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TVD building method
Click below to download documents on our TVD construction method:

Our TVD (transformable variable design) process was patented in 1996 by the German State Institute for Patents in Frankfurt and all materials used in this production carry certificates of quality. These products are approved under German and EU standards.
 
In essence, our TVD method uses insulated steel frame panels, which are assembled in situ. Spaces are then made in the panels for the windows and doors and the first fixings for utilities are installed. The structure is then sprayed in situ with composite concrete and rendered. The resulting dwelling is a monolithic structure with uniformed concrete walls and slabs that unite load carrying, energy conservation and sound insulation functions. The continuous walls (with thermal insulation and without thermal bridges) result in a high-energy efficiency. Our TVD buildings are earthquake resistant (up to an unusually high level on the Richter Scale) and have excellent fire resistance. 
 
Our TVD building method is suitable to create any shape according to the architectural design and provides the same high-standard of build whether for social housing or luxury dwellings, with regard to the finishing, thermal and sound insulation in particular.  This, in turn, gives the client the possibility to select conventional (brick or render) or niche market material (stone, composite or glass) for the final finish.
 
The prior production of panels in our manufacturing plant, standardised connections, adapted tools, together with a computerised control of the whole building process enables a quick and precise completion of any building, up to 8 stories high.
 
The technology, which includes the spraying of concrete, combines and integrates several building phases of the conventional building process. This therefore reduces the number of different operations required during the construction process, thus lowering montage and transport costs and lowering energy costs in the finished building.

Axonometric view of thermo-panel
 
More specifically, the basic building elements are “thermo panels” which consist of a prefabricated steel frame (made from two-spaced inter-connected reinforcement steel meshes, which encloses polystyrene insulation foam blocks and connection elements). Thermal insulation gives the panel its physical characteristics. This foam structure stiffens the lattice and serves as a horizontal or vertical support for the spraying of the concrete, thus eliminating the need for formworks.
 
Welded wires are standardised web-reinforcing wires and fibre composite connectors are remarkably strong, non-corrosive and chemical-resistant. They unite the meshes and thermal insulation, forming a space truss system. This technology enables any architectural shape to be designed as thermo panels; the exterior shell of the building is designed without using metal connection devices or solid sections, thus enhancing energy and moisture performance.
 
The panels are dry-set and completed in-situ with the spraying of concrete. They are also treated with a final coating for fireproof protection.
 
The quantity and size of the panels are determined according to each individual project. The panels are 0.6 – 1.2 metres wide and 2.6 – 6.0 metres high. They have three different thicknesses, with each one corresponding to a specific use - i.e. 10, 15 and 20 cm for walls, slabs and base plate respectively.
 
The types of panel elements are:
  • Bearing panels for facades and load bearing interior walls to guarantee a static, dynamic, stable and resistant structure
  • Non-bearing panels for partition and decorative walls (thickness: 10cm)
  • Slab elements for floors and ceilings
  • Base plate elements for foundations
  • Roof panels (thickness: 20cm)
These panels are produced in our manufacturing plant while the on-site excavations are made. The foundations are made by putting a layer of gravel, thick MB 15 concrete layers and PVC membrane hydro-isolation with steam dam in dimensions suitable to the specific project. The foundations with final concrete slab are then prepared.
 
Once on site, the panels are directly assembled with high precision. Their construction is simple and does not require high-level energy consumption. The biggest building element does not weigh more than 25 kilograms and can easily be handled by a single person.
 
Electrical, water supply and sewerage connection installations outside of the building and in the foundations are installed. The installations inside the residential unit are not visible and are installed inside the wall panels. The first fixing electricity installations are done by using PVC tubes that are in-built into the wall panels with socket outlets. The electricity installations are completed in accordance with the valid technical regulations. The water piping is made of PVC pipes or zinc-coated pipes depending upon the project specification. The sewerage and draining installations are made of PVC pipes and moulded pieces.
 
Through unification, the work is simple, repetitive and quick, including the spraying of concrete. This concrete mortar (with a maximum grain size of 6mm) is ready-mixed on site and transported through a pressurized tube. It is sprayed in 2-3 layers and at the same time, compacted onto the thermo-panel. The standard amount of cement used for the concrete is 350-450 kg/m3 with water/cement ratio of  <0.5 and fluid additives.
 
The final phase is done after the completion of the plumbing, insulating, electrical installations, plaster, rendering works, doors and windows.
 
The thickness of the finished insulated walls varies depending on their use (bearing/non-bearing, outer/inner walls, slabs and base plate). In general, the reduced wall thickness results in an increased useable area from a better coefficient of gross/net area.
 
With regard to thermal isolation based on low-energy house:
- Thermal resistance coefficient: K=0.40   W/m2K   (wall thickness of 20cm)
- Thermal resistance coefficient: K=0.80   W/m2K   (wall thickness of 15cm)
 
Below provides a brief example of our basic material. Naturally this can be changed by the architects/clients’ instruction:
  • With regard to paintworks, outdoor façade paint will be used for walls, columns and beams. The inside walls and ceiling will be finished with indoor paint dispersion and waterproof paint will be used for the kitchen and bathroom.
  • Regarding the doors, windows and any railings: Alu-door: 105/210cm with fittings; one wing; Alu-windows: 2 x 100/100cm, 2x80/60cm, one wing, sliding. Interior wooden doors for kitchen and bathroom: 71/205 cm and 81/205cm; Protected metal railing for terrace.
  • The flooring can include stone, porcelain (or ceramic) tiles, linoleum, PVC
  • The roof is covered with aluminium sheet roofing or other roof tiles according to preference
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