GK
G.A. Kerkdijk
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Design and testing of plant-fibre composite profiles for structural façade applications
Material selection, profile design and experimental validation of plant-fibre composites mullions in curtain wall applications
This report investigates the feasibility of using non-wood plant-fibre reinforced composites as structural profile materials for stick-built curtain wall façades in low- and mid-rise buildings. The work is motivated by the need to reduce embodied carbon in building envelopes and by the absence of systematic research on plant‑fibre composites in aluminium-like mullion and transom geometries. Existing studies predominantly address coupon-scale behaviour or flat panels and rarely integrate mechanical performance, manufacturability, regulatory compliance, and environmental impact at the profile level.
The study aims to determine to what extent plant‑fibre composites can be developed into manufacturable façade profiles that meet the mechanical, environmental, and regulatory requirements of aluminium curtain wall systems. To this end, a structured methodology is adopted, comprising literature review and material selection, definition of performance criteria, iterative experimental manufacturing in three phases, mechanical testing (tension, bending, fastener fixation, thermal expansion), life-cycle assessment, and a basic validation against European curtain wall performance criteria (EN 13830). Cross‑stitched flax fibre in a low‑viscosity epoxy matrix is ultimately selected, and filament wrapping combined with vacuum bagging and oven curing is developed to produce 50 × 100 × 4 mm rectangular hollow profiles.
Results show that the flax‑fibre/epoxy profiles achieve low-to-moderate tensile strengths, stiffness comparable to structural timber, exhibit progressive, damage‑tolerant failure, and attain an embodied carbon of about 12.2 kg CO2‑eq/m, exceeding a 70% reduction relative to conventional aluminium profiles with ≈ 51.1 kg CO2‑eq/m. The profiles satisfy key criteria for wind load resistance and self‑weight but remain limited by lower stiffness than aluminium, unresolved fire performance, uncertain long‑term hygrothermal durability, and thermoset‑driven end‑of‑life constraints.
The report concludes that flax‑fibre/epoxy curtain wall profiles constitute a technically feasible and environmentally promising proof of concept rather than a direct drop‑in replacement for aluminium. It contributes a complete, profile‑scale evaluation framework and a validated manufacturing route, thereby providing a basis for further research on bio‑based façade profiles in the context of low‑carbon and circular construction. ...
The study aims to determine to what extent plant‑fibre composites can be developed into manufacturable façade profiles that meet the mechanical, environmental, and regulatory requirements of aluminium curtain wall systems. To this end, a structured methodology is adopted, comprising literature review and material selection, definition of performance criteria, iterative experimental manufacturing in three phases, mechanical testing (tension, bending, fastener fixation, thermal expansion), life-cycle assessment, and a basic validation against European curtain wall performance criteria (EN 13830). Cross‑stitched flax fibre in a low‑viscosity epoxy matrix is ultimately selected, and filament wrapping combined with vacuum bagging and oven curing is developed to produce 50 × 100 × 4 mm rectangular hollow profiles.
Results show that the flax‑fibre/epoxy profiles achieve low-to-moderate tensile strengths, stiffness comparable to structural timber, exhibit progressive, damage‑tolerant failure, and attain an embodied carbon of about 12.2 kg CO2‑eq/m, exceeding a 70% reduction relative to conventional aluminium profiles with ≈ 51.1 kg CO2‑eq/m. The profiles satisfy key criteria for wind load resistance and self‑weight but remain limited by lower stiffness than aluminium, unresolved fire performance, uncertain long‑term hygrothermal durability, and thermoset‑driven end‑of‑life constraints.
The report concludes that flax‑fibre/epoxy curtain wall profiles constitute a technically feasible and environmentally promising proof of concept rather than a direct drop‑in replacement for aluminium. It contributes a complete, profile‑scale evaluation framework and a validated manufacturing route, thereby providing a basis for further research on bio‑based façade profiles in the context of low‑carbon and circular construction. ...
This report investigates the feasibility of using non-wood plant-fibre reinforced composites as structural profile materials for stick-built curtain wall façades in low- and mid-rise buildings. The work is motivated by the need to reduce embodied carbon in building envelopes and by the absence of systematic research on plant‑fibre composites in aluminium-like mullion and transom geometries. Existing studies predominantly address coupon-scale behaviour or flat panels and rarely integrate mechanical performance, manufacturability, regulatory compliance, and environmental impact at the profile level.
The study aims to determine to what extent plant‑fibre composites can be developed into manufacturable façade profiles that meet the mechanical, environmental, and regulatory requirements of aluminium curtain wall systems. To this end, a structured methodology is adopted, comprising literature review and material selection, definition of performance criteria, iterative experimental manufacturing in three phases, mechanical testing (tension, bending, fastener fixation, thermal expansion), life-cycle assessment, and a basic validation against European curtain wall performance criteria (EN 13830). Cross‑stitched flax fibre in a low‑viscosity epoxy matrix is ultimately selected, and filament wrapping combined with vacuum bagging and oven curing is developed to produce 50 × 100 × 4 mm rectangular hollow profiles.
Results show that the flax‑fibre/epoxy profiles achieve low-to-moderate tensile strengths, stiffness comparable to structural timber, exhibit progressive, damage‑tolerant failure, and attain an embodied carbon of about 12.2 kg CO2‑eq/m, exceeding a 70% reduction relative to conventional aluminium profiles with ≈ 51.1 kg CO2‑eq/m. The profiles satisfy key criteria for wind load resistance and self‑weight but remain limited by lower stiffness than aluminium, unresolved fire performance, uncertain long‑term hygrothermal durability, and thermoset‑driven end‑of‑life constraints.
The report concludes that flax‑fibre/epoxy curtain wall profiles constitute a technically feasible and environmentally promising proof of concept rather than a direct drop‑in replacement for aluminium. It contributes a complete, profile‑scale evaluation framework and a validated manufacturing route, thereby providing a basis for further research on bio‑based façade profiles in the context of low‑carbon and circular construction.
The study aims to determine to what extent plant‑fibre composites can be developed into manufacturable façade profiles that meet the mechanical, environmental, and regulatory requirements of aluminium curtain wall systems. To this end, a structured methodology is adopted, comprising literature review and material selection, definition of performance criteria, iterative experimental manufacturing in three phases, mechanical testing (tension, bending, fastener fixation, thermal expansion), life-cycle assessment, and a basic validation against European curtain wall performance criteria (EN 13830). Cross‑stitched flax fibre in a low‑viscosity epoxy matrix is ultimately selected, and filament wrapping combined with vacuum bagging and oven curing is developed to produce 50 × 100 × 4 mm rectangular hollow profiles.
Results show that the flax‑fibre/epoxy profiles achieve low-to-moderate tensile strengths, stiffness comparable to structural timber, exhibit progressive, damage‑tolerant failure, and attain an embodied carbon of about 12.2 kg CO2‑eq/m, exceeding a 70% reduction relative to conventional aluminium profiles with ≈ 51.1 kg CO2‑eq/m. The profiles satisfy key criteria for wind load resistance and self‑weight but remain limited by lower stiffness than aluminium, unresolved fire performance, uncertain long‑term hygrothermal durability, and thermoset‑driven end‑of‑life constraints.
The report concludes that flax‑fibre/epoxy curtain wall profiles constitute a technically feasible and environmentally promising proof of concept rather than a direct drop‑in replacement for aluminium. It contributes a complete, profile‑scale evaluation framework and a validated manufacturing route, thereby providing a basis for further research on bio‑based façade profiles in the context of low‑carbon and circular construction.