(23.

4) Hh2 JAN 2001

Cellular Beams Design Guide

Introduction
CELLULAR BEAMS Cellular beams are one of the most significant developments in steel construction of the past 20 years. Since their introduction in 1987, cellular beams have been used in over 3500 projects, in over twenty countries. The structural integrity and design criteria of cellular beams have been verified following full-scale destructive testing at Bradford University in 1988, Leeds University in 1995, and University of Mancester Institute of Science and Technology (U.M.I.S.T) in 2000, under the supervision of the Steel Construction Institute. (S.C.I.). WESTOK Westok are Europes leading supplier of castellated beams, and the inventors of cellular beams. Established in 1985, Westok are members of the British Constructional Steelwork Association (B.C.S.A.), and The Steel Construction Intstitute (S.C.I.). Westok is committed to the highest quality of service and workmanship.

Westok Limited Horbury Junction Industrial Estate Horbury Junction Wakefield West Yorkshire WF4 5ER Tel: Fax: E-Mail: Web: 01924 264121 01924 280030 info@westok.co.uk www.westok.co.uk

Contents Floors
3. 4. 5. 6-7. 8-9. Floor Beam Design Form Applications Flexibile Geometry & Properties Clear Span or Short Span? Service Integration

10-11. Dynamic Performance 12. 13. Deflection / Cambers Car Parks

Insert

CELLBEAM Program Design Guide & Section Property Tables

Roofs

15. 16.

Roof Beam Design Form Applications

17-19. Curved Beams 20. 21. Tapered Beams & Cantilevers Spine Beams

Columns Design

22.

Cellular Columns

24. 25.

Technical Support How to Specify Cellular Beams

26-27. Avoiding Infills to Cells 28. Welding & Testing

29.

Records........to be Broken

Roofs

CELLULAR ROOF BEAM

DESIGN ENQUIRY FORM
Company: Name: Tel: E-Mail: Project: Beam Ref: Fax: Address:

LAYOUT

Rafter ( Span

) Metres

Spine ( Centres

) Metres

Notes:

Full Restraint ( ) Partial Restraint ( )

No Restraint ( ) Restraint Centres Unfactored Unfactored Unfactored Unfactored Unfactored Metres kN/m2 kN/m2 kN/m2 kN/m2 kN/m2 mm mm Metres

LOADING

Live Roof Decking Min. Dead (wind uplift) Wind (net: up or down) Other

LIMITS

Maximum Depth (leave blank if no limit) Minimum Diameter (leave blank if no limit)

RADIUS

Approx Radius (if applicable)

The cellular beam proposed below is one of MANY possible solutions. Please advise if any of the dimensions shown are unsuitable. For completion by Westok
CELLULAR BEAM: GRADE:
Notes:

....................mm OVERALL DEPTH ..................mm ....................mm DIAMETER ...................mm

Top Tee:

CENTRES ....................mm

Btm Tee:

Signed ............................................................Date: .......................... Checked ....................................................Date .................... WESTOK DESIGN NO: REV:

PLEASE PHOTOCOPY THIS FORM

FAX: 01924 280030

Roofs

Roof Beams - Applications

The economic span range depends on the loading and frame centres, but may be generalised as below: 20m PITCHED PORTAL CURVED PORTAL STRAIGHT SIMPLY-SUPPORTED CURVED SIMPLY-SUPPORTED 20 - 40m >40m

          

The production process considerably improves the section properties of the parent beam used:Example: 762 x 267 x 134 Kg/m BEFORE AFTER 750 cells @ 950 mm c/c Depth 1111 mm 2108 kNm 330053 cm4 IMPROVEMENT

Mcx Ixx

1430 kNm 150700 cm4

+ 47% + 119%

COMPARISON v TRUSSES Beyond the range of portal-frame construction cellular beams are the ideal solution. A cost comparison between cellular beams and trusses invariably favours cellular beams. Built-up truss fabrication is more labour intensive and painting costs are considerably higher.

R.A.S.E., Stoneleigh
45 metre span simply-supported roof beams, chosen as an economical alternative to trusses. Engineer: R.M.J.M. Architect: R.M.J.M. 80 tonnes of cellular beams.

