ICAMES 2015

TWENTY-FIRST INTERNATIONAL
CULTURAL AND
ACADEMIC MEETING OF
ENGINEERING STUDENTS
BOAZ NVERSTY,
ISTANBUL, TURKEY ENGINEERING SOCIETY
May 02-09, 2015

GHEORGHE ASACHI TECHNICAL UNIVERSITY OF IAI, ROMANIA,

FACULTY OF CIVIL ENGINEERING AND BUILDING SERVICES

ETFE a sustainable alternative

to traditional glass
TEAM MEMBERS:

Marius-Cristian BRESCU-IFTIMIE
Mihaela-tefania MILU
Rita-Cristina PITA

TEAM ADVISORS:

Senior Lecturer PhD. Ioana OLTEANU

Senior Lecturer PhD.Ionu-Ovidiu TOMA
olteanuioa@yahoo.com
iotoma@ce.tuiasi.ro
pistaritacristina@gmail.com
milumihaela20@gmail.com
mariusbraescu@gmail.com

ICAMES 2015

ETFE a sustainable alternative

to traditional glass
Project abstract: Ethylene Tetrafluoroethylene (ETFE) a stable, durable and
easy to join polymer has been developed due to intensive research in building
materials technology focused on sustainability and it can be used in civil engineering
especially as a sustainable alternative to traditional glass in double skin faades
and roofs of buildings. The advantages of ETFE in comparison to glass are the
reduced specific weight and embodied energy, the self-cleaning property and the
high corrosion resistance. This project refers to a comparison study regarding the
advantages of using ETFE in civil engineering, focusing on the reduction of the
amount of material of the load bearing structure due to the fact that ETFE is 100
times lighter than glass.
Keywords: sustainability, light-weight, double envelope, low embodied
energy, self-cleaning material, adaptable, natural ventilation, high corrosion
resistance;

1. Introduction
The greenhouse effect is a natural phenomenon of maintaining the temperature of
the Earths surface. Through this process part of the solar radiations are retained in
the Earths atmosphere as a result of the presence of greenhouse gasses such as water
vapor, carbon dioxide, methane, nitrous oxide, ozone and chlorofluorocarbons. In
the past decades the concentrations of the greenhouse gasses have increased and
according to The World Business Council for Sustainable Development, the building
sector is accountable for 40% of the world energy use, thus the resulting carbon
emissions are in substantial amounts.
The lowering of energy consumption in new or already existing buildings has gained
a lot of attention in the past few years and notions such as passive building or zero
energy building have been introduced in civil engineering vocabulary. One of the
solutions that is implemented in order to improve the buildings energy performance
is the double-skin faade concept.
A double-skin faade consists of two skins placed in such a way that the air flows in
the intermediate cavity. The main advantages of a double-skin faade are: natural
ventilation, thermal and acoustic insulation [1]. Even though the most common

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material choice for this concept is glass, the following report shows why Ethylene
Tetrafluoroethylene is a viable sustainable alternative.

2. Material description
2.1.

History

ETFE is a relatively new material in the building industry. It was developed by Dr.
Plunkett, Fig. 1, in 1938and it is one of the 7 fluoropolymer generated from the
invention of PTFE (poly tetrafluoroethylene), also known as Teflon. ETFEs
distinctive property of the other six polymers is the capability of being extruded. The
first commercialized film was named Tefzel,[2].

Fig.1: Dr. Roy Plunkett[12]

2.2.

Fig. 2: Raw ETFE granules [13]

Manufacturing process

Unlike many synthetic plastics, ETFE does not derive from petrochemical
substances. The raw material is called chlorodifluoromethane and the Montreal
Treaty on ozone depleting substances includes it in the 2 nd class of substances,
meaning that it does not contribute to global warming. The raw material is turned
into tetrafluoroethylene at 125 Celsius degrees. The TFE is then polymerized with
ethylene and ETFE results (25% ethylene and 75% TFE), Fig.3. After this process
it results a powder which is turned into granules, Fig.2, by heating at 265-285
degrees. The granules can be turned into rods, sheets and films. In building industry,
ETFE films are used especially for cladding. The films can also be transparent,
translucent, printed or colored, [2].

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Fig. 3: Industrial synthesis of ETFE [3]

2.3.

