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Building the future with carbon
What will the facades of the future look like? Lightweight, delicate, durable—and above all, sustainable. The carbon sandwich facade system, which has been successfully implemented as part of a pilot project in Eschweiler, meets precisely these requirements. The system was developed in close cooperation between nesseler bau gmbh, the RWTH Aachen University and solidian&kelteks – and is a prime example of partnership-based innovation in the construction industry.
Think sustainably, build intelligently
In view of climate policy requirements and resource scarcity, one thing is clear: conventional facade systems are reaching their limits. The carbon concrete facade shows how future-oriented construction can succeed – with clear advantages in terms of ecological balance, service life, and design freedom. And best of all, the system is open-ended – solidian&kelteks is in the approval process for its sandwich facade system, actively driving forward the development of sustainable buildings. Once approval has been granted, builders, planners and prefabricated component manufacturers will benefit from simple and uncomplicated implementation. Until then, however, planning and construction can already take place with approval on a case-by-case basis.
The system
The carbon sandwich facade is based on a three-part system structure:
- Support shell: classic concrete with steel reinforcement
- Connecting elements: GRP-based, thermally decoupled fasteners (solidian Z-Conn & PIN-Conn)
- Facing shell: ultra-thin, CFRP-reinforced concrete shell (solidian GRID)
Key technical data
- Facing shell thickness: 30–70 mm
- Insulation thickness: up to 250 mm
- Concrete quality of facing shell: C35/45 to C50/60
- Weight: reduction of up to 50% compared to conventional reinforced concrete facades
- CO₂ footprint: approx. 42% lower (according to life cycle assessment in accordance with EN 15804)
- Reinforcement: solidian GRID and solidian ANTICRACK
- Assembly: high degree of prefabrication possible, including factory-installed windows
Pilot project in Eschweiler
The innovative facade system was used in practice for the first time at the new nesseler Group company site. The results speak for themselves:
- Thanks to CFRP reinforcement, the facing shell could be reduced from 8 cm to just 3.5 cm
- The weight per element fell from 2.4 t to 1.2 t
- The delicate appearance is combined with high durability and minimal maintenance
- The facade is a design highlight – with shimmering, machined surfaces and custom corner solutions.
- The architecture was designed by the nesseler Group in Weisweiler.
- Carbon concrete with architectural concrete in “Nordic White” and “Labrador Black.”
Thanks to factory prefabrication, including windows, installation on the construction site was particularly efficient – a major advantage when working to tight schedules.
Why carbon?
Carbon reinforcement (CFRP) has properties that are superior to those of conventional structural steel:
- Corrosion-free: no thick concrete layer is required to protect the reinforcement
- Higher tensile strength with significantly lower weight
- Design freedom thanks to filigree component dimensions
- Ideal for weather-intensive applications
These properties not only enable more sustainable buildings, but also open up completely new architectural possibilities – without compromising on performance.
Award-winning innovation
The carbon sandwich facade was awarded second place in the fassadentechnik AWARD 2024. This award not only recognizes technological progress, but also underlines the potential for widespread practical application.
Images: © nesseler bau gmbh
