ENGINEERING CALCULATIONS

APPLICATION FEATURES
ENGINEERING LOADS / SPAN / SHEAR / RULES OF THUMB / THEORY / CANTILEVER

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Email: info@bondor.co.nz
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ISO 9001
 Theory
Panel failure occurs principally when a plastic hinge forms a compression failure of the
panel skin. ULS curves are based on this mechanism of failure.

For flat panels, (including lightly profiled)

From Allen, H.G.

Critical buckling wavelength = 2 x t x C ( Est/ E Core ( 1 - νst2))

Where C = Pl (( 3 - νCore ) ( 1 + νCore )/12) ⅓----------------------

Applied Bending Moment can be calculated using

M ult = W DL x b L 2⁄8 Ksh1 + WLL x bL2⁄8 Ksh2

Where:
WDL = Panel Dead Load
WLL = Panel Live Load
b= Panel Width
L= Single Span Length
Ksh = Sharing Factor 1.03 for Distributed Load

Now σcrit (95%) = B1 ( Est/ (1-ν st2) x E core2)⅓ 5% lower probability limit from Allen H.G.

Where B1 = 3 x(12x(3- νcore)2 x ( 1 + νcore)2) -⅓

Est = 205 Gpa
E = 2.8 MPa
ν = 0.15
B1 = 0.617 for 75 mm plus panel
B1 = 0.53 for 50 mm panel

σcrit 72.2 MPa for 50 mm panel

σcrit 74.3 MPa for 75 mm to 300 mm panel

Creep of the plastic laminate induced by heavy loads reduces load-bearing capacity of
insulated panel. This can be accounted for with a long-term load reduction factor.

It has been reported, Davies, J.M., That creep related deformation is partially recovered
after unloading. No data for reloading has been reported. Suspect rapid return to creep
loaded deformation.

For different load types different Ultimate Limit State maximum bending moments are
allowed.

b = Panel width
Earthquake use; M ult = 1.3 x σcrit x b.t.c
Loads less than an hour (wind) M ult = σcrit x b.t.c t = Skin thickness
Loads less than 1 year M ult = 0.65 x σcrit x b.t.c c= Panel core
Load more than 1 year M ult = 0.5 x σcrit x b.t.c

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 The critical skin thickness is on the face, which is under compression. In wind uplift
application the internal ceiling skin is the critical thickness, in internal negative pressure
applications the external skin is the critical thickness.

Accordingly, a combination of span charts should be used for an application of a panel

which has a combination of two skin thicknesses. This has been catered to in Fig 1.

The critical difference with the panels with thin panels (50 mm) is the top skin will pass
through the neutral axis under normal conditions before buckling failure initiates.

Fig 1: Panel Span (m)

• Allowable UDL accounting for ULS SLS Span/200 single or multiple span condition

PANEL THICKNESS 2.0 2.4 3.0 3.6 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0

50 mm 2.20 1.77 1.33 1.03 0.88 0.59 0.41 0.30 0.23 0.18 0.15 0.12 0.09

75 mm 3.36 2.73 2.09 1.66 1.42 0.91 0.63 0.46 0.35 0.28 0.23 0.19 0.16

100 mm 4.52 3.70 2.86 2.29 1.89 1.21 0.84 0.62 0.47 0.37 0.30 0.25 0.21

125 mm 5.69 4.67 3.64 2.92 2.36 1.51 1.05 0.77 0.59 0.47 0.38 0.31 0.26

150 mm 6.86 5.64 4.41 3.50 2.83 1.81 1.26 0.93 0.71 0.56 0.45 0.37 0.31

175 mm 8.02 6.61 5.19 4.08 3.31 2.12 1.47 1.08 0.83 0.65 0.53 0.44 0.37

200 mm 9.19 7.59 5.96 4.66 3.78 2.42 1.68 1.23 0.94 0.75 0.60 0.50 0.42

250 mm 11.53 9.53 7.52 5.83 4.72 3.02 2.10 1.54 1.18 0.93 0.76 0.62 0.52

>0.87 KPa Minimum Exterior Span data is generated in accordance with AS/NZS 1170: 2011
Based on 5% LPL 80% Confidence
>0.5 Minimum Internal

<0.5 KPa Special Design

Now

Panel dead load is excluded in the span charts, dead load and applicable safety
factor is included in applied load.