Benefits of ETFE

2.3.1. Light transmission and solar control

Across the visible and ultraviolet ranges, ETFE film is very transparent, allowing
approximately 95% and 85% transmission. [4]
When light is not needed, ETFE film can be treated in a number of ways to
manipulate its transparency and radiation transmission characteristics. Adding extra
layers of ETFE foil to a cushion also allows light transmission and solar gain to be
controlled. Multi-layer cushions can be constructed to incorporate movable layers
and intelligent printing, Fig. 4. In these type of cushions, the top and middle layers
are printed in a corresponding pattern which when pressed together cover 100% of
the surface with fritting. The middle layer is programmed to rise and fall (using air
pressure) to increase and decrease the percentage of printed area and therefore
control solar gain, Fig. 5.[4][5]

Fig.4: Printed ETFE foils [8]

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Fig. 5: ETFE performance in case of intelligent printing [19]

2.3.2. Weight and plasticity

ETFE foil is extremely light weight in comparison with glass, almost 100 times
lighter. This property results in a reduced structural framework, hence considerably
less dead load on the supporting structure [5].Moreover, steel structure can be
combined or replaced by timber, like in the case of Nice Stadium, France, Fig. 6,
where the modules consist of one row of timber crosses connected by steel
tetrahedrons to a steel tube [1],[6].
This material is able to stretch up to three times its original length without losing its
elasticity [11]. Even though the breaking point is up to 600% the films are still
structurally resistant [8]. Due to its high resistance and elasticity, ETFE is considered
a great solution for places where earthquakes may occur. Unlike glass, which will
shatter in such scenarios, ETFE will deflect or break, but it wont cause severe
damage [4].

Fig. 6: Structural model of Nice Stadium in France [6]

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2.3.3. Durability and cost effectiveness
ETFE does not degrade or change any of its properties under exposure to
environmental pollution, UV light, harsh chemicals or extreme temperature
variations. For the first time it was used in construction in 1982 when a fluorinated
ethylene propylene film on the roof of Burgers Zoo Hall in Arnhem, Netherlands,
Fig.7, failed and had to be replaced. The structure is still in service and the material
shows no signs of degradation. The estimated life expectancy of foils is more than
50 years [7].
The installation cost of ETFE can be approximately reduced to half the price of
conventional high performance glass [4]. Moreover, due to the lightweight nature of
the material supporting systems and foundations can be designed more efficiently.
By providing ample natural daylight, the indoor lighting demand and the energy
costs are reduced [8].

Fig. 7: ETFE roofing at Burger Zoo in Arnhem, Netherlands [20]

2.3.4. Environmental impact

The embodied energy for ETFE is 315 MJ/m while for glass is 371.21 MJ/m. The
real difference though is made by the lessening of the frame and supporting system
dimensions, not to mention that replacing steel with timber is also a viable choice
[1]. The nature of the product improves the buildings properties of insulation and
daylighting, therefore it contributes to the low energy aspect of the building. Flexible
photovoltaic cells can be integrated with either a single layered or cushioned system
to meet performance requirements, [8]. This has been tried at a carport roof in
Munich, Fig. 8, and provides an average of 1,000 kWh/kwp electrical energy per
year, [18].

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Being 100% recyclable, wastes from the manufacturing process and even old ETFE
elements can be remolded into new products. The recycling is aided by the absence
of additives in the manufacturing process and the only thing that is required for
recycling is the melting of the material. An old or damaged piece of ETFE foil can
be simply removed from the structure, heated to melting temperature with new ETFE
granules, Fig. 9, and extruded to create more films. This is a great contribution to
the stainability current [2]
One of the most attractive attribute of ETFE is the self-cleaning property, especially
when considering the costs of cleaning a large greenhouse. Being derived from
Teflon it is anti-adhesive so occasional rainfall is enough to clean it. Even though
the foil can be penetrated by sharp objects, it has considerable tear propagation
resistance [2].
ETFE film has a very unique behavior in the presence of fire. It is classified as selfextinguishing because instead of melting and dripping it shrinks away, thus allowing
smoke and fire to be vented to the exterior [4].

Fig. 8: ETFE roof with integrated photovoltaic cells [18]

Fig.9: Melted ETFE waste before extrusion [13]

3. Case study
3.1.

Structure description

The numerical simulations are made on a structure which is an office building,

Fig.10. The envisioned structure has 10 floors with a height of 34 m and is a frame
structure having almost 80% of its exterior surface as double ventilated faade.
Given the fact that the glazed surface is large, it is suitable for us to point out easily
the difference between the classic glass and ETFE material.
The materials used for this structure are steel for columns, being used an H400X509
profile and for the slab it is used reinforced concrete of 15 cm thickness. For the
faade we chose layers of glass and ETFE, 15mm thick.

