "Design of Plywood Stressed Skin Panels", published by the Council of Forest Industries (COF!) of British Columbia, lS8~.

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FIGURE 5:

GENERAL DESIGN SEQUENCE, 75-3000 STRESSED SKIN PANELS

1 Select trial section geomeb:y L

i 2 Calculate panel section p:opert:i.es

~ 3 Calculate allowable compr".:.ion REqUired load

flange loads exceeds allowable

1. BtX:lclin9 j

2. Bending

3. Planar shear

4. Defl.ect:ion

~ 4 Compare allowable loads

-'"

with required load

• 5 Calculate allowable panel loads

1. Bending

2. Bcdzontal shear

3. Planar shear

4. Defl.ect:ion

• 6 Compare allowable

loads with required loads

• 7 Final det:aili.BJ

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In general, the flanges of a stressed skin panel are not uniformly stressed. The stress distribution is rela'ted to the span of the panel and the clear spacing between the webs. To account for this, correction factors are applied in the calculations on allowable loads. Section property calculations are based on the whole panel cross-section.

The final selection of the correct panel geometry and conf iguration is based on trial and error. When the panel section has been selected, the allowable properties for the webs and flanges must be determined in order to determine the ultimate loads, spans and deflections.

Calculation of Allowable Loads

The load-carrying capacity of the panel itself can be calculated using the applicable formula for the follow­ing conditions:

a) load-carrying capacity of the compression flange - buckling - transverse bending - planar shear - deflection

b) load-carrying capacity of panel - compression/tension in skins - bending in stiffeners - horizontal shear of panel - planar shear of panel - deflection of panel

Note that the values calculated for the panel sections are maximum total loads, that is, panel weight plus dead load plus live load. The applicable dead loads must be deducted from the total calculated load, to obtain the maximum safe live load the panel can carry.

These formulas do not include a safety factor. I t is recommended that a safety factor of not less than 2 be applied. In this case, safety factor is defined as the ratio of panel strength to the expected maximum load. A safety factor of 3 has been applied to the 75-3000 panels. Load capacities and span limitations were calculated and confirmed with test results for deflections of 1/360, 1/2~0 and 1/180 respectively.

Upon completion of all these calculations, the lowest calculated load was found to be the load governed by

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deflection. According to the provlslons of the National Building Code of Canada, this lowest calculated load can be used as the maximum live load for the panel.

2.6 S~stem Features

In addition to the advantages listed in section 1.3, the 75-3000 building system has some notable additional features.

STRENGTH

Structural tests completed to date indicate that the panel has superior strength. I t is stiff and has good racking resistance compared to a standard wood-frame wall with sheathing on one side only. Because of stiffness, its deflections are limited and the panel may be used for walls under significant wind load conditions and as floors and roofs under signif icant transverse loadings, such as heavy snow loads.

PORTABILITY

Si nce all of the connection detai ls specify that all Joi nts are field screwed, it is possible to erect the structural shell, and then disassemble and re-erect the entire package without damage to the structure. It can be a reuseable and relocateable structure.

MOISTURE PERMEANCE

Permeance tests for the panel skin and core are within specif ied 1 imi ts ; consequently, no vapour barrier application is required on the interior perimeter walls.

FLEXIBILITY

All of the 75-3000 wall panels include a continuous ,top header around the entire periphery of the exterior load­bear i ng walls. As a result, it is possible to cut openings for windows and doors at any desired location. Addi tional windows may be added simply by cutting a opening of appropriate size and installing the desired window. No additional framing is required around the opening, provided it does not exceed 1.8 m (6 ft.) in width.

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3.0 CERTIFICATION REQUIREMENTS

3.1 Ce~tl~lcatlon P~ocedu~es

In o~de~ that 75-3000 System can be used for residential and small commercial construction without a complete engineering analysis performed for each structure, approval of certain building agencies must be obtained. Applicable approvals for the 75-3000 System are the Cent~al Mortgage and Housing Corpo~ation (CMHC), the Bui ldi ng Standa~ds Branch of Alberta Labour, the Canadian Standards Association (CSA), and in the U.S.A., the International Conference of Building Officials ( I CBO) and aff i 1 iated organizations. Each organization has its own set of standards that must be met. From this information, a flow chart was established to outline the certification procedure to be followed:

1) Combine the certification procedures for all of the agencies and establish a maste~ list of information required.

2) Identify all of the requi~ed tests, including a) structural tests, b) fire ratings and thermal barrier

tests, c) permeability water vapour trans­

mission test, and d) othe~ tests.

3) Obtain certification data for each of the main components of the panel ie. (OSB, foam and glue) .

~) Identify testing agencies qualified to perf,orm the necessary tests.

5) Perform tests and obtain test data. 6) Prepare a quality control manual and designate

a quality control agency to audit plant facil­ities.

7) Submit completed applications fo~ certification to each of the agencies.

8) Following review of submitted application by each of the agencies, p~ovide any additional information as requested.

9) Construct the necessa~y prototype projects required to satisfy the agencies.

10) Allow a period of four to six months for the certification agencies to review and respond to the application, and to prepare a product evaluation report.

11) Use the product evaluation report(s) acco~ding

to the conditions and limitations set out in them.

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Since ICBO and CMHC approvals may give easier access to three of the other agencies, they were sought first.

3.2 CMHC Requirements

CMHC requires that panel components be designed with the framing according to the requirements of the residential standards or part 9 of the National Building Code (NBC), Alternatively, CMHC will evaluate a new and innovative product on the basis of tests performed at a CMHC approved laboratory and associated engineering data. See Appendix F, CMHC Building Evaluation Report Technical Requirements.

Testing of the panels must be done, if applicable, in accordance with the test standard ASTM E72 "Standard Methods of Conducting Strength Test of Panels for Building Construction". Tests on the 75-3000 panel system was performed at the Coqui tlam, B. C. laboratory of Warnock Hersey Professional Services Ltd. This facility has CMHC approval.

Mater ials used in the construction of the panels must also meet standards. Foam must meet 51GP 21M "Urethane Unfacted Test" and a surface burning test, as per CSA CAN~-S102-M80. The glue used must be certified as an exterior type of glue. The OSB has already been evaluated by CMHC.

CMHC's list of acceptance requirements included:

DOCUMENT NO.

06111 CMHC

ME8307 CMHC

0611~ CMHC

06110 CMHC

ME8305 CMHC

TITLE

Light Wooden structures framing

Diaphrams

Stress-skin panels (plywood)

Framing and sheathing

Sheathing membrane

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APPLICATION

-Lumber quality -Lumber grade -Panel assembly

-All aspects of design

-Reference standards

-Testing plywood -Thickness -Nails

-All aspects of vapour barrier

DOCUMENT NO.

07150 CMHC

07212 CMHC

ME8309 CMHC

TITLE

- breather type

Rigid board insulation

Floor framing Test procedures

APPLICATION

-Plastic rigid insulation quality

-Floor and roof structural test required

CMHC requires that the panel components be designed with the framing according to the requirements of the Residential Standards or Part 9 of the National Building Code (NBC). (See Appendix F, CMHC Building Evaluation Report Technical Requirements.) Alternatively, the system can be engineered according to Part ~ of the NBC. In either case, the system would be limi ted to use in buildings of fewer than three storeys in height and 600 sq.m in area.

The strength of stress skin panels is to be based on structural stress limitations in CSA CAN3-086 "Engineering Design in Wood", and requires confirmatory structural strength tests according to load test requirements as defined in ASTM ME8309.

CMHC also requires that ten successful prototype structures be erected before approval is granted. To date, thirteen prototypes have been completed.

3.3 ICBO Requirements

ICBO together with its sister agencies CABO, BOCA and BCMC are the approval agencies for certification of building products in the US. The ICBO is responsible for the western US region.

The ICBO and affiliated organizations will accept a panel construction type based on either load tests or a rational analysis. Testing must be done by an approved testing agency. Required tests include structural tests in accordance with ASTM E72-80, density and water absorption tests as per ASTM C272. If the analysis route is chosen, supplemental panel tests may be necessary in order to verify design assumptions, In addition to the above, a quality control manual must be developed, (See Appendix G for the ICBO "Acceptance criteria for Sandwich Panels" and "Quality Control Manual Requirements",)

- 16 -

Under the direction of Warnock Hersey Professional Services Ltd., which is a recognized quality control agency and accredited testing laboratory in the US, Seven S Structures Inc. proceeded wi th an acceptance application for its 7S-3000 panel system.

In order to submit an application, ICBO requirements and acceptance criteria had to be satisfied, in accordance with the following documents:

- ICBO Research Committee Acceptance Criteria for Sandwich Panels, April 1977 (See Appendix G.)

- ICBO Evaluation Service Inc. Quality Control Manual Requirements, April 1986 (See Appendix G.)

Upon completion of this evaluation, an approved ICBO evaluation number will be issued and the product listed as an approved product in the ICBO Building Standards Evaluation Report Listing in its appropriate category. This will allow use of the product within the geographic area under the Jur isdiction of the ICBO. A further submission can then be made to the National Evaluation Service Committee of the Council of American Building Officials. Approval from this agency will grant the 7S-3000 product a National Evaluation Reports CNER) listing. The NER listing provides the product with national approval across the US. Seven S will proceed to obtain an NER listing for the 7S-3000 Building System.

3.~ CSA Requirements

CSA is a non-profit private-sector organization, where standards are widely used by industry and commerce, and are often adopted into regulations by governmental authorities, particularly in the areas of safety, health and the environment. Seven S Structures Inc. contacted CSA to obtain the necessary acceptance requirements for its 7S-3000 Building System.

CSA does not approve building systems. It does perform evaluations of building products which are used in mobile homes. Acceptance of a building system by CMHC or Alberta Building Standards will normally render it acceptable for use in mobile homes.

- 17 -

CSA has advised that CMHC and Alberta Building Standards acceptance be obtained first, and that the system comply wi th the appl icable sections of the NBCC. Once these acceptances are in place, CSA will perform its own evaluation, which wi 11 be mi nimal . Approval of the system wi 11 1 ikely be granted subject to any condi tion unique to its application in mobile homes.

3.5 Alberta Building Standards Requirements

contacted Alberta Labour, Division, Building Standards requirements for provincial Standards Branch requirements as those for CMHC, the Branch to the Alberta Building Code

Seven 5 Structures Inc. General Safety Services Branch, regarding its approval, whi le Bui Idi ng are essentially the same also requires adherence (ABC) .

Initially, three major concerns were expressed by Alberta Building Standards:

1) The 75-3000 building system appeared to require a f ire barr ier such as 12.7 mm gypsum board to protect the foamed plastic insulation, on the inside of the building.

2) They felt that all structural tests should be performed on panels without the foamed i nsul­ation.

3) Construction details, nailing schedules, con­nectors and caulking requirements have to be in accordance with the Alberta Bui Idi ng Code and related Standata.

Representatives of Alberta Building Standards attended a meeting to establish approval requirements and approval procedures for the 75-3000 building system. This meeting established a complete list of structural tests in accordance with ASTM E72-80 which would satisfy all of the approva 1 agenc i es . (See Append i x H , Qua 1 i ty Control Manual.)

3.6 Production Environment

To obtain CMHC and ICBO approvals, 75-3000 panels must be produced in an exacting and certified manner. Such a process involves three elements: a quality control manual, a quality control supervisor and plant certification. The quality control manual identifies cr1teria product parameters and specifies special

- 18 -

testing and control systems. Control Manual.)

(See Appendix H, Quality

Quality control of the product is maintained through an employer designated quality control supervisor. At Seven S Structures Inc. this posi tion is held by the production manager, while the chief engineer oversees the development of quality control systems.

The firm of Warnock Hersey Professional Services Ltd. is retained by Seven S Structures Inc. to provide third­party quality assurance inspection and testing, in accordance with CMHC and ICBO requirements. This firm will make four random and unannounced inspection visits per year to the plant to ensure that the product is being manufactured in accordance with policies set forth in the quality control manual. During these visits, the firm wi 11 inspect production procedures and equipment, and ensure that the manual is current.

3.7 Certified Testing Agencies

For a product to be considered for certif ication, the necessary product tests must be performed by a certified testing agency recognized by the certification authority having jurisdiction. It is advantageous to choose a testing agency which is recognized by all of those agencies in order to avoid costly duplication of tests.

Testing agencies recognized by most of the certification authorities are:

- Warnock Hersey Professional Services Ltd. Coquitlam, BC, Canada

- Factory Mutual Research Corporation Norwood, MA, USA

- Underwriters Laboratories of Canada Scarborough, Ontario, Canada

- National Research Council of Canada Ottawa, Ontario, Canada

Seven S Structures Inc. sought an agency which can also provide the ongoing plant quality control service required to maintain ongoing certification of a manufac­tured product. For Western Canada, Warnock Hersey Professional Services Ltd. from Coquitlam, BC provides all the necessary services, and is recognized by all the certification authorities. As a result, this firm was chosen to perform all of the required tests, to produce the quality control manual and to carry out the ongoing quality control audit at the Grande Prairie pilot plant.

- 19 -

3.8 CertiFication Costs and Funding

The total certiFication costs were estimated to be about $125,000. These costs were related to the following items:

a) in-house testing b) design and engineering costs c) test panel fabrication transportation

costs d) laboratory testing costs e) quality control manual costs f) application fees g) submission preparation costs h) quality control plant inspections

I t is expected that ongoing certif ication costs, per plant, will be $10,000 per year.

Funding for certification costs was provided by Seven S Structures Inc., and grants were provided by Alberta Municipal Affairs and Alberta Forestry.

All of the Innovative Housing Grant Program funding was used to pay for fire and thermal laboratory tests, the associated test panel construction and transportation costs. The Canada Alberta Forest Resource Development Agreement grant was used for physical testing and the preparation of the qual i ty control manual. Receipt of these funds was subject to completion of the tests and preparation of the quality control manual.

- 20 -

~.O TESTING PROGRAM

After Warnock Hersey Professional Services Ltd. was retained by Seven S to perform the required tests, their manager of field inspections and physical testing made a site visit to the Grande Prairie pilot plant and prepared a list of required tests. A tentative testing schedule running from September through November 1986 was established. The following test panels were constructed by Seven S and forwarded to Warnock Hersey for testing:

Wall Panels

Roof Panels

Floor Panels

Fire Test Panels

Water vapour Permeance

Foam Splines

Header Beams

First Series - August 1986

108 (~-1/~")

159 (6-1/~")

159 (6-1/~")

108 (~-1/~")

108 (~-1/"±")

108 (~-1/~")

108 (~-1/~")

108 (~-1/~")

- 21 -

- 1220 x 2~~0 (~'x8') no foam - 9 each

- 1220 x 2~~0 (~'x8') with foam - 6 each

- 2~~0 x 2~~0 (8'x8') with foam - 6 each

- 1220 x ~880 (~'x16') no foam - 3 each

- 1220 x 2~~0 (~'x8') no foam - 3 each

- 1220 x ~880 (~'x16') no foam - 3 each

- 1220 x 2~~0 (~'x8') no foam - 3 each

- 508 x 2~~0 (20"x8') with foam - 12 each

- ~270 x 27~0 (1~'x9') with foam - 2 each

- ~57 x "±57 (18 I x18") with spline - ~ each

- ~57 x ~57 (18"x18") no spline - "± each

- 2~~0 (8') long 15 each

- 91~ (3' ) long no foam - 3

- 1220 ("± ' ) long no foam - 3

- 152~ (5' ) long no foam - 3

- 1830 (6' ) long no foam - 3

each

each

each

each

Second 5eriest :.. December 1986

Basement 108 (1f-1/1f") 21f1f0 x 21f1f0 (8'x8') Panels with foam - 3 each

1S9 (6-1/1f") 21f1f0 x 21f1f0 (8'x8') with foam - 3 each

203 (8") 21f1f0 x 21f1f0 (8'x8') with foam - 3 each

Tests performed on the panels consisted of structural, flame spread and fire endurance tests, as discussed in the following sections.

