GB Eco Panels - Green Build Systems skip to Main Content

An innovative series of construction grade full format panels for fast eco-build construction systems

Green Build Systems (GBS) – Eco Panels are an innovative series of construction grade full format panels for fast eco-build construction systems. The concept is that the panels will make a major contribution toward a Passivhaus and/or high energy reduced building, but there is also enough flexibility in our manufacturing systems to engineer different grades of insulation and heat loss, according to requirement.

Unique features – an advanced product

  • GB Insulated composite ECO-Wall Panels
  • GB Insulated composite Eco-Floor Panels
  • GB Insulated composite Eco-Roofing Panels

There are multiple combinations of panel sizes to suit the end product with a thickness of between 125 mm – 300 mm, depending on use and the level of insulation required.

Roof and Floor Panels may be 3 mtr, 4 mtr, 6 mtr or even 12 mtr lengths, with a width of either 1.2 or 2.4 mtrs.

Wall Panels may be up to 2.9 mtrs high, and are usually 6 mtrs in length x 300 mm deep.

If the panel is only required to be 150 mm deep then 12 mtrs lengths are feasible.

With the various challenges faced within the building and construction industries, GBS is utilising the latest in advanced materials combined with scientific, technological and manufacturing innovation in order to create the range of GB Eco Panels.

Future-proof materials

Our unique insulated composite panels (patent pending No. GB1814759.5) are, we believe, the next level in technological advancement for building materials and methods. Our Eco Panels comprise a unique composite featuring strength, waterproof and fireproof qualities.

Precision engineered for air-tight construction

Standard SIPs (Structurally Insulated Panels) are a high-performance building material for use in residential and light commercial construction. The panels consist of an insulating foam core sandwiched between two structural facings, typically oriented strand board (OSB). SIPs are manufactured under factory-controlled conditions and can be fabricated to fit most requirements. The result is a building material that is strong, energy efficient and cost-effective.

GB Eco-Panels utilise SIPs as a component part and are made to precision engineering standards, utilising advanced technology in automated conditions, and comprise a patented method of a plurality of structural insulated panels (SIPs), laid to intricate patterns, and reinforced by resin seal layers. Within this system our SIPs may be multi-layered in differing patterns (depending on the usage of the final insulated panel), subjected to high compression levels within a specially commissioned vacuum press; and cured. This method maximises the overall strength of the composite panel but also makes it substantially free from air cavities.

Engineered composite panels designed to contribute to Passivhaus standards

U values express the measure of thermal conductivity – the ease by which heat can escape through a structure. The lower the U value the less heat escapes, and the U value is expressed as W/m2K.

Building Regulations standard is 0.3W/m2K and our insulated eco-panel has been measured and calculated at 0.1W/m2K, which meets the Passivhaus standard and in many countries actually exceeds it.

Our aim has always been to produce a flexible and practical system of insulated composite panels, suitable for multi-construction applications, where the u-values and air-tightness, coupled with our systems of bridging, are sufficient to provide an airtight structural member with resilient strength capable of contributing to Passivhaus (Passive House) standards.

Heat loss protection and research

A considerable amount of work has been conducted by our structural engineering consultants in mechanical design and analysis, particularly with regard to heat loss not only of the overall building when constructed, but also in areas of traditional heat loss, such as the joints where panels are connected, window frames and doors, etc.

A great number of thermal tests have been conducted, using both physical tests and mathematical modelling, in order to determine the precise conditions and materials required before our final designs have been agreed.

One example is that our tests demonstrated that over a plotted region (200mm either side of the joint), we were able to determine estimations of heat loss for a number of “standard panel joining systems.


Showing various types of joint heat loss imaging

Configuration
Heat Flux (W/mm 2
U value (W/m 2 /K (20degC temperature difference)
Increase above single SIPS panel (%)
Plain single SIPS panel (double OSB)
3.675E-06
0.184
Model B1 (angle joint)
4.24E-06
0.212
15.6
Model B2 (wood joint)
5.56E-06
0.278
51.7

Table 3.1 Models B1 and B2 Heat Conduction Properties

We have had a great many tests conducted, in order to determine the best system of joining panels from GRP angles and wood, through aluminium, to various mixtures, until we reached the medium which increased the U value the least. We are currently patent pending on this joint style.    

Aiming to Passivhaus / Passive House / Zero Carbon standards

Clearly a single panel cannot claim to meet a Passivhaus standard, as it requires the test to be conducted on an entire structure which includes such elements such as:

  • The Space Heating Energy Demand is not to exceed 15 kWh per square meter of net living space (treated floor area) per year or 10 W per square meter peak demand;
  • The Renewable Primary Energy Demand (PER, according to PHI method): the total energy to be used for all domestic applications (heating, hot water and domestic electricity) must not exceed 60 kWh per square meter of treated floor area per year for Passive House Classic;
  • In terms of Airtightness, a maximum of 0.6 air changes per hour at 50 Pascals pressure (ACH50), as verified with an onsite pressure test (in both pressurized and depressurized states;
  • Thermal comfort must be met for all living areas, during winter as well as in summer, with not more than 10 % of the hours in a given year over 25 °C.

We have had a great many tests conducted, in order to determine the best system of joining panels from GRP angles and wood, through aluminium, to various mixtures, until we reached the medium which increased the U value the least. We are currently patent pending on this joint style.    

GB Panel Applications

Roofing – the GB Roofing Eco Panel can be used for multiple roofing applications with fast and accurate on-site installation.

External / Internal Walls – The GB Wall Eco Panels excellent thermal performance and low air permeability makes it the panel of choice for energy saving and / or fast installations.

External / Internal Walls – The GB Wall Eco Panels excellent thermal performance and low air permeability makes it the panel of choice for energy saving and / or fast installations.

Flooring – The GB Floor Eco Panel system provides an ideal base for multiple flooring scenarios, particularly where high thermal performance, durability and fast-build are requirements.

With high levels of accuracy, air-tight joints, little trimming or modifying required, the GBS full format eco panels are the ideal solution for fast-built, energy saving modular buildings.

Total Flexibility

Manufactured in a range of sizes up to 12 meters long, our composite panels offer opportunities for fast-build projects or structures, may be ready-assembled for off-site construction, and, can be ordered with services built-in.

The provision of offset SIP layers surprisingly solves the problem with SIPs, which is that they cannot be used to span gaps of greater than 6m without the use of a supporting member (such as a steel frame). As a result, the offset SIP layers feature avoids considerable expense and time-delays in a building project, and the precision engineered manufacture further negates the need for on-site cutting and sizing and “making good”.

We have had a great many tests conducted, in order to determine the best system of joining panels from GRP angles and wood, through aluminium, to various mixtures, until we reached the medium which increased the U value the least. We are currently patent pending on this joint style.    

Back To Top