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For free roof beam design service please use form on page 15

Curves
Cellular beams are the perfect solution for curved roof applications, combining a considerable weight saving compared with plain sections and a low-cost manufacturing process.

Roofs

Step 1 Two beams are split, the first using a special top tee cut (red) and the second using a special bottom tee cut (blue).

Step 2 A bottom tee is bent to the required radius.

Step 3 A top tee is curved and welded to the bottom tee. The process is repeated using the so far unused tees to create a pair of curves

ASDA Superstore, Tamworth

30 metre span, 108 metre radius beams. Engineer: M.J.M.C. Architect: Darnton Elgee 140 tonnes of cellular beams.

For free roof beam design service please use form on page 15

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Roofs

Curves - Economics
Pitched Roof or Curved Roof? The cost difference between pitched and curved roof construction has never been as low as it is today. The minimum cost difference is likely to be achieved at a radius of around 150m. This minimises the number of splices required and allows the use of standard roof cladding products.

Braced Frame or Curved Portal Frame? A portal solution provides a cost-effective frame but with the penalty of large stanchions. In many applications this is undesirable. A braced frame solution using simply supported curved cellular beams allows slender columns, often containable within the wall construction.

Plain Beams or Cellular Beams? Cellular beams offer economies compared to plain universal beams due to weight savings of up to 40% and the ease of curving. The relative cost of plain and cellular beams depends on many factors, but may be generalised as below:

Tight Radius Up to 16m Span > 16m Span Plain Plain/Cellular

Medium Radius Plain/Cellular Cellular

Large Radius Cellular Cellular

Consult Westok for specific advice

Parkland Textiles, Nottingham

36 metre span, 120 metre radius beams. Engineer: WSP Architect: Nicholas Grimshaw & Partners 190 tonnes of cellular beams.

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For free roof beam design service please use form on page 15

Achievable Radii
Curved cellular beams fall into two categories: A) Curved in-house, therefore at minimum cost B) Curved in collaboration with section-bending company
ORIGINAL SECTION SIZE Upto 305 x 165 TYPICAL BEAM DEPTH 450 LENGTH OF BEAM* 10 M 12 M 14 M 16 M 14 M 16 M 18 M 20 M 14 M 16 M 18 M 20 M 14 M 16 M 18 M 20 M 16 M 18 M 20 M 22 M MINIMUM RADIUS A 20 M 30 M 40 M 50 M 50 M 60 M 80 M 95 M 60 M 75 M 90 M 110 M 65 M 80 M 100 M 125 M 95 M 115 M 140 M 170 M B 15 M

Roofs

Upto 457 x 191

650

20 M

Upto 610 x 229

850

30 M

Upto 762 x 267

1100

35 M

Upto 914 x 305

1350

45 M

THIS TABLE IS APPROXIMATE. CONSULT WESTOK.

* The achievable radius of a beam is not subject to the overall span, but to the length of the pieces.

A tighter radius can be acheived by introducing a splice. Splices at 1/3 points allow an even tighter radius.

Liverpool FC Academy
44 metre span beams, spliced at 1/3 points. Engineer: Scott Wilson Kirkpatrick Architect: Knowsley Design Consultants 80 tonnes of cellular beams.

For free roof beam design service please use form on page 15

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Roofs

Tapered Beams & Cantilevers

Cellular beams provide a very economical method of producing tapered members. Step 1: Profile at angle of required taper

Step 2: Spin one tee 180, and re-weld

Dunfermline A.F.C. Long cantilevers can be made by splicing multiple sections. Actual example: (Carlisle United F.C.) 28m pure cantilever:-

15m 762 x 267 x 173 kg/m

13m 457 x 191 x 74 kg/m

Rushden & Diamonds F.C. Simply-supported tapered beams in a pitched roof minimise building height.

Centennial Park, Elstree

High specification light industrial units, widest span 36 metres. Tapered from 500mm at the eaves up to 750 mm at the apex. Engineer: Peter Brett Associates Architect: EPR Architects 95 tonnes of cellular beams.