If.l Structural Tests

Structural tests performed on the three types of 75-3000 panels - wall, floor and roof were:

Transverse load - wall, floor and roof panels Axial load - wall panels Racking - wall panels

A copy of the test report on the above tests are given in Appendix D which indicates that these tests were passed.

The structural tests confirmed the suitability of the 75 panels for use in residential structures.

The results of the transverse load tests were used to establish a preliminary set of span tables. Results from the axial load and racking tests indicated that the 75 wall panel is not only strong enough to carry com­monly encountered loads, but is actually stronger than a 2xlf stud wall of convention construction.

1f.2 Thermal Tests

Three types of thermal tests have been performed on the 75-3000 panels:

Fire endurance - wall panel Fire endurance - wall panel with plaster Flame spread - wall panel

Copies of the test reports on the above tests are given in Appendix E. The panels without a fire protective layer (for example, gypsum wallboard) passed the National Building Code requirements but failed the Alberta Building Code requirements.

- 22 -

To summarize the findings of these reports, the flame spread classification ranges from 126 to 1 'iO, with a smoke developed value of 'i6S. 8y itself, a load-bearing wall was found to have a rating of seven minutes. An addi tional fire barrier, such as gypsum wallboard, is required in Alberta in order to bring it up to the required standard for use in residential construction of ten minutes.

~.3 Other Tests

Water vapour permeance tests for wall panels and structural tests (See Appendix I) on basement panels have also been performed. Two types of samples were tested. The first was a 'iSO mm x 'iSO mm C18"x18") sample without any joints. These were tested for approximately three months and showed a water vapour transmission of O. The second included a standard JOint running the full width of the specimen. This was tested for approximately three months and showed a water vapour transmission of O. These results indicate that a separate vapour barrier is not necessary with 75-3000 wall panels.

~.~ Modification and Retests

8ased on the preliminary series of tests, two changes to the panels were made to increase panel strength and to simpl ify field erection. One was the development of a lap JOint, as opposed to the spline joint previously in use. This proved to be a simpler and more convenient method of joining panels. The C-stud was also changed. Prev iously, the stud web was glued and stapled to the plain pieces of 058 used as flanges. A dado is now cut in the flange pieces to fit the web resulting in a stronger JOint. Retests were done and the findings were incorporated in the test results.

~.5 Summarw of Test Results

Structural, thermal and water vapour permeance tests were performed on the 75-3000 panels. Detailed test results may be found in Appendices D and E.

STRUCTURAL TESTS

Structurally, the 75-3000 panels can be used for housing and small buildings as governed by Part 9 of the

- 23 -

National Building Code. They may be used as walls, roofs and floors, subject to the span limitations established by the test results. The maximum transverse load allowed on a wall panel with a maximum allowable deflection is 28 kN/m (1900 lbs./lin. ft.). A 2.~ m (8 ft.) high wall panel is capable of withstanding a maximum wind load of 3.0 kPa (6~ Ibs./sq. ft.) for a deflection of 1/180. Maximum roof spans and floor spans for a live load of 1.92 kPa (~O Ibs./sq. ft.) is ~.3 m (1~ ft.).

Thermal tests indicate that the burn-through period for an unprotected load bearing wall panel is nine minutes. Flame spread characteristics of the panel are:

flame spread classification smoke developed fuel contributed

- 126 to 1~0 - ~6S - 100

As a result, the foamed panel must be protected with a thermallfire barrier equivalent to 12.7 mm (1/2") dry­wall on the inside of the building.

Water vapour permeance tests on all samples, including those with jOints, were OJ this indicates that the panel does not require a vapour barrier application on the warm side of the panel.

- 2~ -

5.0 PANEL PRODUCTION

The manufacture of a 75-3000 panel can be divided into two parts: component cutting and manufactur i ng oper­ation, and component assembly. Depending upon the intended appl ication, a panel may be filled with poly­urethane foam insulation.

The Grande Prairie plant currently combines both operations, although it is possible to have them in separate plants. This is expected to be the case in the future.

5.1 Manufacturing Methods

Raw materials consist mainly of sheets of oriented strand board (OSB), glue and foam chemicals. In the shop, the OSB is cut to size for use as panel skins, headers, base plates and C-studs. Components of the panel are glued and stapled together. If the panel is to be foamed, it is placed in a hydraulic press where the panel cavities are filled and allowed to cure. After curing, the panels are inspected and either shipped or culled.

5.2 Facilit~ and Equipment Requ1rements

The current plant has an area of approximately 670 sq. m 7,200 sq.ft.). Equipment is comprised of saws, assembly tables for C-studs and panels, a hydraul ic press, foam gun, and equipment for transporting and handling raw materials and finished panels, including an overhead crane, rollers and conveyors, and a forklift.

If the component cutting and manufacturing operation is set up separately from the assembly operation, the com­ponent cutting plant should be set up in a central location, close to material suppliers. At this plant, the OSB would be cut to shape for panel skins and C­studs, and C-studs assembled. Thus, equipment for large-scale cutting and dadoing would not be necessary at the assembly plants.

A number of assembly plants could be served by one component plant. The assembly plants would receive pre­cut panel skins, C-studs, glue and foam from the compo­nent plant. The panels would be assembled, foamed if necessary, and shipped to customers.

- 2S -

6.0 MARKETING AND PRODUCT DISTRIBUTION

The 75-3000 Building System is an innovative system with great potential, but to sell the product, the market must be identif ied and the product introduced to the market.

6.1 Potent!al Market

Major advantages of the 75-3000 building system are its high insulation value and modular construction. These advantages make it particularly attractive for residen­tial and small commercial structures in areas where temperature extremes can occur (most of North Amer ica falling within this category).

At the time of writing, 75-3000 building system is still in the process of finding its way into residential and commercial structures. Some single-family dwellings and a warehouse have been constructed. These buildings have shown the system to be convenient and practical.

Some other potential applications include small apart­ment blocks, motels,· house packages, mobile homes and construction camp trailers. Sales to individuals through building supply companies is also a possibility, although the panel size may be difficult to handle for those who don't have the appropriate equipment.

Currently, efforts are being made to promote the product in Alberta. The main thrust is toward house builders wi thin shipping distance of the Grande Prairie pilot plant.

Sales of the 75-3000 building system are currently limited by the relatively remote location of the pilot plant, which makes shipping costs a major deterrent to sales. Separating plant functions into component manufacturing plants and assembly plants, and locating the latter in central areas close to supplies and mar­kets would reduce shipping costs while increasing capacity. Initially, a component and assembly plant may be set up in the Edmonton area, with future expansion to the rest of Alberta and other provinces.

6.2 Export Potential

Sales of the 75-3000 building system to areas outside Canada seem to have great potential. Climatic con­ditions in the United States, Japan and Europe would

- 26 -

seem to provide a rich market for the panels. The system is also attractive for housing in tropical cl imates as the high insulation value keeps heat out quite effectively.

Historically, the European and Japanese markets have been diff icul t to penetrate. Japanese bui Iders have been reluctant to accept new foreign types of construc­tion; whi le wi thi n the European Economic Communi ty, a number of competing energy-efficient housing systems are already being manufactured. Shipping costs to both areas would be considerable until local plants could be set up. The Amer ican market may prove to be more attractive and will be considered upon receipt of ICBO approval. The current low value of the Canadian dollar makes our prices attractive, although protectionist elements in the US may attempt to hinder sales through taxes and tariffs.

6.3 Franchise Distribution Network

Seven S Structures Inc. plans to sell manufacturing franchises to individuals or companies wishing to pro­duce and sell the 7S-3000 building system. The fran­chise will entitle them to build a Seven S assembly plant in their market area.

The manufacturer will purchase panel components through Seven S, as well as supply plant facilities. A royalty on sales will be paid to Seven S, and sales will norm­ally be restricted to a specific market area.

For its part, Seven S will provide panel components, assist franchisees with basic plant design, perform all required testing and obtain required approvals from various agencies. Seven S will also provide all specialized equipment necessary for a panel assembly plant and provides for plant start-up.

Promotion of the system will be a joint effort, with Seven S providing sales literature and sales management, and local promotion being handled by the manufacturer.

6,~ Present Marketing Status

A strategic marketing plan is being developed by Seven S Structures Inc., with the help of a marketing specialist. This plan will determine which segments of

- 27 -

the market should be catered to, and the manner in ~hich these market segments can be accessed.

Currently, Seven 5 is handl i ng i ts o~n promotion and sales. Prototype structures have been constructed in Creston, BC, in Grande Prairie and in Edmonton. A brochure has been prepared and distributed to home builders across the province in order to make the 75-3000 building system kno~n. A catalogue of specu­lative building plans is being dra~n up; plans include ~arehouses, shops, houses, cottages and mobile homes.

A promotional video is being prepared, as ~ell as liter­ature aimed at architects and engineers. This promotion ~ill familiarize an influential segment of the construc­tion industry ~ith the 75-3000 building system.

- 28 -

7.0 CONCLUSIONS AND PRODUCT STATUS

The 75-3000 building system has great potential. The system has been successfully used in a number of proto­type structures, and evaluation tests to date have been very promising. Warnock Hersey Professional Services Ltd., an approved testing laboratory for both CMHC and its American counterparts, ICBO, performed the test series on the panels, and adjudged them completely sat­isfactory for residential and small commercial buildings. Formal application for approval by CMHC and ICBO has been made.

CMHC is in the process of preparing the evaluation report for the system, which would allow it to be used as an acceptable building product in Canada, subject to the restrictions set out in the evaluation report.

ICBO is currently evaluating the system for general use as a standard building component subject to certain con­ditions and restrictions.

Based on the completed structural and thermal test results, a request for approval of the 75-3000 building system has been submitted to Alberta Building Standards for its review and approval.

A patent for the 75-3000 bui Idi ng system has recently been issued in the United States. Patent applications for Canada, Australia, and some European and Asian countries have also been submitted. The "75-3000" trademark has been registered in Canada and application is being made in the US.

At present, interest in the 75-3000 panel system is growing, in both the domestic and international markets. Orders, have been received from as far away as the Caribbean, and negotiations for projects in eastern Canada are continuing. The future plans for Seven 5 Structures Inc. encompass a public stock offering, licensing of panel fabrication plants, and participation in foam blending and OSB manufacturing operations. This will all result in a self-sustaining company, with a bright future.

- 29 -

APPENDIX" A"

Panel Components

A-I

.--------------------------------------------, DETAILS: 7S -3000 BUILDING SYSTEM

ICD I I I

I i

EXTERIOR w:.u.

eASEMENT W'\~~

PANEL USES

i' f, COkIIHl,oW$

Cl.o!oto e£a f,)",,,, ,,..:. ....... h,:jH

WINDOW OPINING CUT INTO WAIL 'ANIL.

0001 MINING CUT UilO WAU 'ANIL.

@

TYPICAL. PANEL. SECTION

• o I

4 •

. '. . ..... -----1 SECOND TOP PLATE ~-----~~~~~M 1,- O.S.B. Field installed

• ... ..... ,..,

..

~+I------I FIRST TOP PLATE ;- O.S.B. Factory installed

to wall skin

..... ___ --1 INTERIOR WALL SKIN 3/S- O.S.B.

INTERIOR CORE ~~--------~Polyurethane foam insulated R-28

Factory foamed in place. "

7f--I,.e.-===t.;:1-__ ~ EXTERIOR WALL SKIN /S- O.S.B.

"

STANDARD BASE PLATE --~ It- O.S.B. Base plate, glued to wall skins .

.

'.

, ,

• .I:' ' ' ,..,

:

l 3;- l .. ..

SEVEN S STRUCTURES INC .•

TITLE 7S-3000

EXTERIOR WALL PANEL VERTICAL SECTION

STAMP

BOTTOM PLATE - O.S.B. Factory installed.

See Connection Details for connecting Wall Panels to floor systems and roof systems •

STAMP REV

owe.

001

~ A - 3 .-4

TYPE STUDS X Y

4WP 3 1200 555 8WP 5 2438 587 12WP 7 3658 595 16WP 9 4877 600

20WP 11 6096 601 24WP 13 7315 602

'I'=-I+-------O.S.B C-STUD

~===H-------3/8· O.S.B. EXTERIOR SKIN

1t--------3/;;· O.S.B. INTERIOR SKIN

INTERIOR CORE ...!:::tt-------iPolyurethane foam insulated R-28

Factory foamed in place

,..------1;· PANEL LIP

SEVEN S STRUCTURES INC.

TITLE 7S-3000

EXTERIOR WALL PANEL HORIZONTAL SECTION

STAMP STAMP

Z

588

598

600

603

REV

OWci.

002

A - 4

.--- LAP OR SPLINE JOINT

SEVEN S STRUCTURES INC.

TITLE TYPICAL FLOOR PANEL

LAYOUT

STAMP STAMP REV.

owe.

027

A - s

r r --li--r--r-l I i I II II I

i I II I: I I ~ I III II I I ~ I I II II II' ! I II I I I

~ I II 11 II i I· II II II * I II, 1\

I I II I . [I II L_ lL __

SEVEN S STRUCTURES INC.

TITLE

TYPICAL 7S-3000 ROOF PANEL

STAMP STAMP

LAP OR SPLINE JOINT

TYPICAL O.S.B. STUD

REV.

030

APPENDIX "s"

Panel Joint Detail

•. _----, 8 - 1

,.....--------- TYPICAL 7S-3000 ROOF PANEL

/ 1 ,,'

,'. ' , .,,'

I

SEVEN S STRUCTURES INC.

TITLE

ROOF PANEL TO ROOF LAP JOINT CONNECTION

T I . '\ .

, " , 'I

v '1

1

~TYPICAL 7S-3000 ROOF PANEL . ,

~YPICAL LAP JOINT Secure ROOF PANEL to ROOF PANEL

L....._~ using 1"- x 110 wood screws @ 6- O.C., both sides.

I

Apply a continuous bead of PLSOO to each panel lip prior to joining.

I-

STAMP STAMP REV.

D\~C.

002

\ . . ..

\ l.:..i":

\ r'~ , .

SEVEN S STRUCTURES INC.

TITLE

TYPICAL ROOF CONNECTION USINC SPLINE

1 "'I-

-1

STAMP

B-2

-~eld a pply a continuous bead of o inside of each lip prior

uring with screws. PLSOO t ~o sec

7S-3000

- -

"

~

~PICAL .... Secure

1,- x • r-Eoth si

7S-3000

ROOF PANEL

r . '. ' .

1 ROOF SPLINE

between panels using 10 wood screws @ 6- O.C. des

ROOF PANEL

STAMP REV.

OWC.

