Integrated Strategies for Structural, Thermal, and Fire Failure Mitigation in Lightweight TRC/CLCi Composite Facade Panels

The thermally efficient and lightweight TRC/CLCi composite panels for functional and smart building envelopes, funded by the iclimabuilt project (Grant Agreement no. 952886), offer innovative solutions to sustainably address common failure risks in facade systems. This work specifically emphasizes strategies for mitigating structural, thermal, and fire-related failures through targeted material selection, advanced design methodologies, and rigorous validation protocols. To effectively mitigate structural failures, high-pressure concrete (HPC) reinforced with carbon fibers is utilized, significantly enhancing tensile strength, reducing susceptibility to cracking, and improving overall durability. To counteract thermal bridging—a critical failure mode compromising energy efficiency and structural integrity—the panels employ specially designed glass-fiber reinforced pins connecting HPC outer layers through the cellular lightweight concrete (CLC) insulation core that has a density of around 70 kg/m3 and a thermal conductivity in the range 35 mW/m∙K comparable to those of expanded polystyrene and Rockwool. These connectors ensure effective load transfer and maintain optimal thermal performance. A central focus of the failure mitigation strategy is robust fire behavior. The developed panels undergo rigorous standardized fire tests, achieving an exceptional reaction to fire classification of A2. This outcome confirms that HPC layers maintain structural stability and integrity even under prolonged fire exposure, effectively preventing catastrophic failures and ensuring occupant safety. In conclusion, this work highlights explicit failure mitigation strategies—reinforced concrete materials for structural stability, specialized glass-fiber connectors to prevent thermal bridging, rigorous fire behavior protocols, and comprehensive thermal performance validation—to produce a facade system that is robust, energy-efficient, fire-safe, and sustainable for modern buildings.