Structural Decking: High Rise Buildings and Ibs Adoption

JP1

STRUCTURAL DECKING: HIGH RISE BUILDINGS AND IBS ADOPTION

Suraya Johari, Technical & Design Manager

March 16, 2019 Slide 3

JP1 Title Slide- The Master Title will be in CAPITAL, Font Size 26, Font Color White, Background 1; Font Type-Calibri Joshi, Punit, 11/20/2018 AGENDA Session 1: Adoption of structural steel decking for composite slab design and 1 permanent formwork in high- rise buildings 1.1 high- rise buildings Overview

1.2 Introduction to Steel Decking Formwork design, Composite slab design, Fire design, Advantages of steel 1.3 decking in composite slab design and permanent formwork 1.4 Structural Decking Design and Case Study

1.5 Case study on composite slab design and formwork design

2 Session 2: IBS Score calculation - Structural steel decking as permanent formwork and innovative system. High- rise buildings Overview

Image: The Skyscraper Centre Tallest buildings in the world

- 10 Tallest Building in the world from 484m to 828m height - All building are Steel Concrete Composite structures

Source: The Council on Tall Buildings and Urban Habitat's (CTBUH) 2017 Material of the 100 tallest buildings in the world

Source: The Council on Tall Buildings and Urban Habitat's (CTBUH) 10 Tallest buildings in the Southeast Asia (2018)

Source: insta-stalker.com STRUCTURAL DECKING FOR ICONIC BUILDINGS

Petronas Twin Towers TRX 106 Kuala Lumpur, Malaysia Kuala Lumpur, Malaysia Built:1998 Built: 2018 Profile: Lysaght Bondek Profile: Lysaght Smartdek STRUCTURAL DECKING FOR ICONIC BUILDINGS

Marina Bay Sands Singapore Built: 2015 Profile: Lysaght Powerdek STRUCTURAL DECKING FOR ICONIC BUILDINGS

Merdeka PNB 118 Kuala Lumpur, Malaysia Built: In Progress Profile: Lysaght Bondek II Planned Building City Height (m) Height (ft) Floors completion Merdeka PNB 118 Kuala Lumpur 644 m 2,113 ft 118 2024 The Exchange 106 Kuala Lumpur 492 m 1,614 ft 106 2019 Fairmont KL Tower 1 Kuala Lumpur 380 m 1,247 ft 78 2020 Oxley Tower #1 Kuala Lumpur 341 m 1,119 ft 79 2017 Southpoint: Mid Valley Tower Of Light Kuala Lumpur 286 m 938 ft 60 TBD Astaka #1 Johor Bahru 279 m 915 ft 70 2018 Fairmont KL Tower 2 Kuala Lumpur 278 m 912 ft 71 2020 STAR Residences & Boulevard Kuala Lumpur 265 m* 869 ft 58 TBD Astaka #2 Johor Bahru 259 m 915 ft 65 2018 Vogue Suites, KL Eco City Kuala Lumpur 243 m 820 ft 63 2017 Tropicana The Residence & W Hotel Kuala Lumpur 232 m 761 ft 55 2016 Elite Pavilion Kuala Lumpur 230 m 755 ft 50 2017 Equatorial Plaza Kuala Lumpur 225 m 738 ft 51 TBD Sentral Residences (×2 towers) Kuala Lumpur 210 m ×2 689 ft 57 2017

Under construction Under Sky Suites @ KLCC (×3 towers) Kuala Lumpur 209 m** ×3 686 ft 62 TBD Expressionz Professional Suites Kuala Lumpur 208 m** 689 ft 52 TBD Arte S Tower B Penang Island 170 m 558 ft 49 2015 1.* = CTBUH Pinnacle & Sheraton Hotel Petaling Jaya 165 m 541 ft 45 2017 estimated data, ** = Setia V Residence Penang Island 189 m** 495 ft 48 2016 minimum Celcom HQ Petaling Jaya 140 m** 459 ft 35 2017 height Introduction to Structural Decking • Lysaght® Bondek® II • Lysaght® Smartdek, • Powerdek

Image: The Skyscraper Centre Decking

Powerdek Bondek Smartdek code BS 5950 Part 4 as either re-entrant, trapezoidal Self-researched by LYSAGHT R&D

Material Specification BMT, mm 0.75, 1.00, 1.20 Coating Class Z275 (275 g/m2) (Mass)

G550 (0.75 &1.0mm) Yield Strength G500 (1.2mm)

Standards AS 1397 / BSEN10147 Lysaght® Bondek® II – Material

The name “Bondek” has been made from: “Bon” = grip or bond with concrete “dek” = stable working platform or deck Lysaght® Bondek® II – Material