031

APPENDIX "C"

Span Ratings

",

,. If .-••

REPORT OF:

AT:

PROJECT:

REPORTEO TO:

c - 1

Warnock H~ Professional ~rvic~ ltd. 211 Schoolhouse St .• COQuitlam. B.C. V3K 4X9· (604) 520·3321 • Telex 04·351404

Transverse Load Test

Coquitlam Laboratory

50489 C7 493600

Seven S Structures Inc. 10833 - 97th Avenue, Grande Prairie, Alberta T8V 4Y9

INTRODUCTION:

}IJ\ "i '). 9 iSS7

OATE May 14, 1987

REPORT NO.

OROER NO.

As requested, we have carried out transverse load tests on your 4" and 6" foundation wall panels. Tests were carried out with the polyurethane foam in the panel cavity and on an 8ft span with the plywood skin on top (i.e. in compression). These tests were carried to give an indication as ~o the structural contribution of the foam core to the panels overall strength and to give some indication as to whether the panels should be tested with foam in the cavity.

TEST RESULTS:

For 4" Walls - Foundation Wall

4' wide x 8' long sample EI on 8' pane_ x 4' wide EI for l' wide = 149.19 x

= 149.19 x 106 lb. m2 106 = 37.30 x 106 lb. in2

4

Maximum span (L) for 40 psf loading:

a)

b)

For deflection = L/180 L3 = 384 x 37.30 x 10 6

180 x 5 x 3.33

Therefore Span (L) = 14'0"

For deflection = L/240 L3 = 384 x 37.30 x 106

240 x 5 x 3.33

Therefore span (L) = 12'9"

.•• /2

AL.L. REPOR'1"S ARE ~E CONFIOEN'T1AL. ~RTY 0' CLIENTS. ~8UCATION 0' STATEMENTS. CONCI.USIONS OR EXTRACTS FROM OR REGAROING OUR REPORTS IS NOT PERMITTED WITHOUT OUR wRITTEN AI'PROVAL.. ANY L.IA8IUTY ATTACHED ~EAETO IS L.IMITEO TO ~E FEE CHARGEO

FORM I I KE.8<>E

c - 2

Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Page 2

TEST RESULTS: Continued

c) For deflection = L/360 L3 = 384 x 37.30 x 106

360 x 5 x 3.33

Therefore span (L) = 11 '1"

1/4 pt Loading on 8 ft. Span

Maximum load applied 10,000 lbs. *

Maximum allowable based on Ultimate/3 = 104 lbs./sq.ft.

Maximum allowable based on L/360 = 107.9 lbs./sq.ft.

Therefore 104 lbs./sq.ft. governs

For 6" Wall - Foundation Walls I

4' wide x 8' long sample EI on 8' panel x 4' wide = 347.59 x 106 lb. in2 EI on l' width = 86.90 x 106 lb. in2

Maximum span (L) for 40 psf load

Deflection = L/360

L3 = 384 x 86.90 x 106 360 x 5 x 3.33

Therefore span (L) = 14'9"

1/4 pt. Load on 8' Span

Maximum load applied = 10,000 lbs. *

Maximum allowable based on L/360 = 251 lbs/sq.ft. (8' span)

NOTE: * Neither wall broke at the maximum test load of 10,000 Ibs.

... /3

C - 3

Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Page 3

WARNOCK HERSEY PROFESSIONAL SERVICES LTD.

LQL ~r F. Mawani, P. Eng.,

Manager, Field Inspections and Materials Testing

FM/tr/87.0S.14

480.D4.PC

I

APPENDIX "0"

Structural Test Results

. ~~--' ...... :::..:. -... ~ . ill" :... .-, ...

VANCOUVER

D - 1

Warnock H~ Professional ServiceS Ltd • 211 Schoolhouse Street. Coquitlam. B.C. V3K 4X9 Tel: (604) 520-3321 Envoy WPM 8076

REGINA

REPORT OF:

TRANSVERSE LOAD TEST

AXIAL LOAD TEST

RACKING LOAD TEST

ON

SEVEN S STRUCTURES INC. PREFABRICATED O.S.B. WALL

PANEL SYSTEM

REPORT NO. 1/86

DArE: NOVEMBER 10, 1986

BY: t. t'Zwt:--F. MAWANI, P. Eng.,

Manager, Field Inspections & Physical Testing

WINNIPEG THUNDER BAY SAULT STE MARIE HAMILTON TORONTO

ANTIOCH WASHINGTON INTERHA TlOHAL AFFIUA TlONS

.­... -- - -

'~."'- .. ' ~-'.~/" ! __ .. _ 41" ......

-....... /'" . . '. ~ ... '

.-

MONTREAL DARTMOUTH

D - "

Warnock Hersey Professional Services Ltd.

TABLE OF CONTENTS

INTRODUCTION & DESCRIPTION OF SEVEN S STRUCTURE PREFABRICATED O.S.B. WALL PANEL

TRANSVERSE LOAD TEST

CALCULATIONS FOR TRANSVERSE LOAD TEST

AXIAL LOAD TEST

RACKING LOAD TEST

DISCUSSION OF TEST RESULTS

APPENDIX

PAGE

1

1

2 - 5

6

7

8

l) - 3

Warnock Hersey Professional Services Ltd.

INTRODUCTION:

As requested, we have carried out structural Load tests on Seven S Structures Inc. prefabricated wall, roof, and floor panels~ The tests were conducted in accordance with ASTM Standard E72-80 "Standard Methods of Conducting Strength Tests of Panels for Building Construction." The purpose of these tests was to determine the structural properties of the prefabricated panels developed by Seven S Structures Inc. All structural tests were conducted on panels without the polyurethane core.

DESCRIPTION OF THE SEVEN S STRUCTURES PREFABRICATED PANELS

a) The prefabricated wall panels are constructed with a 3/8" O.S.B. skin on either side, glued to the wall spacer with waterproof Phenol-Resoranol glue. Wall spacers are spaced at 24" O.c. The total panel thickness is 4 1/8".

b) The roof panels are constructed similar to wall panels except that the total thickness of the panel is 6 1/2".

c) The floor panel is constructed with a 5/8" O.S.B. skin on topside and 3/8" skin on the underside. Total thickness of the floo"': panel is 6 7/8" and 'the spaces are at 16" o.c.

Note: All structural tests were conducted on panels without the polyurethane foam.

TEST PROCEDURES:

1. TRANSVERSE LOAD TEST

Tes~s were carried out in accordance with ASTM E72-80. Tests were performed on three like specimen of the wall system without the polyurethane infill. The test specimens were submitted by Seven S Structures. Four feet by eight feet test panels without the polyurethane infill were placed horizontally in the test frame on a span of 90". Loads were applied at the quarter points, using a hydraulic ram and pump system. At each increment of the load, the deflection of the panel at mid span was measured, using dial indicators reading to one thousandth of an inch. An average of two readings (one on either side of the panel) was calculated. Load deflection data is tabulated and plotted. Stiffness of the four feet wide panel was calculated using linear regression and standard engineering formulas for loading conditions.

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Warnock Hersey PJofessional Services Ltd.

Seven S Structures Inc. Report 1/86 Page 2

CALCULATIONS FOR TRANSVERSE LOAD TEST

Note: All test results are calculated on deflections recorded immediately after load application at each load increment.

Stiffness EI of 4' wide section. 11P L3 2 x.o. x 384

Where P • Total Load (lbs) L = Span ins. A = Def lection ins.

A. WALL PANELS

A.1 8 FEET SPAN

Test 1 EI = 65.7 x 106 lb.in2

Test 2 EI = 67.5 x 106 lb.in2

Test 3 EI = 65.1 x 106 lb.in2

Average EI = 66.17 x 106 lb.in2

Ultimate

Ultimate

Ultimate

Ultimate

• . . Average EI/Wall Column • 66.1 x 10! 3

Load =

Load =

Load =

Load =

• 22.03 x 106 lb.in2

2946 lbs.

3122 lbs.

2721 lbs.

2930 lbs.

• . . From the above results, limiting loads for various spans have been calculated as below:

For wall panels with spacers at 24" o.c.

SPAN (L) FT. ALLOWABLE LOAD (PSF) FOR DEFLECTION OF:

L/180 L/240

8 63.7 47.7

9 44.8 33.7 . 10 32.8 24.4

Note: Wind blowing at 7S wall.

mph exerts a load of 14 psf on the

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Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Report 1/86 Page 3

B. ROOF PANELS

" B1 • 16 FEET SPAN

Test 1 EI ::: 164.2 x 106 lbs. in2 Ultimate

Test 2 EI = 171.8 x 106 lbs. in2 Ultimate

Test 3 EI ::: 160.8 x 106 lbs. in2 Ultimate

Average EI ::: 165.6 x 106 lbs. in2 Ultimate

. . . Average EI/Spacer Column ::: 165.6 x 106 3

Load :::

Load :::

Load :::

Load :::

= 55.20 lb. in2

3340 lbs.

3335 lbs.

2924 lbs.

3200 lbs.

• . . From the above results, limiting loads for various 16 feet spans have been calculated as below:

For roof panels with spacGrs at 2~" o.c.

SPAN (L) FT. ALLOWABLE LOAD (PSF) FOR DEFLECTION OF:

16

B.2 8 FEET SPAN

Test No. 1 EI ::: 121.9 x 106

Test No. 2 EI ::: 135.8 x 106

Test No. 3 EI ::: 106.8 x 106

lb.

lb.

lb.

SPAN/180

20

SPAN/240

15

in2 Ultimate Load :::

in2 Ultimate Load :::

in2 Ultimate Load :::

SPAN/360

10

4622 lbs.

3684 lbs.

4254 lbs.

Average EI = 121 .5 x 106 lb. in2 Ultimate Load = 4187 lbs.

Average EI/Spacer Column = 121.5 x 10i 3

= 40.50 x 106 lb. in2

o - b

Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Report 1/86 Page 4

B.2 8 FEET SPAN: continued

From the above results, limiting loads for eight feet span have been calculated as below.

For roof panels with spacers at 24" o.c.

SPAN (L) FT. ALLOWABLE LOAD (PSF) FOR DEFLECTION OF:

8

C. FLOOR PANELS

C.1 16 FEET SPAN

SPAN/180

117

SPAN/240

88

SPAN/360

59

Test No.1 EI. 196.1 x 106 lb.in2 Ultimate Load = 3645 lbs.

Test No.2 EI = 185.6 x 106 lb.in2 Ultimate Load = 3366 lbs.

Test No.3 EI = 195.3 x 106 lb.in2 Ultimate Load = 3686 lbs.

Average EI • 192.3 x 106 lb.in2 Ultimate Load = 4557 lbs.

• • • Average EI/Spacer Column • 192.3 x 106 4

• 48.1 x 106 lb. in2

From the above results limi ng loads for 16 feet span have been calculated as below.

For floor panels with spacers at 1 -" o.c.

SPAN (L) FT. ALLOWk9LE LOAD (PSF) FOR DEFLECTION OF:

16

SPAN/180

26.0

SPAN/240

19.6

SPAN/360

13.0

i -

0-7

Warnock Hersey Professional Services Ltd.

Seven S Structures Report 1/86 Page 5

C.2 8 FEET SPAN

Test No.1 EI = 184.1 x 106 lb. in2 Ultimate Load = 8467 lbs.

Test No.2 EI = 171.6 x 106 lb. in2

Test No.3 EI = 177.5 x 106 lb. in2

Ultimate Load = 7966 lbs.

Ultimate Load = 8031 lbs.

Average EI = 177.7 x 106 lb. in2 Ultimate Load = 8155 lbs.

Average EI/spacer Column = 177.7 x 10 6 4

= 44.4 x 106 lb. in2

From the above results limiting loads for eight feet span have been calculated as below:

SPAN (L) FT.

8

ALLOWABLE LOAD (PSF) FOR DEFLECTIONS OF:

SPAN/180

193

SPAN/240

144

SPAN/360

96

•

..

I I ..

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Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Report 1/86 Page 6

2. AXIAL LOAD TEST

Tests were carried out on the wall panels in accordance with ASTM E72-80. Tests were performed on three like specimen four foot wide by eight foot high. The specimen was placed in the load frame vertically and the load was applied with a hydraulic ram and pump system.

At each increment of the load, the deflection at the center of the wall was recorded and set after the load was removed at each increment. The results were tabulated and plotted.

TEST RESULTS:

PANEL NUMBER

1 2 3 Average

Ultimate Load (lbs) 32,990 32,010 34,120 33,040

Ultimate Load 10,996 10,670 '1,373 11,013 (lbs/spacer col.)

Allowable Ultimate Load 3,665 3,557 3,791 3,671 (lbs/spacer) with safety factor of 3.

Allowable Load lbs/lin ft. 1,832 1 ,779 1 ,896 1 ,835

Lateral Deflection of the 0.091 0.053 0.066 0.070 Wall at centre at maximum allowable axial load •

Note: When designing wall panels, please ensure that allowable stress values for lumber species is not exceeded.

, .. ! -

..

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Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Report 1/86 Page 7

3. RACKING LOAD TEST

Racking load test was performed on three like specimens. Tests were performed on eight feet by eight feet wall panels in accordance with ASTM Standard E72-80.

The panels were placed vertical in the test frame and the load was applied using a hydraulic ram and pump system. Deflections and sets were measured using a dial indicator reading to 0.001".

Test results were tabulated and plotted on a graph.

TEST RESULTS:

PANEL NUMBER

1 2 3 Average

Ultimate Load (lbs) 12,800 14,040 13,060 13,300

Ultimate Load 1 ,600 1 ,755 1 ,685 1 ,680 (lbs/lin.ft.)

Allowable Ultimate Load 533 585 562 560 (lbs/lin.ft.) with safety factor of 3

u - 1 U

Warnock Hersey Professional Services Ltd.

Seven S Structures Inc. Report 1/86 Page 8

DISCUSSION OF TEST RESULTS

1. TRANSVERSE LOAD TEST

1.1 WALL PANELS

From the test results it can be seen that the wall panels can withstand a load of 47.7 psf on a span of eight feet with a deflection limit of span/240. Wind blowing at 75 m.p.h. exerts a force of 14 psf, so it can be seen that the wall panels are sufficiently strong to withstand wind loads commonly experienced. The wall panels are stronger than the common 2" x 4" stud wall at 16" o.C.

1.2 FLOOR PANELS

Floor panels on eight foot span can carry loads of up to 96 psf deflection limit of span/360, however at 16 foot span the allowable load falls down 13.0 psf and as such taking the lowest EI value into consideration, floor spans of 10 foot span with deflection limit of span/360 can carry loads up to 50 psf which falls wi thin th'e common range of residential floor loads.

1.3 ROOF PANELS

Eight foot roof panels can support loads of 59 psf with deflection limits of span/360 and the load carrying capacity is greatly reduced at 16 feet span to 10 psf. Therefore it is recommended that to obtain a higher load carrying capacity on greater spans, the roof panels be designed with a stiffer section of spacer column.

2. AXIAL & RACKING SHEAR - WALL PANELS

Axial and Racking shear test results indicate that the wall panel is capable of Withstanding axial loads of 1835 lbs/lin ft. and 560 lbs/lin ft. of shear load. The allowable axial load is within the normal range of the loads encountered commonly in residential construction and the allowable racking is in excess of the loads that it would normally be subjected to.

FM/lsw 86.12.19

480.06". PC

-. -

-•

D - 11

Warnock Hersey Professional Services Ltd.

