GELCLAD has been carried out fully in line with the project plan. Many challenges have been addressed and significant outcomes succeeded. The work performed and major results achieved can be summarised as follows:
- From over 100 extensive compound formulations, a group of 3 optimised GELCLAD skin frame systems have been successfully developed. Complementary, both memory shape metals and polymer composites were formulated to generate the smart adaptive controlling ventilation system.
- A Foamable Extrudable Aerogel (FEA) core/layer has been successfully formulated. After testing over 70 formulations, the best candidate was defined, with a water-based APD silica aerogel foam having a density around 130kg/m3 and a thermal conductivity of 15mW/mK, processed by a ground-breaking extrusion technique at industrial-pilot scale.
- Following simulation and engineering GELCLAD design, various manufacturings were scaled-up to produce GELCLAD panels. In addition to the co-extrusion/novel tools, alternative lamination and online filling solutions were developed for ecoWPC/FEA assembly. Three different pilots at the UK, Slovenia and Germany have been successfully set-up representing various industrial solutions accomplished at a full-scale, towards future market demand.
- GELCLAD panels and ventilation systems have been subjected to an extensive testing campaign by an accredited Body in accordance with relevant EN and ISO standards. Apart from complete technical product datasheets, material formulation, advanced compounding and processing requirements for GELCLAD production were systemised and documented for future GELCLAD certification.
- Full-size GELCLAD panels were installed on a real-size building in Gijon, Spain and on a pilot infrastructure in Ljubljana, Slovenia (JUB). These public demos were used for installation training and in-situ environment performance assessment and validation. Complementarily validation tests made in Coimbra, Portugal have demonstrated a high level of thermal improvement achieved while refurbishing an original building wall.
- A full set of 2D and 3D BIM supporting tools were realised for dissemination, communication and future exploitation. Also, virtual building cloud-based models were generated on both VR and AR for architectural and technical design demonstration.
- LCA and LCCA analysis have modelled conservative and ambitious scenarios for various GELCLAD panel’s compositions, designs and service lifetime frames, making a benchmark comparison with market products. Results have indicated that future marketable GELCLAD panels are able to perform favourably (embodied carbon) and compete counterparts in terms of costs.
- Channelled by intensive media coverage and social media activity and supported by a diversified list of dedicated promotional tools, the project was represented at multiple conferences, workshops and trade fairs promoting GELCLAD’s value proposition. More than 300 dissemination activities have been implemented, potentially reaching more than 50.000 stakeholders. The project has been particularly active in networking activities with other H2020 R&D projects in the scope of the AMANAC cluster and by promoting EU’s R&I Programme and EEB agenda. GELCLAD has interacted with other nanomaterials-related clusters and the consortium represented in standardization committees.
