This page provides background on the development of HyperWall panels and summarizes key test results to date. It is a “living document” that will be updated periodically as additional tests are completed. The date at the top of this report indicates when the most recent version was posted.
Research and Development History
TheHyperWall™ system offers an innovative approach to building construction that combines prefabricated structural composite panels with optional pre-installed glazing and on-site installation. It’s a complete architectural building skin system that allows for faster-constructed buildings with fewer trades and subcontractors to coordinate on-site.
The HyperWall panel system is the culmination of a four-year research project established to meet the following goals:
Reduce on-site labor
Reduce construction time
Reduce installed cladding costs (compared to architectural precast concrete)
Reduce timelines to enclose buildings by 33%
Reduce embodied carbon by at least 50%
Reduce the need for high-risk work on scaffolds and in bucket lifts
Enable architects to achieve more innovative building designs
Multiple options for materials and methods were considered, of which three different technologies were eventually selected for further evaluation:
[.green]Precast concrete —[.green] lightweight concrete utilized in a traditional way
[.green]Partial composite —[.green] panels comprised of steel studs and expanded polystyrene (EPS) foam
These were incorporated into an 80 feet by 40 feet, two-story demonstration building, which included six exterior wall finish options, as well as off-site and on-site prefab. The building used products from four wall panel manufacturers, with designs ranging from combination to fully composite materials.
Demonstration building in Manassas, Va.
The demonstration building was erected in Manassas, Va., near Dulles International Airport. It was later moved and donated to Virginia Tech, where it is now used for research projects by their building construction department.
Ultimately, an all-FRP structural composite panel system stood out to the R&D team for its light weight, simple installation, versatility and cost-competitiveness. Further research verified that the system could meet the goals of the project, satisfy all relevant building codes, and offer a practical alternative to other technologies.
Now in commercial production, the HyperWall panel system is being utilized by leading construction, architecture and development firms in advanced, sustainability-focused projects.
Structural composites are poised to revolutionize the building industry.
HyperWall panels have passed all of the following tests:
Flammability Testing
Test
Description
NFPA 285
Evaluates the fire performance of exterior wall assemblies, specifically their resistance to vertical and lateral flame spread when exposed to an intense fire scenario. It ensures that materials used in wall construction meet safety standards for preventing the spread of fire in multi-story buildings.
NFPA 268
Assesses the ignition resistance of exterior wall assemblies when exposed to radiant heat. It evaluates the ability of the wall system to resist ignition under specific conditions, ensuring materials meet safety standards to prevent fire initiation on the building’s exterior.
ASTM E84
Also known as the Steiner tunnel test, this trial measures the flame spread and smoke development characteristics of building materials. It determines how quickly flames spread across a material’s surface and the amount of smoke produced, helping to classify materials for fire safety in building codes.
NFPA 285 testing
Coupon-Level Structural Testing
Test
Description
ASTM D570
Measures the water absorption of plastic materials by determining the amount of water absorbed after immersion. It helps evaluate a material’s resistance to water penetration, which is crucial for assessing its suitability for various applications where moisture exposure is a concern.
ASTM E831
Measures the linear thermal expansion of solid materials using a thermomechanical analyzer. It determines how much a material expands or contracts with temperature changes, which is essential for evaluating the material’s dimensional stability in varying thermal environments.
ASTM D3039
Determines the tensile properties of polymer matrix composite materials. It measures the material’s strength and elongation under tension, providing key data on its performance under tensile loads, which is crucial for assessing its suitability in structural applications.
ASTM D6641
Determines the compressive properties of polymer matrix composite materials using a combined loading compression (CLC) test fixture. It measures the material’s compressive strength, modulus and strain, providing essential data for evaluating its performance under compressive loads in structural applications.
ASTM D7078
Measures the shear properties of composite materials using a V-notched rail shear method. It determines the shear strength and modulus of the material, providing critical data on its performance under shear stress, which is important for assessing its suitability in various structural applications.
ASTM D2344
Measures the short-beam strength of composite materials to evaluate their interlaminar shear properties. This test provides insight into the material’s ability to resist delamination and shear stress between layers, which is crucial for assessing the structural integrity of laminated composites.
ASTM D732
Determines the shear strength of plastic materials using a punch-type shear test. It measures the force required to shear the material, providing valuable data on its shear resistance, which is important for evaluating its performance in applications where shear stress is a factor.
ASTM D953
Measures the bearing strength of rigid plastics by determining their ability to withstand compressive loads applied through a fastener, such as a bolt or rivet. This test is essential for evaluating the material’s performance in applications where bearing stress is critical.
Full-Scale Structural Testing
Test
Description
Custom Panel Performance and Connections Testing
Multiple full-scale structural tests have been performed at the request of the Building Composites internal structural architecture team. The primary purpose of these custom assessments is to validate our design methodology, simultaneously testing the panel performance and connections.
Analytical and FEA designs were created, followed by full-scale testing, which validated the accuracy of both models. This was an important confirmation for the team, since HyperWall panels are customized to the specific shape and size required by each architect — it’s not possible to do full-scale testing on every different shape and connection configuration.
Coating Testing
Test
Description
AAMA 625-10
Specifies performance requirements for superior organic coatings on fiber-reinforced thermoset profiles, such as pultruded fiberglass. It includes tests for weathering, color retention, chalk resistance and coating adhesion, ensuring long-term durability and appearance for these architectural components.
ASTM D3359
Assesses the adhesion of coatings to substrates using a tape test. It evaluates how well a coating adheres by scoring the surface and applying tape to determine the amount of coating that peels off, ensuring the durability and effectiveness of the coating.
Functional Testing
Test
Description
ASTM E331
Evaluates the water penetration resistance of exterior windows, skylights, doors and curtain walls when subjected to a controlled water spray and air pressure. It ensures that these building components can withstand wind-driven rain and prevent water infiltration into the building.
ASTM C794
Measures the adhesion properties of sealants to various substrates by determining their peel strength. This test assesses how well a sealant adheres to surfaces, ensuring its effectiveness in maintaining seals and preventing leaks in building applications.
ASTM C1363
Measures the thermal performance of building envelope assemblies by determining their thermal resistance (R-value) and thermal transmittance (U-factor). This test simulates real-world conditions to assess how well a wall, roof or floor system resists heat flow, ensuring energy efficiency in building designs.
Note: R-values for HyperWall panels are dynamic because the ratio of FRP to foam varies by application. Testing was performed on 5-inch and 9.5-inch specimens; R-values for other designs can be calculated by interpolation between the results.
ASTM E90
Measures the airborne sound transmission loss of building partitions and elements, such as walls and doors. It determines the Sound Transmission Class (STC) rating, indicating the material’s effectiveness in reducing noise transmission, which is crucial for assessing acoustic performance in building design.
Note: As with R-values, STC reductions will vary. The same testing and interpolation methodology used for ASTM C1363 will be utilized for STC values.
ASTM E283
Measures air leakage rates through exterior windows, curtain walls and doors under specified pressure differences. It assesses the airtightness of building components, helping to ensure energy efficiency and weather resistance in building designs.
For More Information
Full testing reports are available upon request. Contact Andrew Elliot at [.nowrap]aelliot@building-composites.com[.nowrap] for details.
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