A P PEN 0 I X

--

-

o - 12

TRANSVERSE LOAD TEST DIAGRAM

I .... ~ ___ .....l _____ ... To hydraulic

J"" .,' 221/2-...,...-221/2-....... -221/2-....... -221/2

3.5 1----------- 90

1. Hydraulic Ram 2. Calibrated Pressure G.!uqe 3. 4" x 48" I Beam 4. 4 x 4 X 48" Beam 5. l"x 48" Steel Roller 6. 1/4" x 3" x 48" Steel Plate

pump

7. Dial Micrometer ( 1 ea~h side, attached to reaction frame) 8. Test Specimen 9. Cement Block

10. Reaction Frame

Note:. All dimensions are mea~ured in inches unless otherwise noted.

o - 13 AXIAL LOAD TEST DIAGRAM

To Hydraulic Pump

1\

..

.. ;.

l. Calibrated Pressure Gauge 7. Dial Micrometers (4 ) 2. Hydraulic Rams 8. L. Bracket 3. 4" X 48" I Beam 9. Wire Clamp 4. 1/4" x 6" x 48" steel plate 10. Wire 5. Steel Rod 11. Deflectometer 6. Test Specimen 48 x 96 12. Reaction Frame ..

..

-

..

-

..

..

..

o - 14

RACKING SHEAR TEST DIAGRAM

I I I I~. I ~

L .. =-:=-:.~ ... -:-=. ===A ==;Jr========:::::1 SECTION A-A

1. Hold down plate and roller 7 • Reaction Frame 2. Lateral Guides 8. Hold down rod 3. Hydraulic Ram 9 • Bolts 4. Roller 10. Stop 5. Dial Micrometer 11. 2 x 12 Timbers 6. Calibrated Hydraulic Gauge

f'... .J 'q" W

-;" ~

... I

~

l1' - t

0 -" (I • ,

~. . , ~: , . ~;

I I , t I

I

i , ' -,7, : I

----

bl _ .. '- ·

() .. • ~ "'" x w

-. _._t ·

I -r·· .,'-----.. . . , ( , ,

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D - 15

W

~ u:. J 2 ~ ... 1

~~pyright April 1985 SEVEN S STRUCTURES INC.

SECOND TOP PLATE (5/8")15.9 O.S.B. field installed

FIRST TOP PLATE (3/8-)15.9 O.S.B. factory installed

STANDARD TOP HEADER 2-(1/2~)15.9 O.S.B. wall skins are glued to header

INTERIOR WALL SKIN (3/8")9.5 O.S.B.

~OW WALL PANEL(24'max.) (3/8-)9.5 O.S.B •. (3 5/16-)polyurethane core (3/8-)9.5 O.S.B. outer skin

Note: polyurethane is foamed in place after vertical FOAMSTUDS have been inserted and glued to skins

Window or dOOr openings may be cut into wall panel anywhere below the top header

EXTERIOR WALL SKIN 3/8"9.5 O.S.B.

STANDARD BASE PLATE 2-(5/8")15.9 O.S.B • wall skins are glued to plate

BOTTOM PLATE ~~~' ::;:'~' :::;" ;:'~' ':-~t:-----~_.£( ~1 1~2" ) 12.7 O. S • B.

FICURE NO.1 LOW WALL PANEL(EXTERIOR)

VERTICAL SECTION

3-'A~) \~S \~.~ ( ~~--~~ 8/\~.~

---··r r-.j ~ ~ I'

~ ~

~

o - 16

FACE VIEW STANDARD

Copyright April 1985

SEVEN 5 STRUCTURES INC.

O. S. B. WALISPACER

(5/8-)15.9 O.S.B.

FIGURE NO. 2A O.S.B. WALISPACER FACE VIEW

-- ~.~ l ~8") (~h 'I) ~~~ I ... ---, Fo:L ,

, - ,

• t -" f---

~ . -' . , . . --/--

j

f:?%;I) -84.1

.,

.. , 1---

.. I I .. --.-'1

..

-

D - 17

I I

TOP VIEW STANDARD F 2-(3/8")9 • polyuretha

Copyright April 1985

SEVEN S STRUCTURES INC.

OAMSPLINE 5 O.S.B. skins ne foam core

FIGURE NO.3 FOAMSPLINE

LONGITUDINAL SECTION

42.

-t---: 1

- : .. ' .

~;

.. 7 i ~!

I

I I /.

, - .. : . .. ....

, . \.. ", ......

\ ... , '.. t ~... I ••

Copyright April 1985 ~~~~N 5 STRUCTURERS INC~

, .. ,....... -., .....

... ,.. - ,. ...... -

SECOND TOP PLATE (5/8-)15.9 O.S.B. field installed

TOP VIEW

SECOND SKINS (3/8-)9.5 O.S.B. field installed

eut to fit as needed

LONGITUDINAL VIEW

WALL EXPANDER shipped as a standard (24") 610 wide section,may be cut to any required width to fit, in the field. Insert as a spline'.arid 'complete' by installing second skins in the field, cut to fit.

BOTTOM PLATE (l/2-)l2.7 O.S.B.

FIGURE NO.4 WALL EXPANDER

VERTICAL SECTION

If\ i \) ~

--... , i

~ I "-..I I , I I

--'Ii'

..

.. , -' I •

D - 19

Copyright April 1985

SEVEN S STRUCTURES INC.

1\ 'Z II) e>oS ~,~~--------_\~------------------?~

,

\ ..... , .. . . ' .' .. ' .'.

_._- . . . . . ... ' .. ~. , . :. ,

-----., ... - ... _.- . . ,

~,

. '-_. - r

." .... " ..... f , (

IL

.

,. .

. 'r

I , I . . -. .

CORNER PANEL (3/8-)9.5 0.5.B skins on both sides (8'1 1/8-)2467 high has top header and bottom base plate similar to wall panel Corner panel has solid gussets at (24")610 olc Entire assembly glued and assembled in factory .

FIGURE NO.5 . CORNER PANEL

HORIZONTAL SECTION

•

.-

•

I •

I .. .,

: , •

o - 20

Cut off protruding skins ..------1 from a standard wall panel

to start corner

-- · . . . . . . '. . . I- · . . . . . ..

I .: I '~ · f .1- --- I I

I , . I t • I I I · \ I

\ i ,. ."'- I

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,-- f · '. . . . . - -. .. . .. . . - . . • .. ~ > .. -- • •. • -;;;;f • , , . f-- l : , I-

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· I' I :1--- ' .

, L I .f--- ',-

rr· - -. '1---• -' · · · , --

r •

I I I t

I 1 . "

Copyright April 1985

StVEN S STRUCTUERS INC.

/ . . . ........ I

f , ,I

· · , ·

,. .... I

STANDARD LOW WALL PANEL

· . • I STANDARD WALL EXPANDER ,

· tr !"'. - -,' · · I 1-' ~ -! -If Li. ~r:- - • , ...... r , · ~--~ - (

I ,

· , f

---, f

• · · , , ,

,~ .... -. I

I . --~ r:::::::::;' -'

. I/'~

cut to fit in field lap outer corner

STANDARD

and install

skin to tie in

LOW WALL PAN EL

FIGURE NO.SA ALTERNATE CORNER DETAIL HORIZONTAL SECTION

..

..

•

, ,.

~

1 ,-~ ~ 2

,~,<;J .... \)'~- .

.1

-=-'\;.-- --~

6"'2 - ~ t.J ti:.. - .)

-:--- ..J

D . 21

-Copyright April 1985

SEVEN S STRUCTURES INC.

HORIZONTAL SECTION VI~W

PELIlVATION VIEW

----1---f;:-~'-:-:;:~~-;:~:;::;§~=+~·~~I STANDARD -'- -T-'--'T'"'T--_ - -- - rr !I I CORNER PANEL

I 1 ,. I I I,

,. -_ • ...!'Ik----IIi-" ·1-1 -----------+"!1 I I'

I : I ~ ~~ > ~ ~---~~~.~=-~-==~;;.=--~~~~5ea---~----,._-.-_._- --- r,--- - ---'T STANDARD

FOAMSPLINE 1 •

, : 1 I II! "" ___ • .....!I ___ ~ ......... ________ ~

: 1 I, I I I ---+t---t---I STANDARD I 'J "I I----or :: ---- :1 1 LOW WALL PANEL

I ~ ____ ...................... ~..... g

"0- -r :1 11 ~ '", , .. : ... 1--.--..----"'1111'---.... 11 ; -t

I I II .( _.1 ______ ~

I : I I I ..l. ..J.

-- _ . ..l>~_t:, .J;;:--==-=-=-=====:::;J, ~ -i ---'k-- iIr-:----------'I Ir-t-------, ~

II " 171' J I.,

H--- -'t--· .... -------......... -~I " ;" I I, ~

I

I'

STANDARD WALL SPACER

STANDARD LOW WALL EXPANDER

I ""J I- ~ ---o\Ir\ -1rt;--..-----'-tU--~__11 STANDARD

I I BASEPLATE

I- --\ I

---.. ---., r'

I II ]·-------4 STANDARD

TOP HEADER

FIGURE NO.6 TYPICAL WALL ASSEMBLY EXTERIOR WALL SYSTEM

o - 22

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APPENDIX "E"

Thermal/Fire Test Results

E - 1

• • •• Warnock H~rsey Professional ~rvices Ltd. :: ~ 1 Schoolhouse Street COQUltlam B C V3K 4X9 ie, i604) 520·332' Telex 04-351404

STANDARD FIRE ENDURANCE TEST PROGRAM

CONDUCTED ON A

LOAD BBARING WALL WITH ErtBltIOit PLASTIm FINISB

CLIENT

SEVBN S STROCTUB.ES INC. 10833 - 97TH AVENUE,

GRAND PB.A.IRIB, ALBERTA TSV 4Y9

REPORT PREPARED BY

WARNOClt BERSBY FIllB IaABOB.A'.rORIBS DIVISION

211 SCHooLHOOSE STRBB'l' COQOl:TLAH, B. C.

V3lt 4X9

REPORT NUMBER: 4550

JOB NUMBER: 50491 C7 516200

DATE TESTED: October 2, 1986

TEST STANDARD: CAN4-S101 & ASTM E119

lNOV 2 4 1986

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Warnock Hersey Professional Services Ltd.

PRBPACE

This report describes the tests, stan9ards and details of the test specimen as installed for this program.

The report does not imply product certification. Products must bear "WHI certification marks" in order to demonstrate Warnock Hersey certification.

E - 3

Warnock H~rs~y Professional S~rvices Ltd.

INTRODUCTION

TEST INSTALLATION (CONSTRUCTION)

THE FIRE TEST

FIRE TEST OBSERVATIONS - EXPOSED - UNEXPOSED

THE HOSE STREAM TEST

CONCLUSION

TABLE 1

TABLE 2

FIGURE 1

FIGURE 2

FIGURE 3

TABLE OF CON'rEN'l'S

PAGE NO.

1

2

3

4 5

7

E - 4

Warnock Hersey Professional Services Ltd.

Report No. 4550 Page 1

DlTJlODOC'lION

On October 2, 1986 the Fire Laboratories Division of Warnock Hersey conducted a standard fire endurance test on a Load Bearing Wall supplied by Seven S Structures Inc. for a fire resistance rating. Testing was conducted in accordance with CAN4-S101-M82 and ASTM E119-84 Standard Method of Fire Endurance tests of Building Construction and Materials.

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Warnock Hersey Professional Services Ltd.

Report No. 4550 Page 2

TES'r INS'l'ALLA'rION ( CONS'rRUC'rION )

The test portion was assembled from two panels to form a wall 9' - 2 3/4 11 (2813 rom) high by 14'4" (4368 rom) wide. The larger panel was 8' wide. The smaller panel was 6'4" wide. The wall panels were assembled from studs, top and bottom plates, wall reinforcing and face panels, all of which were cut from various thicknesses of oriented strand board (O.S.B.) A vertical crossection of the wall is shown in Figure 1. The studs as shown in Figure 2 were installed on 24" maximum centers. These components were glued with Phenol Resorcenol from Borden at all joints. In addition the face panels were stapled. These staples were spaced at 3" on the end studs and along the bottom plate, and at 6" along intermediate studs. Three rows of staples spaced at 6" were used on the top header. Single sheets of O.S.B. formed the surface of each panel. The cavities between the studs were filled with polyurethane foamed in place. One surface of the panels was covered with 1/4" (6 rom) of acrylic plaster.

At the joints between the panels the facing extended 1 3/4" (44 rom) beyond the studs. The cavity at the joint was filled with a filler made from polyurethane foam covered on the outer sides with 3/8" (9.5 mm) O.S.B. PL40Q caulking was applied to the filler before it was installed in the wall. Each face panel was screwed on 6" centers. The assembly,was completed by attaching a 1 3/8" (34.9 mm ) O.S.B. plate on the top of the wall with 2 1/2" wallboard screws spaced 24" and placing the wall on a similar plate at the bottom. On the plastered side of the wall the surface was finished with acrylic plaster at the jOint. The wall was installed in the furnace with the plastered side exposed to the fire.

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Warnock Hersey Professional Services Ltd.

Report No. 4550 Page 3

A load of 1500 lbs. per lineal foot was applied to the wall with hydraulic cylinders. This load was maintained throughout the test.

The moveable frame containing the test assembly was secured to the furnace. The pilot burners were ignited and burned until the temperature inside the furnace reached 20 ~ 2°C (70 ~ 3°F).

All burners were fired and timing was begun immediately upon achieving maximum high fire.

Observations were made throughout the fire exposure period.

The temperature inside the furnace was monitored by twelve uniformly distributed thermocouples. These readings were automatically plotted approximately once every minute. See Figure 3

Deflections were measured across the test assembly at midheight. See Table 2

Temperature on the unexposed surface of the wall were obtained according to the test standard. The temperature rise at each pOint was calculated. A summary of this data is shown in Table 1 •

E - -:

Warnock Hersey Professional Services Ltd.

Report No. 4550

MINUTES: SECONDS

, : 40

2:20

7:00

7:42

10:39

l' : 00

15:00

FIKE TEST OBSERVATIONS

EXPOSED PACE

Page 4

DESCRIPTION

Wall face smoking and starting to burn.

Full combustion in furnace. Vigorous burning of wall face.

Plaster coating flaked off and piled on sill.

Strand board falling off in small pieces.

Vigorous burning of wall face continues.

Pieces of strand board continues to drop off wall.

Fire test stopped.

..

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Warnock Hersey Professional Services Ltd.

Report No. 4550

MINUTES:SECONDS

7:42

12:17

13:50

14: 45

15:00

FIllE 'l'BST OBSERVATIONS

OHBDOSBD FACE

Page 5

DESCRIPTION

Foam "sizzling".

Smoking at two pin holes in. face.

Burn through at left hand corner.

Wall is buckling and is unable to support the load. Burn through at several points.

Fire test discontinued •

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Warnock Hersey Professional Services Ltd.

Report No. 4550 Page 6

'!'lIE BOSE S'rREAH TBS'!

A Hose stream test was not conducted because the wall had already failed due to burn through during the fire test.

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Warnock H~rsey Professional Services Ltd.

Report No. 4550 Page 7

CONCLOSIONS

To achieve the minimum rating of 20 minute a wall must not burn through and it must not allow water from the hose stream test to project through it. A load bearing wall must support the load for the rating period of 20 minutes.

This wall had burned through in 9 minutes and at this point would have allowed water to penetrate. At 14 minutes 45 seconds the wall was unable to support the applied load.

Therefore the Load Bearing Wall did not meet the requirements of the CAN4-S101-M82 and ASTM E119-84. test standard.