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For free roof beam design service please use form on page 15

Spine Beams
Hit and miss spine beams are a common method of increasing usable floor space in a single storey building. Cellular beams efficiently span 3, 4 or even 5 bays between columns, creating vast open floor areas at minimum cost. Cellular spine beams also eliminate expensive rafter/spine dropped haunch arrangements.

Roofs

Simple connection into a cellular valley beam.

Costly dropped haunch beneath a plain valley beam.

Cellular spine beams can be cambered free of charge for drainage. Asymmetric sections maximise efficiency where subjected to lateral torsional buckling.

Asymmetric cellular spine beam

Royal Mail Scottish Distribution Centre, Wishaw

Clear floor area of 72m x 24m. 24 metre span spine beams supporting twin 36 metre span rafters. Connection entirely within spine beam depth to avoid dropped haunches. Engineer: Blyth & Blyth Architect: Bradford Robertson 60 tonnes of cellular spine beams and 170 tonnes of curved cellular beams.

For free roof beam design service please use form on page 15

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Columns
Cellular columns are most efficient in cases where axial loads are small, such as gable columns and wind-posts.

High-bay columns are a particularly suitable application, where the increased inertia of a cellular beam is required for the large deflections in the tall columns.

In conditions where wind-reversal is the dominant criterion, asymmetric cellular beams can be adopted, using the wider tee as the unrestrained flange.

Asymmetric columns for wind reversal

Ideal Hardware plc, Chessington

16.5 metre high columns supporting 48 metre clear-span roof. Cellular columns 1150mm wide. Engineer: Pell Frischmann Architect: Pell Frischmann 60 tonnes of cellular columns and 180 tonnes of curved cellular roof beams.

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Design

Technical Support
Westok provide comprehensive engineering support at any stage of a project design. OFFICE BASED DESIGN SERVICE Instant technical advice and full designs from Westoks Technical Department. REGIONAL ADVISORY ENGINEERS Advisory Engineers can attend project design meetings to help optimise the design of a specific project, and to help engineers gain a familiarity and expertise in cellular beam design. TECHNICAL SEMINARS In house technical seminars can be arranged to promote the efficient design of cellular beams, and proficiency with the associated software, CELLBEAM.

CELLBEAM SOFTWARE All cellular beam designs are carried out using the analysis program, CELLBEAM, writen by the Steel Construction Institute. The results are based on full scale destructive testing: Bradford University 1988 Leeds University 1995 U.M.I.S.T 2000 The program is available free of charge and is enhanced on a regular basis. Technical support is offered without charge or obligation. Please do not hesitate to use it.

LIDL Distribution Centre, Runcorn

Multi-bay portal, widest span 40 metres. Plated haunches connecting to curved cellular beams. Engineer: G.H.A. Architect: Fletcher Bennett 180 tonnes of cellular beams.

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For free design service please use forms on page 3 and page 15

How to specify Cellular Beams

Given the flexibility of cellular beam geometry, a tabulated specification on drawings is the best way of conveying information to all interested parties. The table shown below is not the only solution, but is one of the most commonly used approaches:

Beam Depth Mass Mark mm Kg/m

Material top 356 x 171 UB 67

Grade

Cell Data Camber dia pitch infills

Notes

Studs 19 Dia.L.A.W

INTUMESCENT DATA HP/A Factor

CB1

466

82 btm 305 x 305 UC 97

S355

CL cell 300 450 See 30 mm 300 mm dwgs from top flange

2 Per Trough

196

1.35

NOTATION The standard notation of an asymmetric cellular beam (A.C.B.) using the above example, is as follows:
Bottom tee flange-width Cell Pitch

466 x 171/305 x 82kg/m ACB. (300 @ 450, S355)

Depth Mass Cell Diameter Steel Grade

Top tee flange-width

The standard notation of a symmetrical cellular beam (C.U.B.), is as follows:

Ex 762 x 267 x 134 UB Cell Pitch

1160 x 267 x 134kg/m CUB. (800 @ 1000, S275)

Depth Mass Cell Diameter Steel Grade

Governors House, London

15.5 metre span floors. One of the earliest clear-span cellular beam projects. Engineer: Ove Arup Architect: Sidell Gibson 350 tonnes of cellular beams

