The Construction of a High-Rise Development Using Volumetric Modular Methodology

ctbuh.org/papers

Title: The Construction of a High-Rise Development Using Volumetric Modular Methodology

Author: Phillip Gardiner, Managing Director, Irwinconsult

Subjects: Architectural/Design Building Case Study Construction Economics/Financial

Keywords: Design Process Economics Modular Construction Sustainability

Publication Date: 2015

Original Publication: The Future of Tall: A Selection of Written Works on Current Skyscraper Innovations

Paper Type: 1. Book chapter/Part chapter 2. Journal paper 3. Conference proceeding 4. Unpublished conference paper 5. Magazine article 6. Unpublished

Phillip Gardiner, Managing Director, Irwinconsult

The SOHO Tower is a 29-level modular building the cost and shortage of a skilled construction Another driver was the foundation in Darwin, in the far north of Australia, a workforce led to a decision to investigate a conditions. Darwin is underlain cyclonic region. The building was designed to volumetric modular alternative, with modules predominantly by a crust of soft Porcellanite incorporate a basement and eight floors built delivered complete with all finishes, joinery rock overlying softer Cretaceous sedimentary with conventional reinforced concrete followed and fittings. It was essential however that deposits of Phyllite to a very significant by 21 levels of volumetric modular apartments. the building layout and appearance not be depth. Buildings have been typically founded The modules were constructed and fully finished changed in any substantial way. This was a on pads or rafts founded in the soft rocks in Ningbo, China and shipped to Darwin. Unlike significant challenge. at bearing pressures that would not cause most modular systems, a concrete floor was unacceptable levels of settlement. The used with concrete columns poured on-site into formworks contained within the modules. The building’s lateral stability system came from the central core using a modular precast concrete system, above level 7. The choice to “go modular” was driven by a constrained and high-cost labour market. The concrete floors were initially a client request, but proved to have other advantages. The concrete columns satisfied the loads generated by 21 levels of concrete-floored modules.

Why Modular? At the time of commencing design in 2011 and construction in 2012, Darwin was in the midst of a boom in construction and a significant shortage of accommodation. This was predominantly driven by the development of a large gas processing plant employing many thousands of workers, including construction workers, but also a large number of “fly-in-fly-out” specialists residing in hotels and apartments across the city.

The SOHO tower had been initially designed, received planning approval and its’ apartments substantially presold based on conventional construction, nevertheless

Right: Architectural apartment floor plans. Source: Irwinconsult Opposite: Construction image of SOHO. Source: Irwinconsult

136 allowable peak bearing pressure on this Given that contracts of sale were in place Modular Design Options site is 500 KPa, a challenge for a 30-story for the apartments, the developer, who The first design solutions presented building that would typically require a full was also the building contractor, ultimately for consideration were steel framed in raft across and beyond the tower footprint. had a preference for a concrete floor and a line with what had been seen in local Lighter construction methodologies, such building that, when completed, matched Australian markets and on a research trip as modular, were also considered to be an as closely as possible one of conventional to China. Systems that would deliver 21 advantage for this circumstance. construction. There was also a planning levels were not encountered, however, limit on total building height of 90 meters. and even less so given that they had to Critical Design Parameters This fixed story heights at 3 meters. conform to a predetermined layout and The geotechnical conditions have been resist cyclonic wind loads. Sketch designs summarized in the previous section. The other critical criterion was the design for a steel framed solution with tubular There was an absolute limit possible on for shipping and handling. The lifting steel columns and a steel framed floor with building mass and this had already driven system relied on a vertical lift from the “autoclaved aerated” floor panels were the reconfiguration of car parking to eight perimeter columns. Spreader beams developed. A prototype was built in the omit a basement. The original scheme were designed and fabricated to satisfy this developer/contractors’ precast concrete proposed two basements, which resulted requirement in the factory, on the wharf and factory, although it was already planned to in insufficient residual “rock” thickness on-site with appropriate dynamic factors construct the modules in China. above the softer sedimentary materials to of 200% as prescribed in the ABS Rules for spread loads and control both absolute and Certification of Containers 1998. Details were developed to achieve differential settlements. This controlled the the necessary fire ratings and acoustic maximum possible weight of the structural Transport on a 2.4-meter-wide truck without separation. The relevant Australian Standards system and applied finishes. any special frames controlled much of the required a 90-minute resistance for structural floor design, particularly to avoid excessive elements and 60 minutes for non-structural The severe cyclonic conditions in Darwin deformations under dynamic loads. fire walls in a building of this size fully result in very high wind loads. The average equipped with sprinklers. applied wind pressures to the building were Stacking of modules up to four high at the determined by wind tunnel testing to be 7 factory and storage yards also had to be Difficulties envisaged with the steel solution KPa (unfactored) with peak local pressures considered, as did two-high stacking onboard were: on façades in excess of 13 KPa. This a ship. The requirements for ship transport, • Each apartment comprised two precluded the use of self-braced modules. including temporary lashings, were also modules measuring 10 meters x 4.2 A “traditional” core with an outrigger wall designed to comply with the ABS Standard. meters and 3.9 meters respectively. was found to be the best structural solution For a fully steel framed option, the to control wind induced deflections. The The modules were designed to comply wall between the two modules critical stresses on the core walls were with the Australian Building Codes and would need a 90-minute fire rating tension forces, as with most residential Standards. Where Chinese materials (steel, to protect the steel structure and to buildings, with a partially external core reinforcement, and concrete as well as prevent the spread of fire between and fewer lifts for a given floor area than a plumbing and other components) were floors. While achievable, it added commercial occupation. used, test certificates and reports from NATA complexity and additional fire ratings registered testing laboratories were provided. to ceilings and walls.