TESTED BY:

REVIEWED BY:

G.L. Marks, A.Sc.T. Fire Laboratories Division

/1

H.A. Grisack, A.Sc.T. Manager - Western Region Fire Laboratories Division

HG/lsw 86.11.17

490.D5.PC

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Warnock Hersey Ptofessional5ervices Ltd.

Report No. 4550 Page 8

TABLB 1

TEMPEBATORE RISE ON oma:PoSBD stJRJ'ACIB (Oe)

MJ:ROftS

Thermocouple 5 11 13 14 15

1 -1 -1 -1 0 1

3 0 -1 -1 0 6

5 -1 -1 -1 19 20

7 -1 -1 27 60 34

9 0 1 0 0 75

11 0 -1 -1 -1 -1

13 -1 -1 -1 11

15 -1 -1 -1 0

17 0 0 1 6

E - 1:

Warnock Hersey Professional Services Ltd.

Report No. 4550 Page 9

DBl'LBC'1'IORS _ (in)

I..OCA'fIOR LO.lDZD 5 a.t.Duta. 10 a1nut.ea

A -7 (-.27) -12 (-.47) -14 (-.55)

B -5 (-.2) -13 (-.51 ) -22 (-.86)

C -6 (-.24) -14 (-.55) -27 (-1.06)

D -5 (-.2) -12 (-.47) -26 (-1.02)

B -5 (-.2) -8 (-.31) -19 (-.75)

p - , (-.24) -11 (-.43) -19 (-.75)

G - 5 (-.2) -9 (-.35) -16 (-.63)

B - 5 (-.2) -10 (-.39) -17 (-.67)

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'-pyright April 1985 Canus Industries Ltd.

SECOND TOP PLATE Ul-) J',90.S.B. field installed

FIRST TOP PLATE (5/8-)15.9 O.S.B. factory installed

STANDARD TOP HEADER 2-(5/8-)15.9 O.S.B. wall skins are glued to header

INTERIOR WALL SKIN (3/8-)9.5 O.S.B.

CANUS LOW WALL PANEL (3/8-)9.5 O.S.B. ;. (3 5/16-)polyurethane ~vre (3/8-)9.5 O.S.B. outer skin

Note: polyurethane is foamed ·in place after vertical CANUS FOAMSTUDS have been inserted and glued to skins

EXTERIOR WALL SKIN 3/S-9.5 O.S.B.

STANDARD BASE PLATE 2-(5/8")15.9 O.S.B. wall skins are glued to plate

BOT't'OH PLATE -~~~~=::~a.-:------l""';(~/Ji-t'· ) JJf..9 O. S • B. ,:'t~LtJ IJ.lSTAI..I..I1r;,

FIOURE NO.1 CANUS LOW WALL PANEL(EXTERIOR) VERTICAL SECTION

...,'

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~ Copyright April 1985 Canus Industries Ltd.

FACE VIEW STANDARD CANUS O.S.B. WALLSTUD

FIOURE NO.2 O.S.B. WALLSTUD FACE VIEW

E - 15

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• • •• Warnock H~rsey Professional ~rvices Ltd. 21 i Scnoolhouse Street. COQu,tlam. BC V3K 4X9 Tei 1604) 520·3321 Telex 04·351404

REPORT OF A !'LAME SPREAD 'l'Ef?T PROGRAM

CONDUCTED ON

ORIENTED STRAND BOARD WALL PANELS WITH URETHANE FOAM CORE INSULATION

CI.IENT

SEVEN S STRUCTURES 10833 - 97 AVENUE

GRANDE PRAIRIE, ALBERTA T8V 4Y9

REPORT PREPARED BY

WARNOCK BERSEY FIRE LABORATORIES DIVXSIOB

211 SCHooLHOOSE S'l'REB'r COQOI'rIaAM., B. C.

V3K 4X9

REPORT NUMBER: 51 48

VANCOUVER JOB NUMBER: S0493-C7-S1480~

DATE TESTED: SEPT 9/86

TEST STANDARDS: CAN4-S102-M83 ASTM-E84-84a

Warnock Hersey Professional Services Ltd.

PREFACE

This report describes the tests, standards and details for the sample of prefabricated walls manufactured by Seven S Structures.

The report does not automatically impiy product certification. Products must bear WHI labels in order to demonstrate Warnock Hersey certification.

E - 18

Warnock Hersey Professional Services Ltd.

TABLE OF CONTENTS

INTRODUCTION

MATERIAL SPECIFICATIONS

TEST PROCEDURES:

FLAME SPREAD CLASSIFICATION SMOKE DEVELOPED FUEL CONTRIBUTED

TEST RESULTS

CONCLUSIONS

TIME/TEMPERATURE CURVES

SMOKE DEVELOPED CURVES

, 2

3 4 4

5 & 6

7

E - 19

Warnock Hersey Professional Services Ltd.

Report 5148 Page 1

INTRODUCTION

On September 9, 1986 the Fire Laboratories Division of Warnock Hersey conducted a test program to determine the surface burning characteristics of Seven Structures "Prefabricated Walls". I

Testing was conducted in accordance with CAN4 S102 M83 and ASTM E84 "Standard Test Method for Surface Burning Characteristics of Building Materials."

Upon receipt of the they were placed in an atmosphere of humidity until they

samples at the Warnock Hersey laboratory the conditioning room where they remained in 23 + 3°C (73.4 + 5°F) and 50 + 5% relative reach a constant weight.

3 trial runs were conducted on the sample.

E - '::0

Warnock Hersey Professional Services Ltd.

Report 5148 Page 2

MATERIAL SPECIFICATIONS

The material tested was selected and submitted by the client. It was constructed with 1/2" pelican mill,s oriented strand board and 3 1/2" urethane foam core.

E - 21

Warnock Hersey Professionol5ervices Ltd.

Report 5148 Page 3

TEST PROCEDURE

The results of the test are expressed by three indexes. index expresses the characteristics of the sample under relative to that of select grade' red oak flooring asbestos-cement board.

(A) FLAME SPREAD CLASSIFICATION:

Each test

and

This index relates to the rate of progression of a flame along a sample in the 25 foot tunnel.

A natural gas flame is applied to the front of the sample at the start of the test and drawn along the sample by a draft kept constant for the duration of the test.

An observer notes the progression of the flame front relative to time.

The flame spread classification for red oak flooring is 100, and 0 for asbestos-cement board.

CALCULATIONS:

According to the test is equal to 5363

(195-At)

standard, the flame spread classification when At is the total area beneath the

spread curve, if this area exceeds 97.5 minute-feet.

If the area beneath the curve is less than or equal to 97.5 minute-feet the classification becomes .564 x At.

ASTM E84 Calculations are based on factors of 4900

and 0.515 x At. ( 195 -At)

E -

Warnock Hersey Professional Services Ltd.

Report 5148 Page 4

TEST PROCEDURE Cont'd:

(B) SMOKE DEVELOPED:

A photocell is used to measure the amount of light which is blocked off by the smoke passing down the tunnel duct.

When the smoke the output from time is recorded red oak which is

CALCULATIONS:

from a burning sample blocks the light beam, the photocell decreases. This decrease with and compared to the results obtained for 100.

10,000 (smoke integrator reading) x 100 = smoke developed 630

(C) FUEL CONTRIBUTED:

This is a measure of how much heat energy is given off by the burning of the sample in addition to that which is supplied by the natural gas burners.

The air temperature at the vent end of the tunnel is monitored throughout the test and the results are plotted versus time and compared to the results for red oak.

CALCULATIONS:

[1.5 x (temperature integrator reading}] - 4968 x 100 = fuel 4195.5

contributed

E - 23

Warnock Hersey Professional Services Ltd.

Report 5148 Page 5

TEST RESULTS

FLAME SPREAD

The resultant flame spread classifications, is as follows: (rounded to nearest 5)

FLAME SPREAD CLASSIFICATION

Area under Trial # Temperature

#1 159

#2 157

#3 152

Avg. 156

SMOKE DEVELOPED

Time Curve

F.S.C. (5102)

154

144

127

140

F.S.C. (E84)

136

129

114

126

The areas beneath the smoke developed curve and its related classification, is as follows: (rounded to nearest 5)

TRIAL II

111

#2

#3

Avg.

AREA UNDER CURVE

3525

2400

2900

2942

SMOKE DEVELOPED

559

380

460

465

E - 24

Warnock Hersey Professional Services Ltd.

Report 5148 Page 6

TEST RESULTS: Cont'd:

FUEL CONTRIBUTED:

The resultant areas under the time/temperature curve and its related classification, is as follows: (rounded to nearest 5)

TRIAL #

#1

#2

#3

Avg.

AREA UNDER CURVE

6363

6236

5875

6158

FUEL CONTRIBUTED

109

104

91

100

Warnock Hersey Professional Services Ltd.

Report 5148 Page 7

CONCLUSIONS

The sample of Oriented Strand Board structural Panels submitted by Seven Structures exhibited the following flame spread characteristics, when tested in accordance with CAN4 S102 and ASTM E84 Standard for Surface Burning Characteristics of Building Materials.

FLAME SPREAD CLASSIFICATION

140 126

SMOKE DEVELOPED

465 465

** This is an apparent value, not a real.value

WARNOCK HERSEY

TESTED BY:

REVIEWED BY:

HAG/cw

490.D5.PC

. H.A. GRISACK, A.Sc.T. Manager - western Region' Fire Laboratories Division

FUEL ** CONTRIBUTED

100 100

E - .26

********* WARNOCK HERSEV *********

FLAME SPREAD RESULTS FOR

SEVEN STRUCTURES

PRODUCT: WALL PANELS / URETHANE CORE

TEST DATE: O~/09/86

TEST STANDARD: CAN4 S102 M83

WORK ORDER: sI)4~3-C7-s14800

RUN NUMBER: 1

******* rLAME TRAVEL IN rEET vs TIME IN MINUTES *******

as

I.~ ~~, ..

15 I /

TIME Ir-.! Mlr-.! 10

*************** TEST RESULTS ***************

AREA UNDER TIME TEMPERATURE CURVE 159 FT-MIN

rLAME SPREAD CLASSIrICATION rSCl 154

SMOKE DEVELOPED SSg

rUEL CONTRIBUTED 109

MAXIMUM DISTANCE REACHED 25 FT. AT 160 SEC.

t. -

********* WARNOCK HERSEV *********

FLAME SPREAD RC5UL18 FOR

SEVEN STRUCTURES

PRODUCT: WALL PANELS / URETHANE CORE TEST DATE: 09/09/86

TEST STANDARD: CAN4 S102 M83

WORK ORDER: S0493-C7-S14800

RUN NUMBER:

******* FLAME TRAVEL IN FEET vs TIME IN MINUTES *******

25

:.J

TIME IN MIN I~

*************** TEST RESULTS ***************

AREA UNDER TIME TEMPERATURE CURVE 157 FT-MIN

FLAME SPREAD CLASSIFICATION FSC1 144

SMOKE DEVELOPED 380

FUEL CONTRIBUTED 104

MAXIMUM DISTANCE REACHED 25 FT. AT 168 SEC.

E - ~8

********* WARNOCK HERSEV *********

FLAME SPREAD RESULTS lOR

SEVEN STRUCTURES

PRODUCT: ~ALL PANELS, 1 URETHANE CORE

TEST DATE: 09/09/86

TEST STANDARD: CAN4 5102 MB3

WORK ORDER: 50493-C7-S14800

RUN NUMBER:

******* tLAME TRAVEL IN tEET vs TIME IN MINUTES *******

25

/

/ 15

Ie

lei TIME 1M MIN

*************** TEST RESULTS ***************

AREA UNDER TIME TEMPERATURE CURVE 152 tT-MIN

tLAME SPREAD CLASSItICATION tSC1 127

SMOKE DEVELOPED 460

tUEL CONTRIBUTED 91

MAXIMUM DISTANC~ i~EACHED 25 FT. AT 192 SEC.

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E - 29

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E - 34

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... . .-.-Warnock Hersey Professional Services Ltd. 211 Schoolhouse Street. Coqultlam. B.C. V3K 4X9 Tel: (604) 520·332 '. Telex 04·351404 ,

. '

S'UHDAlU) lrIU BNDtJIlANCE TEST PI.OGRAM

CONDUCTED ON A . /

LQAD BEARING WALL

CLIEN': ....

SE'VBti S S'rRtJc:rtJUS me. 10833 - 97TH AVE&UE,

GRAm) PB.lIRIB, ALBERD 'rav 4'Y9

REPORT PREPARED BY

WAllNOClt HDSEY FIRB LABOllATORIBS DIVISION

211 SCBOOLllOtJSB S'R.BB'r eOQtJI'l'LAK, B.C.

V3~ 4X9'

REPORT NUMBER: 4550(a) ,

JOB NUMBER: 50491 C7 5,.6200

DATE 'rESTED: September 30, 1986 .'

TEST STANDARDS: CAN4-S101 & ASTM E119

'NOV 24 1986

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Wornock Hersey Professlonol ServIces Ltd.

INTRODUCTION

TEST INSTALLATION (CONSTRUCTION)

THE FIRE TEST

FIRE TEST OBSERVATIONS - EXPOSED - UNEXPOSED

THE HOSE STREAM TEST

CONCLUSION

TABLE 1

TABLE 2

FIGURE 1

FIGURE 2

FIGURE 3

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TABLE OF CONTENTS

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Warnock Hersey Professional Services Ltd.

PUFACE

This report describes the tests, standards and details of the test specimen as installed for this program.

The report does not imply product certification. Products must bear "WHI certification marks" in order to demonstrate Warnock Hersey certification.

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E - 38

Warnock Hersey P(ofesslonal Services Ltd.

Report No. 4550(a) Page 1

On September 30, 1986 the Fire ~aboratories Division of Warnock Hersey conducted a standard fire endurance test on a Load Bearin9 Wall supplied by Seven S Structures Inc. for a fire resistance ratin9. Testin9 was conducted in accordance with CAN4-S101-M82 and ASTM E119-84 Standard Method of Fire Endurance tests of Buildin9 Construction and Mater~als.

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Warnock Hersey ProfessIonal Services Ltd.

Report No. 4550(a) Page 2

TBS~ ·INS~~ION ( CONSTRUCTION )

The test portion was assembled from two panels to form a wall 9' - 2 3/4" (2813 mm) high by 14' - 4" (4368 mm) wide. The larger panel was 8' wide. The smaller panel was 6'4" wide. The wall panels were assembled from studs, top and bottom plates, wall reinforcing and face panels, all of which were cut from various thicknesses of oriented strand board (O.S.B.) A vertical crossection of the wall is shown in Figure 1. The studs as shown in Figure 2 were installed on 24" maximum· centers. These components were glued with Phenol Resorcenol from Borden at all joints. In addition the face panels were stapled. These staples were spaced at 3" on the end studs and along the bottom plate, and at 6" along intermediate studs. Three rows of staples spaced at 6" were used on the top header. Single sheets of O.S.B. formed the surface of each panel. The cavities between the studs were filled with polyurethane foamed in place.

At the joints between the panels the facing extended 1 3/4" (44 rom) beyond the studs. The cavity at the joint was filled with a filler made from polyurethane foam covered on the outer sides with 3/8" (9.5 mm) O.S.B. PL400 caulking was applied to the filler before it was. installed in the wall. Each face panel was screwed on 6" centers. The assembly was completed by attaching a 1 3/8" (34.9 mm ) O.S.B. plate on the top of the wall with 2 1/2" wallboard screws spaced 24" and placing the wall on a similar plate at the bottom.