For free design service please use forms on page 3 and page 15

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Avoiding Infills to Cells

Eliminating Infills To avoid the unnecessary infilling of cells, care should be exercised in specifying the distance to the first cell. Step 1 - Design the optimum member for structural efficiency. Step 2 - Make slight adjustments to cell-pitch so that there is a full web-post at each end of the beam using the equation below, where n is the number of cells:S= D0 S - ___ 2 L + D0 (n+1)

D0 S - ___ 2

D0 S L Step 3 - Re-check design using the new cell-data. CHANGING THE CELL PITCH BY ONLY A FEW MILLIMETRES CAN OFTEN COMPLETELY ELIMINATE INFILLS. D0 S - ___ 2

Roof Beams In simply supported designs, infills should not be required.

_ D0 __ - 2

Irrespective of whether straight or curved, it should be possible to leave a full web-post at the beam ends. In fixed-end or portal conditions, consult Westok.

David S. Smith Packaging, Cambridge

Only six infilled cells in the entire supply of rafters and spine beams. Engineer: G.H.A. Architect: Carden Croft & Co. 350 tonnes of cellular beams.

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For free design service please use forms on page 3 and page 15

Avoiding Infills to Cells

Floor Beams In a serviced floor the best approach is to optimise the cell pitch so that no infills are required for the beams on grid. This fixes the cell layout for the intermediate beams. The example shown below is typical, limiting the infills to only two half cells in every other beam:-

CB1

CB2

CB2

CB1

full web post

CB1

full web post

2 infill*

CB2

2 infill*

* Steelwork contractors are increasingly choosing a fin-plate connection, which completely avoids notching and half infills. Even in irregular buildings, infills can normally be limited to no more than an average of one per beam. If your design requires more infilling than suggested above please consult Westok. Our Advisory Engineers will help you minimise / eliminate infilling.

McVities, Carlisle
Two out of three beams without infills. Every third beam required two half infills. Engineer: A L Daines & Partners Architect: Johnson & Wright 310 tonnes of cellular beams.

For free design service please use forms on page 3 and page 15

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Welding and Testing

IN HOUSE TESTING - Non Project Specific

Westok produce solely cellular and castellated beams. As a result Westok is highly skilled in this welding technique. Over 10% of output is tested, and verified by an independent testing company. Inspections are completely random, using Ultrasonic and Magnetic Particle Inspection methods. Whilst this does not guarantee the testing of a given beam or project, it ensures total confidence in weld-quality at all times. The records of these random tests are available for inspection by any party at any time.

NATIONAL STRUCTURAL STEELWORK SPECIFICATION When NSSS is required it states that for castellated and cellular beams, 5% of welds should be tested by Ultrasonic and MPI methods.

DIFFERENT TESTING REQUIREMENTS Westok will test the welds of a project to any specific requirements. It is important to make testing requirements clear in the project specification. Any testing must be carried out at Westok.

Shearwater Offshore Platform

Cellular beams used to minimise the weight of the platform. 100% weld-testing carried out. Consultants/Fabricators: Odebrecht Oil & Gas Ltd 80 tonnes of cellular beams.

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Records....to be Broken
McAlpine Stadium, Huddersfield Town F.C.
37.5 metre rafters transported to the award winning stadium in a single piece Engineer: YRM Architect: Lobb Partnership.

David S. Smith Packaging, Cambridge

52 metre span, lightly curved portal rafters. 610 x 229 x 113kg/m. Engineer: G.H.A. Architect: Carden Croft & Co.

Daimler-Chrysler, Seitenwelle, Germany

The 1300 tonnes for this production plant shares top-spot with the DHL building at East Midlands Airport. Engineer: Strehle & Partners Architect: Daimler-Chrysler A.G.

Middlebrook Leisure Centre, Bolton

2.5 metre deep spine beams, ex 1016 x 305 UB with large spacer-plate welded inserts. Engineer: Bradshaw Gass & Hope Architect: Bradshaw Gass & Hope

Horbury Junction Industrial Estate, Horbury Junction, Wakefield, England WF4 5ER Tel: +44 (0) 1924 264121 Fax: +44 (0) 1924 280030 E-mail: info@westok.co.uk