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• The limit on floor-to-floor height • The number of elements and time site crane at its maximum reach for the and a less than ideal location of to fabricate modules was considered placement of the modules. plumbing risers made it difficult to excessive. Particularly given that a connect sewers from showers and new manufacturing facility was to The concrete floor was designed as a slab other fixtures under the floor without be established by the developer with perimeter beams and cross beams penetrating multiple steel joists or in Ningbo with a Chinese, but located to intersect with the perimeter compromising ceiling heights. Australian-owned partner. There columns. The cross beams assisted to reduce • The width of the modules would have would not be time to set up the the slab thickness as well as ensure columns made it necessary to transport them production lines needed to achieve were well connected to the floor. They also on spreader beams on trucks both in program and quality. allowed a 4.2-meter-wide module to sit China and Australia after shipping. on a 2.4-meter-wide standard truck bed without the need for a spreader frame. Truck • Darwin has a very tropical Following this experiment, a “concrete” transport of the modules was determined to humid climate and there were solution was developed, the significant be the critical load case for the slabs, after an real concerns with controlling limitation of this being the weight for both allowance for a 170% dynamic impact factor condensation on cool exposed building loads and foundation constraints, was considered along with the serviceability steelwork in interstitial spaces as well as handling and transport from limitations necessary to prevent cracking of between the modules. the factory to the site. An initial target maximum of 22 tons per module was set the plasterboard, glazing, tiles and joinery based on the anticipated capacity of the incorporated into the completed modules.

138 Opposite: A typical structural layout for apartment and hotel module floors and ceilings. Source: Irwinconsult Right: Column and corbel details. Source: Irwinconsult

The 125-millimeter slab and beams (300 millimeters wide x 250 millimeters deep) are of smaller proportions to most conventional concrete structures and required some control of detailing and placement of reinforcement. Various configurations of tensile and shear reinforcement were trialed to ensure easy placement and quality. Beams were also positioned so that no sewer pipes had to cross them. The slabs incorporated concrete corbels at the front and rear to support the corridor slabs and balconies that were constructed predominantly with precast concrete elements added after the erection of the modules. The floor slabs were poured upside down on steel forms at the factory. This ensured the consistent set out of wet areas and accurate grades to wastes.

The slabs also contained cast in steel fitments for the attachment of wall framing and mullions for glazing. The reinforcement for the cross beams had threaded ends which allowed the attachment of steel column forms via “elephant foot” ferrules which also served to anchor the reinforcement to the columns.