"

E - 40

Warnock Hersey Profes~lonal Services Ltd.

Report No. 4550(a) Page 3

A load of 1500 lbs. per lineal foot was applied to the wall with hydraulic cylinders. This load was maintained throughout the test •

. The moveable frame containing the test assembly was secured to the furnace. The pilot burners were ignited and burned until the temperature ins~de the furnace reache,~ 20 .:!:. 2°C (70 .:!:. 3°F).

All burners were 'fired and timing was begun immediately upon achieving maximum high fire.

Observations were made throughout the fire exposure period.

The temperature inside the furnace was monitored by twelve uniformly distributed thermocouples. These readings were automatically plotted approximately once every minute. See Figure 3

Deflections were measured across the test assembly at midheight. See Table 2

Temperature on the unexposed surface of the wall were obtained according to the test standard. The temperature rise at each pOint was calculated. A summary of this data is shown in Table 1 •

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.-E - 41

Warnock HerseyProfessional Services Ltd •

Report No. 4550(a)

MINUTES: SECONDS

1 : 10

6:60

7:40

t·

;, Page 4

:r:cm 'rES'! OBSEaVlt.'rICNS

EXPOSErJ :rACE

~:~. ~ . . ~' ~: .: ':A '.,

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DESCRIPTION

Face ignited. Furnace f±·lled with orange flame.

Foam burning. Furnace still filled with orange flame.

Pieces of strand board flaking off the samples.

E - 42

Warnock Hersey Professional Services Ltd.

Report No. 4550(a)

MINUTES:SECONDS

9:00

10:20

FIRE TEST OBSBaVATIONS

tmBDOSBD FACE

Page 5

DESCRIPTION

Smoke venting from pin hples in face.

Ignition of unexposed face at various locations. The wall buckled and the load was released.

- M

E - 43

\Varnock Hersey Professional ServIces Ltd.

Report No. 4550(a) Page 6

Tim HOSE S'rRE.lH 'rEST

A Hose Stream test was not conducted because the wall had already failed due to burn through during the fire test.

'.'.

E - 44

Warnock Hersey Professional Services Ltd.

Report No. 4550(a) Page 7

COli CLO S IOliS

To achieve the minimum rating of 20 minutes a wall must not burn through and it must not allow water from the hose stream test to project through it. A load bearing wall must support the load for the rating period of 20 minutes.

This wall had burned through in 9 minutes and at this point would have allowed water to penetrate. At 10 minutes 20 seconds the wall was unable to support the applied load.

Therefore the Load Bearing Wall did not meet the requirements of the CAN4-S101-M82 and ASTM E119-84 test standards.

TESTED BY:

REVIEWED BY:

G.L. Marks, A.Sc.T. Fire Laboratories Division

B.A. Grisack, A.Sc.T. Manager - Western Region Fire Laboratories Division

HG/lsw 86.11.17

490.DS.PC

E - 45

Warnock Hersey Professional Services Ltd.

Report No. 4550(a) Page a

'rABLE 1

'rBMPElU.'r'ORE RISE ON UNEXPOSED SOlU'ACE 'e

MINO'rBS

Thermocouple 1 5 a .',

3 . 0 0 0

4 0 0 0

- - 5 0 0 0

a 0 0 0

10 o· o· 0

13 0 0 0

14 0 0 0 • 15 0 0 0

17 Q 0 0

- -

E - 46

Wornock HerseyProfesslono\ Services Ltd.

Report No. 45S0(a) Page 9

DD'LEC'rIONS JIIDl ( in )

(- indicate. movement away from the furnace chamber)

LOCATION LOADED 5 minute. 8 minutes ....

A -1 (0) -14 (-.55) -16 (-.63)

B -2 (-.1) -19 (-.75) -27 (-1.06)

C o (0) -20 (-.79) -28 (-1.1) .

0 -5 (-.2) -26(-1.02) -30 (-1.16)

E -2 (-.1 )

F - 3 (-.12) -28 (-1.1)

G - 1 (0) -19 (-.75) -27 .(-1.06)

H - 2 (-.1 ) -13 (-.51 ) -18 (-.71)

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-'-pyright April 1985 Canus Industries Ltd.

SECOND TOP PLATE (I~. ) J!'~O.S.B. field installed

FIRST TOP PLATE (5/8-)15.9 O.S.B. factor installed

STANDARD TOP HEADER 2-(5/8-)15.9 O.S.B. wall skins are glued to header

INTERIOR WALL SKIN {3/S-)9.5 O.S.B.

CANUS LOW WALL PANEL (3/8-)9.5 O.S.B. . (3 5/16-)polyurethane ~vre (3/8-)9.5 O.S.B. outer skin

Note: polyurethane is foamed :in..:place after vertioe.l CANtlS FOAMSTUDS have been inserted and glued to skins

EXTERIOR \'iALL SKIN 3/8-9.5 O.S.B •

STANDARD BASE PLATE 2-(5/8")15.9 O.S.B. wall skins are glued to plate

BQ'l"t'OM PLATE -~~t;~:r:~~a:--:""'-__ -L..J(!.ijt-~'. ) 31j.,'1 O.S.B. ,;",1.0 Ii/Sf/H"t.';:/)

FIOURE NO.1 CANUS LOW WALL PANEL(EXTER!OR) VERTICAL SECTION

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r-----"

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~ Copyright April 1985 _ Can us Industries Ltd.

FACE VIEW STANDARD CANUS O.S.B. WALLSTUD

L -L

H .. TYP\~AL

FIGURE NO.2· 2,.8.B. WALLSTUD FACE VI'£W

E - 49

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APPENDIX "F"

C.M.H.C. BUJlding Evaluation Report. Technical RSiuirements

F - 1 ME 830i 06114

V DiaphragIIB Stressed Skin Panels Page 1 of 4

BUILDING MATERIALS EVALUATION REPORTS TECHNICAL REQUIREMENTS

1. Standards

The materials of Diaphragms - Stressed Skin Panels must meet the requirements of the following standards to be eligible for an evaluation.

(A) Plywood shall conform to one of the following:

CSA 0115-1967, "Hardwood Plywood"; CSA 0121-M 1978, "Douglas Fir Plywood"; CSA 0151-M 1978, "Canadian Softwood Plywood"; or CSA 0153-M 1980, "Poplar Plywood".

(B) Insulating materials shall conform to the following:

CSA Al01-M 1977, "Mineral Fibre Thermal Building Insulation"; CSA A247-M 1978, "Insulating Fibreboard"; CGSB 51-GP-20M (1978), "Thermal Insulation, Expanded Polystyrene"; or CGSB 51-GP-21M (1978), "Thermal Insulation, Urethane and

Isocyanurate, Unfaced".

(C) Adhesives shall conform to:

CSA 0112-M Series 1977, "CSA Standards for Wood Adhesives"

We recommend that the adhesive is a plastic resin or a phenol formaldehydes which is a waterproof structural adhesive.

(D) Lumber:

Lumber shall be identified by a grade stamp to indicate its grade as determined by the 1978 NLGA Grading Rules for Canadian lumber. The moisture content shall be not greater than 19% at the time of installation.

The stressed skin panels as a system have to undergo the following appropriate tests.

(1) Strength tests in accordance to ASTM E72-80 "Standard Methods of Conducting Strength Tests of Panels for Building Construction".

-

-.

M£ 8307 ,,-,06114

Diaphragas Stressed Skin Panels Page 2 of 4

BUILDING MATERIALS EVALUATION REPORTS TECHNICAL REQUIREMENTS

(2) Test for Fire Resistance Rating and Sound Transmission Class Rating if the Diaphragms Stressed Skin Panels are installed in a location where certain ratings are required in the National Building Code of Canada 1980 and Residential Standards 1980. The Sound Control can be tested to ASTM E90-7S, "Laboratory Measurement of Airborne - Sound Transmission Loss of Building Partitions", or ASTM E336-77, "Measurements of Airborne Sound Insulation in Buildings". The fire resistance rating has to be tested to ULC-S101-1977 "Standard Methods of Fire Endurance Test of Building and Materials".

These standards may be purchased from:

Canadian General Standards Board c/o Supply and Services Canada Place du Portage, Phase III, 2B3 11 Laurier Street Hull, Qu6bec KIA OSS

The Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale, Ontario M9W 1tl3

American Society for Testing Materials 1916 Race Street Philadephia, Pennsylvannia 19103

2. Laboratory Testing

Testing, which is at the expense of the manufacturer, must be conducted in Canada by a recognized independent testing agency.

(1) Sound Control

Sound transmission class ratings must be determined at the facilities of:

Division of Building Research National Research Council of Canada Montreal Road Ottawa, Ontario K1A OR6

-

r - .) ME 13 30 7 06114

'-' Diaphragms Stressed Skin Panels Page 3 of 4

BUILDING MATERIALS EVALUATION REPORTS TECHNICAL REQUIREMENTS

(2) Fire Control

Fire resistance ratings must be conducted by:

Underwriters Laboratories of Canada 7 Crouse Road Scarborough, Ontario MIR 3A9

or

Speakman Centre for Materials Evaluation 2395 Speakman Drive Sheridan Park Research Community Mississauga, Ontario Canada L5K 1B3

or

Warnock Hersey Professional Services Ltd. 3210 American Drive Mississauga, Ontario L4V 1B3

(3) Remaining Test

The remaining tests must be conducted by the Speakman Centre for Materials Evaluation or Warnock Hersey Professional Services Ltd.

Proponents should contact the testing laboratories in order to obtain information regarding fees and samples required for testing. The manufacturers must authorize the laboratories to send copies of test reports directly to CMHC.

3. Submission Package

(a) A completed form, "Application for Building Material Evaluation Report".

(b) Confirmation that the proponent is an authorized representative of a legally constituted company.

F - 8

BUILDING MATERIALS EVALUATION REPORTS APPLICATION PROCEDURES

ME 86/:)4 Page 4 of 4

Evaluation Reports may be withdrawn if, in the opinion of the Materials Evaluation Department, the level of performance, in-situ, of the product is unsatisfactory or if the proponent fails to fulfill his obligations as set out in these documents.

8. Canada Mortgage and Housing Corporation reserves, to itself, its copyright with respect to Evaluation Reports except that the proponent of a product holding a valid Evaluation Report may reproduce the Report for his own purposes, providing the report is reproduced in its entirety without alteration. Alternatively, the proponent may refer to the Evaluation Report using the following phrase: "See CMHC Evaluation Report No. ( )."

9. In keeping with the Canadian Construction Industry's intention to convert to the metric system of measurement, Evaluation Reports will be publishec using metric units. Imperial equivalents will be shown in a secondary position if requested by the proponent. To facilitate the evaluation process, data should be presented using metric units of measuremen't.

APPENDIX "G"

LC.B.O. Acceptance Criteria far Sandwich Panels

LC.B.O. Quality Control Manual Requirements

G - 1

I nternational Conference of Building ·Officials Research Committee

ACCEPTANCE CRITERIA FOR SANDWICH PANELS April,1977

INDEX

Pa,c

1. SCOPE 1.1 Test Options .................................. . 1.2 Testin, AfeDC:)' and Reportin, .................... . 1.3 Facton 0 WelY ••••••••••••••••••••••••••••••• 1.4 Supplementll)' Information •.•••••••••••••••••••••

1. PANELDESCRIPTlON 2. I Dimensions. • • .. • • .. .. • • . • • • • • • .. .. • .. • . . . • • .. 1 2.2 Panel Facincl>taterial ............................ I 2.3 Panel Cores ••••.••••••••.••••••••••••••••.•••• 2 2." Panel Plates and Splines .......................... 2 loS Fastenen. • • • • • • • • • • • • • . . • • • • • • • • . . • • • • • • • • • • • 2 2.6 Door and Window Openin,s-Details •••.•••..•••••• 2

3. MISCELLANEOUS PANEL INFORMA nON 3.1 Su bstitutions .••.•••••••....•••••••.•••.•..••• • 2 3.2 Field Cut on, or Panels ..••.•..••••••••••.....•••• 2 3.3 Load TestS 00 Entire Structures ..•.•••..••......••. 2 3.4 Wall. Floor and Roof Panel Facin,s •••••.•••.••.•... 2 3.S Plumbin,lnstallation Restrictions •••••••••••••••••• 2 3.6 Elec:triea.l J MaUation Restrictions .•••.••••••••.••• • 2 3.7 Flashio,. •••••••. .••.•• . . . . . . .• •• . ••. .••• . • ••• 2

4. PANEL LOAD TEST omON 4.1 Purpose ••••••••.•.•••••..••••••••••••. : • • • • • • 2 ".2 General ••••••.•••••••••.•••••••••• : • • • • • • • • • • 2 ".3 Transverse Load Tests-Wall Panels •••••••••••••••• 2 4.4 Axial Load Tests-Wall Panels ••••••••••••••••• :.. 2 4.S Rac:kin, Shear Tests-Wall Panels ••••••••••••.••••• 3

• 4.6 Impact TestS •••••••••••••••••••••••••••••••••••• 3 4.7 Transverse Load TestS-RooCand floor Panels ........ 3 4.8 Density·Water Absorption Tests-Core Mllcrial •.••••• 3 4.9 Density Tests-Preformed Core Material •••.••...•••• 3 4.10 Tests for OtberThan Foamed Plastic: Cores ........... 3 4.11 Cocfricients of Expansion for Core and Facincs .•.•.••• 3 4.12 TemperalureDifrerentialson Panel Facin,s ••••.•.•••• 3

s. P.~NELANAL\'SISOmON . S.l Purpose •••.•.••••.•••••.•.•••••••••. '" . . • ••• ..

S.2 Facin, r..iaterials .•••••.•••••••••.•••••••....•••• 4 S.3 Core Materials •..••.••••...•••••••••..••••••••. .. S.4 Required Material Tests •••••.•••••••••••.••.•••••• 4 S.S Adhesives •••••.••• :........................... 4 S.6 Required Rackin, Shear Tests ..................... 4 S.7 Cocfricient of Expansion for Corcand Fac:lnp ...••••.• 4

6. ADDmONAL FA8RlCA TOR QUAUFlCA nON PROCEDURES ••••••••••••••••••••••••••••••••••••• 4

1. PANELIDE.''TJF1CAnON ••••••••••••••••••••••••••• ..

•• QUALrTY COSTROL •••••••••••••••••••••••••••••••• ..

1. SCOPE: The inlent of this Criteria is to provide uniform ac:c:ep­lance c:riteria for sand"'ic:h paIld construction except where specifically rquJated by the Unirorm Buildin, Code. Alternate procedures which comply wilh Ihe intenl of this Crilena will be considered.

I.J Plnd JustlneatJoa Opdons: 1.1.1 Panels may be justified by load tests as de$Clibc.'! :~

Parli!'apb 4. Justification by this melhod limits their use to sil.e$ L-.:: malenlls used in the tests. ADowable loads delermined may be ~I~ (or shoner spans or bciahts but extrapolation is not permiuecl.

1.1.1 Panels may be jusdf1ed by a rltional analysis bued o~. allowable SUesses developed as desc:ribecl in Paraaraph S.

1.1 AD testinc must be done by an approved testin,a,cnc:y. Tes:~ may ~ conducted by the proponent provided all phases are moDiIOTe-: b a .qualified independent obServer. with no financial interest. as eke:·· III!ned by the Researc:h Commlttcc prior to teslin,.

