Development of pre-cast composite structural system
(SMART frame) and the embedded energy efficiency
Won-Kee Hong 1 Ji-Hun Kim 1* Seon-Chee Park 1 Hyo-Jin Ko 1 JeongTai Kim 1
1 Department of Architectural Engineering, Kyung Hee University, Yongin 446-701,Korea
*Corresponding Author: J. H. Kim (ruleein@khu.ac.kr)
Abstract
The precast structural systems demonstrate outstanding economy compared to steel structures, but the construction speed is not as fast as steel constructions, preventing precast structural systems from being used widely. This is because it is difficult to install beams for lateral braces during erection.This paper presents pre-cast composite structural system(SMART frame) consisting ofpre-cast concrete, wide flange steeland reinforcement. This structural system is proposed for easy and simple connections of column-beam units to beam unit to form lateral braces during erection. Vertical steel sections with brackets are inserted in between pre-cast columns at joint level. The tree shaped column-beam units are lifted in sites to be assembled with steel sections inserted at both ends of pre-cast beam units. The introduction of steel section both in column-beam and beam units helps precast frames to be erected as similarly as steel frames providing proper lateral resisting frame to prevent lateral instability during erection. The hybrid construction basedpre-cast composite frames introduced in this paper adds the economy of precast concrete structures with steel erection speed. This paper also presents the embedded energy efficiency of the proposed pre-cast concrete frames based on the hybrid characteristics in terms of both structures and constructions.
Keywords: SMART frame, energy efficiency, column-beam unit, pre-cast composite structural system
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1. Introduction
Both the structural performance and constructability of the joints of precast composite structure is one of the importantaspects for design. Jurkiewiez et al. studied a new connection device based on horizontal shear connectors, eliminating the need for welding. The resulting steelconcrete composite beam was subjected to a static bending test [1]. Hajjar demonstrated the benefits of the composite systems relative to more common systems by comparing the performance characteristics of the beams when subjected to service and ultimate loads [2]. In this study, the areas of structure, materials and construction are investigated as a hybrid characteristic to provide versatileprecast composite structural systems.Precast composite structural systems proposed in this paper (SMART frame; hereinafter referred to as SF) consist of precast concrete, wide flange steel and reinforcement. SFseparated and manufactured at low moment locations as shown in Figs. 1 and 2 enables to assemble several floors of frames by one lifting. The precast structures cannot be erected as fast as the erection of steel frames due to the difficulties of the installation of beams for lateral braces during erection. In order for precast frames to be erected as similarly as steel frames requires proper lateral resisting frame to prevent lateral instability during erection.As shown in Fig 5 wide flange section isused to provide connections between precast column-beam and beam units for the erection of precast frames.
Fig 2.Column-Beam unit separated at low bending moment(Lateral Loads) Fig 1.Column-Beam unit separated at low bending moment(Vertical loads) SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 226
2. Principles of SMARTframe
2.1Column-beam unit and beam unit Figure 3 illustrates a column-beam unit. For fast, convenient lifting and construction, steel plates and wide flange steels are inserted between precast columns.The horizontal steel member attached to wide flange steels are connected to steels installed at each ends of composite beams. Figure 4 shows a composite beam unit with embedded steels at both ends of beam. Every 2 or 3-story columns are erected and connected to beams. As shown in Fig 6, using steel sections for erection eliminates the need of construction of slabs for upwards construction similarly to steel frame erections. The construction of slabs will follow without jeopardizing the lateral stability of the frame. The precast column-beam unit (column tree) separated at locations of low moment due to vertical and lateral loads is manufactured, then lifted and connected to beams through steel sections. The connection at these low moment locations reduces stresses for safe and fast connections against both vertical and lateral loads. The weight of the column/unit is designed as light as possible at this separation.
Fig 5.Assembly of Column-Beam and Beam unit Bracket (Wide Flange Steel) Precast Concrete Fig 3.Column-Beam unit Fig 4.Beam unit Steel Plate Wide Flange Steel SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 227
2.2Distinct Features & Advantages of SF Precast structures cannot be erected as fast as the erection of steel frames due to the difficulties in installing beams for lateral braces during erection.As shown in Fig. 6, SF presented in this paper does not have to wait for the construction of slabs. The SF proposed in this study is a hybrid composite structural system that adopted only the advantages of both steel frame structure and precast concrete structure.The presented hybrid construction method of precast structural systems makes it possible to erect precast concrete frames as similarly as steel frame systems with the same construction speed.The SF provides three types of hybrid characteristics. Structural, material and construction hybrid function makes SF suitable and economic. The SF enables the erection of frames as fast as possible and as economic as concrete, as well. During erection stage, composite beams act as wind braces against horizontal load during the erection process before the slab is poured.