“The SOHO tower had been initially designed, received planning approval and its’ apartments substantially presold based on conventional construction, nevertheless the cost and shortage of a skilled construction workforce led to a decision to investigate a volumetric modular alternative, with modules delivered complete with all finishes, joinery and fittings. It was essential however that the building layout and appearance not be changed in any substantial way. This was a significant challenge.“

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Top: Exploded view of the module structure. Source: Irwinconsult Bottom: Lifting a module from storage. Source: Irwinconsult Opposite: Final positioning of a module. Source: Irwinconsult

In order to provide a concrete floor while achieving reasonable weight limits, a lightweight concrete mix was specified using an expanded shale aggregate. A density of 1,600 kg/m3 was proposed and was to be controlled through the monitoring of densities at the factory.

A batching plant had been set up there to ensure a continuous supply of concrete and strict control over strength and density. Testing of trial pours showed that the specified strength could not be consistently achieved at densities less than 1,800 kg/m3 and the designs were adjusted to suit the extra load.

Hot rolled mullions, sills and heads were used to trim the glazing and doors in the end walls to provide some sway stiffness for transport. Cold formed steel studwork was used for other walls with heavy gauge studs used for external walls to allow for the stacking of modules in the factory and on a ship, and to resist the internal wind pressures that could occur if glazing was breached during a storm event.

The design for the modules’ ceiling framing needed to ensure rigidity, water tightness during transport and adequate fire and acoustic separation. This led to a partial concrete solution. A concrete ring beam was incorporated into the perimeter of the ceiling. This ensured that all column load paths were transferred through concrete elements with a fire rating of 90 minutes. Therefore all walls became non-structural in the permanent case, allowing intertenancy walls and the ceiling to have a 60-minute fire rating, satisfied by one sheet of 16-millimeter fire rated plasterboard on steel studs and joists. The internal walls required no fire rating.

The concrete ring beam also corbelled to support other elements and provided rigidity at ceiling level for the lifting and stacking of modules. The lightweight ceiling within the ring beam was constructed from

140 cold formed steel joists with a fire rated position on site. The minor defects in finishes This is something that can be improved on plasterboard lining. A waterproof metal and treatments were only apparent in future projects if some self-guiding fixtures cladding was applied to the outside of modules shipped during a typhoon and were can be incorporated into the design. module walls to provide weather protection therefore subject to more extreme loads. during transport and erection. Stability Systems Ferrules and other attachment points were As mentioned previously, the tower is All steel frames were further protected with built into the modules to facilitate lifting subject to very high wind loads during a a polyurethane foam insulation applied and lashing with standard equipment. They cyclonic event. Lateral stability is provided by by spraying at the factory. This improved were also fully shrink wrapped in plastic connecting modules to the core on a floor- acoustic and thermal insulation and acted to before leaving the factory to provide an by-floor basis. This is achieved by utilizing the eliminate condensation issues. added layer of protection during transport. corridor slabs which connect to the modules and core as diaphragms and by connecting Handling, Transport and Shipping Tolerances and Positioning directly to the outrigger walls running A weight of 22 tons was targeted to meet The modules were manufactured to a centrally from the core. Overall building the anticipated limitations of the site crane. tolerance of +/- 10 mm. For a “stacked” stability is given by the core and outrigger The change to a heavier concrete mix module system over 21 levels cumulative wall structures. Traditionally these would and the addition of bulkheads and other tolerances would have been an issue, have been constructed in Australia using a finishes, pushed the total weight to 26 tons. however given that the columns supporting jump-form or similar system, with the core This was not an issue for handling at the the modules are constructed in situ, the progressing ahead of the floors. factory or for truck and ship transport, but positioning can be adjusted on a floor-by- proved to be right on the safe working limit floor basis. Prior to the erection of each To give flexibility to the program and of the 65-ton tower cranes already in place floor, the tops of the modules on previous make module erection easier, the erection on the site. A redesign of lifting gear from floors were surveyed and Teflon shims of the core could proceed somewhat heavy chains to lighter slings reduced the provided under bearing points to ensure independently and behind the modular total load to be within safe limits. that each module on the next floor was floors by up to four levels. The proximity of aligned and level. Positioning of individual the large tower crane close to the core and Ultimately, the modules were positioned modules was achieved by conventional site the amount of free crane time suggested with minor or no defects arising from their construction techniques, i.e., manpower on that a precast core could be a solution. transport from the factory to their final the end of crowbars and with rope guides.

