During this study, full-size wood composite sandwich panels, 1.2 m by 2.4 m (4 ft by 8 ft), with a biaxial corrugated core were evaluated as a building construction material. Considering the applications of this new building material, including roof, floor, and wall paneling, sandwich panels with one and two corrugated core(s) were fabricated and experimentally evaluated. Since primary loads applied on these sandwich panels during their service life are live load, snow load, wind, and gravity loads, their bending and compression behavior were investigated. To improve the thermal characteristics, the cavities within the sandwich panels created by the corrugated geometry of the core were filled with a closed-cell foam. The R-values of the sandwich panels were measured to evaluate their energy performance. Comparison of the weight indicated that fabrication of a corrugated panel needs 74% less strands and, as a result, less resin compared to a strand-based composite panel, such as oriented strand board (OSB), of the same size and same density. Bending results revealed that one-layer core sandwich panels with floor applications under a 4.79 kPa (100 psf) bending load are able to meet the smallest deflection limit of L/360 when the span length (L) is 137.16 cm (54 in) or less. The ultimate capacity of two-layered core sandwich panels as a wall member was 94% and 158% higher than the traditional walls with studs under bending and axial compressive loads, respectively. Two-layered core sandwich panels also showed a higher ultimate capacity compared to structural insulated panels (SIP), at 470% and 235% more in bending and axial compression, respectively. Furthermore, normalized R-values, the thermal resistance, of these sandwich panels, even with the presence of thermal bridging due to the core geometry, was about 114% and 109% higher than plywood and oriented strand board, respectively.

Strands produced from small-diameter timbers of lodgepole and ponderosa pine were used to fabricate a composite sandwich structure as a replacement for traditional building envelope materials, such as roofing. It is beneficial to develop models that are verified to predict the behavior of these sandwich structures under typical service loads. When used for building envelopes, these structural panels are subjected to bending due to wind, snow, live, and dead loads during their service life. The objective of this study was to develop a theoretical and a finite element (FE) model to evaluate the elastic bending behavior of the wood-strand composite sandwich panel with a biaxial corrugated core. The effect of shear deformation was shown to be negligible by applying two theoretical models, the Euler–Bernoulli and Timoshenko beam theories. Tensile tests were conducted to obtain the material properties as inputs into the models. Predicted bending stiffness of the sandwich panels using Euler-Bernoulli, Timoshenko, and FE models differed from the experimental results by 3.6%, 5.2%, and 6.5%, respectively. Using FE and theoretical models, a sensitivity analysis was conducted to explore the effect of change in bending stiffness due to intrinsic variation in material properties of the wood composite material.

This study explores the potential of using underutilized materials from agricultural and forestry systems, such as rice husk, wheat straw, and wood strands, in developing corrugated core sandwich panels as a structural building material. By leveraging the unique properties of these biobased materials within a corrugated geometry, the research presents a novel approach to enhancing the structural performance of such underutilized biobased materials. These biobased materials were used in different lengths to consider the manufacturing feasibility of corrugated panels and the effect of fiber length on their structural performance. The average lengths for wood strands and wheat straws were 12–15 cm and 3–7.5 cm, respectively, while rice husks were like particles, about 7 mm long. Due to the high silica content in rice husk and wheat straw, which negatively impacts the bonding performance, polymeric diphenylmethane diisocyanate (pMDI), an effective adhesive for such materials, was used for the fabrication of corrugated panels. Wood strands and phenol formaldehyde (PF) adhesive were used to fabricate flat outer layers. Flat panels were bonded to both sides of the corrugated panels using a polyurethane adhesive to develop corrugated core sandwich panels. Four-point bending tests were conducted to evaluate the panel’s bending stiffness, load-carrying capacity, and failure modes. Results demonstrated that sandwich panels with wood strand corrugated cores exhibited the highest bending stiffness and load-bearing capacity, while those with wheat straw corrugated cores performed similarly. Rice husk corrugated core sandwich panels showed the lowest mechanical performance compared to other sandwich panels. Considering the applications of these sandwich panels as floor, wall, and roof sheathing, all these panels exhibited superior bending performance compared to 11.2 mm- and 17.42 mm-thick commercial OSB (oriented strand board) panels, which are commonly used as building materials. These sandwich structures supported a longer span than commercial OSB panels while satisfying the deflection limit of L/360. The findings suggest the transformative potential of converting renewable yet underutilized materials into an engineered concept, corrugated geometry, leading to the development of high-performance, carbon-negative building materials suitable for flooring and roof applications.

A wood-based sandwich panel with a corrugated core was developed as a building material. A matched-die mold manufactured from commercial plywood was used to fabricate the corrugated panels through a cold-forming process. A cold-setting resin was applied on southern yellow pine (Pinus spp.) veneers with an average thickness of 4 mm, and four plies of them were formed into a corrugated geometry using a wooden mold. When the resin was cured, the corrugated panel of veneers retained the corrugated shape after load removal. Facesheets of the sandwich structures were fabricated using three plies of the same veneers. To evaluate the effect of this corrugated geometry on the structural performance, the same veneers — regarding number, thickness, and orientation — used for the sandwich panel were adopted to fabricate laminated flat panels. Both sandwich and laminated flat panels were submitted to a four-point bending test. The results confirmed the sandwich effect, i.e. a 1741% increase in the bending stiffness of sandwich panels compared to that of laminated flat panels. Sandwich panels developed in this study were compared to Structural Insulated Panels (SIPs), wood-framed structures known as stud walls, and sandwich panels produced using a hot-pressing technique. The cold-formed sandwich panels had higher structural performance than commercial building materials.