Fig 2: Dead Load

PANEL THICKNESS XFLAM PANEL

50 mm 0.12 kPa
75 mm 0.13 kPa
100 mm 0.14 kPa
125 mm 0.15 kPa
150 mm 0.16 kPa
175 mm 0.17 kPa
200 mm 0.17 kPa
250 mm 0.19 kPa
300 mm 0.20 kPa

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 Cantilever Panel

Load which may induce failure in a cantilevered application can be derived from

0.6 M ult = WDL x b x L 2 + WLL x b x L2

2 x ksh 2 x Ksh

Assuming a 1.2 kN (a man and a tool box), load may be applied to the edge of the panel
and that load may be shared with adjoining panels, apply a 0.8 kN to the edge of the
panel, thus reducing the load capacity such that;

WDL_ + WLL_ = 2 x Ksh x (0.6 M ult - 800 x L)

bxL2

Shear

For Shear loading of panels, use;

Shear Modulus G Core = E Core /2 x (1 + ν Core)

Testing of panel provides shear modulus for uniformly distributed loads

Gc UDL = 1.61 MPa 50 mm Panel

= 1.93 MPa for 75 mm plus panel

Panels have not been tested for shear failure associated with point loads.

Deflection of panel is generally limited to span / 200 or span / 150

Δ UDL = 5W L4 + WL2 A = b.d

384 D 8 AGcore

Where D = Est / (1 - ν st2) x btd2/2 + E core bc3/12

d = panel thickness = c+2t

Δ Pt Load = PL3/48 D + PL/4 AGcore (100mm dia bearing surface)

Cantilever - UDL

0.6 M ult = WDL x b x L 2 + WLL x b x L2

Ksh 2 x Ksh

Δ UDL = WL4 + WL2 A = b.d

3D 8 AGcore

Cantilever Point Load

0.6 M ult = WDL x b x L 2 + PxL

2 x Ksh Ksh

Δ UDL = WL3 + WL2 A = b.d

3D 8 AGcore

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 Rivets

If the panel faces are reduced in thickness, rivet load capacity will also reduce as per the
following table. Failure is always assumed to occur in the steel sheet in preference to the
rivet.

Fig 3:

SKIN THICKNESS 0.4 mm 0.5 mm 0.6 mm

SHEAR 0.97 kN 1.21 kN 1.45 kN

SLIP- JOINT SHEAR 0.6 kN 0.75 kN 0.9 kN

TENSION 0.5 kN 0.7 kN 0.8 kN

DE-LAMINATING MIDDLE 1.13 kN 1.46 kN 1.6 kN

DE-LAMINATING EDGE 0.41 kN 0.46 kN 0.5 kN

Checking

The load capacities predicted here have been compared with span charts derived from
BRANZ test BR 231/1, STO611 and STO782. Span charts derived from in house testing of a
variety of panels and external tests under cyclone loading have been used to validate the
results presented here. Further the span charts produced here have been compared with
published literature from domestic and overseas panel manufacturers.

Rules of thumb for Panel

Tensile Capacity of a panel with 0.6mm skins is 432kN/panel

Limiting performance is defined by the shear capacity of a rivet being 1.45 kN/rivet for a
4.8mm nominal rivet.

Each panel, regardless of thickness, will provide 100 bracing units per panel at
2.4 m height, (20 bracing unit’s = 1 kN)

It’s reasonable to extrapolate between 1.2m (200 BU’s) and 4.8m (50 BU’s) beyond that
conversion to diaphragm analysis is required.

Shear load is transferred by rivets into the floor/ground or the perpendicular walls/ceiling/
roof at a rate of 1.21 kN per 4.8 mm diameter rivet.

Having rivets at 200mm centres provides 14.5 kN shear capacity per panel (6 on each
side) horizontally and 12.2 kN per metre in vertical joints. Limited by the panels ability to
transfer the shear.

To increase the shear begin stitching the slip joint. Each rivet gives 1.21 kN in shear in the
slip joint.

Compressive Load. Expect failure at 5kN/panel. Allow 1.1kN/panel for serviceability.

For M10 threaded rod and mushroom head fixings use SLS of 5 kN and ULS of 6 kN in
panel. (Note steel brackets are typically rated to 40 kN or above).

Disclaimer
• Details and specification in this brochure may change without notice.
• While every care has been taken to ensure the accuracy of information no responsibility will be accepted for any errors or omissions.
• All information supplied applies only to products manufactured supplied and tested by Bondor New Zealand ltd and companies owned by ASKIN Pty Ltd. Use of the
information in this document for generic specification is a breach of copyright. Substitution with other panel manufacturers products may contravene The Building Act 2004,
and is at the buyers risk.
• Acceptable BMT skin thickness is +/- 0.03 mm.

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 NOTES:

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 NOTES:

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 Telephone: 0800 430 430
Email: info@bondor.co.nz
www.bondor.co.nz

Registered

©BondorNZ JUNE 2016 Quality

ISO 9001