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Left: Core details and lifting sequence. Source: Irwinconsult Opposite: Soho Apartments completed. Source: Irwinconsult

The normal disadvantage of a highly were effective, but time consuming to precast walls and attached to the modules stressed core constructed from flat precast install and created significant congestion. for stability and serviceability purposes only. panels is the difficulty in connecting corners After constructing several floors using and junctions to transfer high shear and this technique the issue was revisited and Balcony floors were tiled in the factory and tensile forces. the team decided to cast vertical circular had the option to pre-fit balustrades before “column” voids into the precast components. erection. They were brought to site with The high crane elevator capacity at the These ranged from 150 millimeters to 250 dividing precast walls as “U” shaped units and core location (38 tons) made it possible to millimeters in diameter. The results showed lifted into position. These were again designed consider using three-dimensional boxes they could contain all tensile reinforcements to be able to be erected on an independent for the core. We rationalized this to four and that the compressive forces could be program to the modules allowing maximum elements being the two stair shafts, the transmitted solely through these “columns.” efficiency of site labor and cranage. three elevator shafts and a front door panel. The consequential benefits were lighter Lessons Learned The precast elements are proportioned and panels with simple vertical reinforcement Despite commencing with very little time to configured to virtually eliminate mechanical and conventional cages and laps for “column build and test prototypes, the construction connections and formwork for “wet-joints.” bars.” This significantly reduced cost and came together as anticipated in the design. The three-dimensional nature also eliminated increased construction speed. Similarly, the However, there are some issues that could the need for any temporary propping. In-situ outrigger walls comprised a combination of be improved: concrete is poured between the panels of the in-situ and precast elements connected to stair and elevator shafts and there is a small the modules at floor/ceiling interfaces. • Reinforcement congestion in small formed and poured section over the heads of beams and columns was delaying the stair doors to provide continuity from the Balconies manufacture and construction door panel to the stair shaft. It would have been desirable to incorporate early on, but detail adjustments the balconies into the modules, but given resolved the issue for the beams. The Connecting precast elements at each the layout that was locked in and the Placement of reinforcement into the floor level to transfer high compression already high unit weights, it was necessary columns between modules was still and very high tensile forces was the to construct the balconies independently. a tedious issue and further research other issue to resolve. The initial concept These were also designed as precast has been done to resolve this for utilized proprietary bar couplers. These concrete units supported by dividing future projects.

142 • A major issue was the ingress of • Keeping module weights less that sophistication. The advantage of this was water into finished modules during 20 tons would be an advantage as that the factory was able to operate as a Darwin’s tropical storms. At critical this is the capacity of many cranes, “construction site in a shed,” with no major times during erection, the shrink wrap trucks, etc. Designs have been investments in plant and equipment and with skin was removed and the columns progressed achieve this while still a relatively unskilled workforce. prepared for concreting. Rain at that maintaining the benefits of concrete time could fill the column voids and in the modular structures. Erection on-site was also able to be water inevitably would find a way • The continual control of quality completed with a casual, unskilled workforce into the modules, staining finishes and work methods at off-shore on short term visas. The system is also and requiring remediation. Better manufacturing facilities is essential. capable of being used on much taller waterproofing systems have been This was resolved by having buildings provided that columns can be developed for subsequent projects. representatives of the contractor’s key accommodated in the planning and that a • The placement of modules into an trades at the factory for much of the core is provided for stability systems. exact position was labor intensive process. This also allowed for training and took longer than expected. The of factory staff in the construction The disadvantages of the system are the incorporation of details that guide methodologies required. weight of the modules relative to steel modules into position will improve this. framed systems and a slower construction program, although this system should achieve • Riser shafts for plumbing were located In Summary program savings of 30% over conventional in bathrooms, meaning that final The designs developed have delivered construction. This could be improved further fitting connections had to be done what is currently thought to be the world’s with the incorporation of more principles of from inside apartments, which had tallest volumetric modular building. This was Advanced Manufacture for Assembly. been delivered complete with all done in a remote city with a constrained finishes, joinery and sanitary ware. labor force and challenging climatic and The lessons learned have resulted in Positioning risers adjacent to corridors geotechnical conditions. improved detailing for a future 50-story and balconies would be preferable. development now in the concept stage. The less work required inside modules Unlike most modular systems, the design and on site, the less clean up and repair of construction aimed to replicate conventional accidental damage required. construction techniques at a low level of

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