• Rolled-formed from hot-dipped, zinc-coated, high tensile steel • 2 dove- tail ribs for every interlocking side lap ‰ “re-entrant” type rib • Tops of ribs are embossed ‰ concrete grip or bond (provide mechanical connection), and slip resistance • Pan flutes/stiffeners ‰ uniform ceiling finish • 600mm cover width ‰ speedy installation LYSAGHT® SMARTDEK® Profile & Dimensions LYSAGHT® SMARTDEK® Material Section Properties LYSAGHT® POWERDEK®

LYSAGHT® BONDEK® II, SMARTDEK®, POWERDEK FEATURES & BENEFITS

G550 and G500

Embossment

And 600mm & 960mm Effective width Composite Slab Design Concepts

Where is the floor slab?

ZOOM IN Composite Slab Design Concepts

Lets remove the facade ZOOM IN Composite Slab Design Concepts

RC Column

Steel Reinforcement bar Concrete pouring

BONDEK II Steel beam

BONDEK II composite floor slab Composite Slab Design Concepts

Concrete pouring

Steel beam

The formwork deck provides a stable working platform to allow wet concrete to be poured. ADVANTAGES OF LYSAGHT® BONDEK® II

1) Steel is a stronger material than timber, and with a deep profile the strength of the sheet is increased substantially This results in: - No time required to strip the formwork (deck) - Added safety conditions to working trades - Savings in time disruption to working trades

Lysaght Bondek ® II w/o propping Conventional construction with propping ADVANTAGES OF LYSAGHT® BONDEK® II

2) The steel sheet is left in place and thus can be utilised as BOTTOM REINFORCMENT for the concrete slab The embossments on the top of the ribs provide the added grip, or bond, with the concrete as done in normal reinforcement This results in increased savings from: • Less cost of conventional reinforcement, and • Less time to install the conventional reinforcement.

Top Reo Top Reo Reo depth Bottom Reo Bondek as Reo Normal Reinforced Slab Bondek Slab ADVANTAGES OF LYSAGHT® BONDEK® II

3) Steel sheet is roll-formed into a deep ribbed profile which result in saving of the cost of concrete due to; • Less concrete from the space/void of dove-tail ribs • If the sheet is used as reinforcement then less concrete cover to bottom reinforcement is required and thus the slab thickness can be reduced.

Top Reo Top Reo

Bottom Bondek Reo Normal Reinforced Slab Ribs give a concrete Additional saving 3 2 saving of 4m per1000m in concrete floor area Bondek Slab ADVANTAGES OF LYSAGHT® BONDEK® II

Key message: Normal reinforced concrete slab requires 2 layers of reinforcement bars and a minimum concrete cover

Top rebars

Reduced RCslab thk Bottom rebars Slab thk

BONDEK II • Replaces bottom reinforcements in a composite slab design • Reduced use of concrete – lighter slab ADVANTAGES OF LYSAGHT® BONDEK® II

4) Steel sheet is roll-formed into a deep profile of long lengths of thickness 0.75, 1.0 and 1.2mm. This results in customised length, lightweight steel decking sheets

Customised, lightweight result in; • Easy and safe handling and laying. • Less time for large areas to be covered quickly • Rapid and safe weather protection to following trades underneath and safe work environment to top surface trades ADVANTAGES OF LYSAGHT® BONDEK® II

5) Steel sheet is roll-formed with safety features (embossing and flutes in the pan) to minimise slip.

2 no.s of flutes per pan

Embossments on ribs to provide mechanical connection between steel and concrete Structural Decking Fundamentals

UNDEFLECTED WET CONCRETE STRUCTURAL DECK BEFORE CONCRETE POUR

critical

DEFLECTED SHAPE

STAGE 1 - FORMWORK

sheeting acts as a formwork carrying wet concrete during construction stage Structural Decking Fundamentals

COMPOSITE CONCRETE SLAB after 28 days

Critical deflection at service DEFLECTED SHAPE

STAGE 2 - COMPOSITE

sheeting acts as an effective tensile reinforcement when the concrete has hardened Structural Decking Fundamentals

STAGE 2 - COMPOSITE

sheeting acts as an effective tensile reinforcement when the concrete has hardened Structural Decking Fundamentals - Formwork Structural Decking Fundamentals - Formwork

Max. construction imposed load = 1.5kPa OR 4.5kPa/span (for span < 3m)

Max. imposed storage load = 4.0kPa l s

LYSAGHT® Structural Decking Systems (Pg 8/20) L l / L s ≤ 1. 2 Connection Detail

Galv. Edgeform Tie-back strap Shear Studs

Min. bearing 50mm Min. bearing 50mm Connection Detail

Min. bearing Min. bearing 100mm 70mm (on materials other than steel beams or concrete beam) TYPICAL SECTION DETAILS