1.2.1. Tesli", procedures m~sl ~c:lude proper justification th.: lest s~mens comply with speCIficatiOns submitted as a pan of ti:~ researc:h report appUc:ation. Fabrication must be observed b,· " qualified representative of the lcain, aaeney. .

1.1.2 Test reports must be complete, inc:ludins panel desc:ripljo~ .. lest set·ups, maMer of teslina, observations. all lest rcadinp. e:: Tesl summaries are notacuptabJc.

1.3 Flctors of Safcty: 1.3.1 Faclors or safery arc set fonh in subsequenl sec:tioru a:;:

arc based on the materials involved, test procedure. panel d,(o=::· tion, and variation ohesw.

~.3.1 ~Iowable values devdopcd under P!lraaraph 1.3.1 are nc: subject to sncreases due to durauon of loadtn' unless specificali' allowed. This includes wind and seismic forces. .

1.3.3 Where loadina conditions result in several modes of rela:e: stressina, the sum of the ratios of ac:tualloads over alloll.·able loac! shaD not cxc:eed one. Wind on a burin, wall is one example of requlr· in. this consideration. .

1.4 Supplementary information may be inc:luded in the rCSQIch !cP<?", provi~~ it relates to the Uni(or.m .Buil~in, C~ Ind is properl;­Justtfied. nlls Includes sound uansrrusSlon Insulallon as specified ir Olaple,t ?S of the Uniform Buildinc Code Appendix and thmna. tran$llUsston data.

2. PANEL DESCRlPnO:-l: The panel description is 10 include th~ rollowin, information:

2.1 Thickness, width and Icnl1h for cac:h panel type .

2.2 PIOel Fldn, Mliertal: 2.2.1 The material must be ac:c:eptable under a curren! roearc~

repon. I nalional product standard. the Uniform Buildinl Code. C' be juslified 10 the satisfaction or the Research Commillcc. The malerill must be clearly identified to determine compliance.

2.2.1 Panel skins classified as wcathcr-cxposed surfaces uncer Section 424 of the Uniform Buildin, Code musl comply as a lI.·cather· resistive barrier.

2.2.3 Pand skins subject to axial or rackina shear loads must have approved values for fastenen. Where no values are rec:oplizec by the Research Committee. faslener tesu muSI be conducted f or bot~. shear and nail· head puJl.wouah at the minimum ed,e distances con· lemplated. Allowlble values for fastenen may controllllOIl.·able pane:. loads when they arc more restrictive than the pa:1C:1 lesl values Specimens shall be conditioned and. where skins arc subject 10 .... el· lin,. shall be additionally tested in Ihat manner. Sections 41 throui~ 67 of ASTM 0-10)7 serve as a ,uide for lest procedures which must b~ Ipproved prior to teslina.

COPVRIGHT.1977 by

International Conference of Building Officials 5360 so. WORKMAN Mill ROAD • WHITTIER, CAlifORNIA 90601 • (213) 699-0S--'

2.:.4 Pa~el facin~s mu\! ha\e name spread and Imol.e density as \:le(lfi~d in Se,'uon J:O~ (b) and Section 5202 of the Code. When 1:'CSC charaClefilllC1 are aff".c-d by the core mJterial of the panel. the 'Qmbined Icction sh;J1 toe testc-d ..... hen deemc-d n~essary by the

clcarch Committee.

2.3 P~nel Core,:

2.3.1 Honeycomb s~:ifications are to include a detail:d descrip­lion or dlumation noting the thickness. cell size. kraft paper ..... eiSht or metal thickness. direction of the paper or metal ribbon. percent im­pregnation of materials. etc.

:U.2 Foamed plastic spcc;fcations are to include the density. thickness. whether it is a preformc-d slab. frothc-d or expanded. foam manufacturer and the type. catalog number. etc. The position of the panel during the frothing or pourinS operation is to be specified.

2.3.3 Other core materials with specifications and descriptions .... ill be considered.

2.3.4 Any adhesi"es used must comply with U.B.C. Standard No. 25·19 or the Research Commillee SLandard for Sandwich Panel Adhesives. Adhesive specifications are to include the type. class, thickness of application. number of coatS. assembly instructions. etc.

2.3.5 When the core material does not completely fill the portion between panel facings. voidl must be detailed or properl)' described. Voidl formed by honeycomb cells are not regulated by this subsection. The method used to maintain voidl during foamins or bonding must be described.

2.3.6 Core materials classified as noncombustible must be justified under Section 41 S of the Code. Combustible core materials. including plastic. must ha ... e a minimum Class l\l name-spread classification and smoke density not exceedins 450 when tested under U.B.C. Standard No. 42·1 in the thickness intended for use.

2.4 Wood plates. splines, studs, blotkins, etc .• are to have wood -cies. srades. preser.,.ati\·e treatments and nwtimum moisture contents ime of panel manufaCTUre specified. Lumber must be stress sraded or <;\ rated material. Lurtlber bonded to panel facinp v.ith adhesives

. ust have a moisture content not in excess of that recommended by the :lhesive manufacturer. ber ..... een 7 and 16 percent. or not exceedin, a dif­-'nce of 5 percent between the fWO materials bonded, whichever is more

i::tive. Complete crou-scctional details, dimensions and sectional . ~perties of the members arc required.

2.5 COMections must be detailed or adequately described. Fasleners lust be properly specified including size.len81h and location.

2.6 Details for door and .. indo"" openinp must be provided 10 arify the maMer of supporting axial. transverse and/or rackina shear lads. This includes the method of resistins wind loadl at door and win-ow iambs. .

3. MlSCELLANEOUS PAA"EL t~TORMAnON:

3.1 No substitution of materials is allowed unless approved by the ~esearch Committee.

3.2 Field cutting of wall openiJliS is not allowed unless Specific: open­IgS or design parameters are appro~'ed by the Research Committee.

3.3 Test loads and maMCf of application of full structures shall be :>edied by the Research Committee when design parameu~rs for the full .:-ucture cannot be readil)' determined by accepted enpneerins prin­:;:Jles.

3.4 Wall panel facinp and tOP facinss of noor and roof panels shall ave sufficient strength to resist concentrated loads and prevent damase ) the core material under loadl to whicb they may be SUbjected.

3.5 Plumbing and waste lines may extend at ri,ht angles throush the ·-all panels but are not permitted \'enicaJJy within the core. Lines shall not nerrupt splines or panel plates unless specifically approved by the 'esearch Committee.

3.6 Electrical outlet boxes and raceways may be installed in the leis during fabrication at predetermined locations only. Electrical

,terns are limited to a single I·inch mlltimum (outside of diameter) vcr· cal raceway at a minimum of 4 feet on center. which is shop installed .1th no more than three outlet box openings 4 inches by 4 inches in size. 'wo Y,·inch vertical race ..... ays rtlay be substituted for the sinsle I-inch

"way pro\ided they are maintained parallel and ..... ithin 2 inches of each :r.

3.6.1 Voids other than those specified in Paragraph 3.6 will be permitted for field or shop installation of electrical .... irin. provided the voids ""ere in the panels tested. See Paragraph 3.2 for field cut openings.

3.6.2 \\'here el~rical race""a)'s interrupt or reduce the cross sec· tion of "all plates. a method of strengthening the plate at that poinl for both lateral and plate uial loads must be developed. detailed and submlttcd for e\ aluatlon.

G 2

Page2of4

3.7 Flashing and othrr wClitherproofing details a~: required for panel joints ..... ali openings. etc.

4. PASEL LOAD TEST OPTIOS:

4.1 In lieu of determining structural and mechanical propenies of panel components for ralional design purpOses, load tests may be con­ducted 10 delermine reasonable ultimate values to ..... hich factors of safety are applied.

4.2 General:

4.2.1 The testS are to be conducted as set forth under Paragraph 1.2.

~.2.2 Except for the impact test, three tests of each type arc reo quired with none \'aryin, more than IS percent from the average of the three. unless the lowest test value is used. The averale result based on a minimum of five tests may be U$ed reaardless of the variations. The results of twO tests may be u$Cd when the higher value does not exceed the lower value by more than S percent and the lower value is u$Cd with the required factors of safety.

4.2.3 Where testS are nOt conducted to failure, the hillhest load achieved for each test will be assumed as ultimate.

4.2.4 Factors of safety are dependent on the consiSlency of materials. the range of test results and the load deformation characteristics of the panel. Generally, a minimum factor of safety of three is applied to the ultimate load based on the averalle of three testS. Lower facton of safety may be assi,ned to panels or systems employins steel or aluminum havin, consistent physical properties.

4.2.5 Allowable loads will be limited by established fastener values or denection limitations if lower than values from panel loadinltests.

4.2.6 Splines or stiffeners. when utilized a10nll the edses of the panel in testS. shall be only that portion of the typical construction relati\'e to the panel bein, tested and not supplemented by adjacent panel spline areas .

4.2.7 Load testS shall be conducted v.ith cOMection details in­tended irr. field installations. The testins agency is to report any varia­tions .

~.3 Transverse Load TestS-Wan Panels:

4.3.1 With the desisned "'ind load imposed, exterior wall panel deflections shall not exceed L/180. Positive and nesative pressure con­ditions shall be considered. wall/ands with different facin, materials on opposite faces must be teSte for loadl actin, both in ..... ardly and out ..... ardly where there is a question of the most cntical direction.

4.3.2 With a S-pound-pcr-square-foot horizontal loadin, im­po$Cd, interior wall panel deflections shall not exceed LlI20 of tbe span for nexible skin material such as metal. plywood, panicleboard and ,ypsum wallboard. A deflection limitation of LI24() of the span is requITed for brittle skin materials such u plaster.

4.3.3 All wall panels shall be loaded in increments to failure with denections taken to obtain denection and set characteristics. Where preloadin, is Jpplied. the loadinS. denection and recovery shall be noted. The amount of preloadins shall not exceed 10 percent of the final allowable load unless approved by the Research Committee.

4.3.4 Transverse load tests on panels havins window or door openings are required unless subject to rational analysis. Load ap­plication must be done in a manner that renects field loading condi­tions.

4.4 AxIal Load Tests-Wan Panels: 4.4.1 Load·bearinll wall panels mUSt suppon an axial loading ap­

plied ""jth an eccentricity of one·sixth the panel thickness to the in­terior or towards the weaker facing material of an interior panel.

4.4.2 The test panels must ha\'e wall sill and cap plate details ..... ilh connections matchlO, the proposed field installation. Axial loadl must be applied uniformly or at the anticipated spacins of the noor or roof (ramtns.

4.4.3 The bOllom edses of the panel facing material shall be held at least Y. inch above the base of the sill plate 10 insure no direct bear· inl of the facings llsainst test equipment framin,. Panels may be in­verted durin; test in, if desired to meet the above loading reo quirements. If. due to denection, the Y.-inch panel base clearance is dissipated. the load a! this point shall be specified.

4.4.4 Lintel sections shall meet the denection criteria of Table No. 23·0 o( the Code.

4.4.5 All wall panels ~hall be loaded in increments to failure with denections taken to obtain deflection and set characteristics. Where preloadin, is applied. the loadin,. denection and recovery shall be noted. The amount of preloading shall not exceed 10 percent of the flOal allowable 103d unless arrroved by the Research Commillee.

Paa, 301. G-3 4.5 IUc"';n\: Shur Trsu-Wan rallt'ls:

4.5.1 Rlc~in, shear tUIl in accordance .. ith ASTM E·72. IS amended b)' t his Standard .• , e rtQuirf<! (or shear walls "'hich rai$! .. ind and seismic forces.

4.5.1 The allo"'able shear I".d is determined (rom the rackinl lo.d .t "'hich • net horizontal denection of ~ inch o«vn, the ultimllc load divided by • r'CtOr o( ,,(tty determined in .ccordance with Pualraph •. 1.4. or the .1I0 ..... ble fastener loads. whichever is the lower. The tCSt panel must be constructf<! and inst.Ued IS intended in the field. includinl connections. Reference is also made to Par'at.ph •. 2.6 of this Standard.

In reference to Paravaph •. S.7, hold-down rods mlY be used pro­vided alIo ...... ble net horizontal denections arc reduced to l< inch.

4.5.3 The "SlOp" detailed In the ASTM E·71 procedure for In· sWlation llainst the toe of the test panel should be located in such I manner that reactive forces are imposed lIainst &he end of the sill plate and clear of the panel spUne Ind ficin, material.

4.5.4 The bottom cdles of the panel flcinl mllcrial must be held at least % inch abo\'e the base of the sill pIlle to insure laainst direct veniw beannl or fricitional shear resistance of the flCinp apinS! test eqwpment framinl. The tcstin,laborltory shall indicate &he load II ..... hich the Yo·inch panel base clearance from &he test rrame is dissipated.

•. 5.5 The panel top horizontal timber sUQested for &he test panel in the ASTM E· 72 sketch shall not be used. The rackin, shear load should be applied directly alainst the typical wall panel lOP plate member or members that duplicate actual field construction unless other ..... ise Ipproved.

4.5.6 All wall panels shill be loaded In Incrcmenu to failure with deflections taken to obllin deflection and set characteristics. Where preloadinl is Ipplied, the 10ldina. denection and recovery ahaIl be noted. The amount of preloldinl shall not exceed 10 percent of the final alIO"'able load unlcss approved b), the Ilcscarch Committee.

•• 5.7 The standard racltinl shear hold-dOWD rods shall JlOl be used. Panel elemenu and connections to the base shall resist &he uplift forees. Sec Par&Jrlph 4.S.1 for alternate.

•. 6 Impact Tesu:

406.1 Impact tcSU shail be conducted trhcn required by the Research Committee.

4.6.2 The tcsu are to be conducted in Iccordance with ASTM E· 12 Equipmenl and Principles for "Impact Load Specimen Horizon­tal" 10 delermine the point 1\ which tbe panel racin, becomes deformed or delaminated Crom the core material. 'Tbe test utiliza • 6().pound Slrld bal drop. Full-size sandwich panels, usually 4 by • reel in size. arc CUI in two, Cormin,lwo 4- by "'(OOt lest panels. The bIlf. plnels are supponed alon,thr two sides and end remainin, from tbe full-size panel, leavinlthe CUI edle unsupponed. The test panels Ire restrained oyer their supports with a sprillJ-Ioaded 'rame to reduce "jump" Ifter impact. The amount of restraint shill be no lesslhan 10 times the weilht of the half.panel. The point of impact for botb tesu shall be &he ,eometric center of the bIlf-panel race. except when I spline or rib occurs 1\ that section. When this occurs, the tar,Cl shall be mo\'ed to impact midwa)' between any splines or n'bs.

4.6.3 The 6().pound standard sand bai Is dropped from a beiaht of 7 feet I total of four umes. The taraCl area Is chen cut Into J1·inch squares. cornered on the middle of the impact area to dclcrminc If delamination has occured. The second balf·panel Is tested and in­spected in the same mlMer. Should no delamination or deformation be found in either panel at &he point of Impact or elsewhere aIon, the cut edle of the pand, the pand Clcin, is considered satisfactory with the speci fie core materia\.

4.6.4 If one of the panels fails ... t01l1 offour half·panels shall be tested in the urne manner. Three of the four panels ahaIl not delaminate from &he facin, material to be considered satisfactory.