3. Analysis on Energy Efficiency
Energy efficiency during the construction of SF suggested in this study is analyzed based on the applicationof SF to apartment buildings.The construction periods required for SF construction was compared with the conventional bearing wall construction[3]. The Framework construction period of 40~50% of the total constructionperiodwas saved when using SF for the construction.
3.1Existing Wall Apartment Building Process As shown in Table 1, the basic framework unit of conventional wall apartment buildings is a single floor and its process lasts for 7 days. Main processes flow in the following order:Marking Wall rebar work Installation of wall form Installation of Slab form Slab rebar work Cleaning& pouring [4].
Fig 6.Construction of Steel, Precast Concrete and SF Critical Path Upwards construction SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 228
Table 1.Process of bearing wall[5] Process 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day Marking
Wall rebar work
Installation of wall form
Installation of slab form
Slab rebar work
Slab electrical & Mechanical component
Cleaning and pouring
3.2 SF-Based Construction of Apartment Building Process Table 2 and Fig 7 show the construction process of SF.The SF column-beam units are manufactured as 3-strory column unit and erected as one cycle. The main processes of the first floor work lasts for 4 days consists of:Marking Core wall rebar work/form installation Installation of column-beam units/beam-units Installation of Deck plates/joint form Slab rebar work Cleaning& pouring. The second and third floors skip installation of column-beam units, so they require 3 days. Fig 7.Construction process of SF SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 229
Table 2.Process of SF Process 1-Floor 2-Floor 3-Floor 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 Day Core Wall rebar work
Installation of Core wall form
Installation of Column-Beam unit
Installation of Beam unit
Installation of deck plate
Installation of joint form
Slab rebar work
Slab electrical & Mechanical component
Cleaning and pouring
3.3 Comparison & Analysis of Framework Construction In general, the basic framework unit for bearing apartment buildings is a single floor and 7 days are needed per floor to complete. 3 days out of 7 days are for wall and slab form works. This implies that form works which are highly affected by workers skill and operation type greatly impacts the overall framework period [6]. On the other hand, SF utilizes 3-story column-beam units, so its basic work unit shall be 3 stories that last for 10 days. The construction of precast concrete composite frames reduces the amount of formworks, securing continuity of frameworks that ultimately reduces the construction period. Table 3 presents the calculated construction period that is required for 30-story apartment housing to compare the bearing wall types and SF types. Based on working days, the conventional wall apartment buildings require 210 days, yet when SF is applied 100 days are required. This represents that SF framework constructionperiod is reduced for 52.4% compared to that applied with the bearing wall type.
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Table 3.Comparison analysis of construction period Structural Type Construction Period Ratio Typical Floor Apartment Building(30-story) Bearing Wall 7 Days /1Floor 210 Days 100.0% SMART frame 10 Days /3Floors 100 Days 47.6%
3.4 Expectations on the Reduction of Construction Period As SFis applied to apartment buildings, the amount of forms used is reduced, decreasing the amount of wastes generated. Energy consumption to treat these wastes has been also reduced. A continuous construction process that does not become critical path is realized which enables efficient operation of tower canes, concrete pump cars and forklifts. This reduces CO 2 emission resulting from energy to run equipments and also from operating those equipments [7, 8]. The steels selectively embedded in the beam units largely contribute to resisting bending moment efficiently, improving the structural efficiency of materials [9, 10]. SF members are applied to satisfy structural performance, reducing floor heights and material quantity [11]. Table 4 demonstrates the quantity compared with that of the typical bearing wall apartment buildings showing reduction in concrete of 38.7% and in steel materials of 10.04%. Energy consumption due to use of concrete and steel material can be reduced and higher reduction effect is anticipated as apartments get taller [12].
Table 4.Comparison analysis of quantities per unit area[13] Materials Amount of material per unit area Reduction Rate(%) Bearing Wall SMART frame Concrete(m 3 /m 2 ) 0.602 0.369 38.70 Reinforcement(kN/m 2 ) 0.528 0.353 - Steel(kN/m 2 ) - 0.122 - Sum(Reinforcement + Steel) 0.528 0.475 10.04
4. Conclusion This study proposes a precast composite structural system designed to provide hybrid functions for structure and constructionareas.The following conclusions are drawn based on the comparisonof the construction periods of SF-applied apartment building with that of the existing bearing wall type.
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1) This paper presents hybrid construction method that provides the economy of precast concrete structures and steel erection speed as well. 2) As a result of analysis on 3-story, 1-cycle process that utilizes 3-story column-beam units, it requires 10 days for completion. When compared to the existing bearing wall apartment building in which 1-floor, 1-cycle process lasts for 7 days, framework construction period can be reduced for 52.4% based on the working days. 3) The amount of concrete and steel used per unit area in SF decreased by 38.7% and 10.04% compared with bearing wall apartment buildings, respectively.