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Fig. 10: Real building

3.2.

Fig.11: Structural model of the building

Numerical Simulations

3.2.1. Strength simulation

The aim of this simulation is to compare the self-weight and the strength of the
building by using glass and ETFE membrane alternating them into a double skin
faade. For this we had used the SAP2000 computer software which provides an
interactive environment in which the user can study the stresses in the structural
elements, the deformations of the building and also design and check the building
elements, Fig. 11.
For this type of simulation we chose 3 cases of double skin faade, the first case
being the one when there are used two layers of classic glass, the second case is for
glass and ETFE layers and the last case is when both layers are made of ETFE
membrane.
Making the analyses for each case we had obtained the following results shown in
Table 1. As a general observation, we can see a reduction of the mass for the entire
building - a reduction of 1.86% is obtained when only one layer is made of glass and
another made of ETFE membrane and a reduction of 3.71% when both layers are
made of ETFE.
The load on the column is minimum in case of two layers of ETFE, which will
influence the design process of the columns, leading to a significant reduction of
material.

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Another conclusion can be made considering the period of vibration, which is lower
for the 3rd case. This can be explained by the fact that the stiffness introduced on the
structure for the ETFE material is lowest, meaning that the overall behavior of the
assembly (cladding and structural system) is closer to the flexible behavior of the
frame structural system.
Mass (tones)
5978,35

T(s)

Nmax(kN)

Sigma max

2,779567

3570,57

55,10138889

Glass + ETFE

5867,32

2,755688

3481,15

53,72145062

ETFE

5756,3

2,731626

3391,73

52,34151235

Glass

Table 1. Results from SAP200

3.2.2. Thermal conductivity simulation

In the past years the construction field has focused on reducing the use of energy and
developing more efficient materials. For this, the materials behaviors in different
environments and climate condition should be evaluated.
We tested 3 types of windows in 2 different conditions by means of Saint-Gobain
Isover SCE program. This program calculates thermic efficiency of a building or a
couple of materials components of a structure in different cases of climate and
environments and the results are very accurate. If some specific characteristics of
the materials are known (density, thermic conductivity, etc.), this program gives
results in form of charts where we can see which the temperature in each point of
the element.
Regular type of window between heated and unheated spaces (glass-air-glass)

External temperature: -150 C

Internal temperature: 200 C
Te= -10.01 0 C
Ti=15.010 C

External temperature: 350C

Internal temperature: 200 C
Te=32.860C
Ti=22.140 C

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Special type of window between heated and unheated spaces (glass-argonglass)

External temperature: -150 C

Internal temperature: 200 C
Te= -11.190 C
Ti= 16.190C

External temperature: 350C

Internal temperature: 200 C
Te= 33.370 C
Ti=21.630 C

Special window with ETFE membrane between heated and unheated spaces
(ETFE-air-glass)

External temperature: -150 C

Internal temperature: 200 C
Te=-13.520 C
Ti=18.520C

External temperature: 350C

Internal temperature: 200 C
Te=34.360 C
Ti=20.640 C

These diagrams represent the temperature evolution in the structure between 2

environments, one heated and one unheated. As shown, the special window with
ETFE membrane has the best results and keeps an optimal temperature on the
internal face of the window. These results confirm that the special type of window
is a better choice than the classical solution.

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All results obtained in Saint-Gobain Isover can be represented in a simple form as
a comparison between extreme values of temperature, Fig. 12 and 13.

Low temperature outside

25
20
15
10
5

15.01

16.19

18.52

-10.01

-11.19

-13.52

0
-5
-10
-15
-20
Ti

Te

Fig. 12: Extreme values of temperature in cold environment

40

High temperature outside

35
30

34.36

33.37

32.86

25
20

22.14

21.63

20.64

15
10
5
0
Te

Ti

Fig. 13: Extreme values of temperature in warm environment

These two charts show us the difference between temperature of the exterior face of
the element and the temperature of the inside face. The classical solution of window
has a high heat transfer and a lot of energy is lost. This loss can be reduced by
introducing an inert gas, argon in our case, between the two layers of glass, but the
best solution is a window with ETFE membrane.
When the special window with ETFE membrane is used, better results are obtained
and the heat transfer between the two environments is reduced. This fact leads to a

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saving of the energy consumed to maintain an optimal temperature indoor and the
buildings become greener by using this material for large glazing surfaces.

