ConExWall
Manufacturing and Assembly
Installation
The ConExWall (eWHC) is a specifically designed smart solution to be used in colder climates, such as continental and alpine locations. What makes it special? It's built with timber, chosen for its eco-friendliness and flexibility in shape and size. It's a dynamic heating and cooling system.
Imagine your wall being a part of your heating setup. The ConExWall can do just that. It's designed to store heat, which means when you have extra electricity from solar panels, you can heat your space longer and hotter. And when you need to buy electricity, it helps you use less.
It's like having a built-in energy saver. But that's not all, it's also smart. With sensors and controls, it monitors the weather, temperature, and air quality to keep your space just right. And underneath its sturdy timber exterior lies layers of insulation, making sure it fits against your wall, no matter its shape or size.
Demo site Kašava, Czech Republic
ConExWall isn't just a wall – it's a sustainable, adaptable, and smart way to keep your space comfortable in cold climates!
The Kašava demo site, situated in the Zlín region of the Czech Republic and owned by the Municipality of Kašava, is undergoing a transformation led by Pich Architects. Originally built in the 1950s as part of an elementary school, the multifamily house – headmaster's residence, nestled into a southern slope. The two-story structure, with a basement, had a smaller usable space on the second floor due to its roof design. While the room orientation is advantageous, the layout no longer meets modern family living standards. Constructed traditionally with bricks and reinforced concrete ceilings, the house relied on a coal boiler for heating until the late 1990s, when it was updated with electric boilers. Today, the building serves as housing, accommodating two apartments for teachers from a nearby nursery school.
The primary goal of the renovation is to enhance energy efficiency and user comfort by upgrading the entire thermal envelope of the building. This involves using PnU kits to insulate external walls and modified prefabricated elements for new roof structures. Recognizing that the existing roof shape didn't optimize space or allow for easy PnU kit application, the design team decided to change the roof's configuration.
In addition to insulation, ventilation units with heat recovery are integrated to enhance air quality and user comfort. Furthermore, renewable energy sources like photovoltaic panels and a heat pump are being installed to decrease primary energy consumption. These measures aim to modernize the Kašava demo site while making it more sustainable and comfortable for its occupants.
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Before installing the ConExWall system, several preparatory steps are required. These involve preparing the current walls by fixing any defects, ensuring flatness, and making space for the anchoring system. Additionally, holes for pipes and cables will be created as per the production plan.
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The installation process begins with setting up an anchoring system for the ConExWall panels on the outer walls. Panels are then installed on the first floor, adjusted to fit heat transfer layers, and cables are routed through prepared openings.
This process is repeated for the second floor and completed with roof panel installation. All connections and testing of technologies are performed during this phase.
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If roofing, photovoltaic (PV), and facade cladding are not assembled initially, they will be installed on-site after panel installation to avoid damage during transport.
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Utility installations such as ventilation units, heat pumps, and electrical systems are installed at this stage. Interior renovations are also carried out as necessary.
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A control system is installed and tested, including the heating, DHW, AHU, and PV systems, as well as plumbing pressure tests.
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The entire system undergoes final testing and commissioning before being connected to the grid.
The ConExWall is made by a Czech company called RD Rymarov (RDR). They use advanced machines to make most of the panels, like bridges and tables that move automatically. They also use forklifts or cranes to move materials around. Workers mainly handle wood and put together the frames, add insulation, and install special parts like heating layers.
Making ConExWall involves five stages:
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Making the frame of the ConExWall. The materials are moved from storage to shaping centres, the timber is cut and prepared. Large materials (boards) are cut into the right sizes and the wall panels are assembled. The same is done for the roof and ceiling panels.
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Installation of components like heaters, windows, doors, ventilation systems, wiring and cable protection pipes.
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Insulation installation to the walls and ceilings.
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Electrical and mechanical components like heaters and ventilation units are installed on the wall panels.
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Finishing touches like adding wooden cladding to the walls if it wasn't done already and the completed panels are moved to a pickup area in the expedition hall.
Results of ConExWall
We can save a lot of time and money in construction by using modern technology and smart planning. Initially, we use things like 3D scanning to carefully map out the building's current condition, which helps us plan better.
Then, we cut down even more time and costs by making parts of the building in a factory instead of on-site. This off-site construction means we're not at the mercy of bad weather, and we can use machines to work faster and more efficiently. We also save on materials and packaging because we transport pre-made panels directly to the site. Overall, this method allows us to finish installing everything in just about a week, with the help of a crane.