This study introduced the SFproviding hybrid functions in terms of construction and structure. It was also proved to be energy efficientdue to the reduction of SF construction period compared with conventional bearing wall apartment buildings. Further investigations of comprehensive studies regarding SF buildings that affect the overall construction period and life cycle cost are needed.
Acknowledgements This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government (MEST) (No. 2012-0000609).
References
[1] Jurkiewiez B, Hottier JM: Static behaviour of a steelconcrete composite beam with an innovative horizontal connection; Journal of Constructional Steel Research 2005; 61(9): 12861300 [2] Hajjar JF: Composite steel and concrete structural systems for seismic engineering; Journal of Constructional Steel Research 2002; 58: 703-723 [3]Hong WK, Kim SI, Park SC, Kim JM, Lee SG, Yoon KJ,Kim SK: Composite beam composed of steel and pre-cast concrete. (Modularized hybrid system, MHS) Part IV: application for multi- residential housing; Structural Design of Tall and Special Buildings 2010; 19(7): 707-727 [4] Hong SW, Park SH, Kim SW, An JK, Son CB, Lee DJ, Lee MK:Analysis of Construction Planning and Scheduling in the Mock-up House forPracticality of Long Life Housing;Architectural Institute of Korea 2009; 25(7):145152 [5] Lee SH, Kim SE, Kim GH, Joo JK, Kim SK:Analysis of structural work scheduling of GreenFrame; Journal of Korea Institute Building Construction2011;11(3):301309 [6] Han CH, Bang JD: Development of an effective time scheduling mechanism of the structural framework for the high-rise Apartment Housing focusing on One Cycle time scheduling mechanism of typical floor; Korea Journal of Construction Engineering and Management 2004; 15(4): 87-96 SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 232
[7] Hong WK, Kim JM, Park SC, Lee SG, Kim SI, Yoon KJ, Kim HC, Kim JT: A new apartment construction technology with effective CO2 emission reduction capabilities; Energy - The International Journal 2010; 35(6): 2639-2646 [8] Hong WK, Park SC, Kim JM, Kim SI, Lee SG,Yune DY, Yoon TH, Ryoo BY: Development of Structural Composite Hybrid Systems (SCHS) and its Applications Regarding the Reduction Capability for CO2 Emissions; Indoor and Built Environment 2010; 19(1): 151-162 [9] Hong WK, Park SC, Kim JM, Lee SG, Kim SI, Yoon KJ,Lee HC: Composite beam composed of steel and precast concrete. (Modularized hybrid system, MHS) Part I: experimental investigation; Structural Design of Tall and Special Buildings 2010; 19(3): 275-289 [10] Hong, WK, Kim JM, Park SC, Kim SI, Lee SG, Lee HC,Yoon KJ: Composite beam composed of steel and precast concrete. (Modularized hybrid system, MHS) Part II: analytical investigation; Structural Design of Tall and Special Buildings 2009; 18(8): 891-905 [11]Hong WK, Park SC, Lee HC, Kim JM, Kim SI, Lee SG,Yoon KJ: Composite beam composed of steel and pre-cast concrete. (Modularized hybrid system, MHS) Part III: application for a 19 story building; Structural Design of Tall and Special Buildings 2010; 19(6): 679-706 [12] Hong WK,LimGT, Park SC, Kim JT: Energy Efficiencies of Linear-Shaped Multi-Residential Apartment Buildings Built with Hybrid Structural Systems; Energy and Buildings 2012; 46: 30-36 [13] Hong WK, Yune DY, Park SC,Yoon TH:An assessment of the energy and resource-efficient hybrid composite beams for multi-residential apartments;Indoor and Built Environment 2011; 20(1): 148-155 SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 233 Author biography Won-Kee Hong Professor of Department of Architectural Engineering, College of Engineering, Kyung Hee University, Yongin 446-701,Korea E-mail: hongwk@khu.ac.kr Profile Professor Hong has more than 30 years of professional experience in structural engineering. Professor Hong's research interests include a new approach to construction technologies based on value engineering and composite structures. He provided many useful solutions to the current structural design and construction technologies issues. Professor Hong has been conducting the research that combines structural engineering with construction technologies. He is the author of numerous papers and patents in this field. Lately he has started research work in hybrid Composite Frame System at the Center for Sustainable Healthy Buildings (CSHeB). Especially, Professor Hong developed the green frame hybrid systems consisting of structural Tee steel beam (or wide flange steel beam), precast concrete and cast-in-concrete. And now he is preparing the development of new long-life and eco-friendly multi-residential housing using this system. Professor Hong received his master and Ph.D degree from UCLA and he worked for Englelkirk and Hart, Inc.(USA), Nihhon sekkei(Japan) and Samsung engineering and construction(Korea) before he joined Kyung Hee University. He also has professional engineering licence from both Korea and U.S.A. SHB2012 - 7th International Symposium on Sustainable Healthy Buildings, Seoul, Korea 18 May 2012 234