• Typical connection details are available in autoCAD format for easy reference Structural Decking Fundamentals - Formwork Structural Decking Fundamentals - Formwork

Published Formwork Design Table Structural Decking Fundamentals - Formwork

Published Formwork Design Table Structural Decking Fundamentals – Composite Slab Structural Decking Fundamentals – Composite Slab Structural Decking Fundamentals – Composite Slab Structural Decking Fundamentals – Composite Slab FIRE RESISTANT Structural Decking Fundamentals – Composite Slab

Key Note for published composite slab design table Structural Decking Fundamentals – Composite Slab Structural Decking Fundamentals – Composite Slab Structural Decking Fundamentals – Composite Slab TESTING AND DERIVATION

FIRE RESISTANCE REPORTS Fire Resistance Certificate from Bomba- BONDEK II Fire Resistance Certificate from Bomba- SMARTDEK TRX EXCHANGE - SIGNATURE TOWER 106

• Height of the building 446 meters (1461 feet) • Floor area : 453,835 m2 (4,885,000 sq ft) • Construction started : 2016 • Smartdek delivered to site: Feb 2017 • Smartdek installation 90th Floor: Feb 2018 • Main contractor : China State Construction Eng... • Estimated completion : 2019

A render of Tun Razak Exchange with The Exchange 106 in the foreground, the KL Tower and the Petronas Towers at the background.

Source: thetowerinfo.com • The main contractor for The Exchange 106 is China State Construction Engineering Corporation, the corporation has built lots of supertall or megatall skyscrapers in China before, it is also going to build many other supertall skyscrapers out of China in recent years, none of them is as tall as The Exchange 106, upon the completion The Exchange 106 will become the tallest building built by Chinese company outside China.

• The construction work for the tower began in May 2016 with a mat foundation concrete pour, the pour took place continuously over a weekend, it is recognized as the second largest continuous concrete pour in the world.The concrete pour involved 8.5 million kg of cement, 16 million kg of sand and 19 million kg of aggregate.

• With the advanced building technology of China State Construction Engineering, the construction speed of Exchange 106 is surprisingly fast, on average it takes them only three days to complete one floor, sometimes, it takes only two days to complete.

thetowerinfo.com THE EXCHANGE 106 - CONSTRUCTION PROGRESS HIGHLIGHTS 2017 THE EXCHANGE 106 - CONSTRUCTION PROGRESS HIGHLIGHTS 2017 THE EXCHANGE 106 - CONSTRUCTION PROGRESS HIGHLIGHTS 2017 THE EXCHANGE 106 - CONSTRUCTION PROGRESS HIGHLIGHTS 2017 G/L: T4 - T7 = 7200mm x 3 = 21600 mm Standard length = 21600 mm/2 = 10800mm Span= 10800 mm/3 = 3600mm Thickness of the slab = 130 THE EXCHANGE 106 - CONSTRUCTION PROGRESS HIGHLIGHTS 2017 Merdeka PNB 118

Merdeka PNB 118, formerly known as KL118 or Warisan Merdeka, is a 118-storey, 644- metre megatall skyscraper currently under construction in Kuala Lumpur, Malaysia. Height: 644 m (2,113 ft) Location: Kuala Lumpur, Malaysia Estimated completion : 2024 Merdeka PNB 118

KL118 BONDEK II DESIGN DESIGN PARAMETERS INPUT PARAMETERS No of Load Combination Load combination Pattern Loading load cases Case Factor DLGsh Total Factor LLQc Total Factor DLFGdc Total DLFGsh+ LLFQc (applied on all 1 200 1.4 0.13 0.182 1.6 1.579 2.526 spans) DLFGsh (applied on all spans) + 202 1.4 0.13 0.182 1.6 1.579 2.526 (LLFQc) (applied on one span F1a = DLFGsh + LLFQc only) n =3 203 1.4 0.13 0.182 1.6 1.592 2.548