4.6.5 Impact tesu on panels havin, sinale or double curvature such as in shells or domes arc 10 be tested with the convex surflce up­ward. The panels shan closely Ipproximlte the •• b), 4-foot nit test panel. l..on,er spans Ire not permitted due to their ateater enellY Ib­sorption characteristics. T CSIS shall othervoiu be the same as for the flit panels.

4.6.6 Panc\s hlvinl metallic facinp which Irt cxcessivel), deformed by the sand bal .. ithout reboundina to their orisina! posi· tion arc considered unsatisf ac:tory.

4.6.7 When there is I qucstion of brillle panel fadnp, sup­plemenlary tcsu may be necessary, as determined by the Research Commillee.

4.7 Tnnsyrrw Lold Tcsts-Roof Ind Floor Pillels:

4. '7. J Allowlble loads for foof Ind noor panels are dttcrmined under Paralraphs 4.1.2 to '.2.7. Panels shall comply with the denec· tion requirement of Tlble No. 13·0 of Ihe Code. Additionally, roof

panel~ shall tw limited to. muimum denection of the sran CI\'Oe: . ISO ""hen subjected to roof h~e load 01 snow load. whlche\cl Ie" e'-

4. '7.1 Deflection rcadinlS are 10 be taken II mid·span I: c.:' edle and the center of the panel. Panels ICSted o~er I double S;:>6r. •.. 10 h'''e the same th!ee deneCtion rcadinJs tlken II the e~pt'(:tC'~ ~:., 1m urn denecllon POint based on analYSis.

4.7.3 Roof panels havinl differenl Clcinl materi.1s on the u~, panel are to be lested so cach rlcinl material will be in compr~~.:: Ind tension. Floor panels or panels tested on I IWo-SpIt! cor.Cltl:· need nOI be tested in both directions .

4.7.4 The "Ba, Mtthod," vacuum chamber or a unli,,::-:-. loadinl of known UNt weilhu shall be used for transverse tCSts.

4.' OetWI)',Wller Absorpllon Tests-Foamed Plastic Core M2ttril:

•• 1.1 The density and Wiler absorption characteris:ic:s c' foamed-in.pl~ce cores arc to be determined f~om the load test. pa~:. after compleuon of tests. The test procedure In ASTM C·271ls to :: utilized .. ·ith the rollowinl revisions.

4.1.1 The conditionin, temperature of Section '.\.1 oC AST'.' C·2'72 is to be increased to IS8 de,rees Fahrenheit, plus or r:.in:J! : delrees, in lieu of the specified 122 dearccs Flhrenheit.

..'.3 Ilcprcsenlltive specimens shall be taken from panels Iha: hlYe been Ideq,:,at~ly ~red. :ne r~rt sh~l s~fy curin, ;::,­cedures. Panels tndlcatlft, obYlous discrepancies In load tCSt res:.::'.: due to insufficient curin, shall nOI be used.

..,.. Six specimens shill be liken from a representative p&I'Ie) c' each Sct subjected to the UIJUVCtSC loadinltest.

'.'.5 The densit)"WIter Ibso."uon specimens are to be obtaine: IS follo-.'I, assumina I .... by .. root pando The previousl), tcsted !-.:. size solid panels are cut IC10U the 4·rOOt dimension .to 8 inches fTC~ each end and then 10naitvdinaJly down the middle of &he rer..a.ir.i~; center portion. Three-inc:h-square samples arc cut from each outsi'~ quitter point of &he end sections and one sample cut from each of :r.: two remainm, center ponions, toWin, six samples from each pa:'!e. The samples arc to be cut I minimum of J inch a .... )' from an)' spline: A sketch Is to be included In the laboratory rcpon locatinl ar.; numbcriAa the location or each specimen. •

..'.6 The 3-1ncb-square samples are cut to maintain &he emir: pand thickness includina fadnp. The volumetric dimensions af: measured "IS received" Ind .fter removal of f.elnls in accordanc! .. ith Paraaraph 3 of ASTM C·l71. The densitY and WIter absorpnc­tesu arc conducted in Iccordlnce with ASTM C-2'71 with Ihe facin:;; removed. Care must be aken to assure that I minimal core mlleria)',. removed. Dimensions are aken after &he fust oven curinl and afl:­each conditionin, or &he absorption tcsu. After &he final oven dt)in~ the specimen dimensions arc recorded. -

'.1.7 The two-hour immcnion linear measurements required :-. ASTM C-l71 rna)' be omitted. .

•• '.' Foam density variations for the different urnple locatio~.' ma)' not vary by more than lS percent from Ill)' other sample take: from &he same pand based on &he lower value of the two beinl coer.· pared.

•••• 9 Subsequent density-water absorption tesu in conjunClic~. wi&h qualitY conuol or rt-eJWftinations by the Ilcsearch Commil\!~ must (ollow che same test procedure as used initially to assure Il'.: validity of comparinl resulu.

•• 9 DeasltJ Tesu-PRformtd FOlmtd Plastic Core Materis. Panels hlvin4 preformed foam cores bonded in place with an Idhesive a:· to have dcnsat)' tesu conducted in accordance with ASTM C·27!. T",' samples arc to be cut from one of each set of panels SUbjected 10 the lUll! transverse loadinl and rackinl shear tesu. respectively. The sarnpl~ a~. to hive the flcinl material removed, tOltther with any .dhesive ir prcanlted core material prior to the densit)· determination. The avera, density values arc to be based on a minimum of six samplcs. Panels ",'," window and door openinp arc to have &heir cores trcated in a simi:;, maMer.

4.10 Densit)" shear and other tCSU for other than foamed plas: .. cores shall be determined by the Rcsearch Commillee.

4.11 Substantial differences In coefficienLS of cxpansion betwee~ core and flcinl materills require justification that this will not c, dctrimenlalto Ihe panel intearity. Tcstinl under ASTM C·J93 after agir. under Cycle B. ASTM C-481 shall be considered sufficient 10 delemm this quality. Heated dry lir shall be increased 10 112 dqrees Fahrenhe, plus or minus 1 de,rees. in Cycle B.

4.1l Substantial diCferences in temperature between flcings 0:' paoel .. ;th hilh coefficienu of cxpltlSion require justification that It wil1 not be detriment II to the panel intearity.

S. PA~EL A~."LYSIS OPTIO:"':

5.1 To provide nexibility in panel size .. ;th minimal full scale panel <:sting. the characteristics and a1lo ... ·able Stresses for each material used in

panels may be determined 10 pennit a rational analysis. Supplemental .s on actual panels ";11 be necessary only to verify desisn assumptions

lnd criteria.

S.2 Each facing material. unJes.s allowable work ins stresses arc :s:ablished in the Uniform BuildinS Code or arc acceptable to the Research Committee. is to ha\'c the follo .. ;ns characteristics determined ~. representative tesu. Waiver of any of the foUo"'ing characteristics :nust be ... iLh Lhe concurrence of the RCKilch Commitlee.

S.l.1 Modulus of elasticilY ('Dendins).

S.2.2 Tension parallel to surfac::e.

5.1.3 Tension perpendicular to surface.

5.2.4 Modulus of rupture.

5.2.5 Compression parallel to surface.

5.2.6 Shear parallel to surface.

5.1.7 Densiry.

5.1.' Shear modulus. 5.2.9 Fastener values in shear and, where applicable, nail· or

screw-head pull-throush for each facina material as set fonh in Parasraph 2.2.3.

5.3 Panel cores shall have the foUO-1DS characteristics established:

5.3.1 Modulus of elasticiry ('Dendin&).

5.3.2 Tension perpendicular to surfac::e.

5.3.3 Compression perpcndic:ular to surface.

5.3.4 Shear parallel to surface.

5.3.5 Shear modulus (in eacb direction for honeycomb and foam materials).

5.3.6 Density for (oam.s and related produc:ts, core size, weiSht and desree of impregnation (or paper honeycomb or the standard identification specification (or aluminum or )jSht Saule Steel honeycomb.

5.4 tests to determine the facinl and cora characterlstlcs.1II as follows: .

5.4.1 Tension-ASTM c·m, "Tension Tat of Flat Sandwich Construction in Flatwise Plane." for cora material, and ASTM 0-' 037. "Evaluatins the Properties o( Wood Base Fiber and Panicle Panel Materials," Sections 20 to 16 and 27 to 32. (or (acin, material.

5.4.2 Compression-AS'TM 1).1037. "Evaluatin, the Properties of Wood Base Fiber and Particle Pand Materials," Sections 104 to 110. Procedure 3, (or facins material.

5.4.3 Shear and Shear Modulus-ASTM C·273, "Shear Test in F1atwise Plane o( Flat Sand .. ich Construction or Sandwich Cores." ror core and {acing material by tension tests.

5.4.4 Modulus of Ruprure-ASl'M C-393. "Flexure Tests of Flat Sandwich Construction." (or evaluation o( racina materials in sand wich construction.

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Page 4 of 4 5 .•. 5 Density-Parasraph •. 8 for rr<)thed or .poured·in·place

foams and ASTM C-271, "Density of Core Materials for Structural Sandwich Constructions." for slab-type foams bonded in place in the panels.

5.4.6 Modulus o( E1asticity-ASTM C-393. "F1exure Test of Flat Sandwich Constructions," (or facins materials in sandwich con. struction.

5.4.7 Fastener Values-ASTM 0-1037. "Evaluating the Proper. ties of Wood·Base Fiber and Partic:Je Panel Malerials," Sections 41 10 67.

5.4.' Compression-ASTM C·365, "F1atwise Compressive Strenllh o( Sandwich Cores." Method "B" for core material.

5.5 Adhesives are to comply with U.B.C. Standard No. 25·19 or the RCKarch Committee Standard for Sandwich Panel Adhesives.

5.6 Rackinl shear loads must be determined under Parasraph 4.5. Density and water absorption tests on six specimens (rom one panel in confomanc:e with Section 4.8 arc required for foamed panels.

5.7 Coefficients of expansion of core and fadns materials shall be investipted as noted in Parqraphs 4.11 ~ 4.12.

6. ADDmONAL FABRICATOR QUAUFlCATION PROCE­DURES: The foUowin, proc:eclures arc necessary for recosnltion of sup­p1emenwy fabricatina facilities:

6.1 A qualified representative of an approved testins aseney shall select at least three panels at random of each panel core type. The panels are to be permanently identified by the laboratory perSOMel and shipped II) the latin,aaeney rac:i1ity.

6.2 Each of the three panels sdected shall be SUbjected to a transVerse load test in accordance with Section •• 3 or 4.7. The test results shall be no lower than 85 percent of the averaae oriainal plant transverse test results.

6.3 For foamed·in-place cores. one panel is to be selected for each panel type and six density-waler absorption specimens cut from the panel and tested in accordance with Sections 4.8 and 4.9. The density-water ab­sorption test averaae shall be no lower than 8S percent of the original plant test avera,e nor shall any specimen vary more than 25 percent in density from any other sample taken from the same panel. based on the lowest value.

6'.4 The preformed core panel density shall aaree with the oricinal core density.

7. PANEL IDENTIFICATION: Panels shall bear the company name. research rcpon number and other information deemed necessary by the Research Committee. The identification must be visible after the ~els are erected. Exterior panels must have the exterior facc clearly identified.

8. QUALITY CONTROL: Quality control procedures with monitorins inspec:tions by an approved inspec:tion aseney shall be developed for each fabrication facility based on the panel construction, application. volume of production. etc. The procedures shall be included in a quality control manual which must be developed jointly by the fabricator and inspection aseney. Panel fabrication is not sanctioned un­til qualiry control procedures have been approved.

e·'· . t·~-..·

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leBO Evaluation Service, Inc. A subsidiary corporation of the International Conference of Building Officials

5360 SOUTH WORKMAN MILL ROAD • WHITTIER, CALIFORNIA 90601 • (213) 699-0543, 4 or 5

QUALITY CONTROL MAlWAL REQUIREMENTS

(Adopted April, 1986)

I. GENERAL:

The quality control manual must be prepared by the manufacturer in consultation with a quality control agency recognized by the ICBOES.

Follow-up inspection frequency must be u speCified by the quality control agency but not less than four inspections per year for facUities in operation during the entire year. Consideration of fewer Inspections will require the written concurrence of the ICBOES. Since plants employing seuonal production schedules are more exposed to quality control related problems because of the Inactive periods, the quality control&lency may require supplemental inspections during each start-up period. The supplemental inspections and other special requirements must be specified in the manual.

In administering a quality control program on a product covered by an ICBOES evaluation report, the inspection agency has the responsibllty of taking necessary action in the event of violations. The determination of a major or minor problem of quality control is by the inspection &lency, who in turn, must advise the ICBOES in writing of a major violation. The ICBOES defines a major violation u a production discrepancy, contrary to quality control procedures, that presents a potential hazard to the user.

Total control by the Inspection agency of Identification methods specified in evaluation reports is necessary in order that the quality control agency can better monitor production of the listed item. This requires that the entire process De acim1nistered by the &lency. Printing of labels may be done by others with the proper control.

D. ADMINISTRATIVE SECTION:

a. Signatures which confer legitimacy to the document. Both the manufacturer and the quality control agency must sign and date the manual.

b. Scope.

c. Table of contents keyed to consecutively numbered pages.

d. Company quality control pollcles.

Iqiona\ Offices: 6738 N.W. Tower Oriw • Kanus Cily, Missouri 64151 • (816) 741·2241 12505 Bellevue-Redmond R~d, Suile 208 • Bellevue, Washington 98005 • (206) 451·9541

603 West 131h Str"" Suite 2·F • AuSlin, Texas 78701 • (S 12) 479·8278

G - 6 Quality Control Manual Requirements

2

e. Organizational charts, resume of key personnel and responsibility pertinent to the quality function for both the manufacturer and the quality control agency.

f. Provision for keeping the manual current, e.g., annual review, revisions, etc.

g. Glossary of terms used where unique to the product or manufacturing process.

h. Name, address and telephone number of the manufacturing facility and individual responsible for supervision of quality control.

i. Frequency of follow-up inspections by the quality control agency including specific details on supplemental inspections for plants employing seasonal production schedules.

j. Identification: F.acslmUe of identification label and details on label control as noted in Section I.

k. Postmanufacture: Information on pacldng and storage if deemed necessary for product performance.

1. A statement that ICBOES will be notified in writing prior to cancellation of the inspection agreement with the quality control agency.

m. A statement that ICBOES will be notified in writing of major deviations discovered by the quality control agency, including disposition thereof.

n. A statement that the manufacturer will notify the quality control agency when production is halted and when resumption is planned. Start up is not permitted untU authorized by the quality control agency.

o. A statement that ICBOES will be notified in writing if follow-up inspections have not been conducted in accordance with the approved manual.

p. A statement that the manufacturer and the quality control agency will promptly investigate and respond to the ICBOES when appraised of field complaints concerning product performance.

m. TECHNICAL SECTION:

a. Production now chart and resume of production methods.

b. Product specification, assembly drawings, manufacturing tolerances.

,

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Quality Control Manual Requirements

3

c. Classification of defects: Clear delineation of major and minor defects must be included.

d. List of major production equipment.

e. Incoming inspection and tests.

f. In-process quality controls, final inspection and test, visual and other sensory standards.

g. Nonconforming Materials: Identification, segregation, classification of defects, material review board, corrective action.

h. Measuring Equipment: Type, model, range, accuracy, calibration.

i. Data Systems: Collection of inspection and test data, recording, summary, analysis and reporting, covering all the foregoing activities including samples of forms, check lists and reports for both the inspection agency and the manufacturer.

CPR:ec