4. Success international projects which use ETFE solution

4.1. Eden Project
Eden Project, Fig.14(a), is located in Cornwall, United Kingdom and consists of two
biomes. The Mediterranean Biome, Fig.14(b), is 135 m long, 65 m wide and 35 m
high and it houses a warm temperate environment. The Tropical Biome, is 240 m
long, 110 m wide and 55 m high and it houses a rainforest environment. ETFE was
the best choice for this project because of several factors:
the clay pit soil has a limited load bearing capacity so a lightweight structure
was necessary;
the original aim was to recreate the 2 climates in a natural way, with the
appropriate height and area;
the achieving of the best light transmission and thermal capacity for the
greenhouses;
the foil has a great geometry and size flexibility.

The cushions for this project consist of three layers of ETFE foil and they are
supported by aluminum frames, supported by steel trusses, Fig.14 (c) [2].

(a)

(b)

(c)

Fig.14: Eden Project [21]

4.2. Allianz Arena

Allianz Arena is located in Munich, Germany and is shared by FC Bayern and TSV
1860. The Stadium is made of double layer ETFE cushions and it combines white
translucent and transparent foils. The faade is composed of printed foil cushions
that are illuminated with red lights, Fig.15 (a), for Bayern games, with blue lights,
Fig.15 (b), for 1860, white, Fig.15 (c) and 15 (d), for Germany National team and
different colors on regular days.

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2.816 cushions of 2 m by 4.25 m were used for the entire structure. What is really
interesting is the fact that the same cushion shape occurs at most twice in the entire
structure. This would have been really difficult to achieve with traditional glazing
but the elasticity of the ETFE made it easy to accomplish [2].

(a)

(b)

(c)

(d)

Fig.15: Allianz ArenaProject [15, 16, 17]

4.3. Shenzhen Water Park

Shenzen Water Park, Fig. 16, is located in East Huaqiao China and has the shape of
a water droplet. The reasons for which ETFE was selected are its durability,
lightweight, insulation properties and cost effectiveness. Even though the structure
is in southern China, the facility needed to be heated during winter months. Because
the structure has a really complex shape, the three layered cushions have several
hundred different geometrically shapes. In the cushions is incorporated LED lighting
which gives the ETFE a dramatic effect [18].

Fig.16: Shenzen Water Park [18]

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References:
1. Koukaroudis Panagiotis-Properties and design guidelines for double-skin faades in
Sweeden, Master Thesis at Chalmers University Of Technology, January 2014
2. Leslie A. Robinson-Structural Opportunities of ETFE(ethylene tetra fluoro ethylene),S.B.,
Civil Engineering Massachusetts Institute of Technology, June 2004
3. Mihai Grecu-Poly(ethylene-co-tetrafluoroethylene)-based permanent motorway roofs
equipped with night lighting sources and thin film solar cells, Acta Technica Napocensis:
Civil Engineering & Architecture Vol. 54 No. 2 (2011
4. Stephen Tanno- ETFE Foil Cushions As An Alternative To Glass For Atriums And
Rooflights Buro Happold Faade Engineering 41-43 Praed Street, London, W2 1NR
5. Amy Wilson-ETFE: The New Fabric Roof, January 2009, www.rci-online.org
6. Adrien Escoffer, Adelyne Albrecht, Franois Consigny- Nice stadium: Design of a flat
single layer ETFE roof,
7. Linda Charbonneau, Maria Anna Polak, Alexander Penlidis- Mechanical properties of
ETFE foils: Testing and modelling, 2014 Construction and Building Materials 60(2014)
63-72
8. http://www.birdair.com/tensile-architecture/membrane/etfe
9. http://www.archiexpo.com/prod/vector-foiltec/texlon-etfe-roof-system-687671386711.html
10. http://www.environmentalleader.com
11. http://www.designingbuildings.co.uk/wiki/ETFE
12. http://www.businesspundit.com/10-accidental-discoveries-that-generated-great-wealth/
13. http://jp1042754017.fm.alibaba.com
14. http://www.infoplease.com/ipa/A0004686.html
15. https://sstamu.wordpress.com/
16. http://commons.wikimedia.org/wiki/File:Allianz_Arena_in_Rot_rot_506022125_Frottma
ning_Abendhimmel_lock_221_und_113_Polizeifahrzeuge_(1500472142).jpg
17. https://www.allianzglobalbenefits.com/news/news_overview.html
18. http://www.makmax.com.au/projects
19. http://rerdm.hyperbody.nl/index.php/project13:Performance
20. http://www.fotodesignandreasbraun.de/index.php?g=13
21. http://www.edenproject.com/