204 1.4 0.13 0.182 1.6 1.579 2.526

DLFGsh + LLFQs (applied on all 1 201 1.4 0.13 0.182 1.6 4 6.400 spans) F1b = DLFGsh + LLFQs DLFGsh (applied on all spans) + (LLFQs) (applied on one span n =3 205, 206, 207 1.4 0.13 0.182 1.6 4 6.400 only) DLFGsh(applied on all spans) + DLFGdc + LLFQc (applied on n-1 =2 1.4 0.13 0.182 1.6 1.579 2.526 1.4 5.032 7.045 adjacent spans, max. left to right) DLFGsh(applied on all spans) + 208, Flla = DLFGsh + DLFGdc + DLFGdc + LLFQc (applied on 209,210,211,2 1.6Qc n-1 =2 adjacent spans, max. right to 12 left) DLFGsh (applied on all spans) + (DLFGdc + LLFQc) (applied on n = 3 one span only) Fdef = Gsh + Gdc Gsh + Gdc (applied on all spans) 1 500 1 0.13 0.13 1 5.032 5.032 CASE 200: 1.40GSH + 1.60QC – (STAGE1) THE EXCHANGE 106 - CONSTRUCTIONMerdeka PROGRESS PNB HIGHLIGHTS 118 2017 Reduce Construction Time! Increase Profitability! Structural Decking Installation

Image: The Skyscraper Centre Structural Decking Installation Structural Decking Installation Structural Decking Installation Structural Decking Installation – Edge Form Structural Decking Installation – Edge Form Structural Decking Installation – Edge Form Structural Decking Installation – Sealing STRUCTURAL DECKS – BONDEK ACCESSORIES

BON-NUT Heavy Duty nut to fit from below into the dove-tail ribs and lock into place Hanging support for M8,10,12 threaded rod For ceilings and services

Rating: 0.60BMT 390kg 0.75BMT 440kg 1.00BMT 670kg INSTALLATION

Load onto transportation Off loaded on site INSTALLATION

BONDEK II bundles hoisted onto BONDEK II can be cut on site steel frames using simple tools INSTALLATION

Laying is done with no machine aid Lap the BONDEK II sheets INSTALLATION

Secure BONDEK II to steel beams Provide necessary Propping EXAMPLE OF INSTALLATION WORK FLOW

Install Edgeform Lay the reinforcement bars INSTALLATION

Remove dirt and contaminants

Pour concrete INSTALLATION Structural Decking – Picture

Road bridge in Silk Highway Structural Decking

Under side road bridge in Silk Highway Structural Decking Structural Decking Structural Decking Structural Decking PROJECT REFERENCE (RBPF OPERATIONS AND TRAINING CENTER)

-Lysaght Bondek II, 1.2mm and 1.0mm THK (For Communication room and adjacent staircase) ~ 126 sq.meters PROJECT REFERENCE: PROPOSED NEW M.R.S. IN BOLKIAH GARRISON

-Lysaght Bondek II, 1.0mm THK (Steel superstructure areas at 1st,& 2nd Floor and connecting bridge) ~ 291 sq.meters Modernization of Brunei International Airport Project

-Lysaght Bondek II, 1.0mm THK (For New BIA Airport terminal, Landside and Link Structures) Qty: 10,790 sq.meters Modernization of Brunei International Airport Project

-Lysaght Bondek II, 1.0mm THK (For New BIA Airport terminal, Landside and Link Structures) Qty: 10,790 sq.meters Structural Decking – Picture

SUBANG AIRPORT - QUICK CONSTRUCTION TIME Structural Decking – Picture

SUBANG AIRPORT - SPOT WELDING/ TACK WELDING (ON I-BEAM) Structural Decking – Picture

SUBANG AIRPORT - PAINTING MILD STEEL STRUCTURES Structural Decking – Picture

SUBANG AIRPORT - INSTALLATION OF SHEAR STUDS Structural Decking – Picture

PEDESTRIAN BRIDGE FOR SPRINT HIGHWAY Structural Decking – Picture

BASEMENT CARPARKS - OPENINGS (HANGINGS) AND ON CONCRETE BEAMS Structural Decking – Picture

LYSAGHT BONDEK II - IN CONCRETE FRAME CONSTRUCTION Structural Decking – Picture

LYSAGHT BONDEK II - BAHRAIN FINANCIAL HARBOUR (STARTED CONVENTIONALLY) Structural Decking – Picture

LYSAGHT BONDEK II - BAHRAIN FINANCIAL HARBOUR (UNDERSIDE OF LYSAGHT BONDEK II) Structural Decking – Picture

LYSAGHT BONDEK II - BAHRAIN FINANCIAL HARBOUR (FORMWORKS) Structural Decking – Picture

LYSAGHT BONDEK II - BAHRAIN FINANCIAL HARBOUR Structural Decking – Picture

LYSAGHT BONDEK II - BAHRAIN FINANCIAL HARBOUR (CLEAR CONSTRUCTION WORK SITE) Structural Decking – Picture

LYSAGHT BONDEK II -Petronas Twin Tower Structural Decking – Picture

LYSAGHT BONDEK II - Greater Nile Petroleum Operating Company, Sudan Structural Decking – Picture

LYSAGHT BONDEK II - Al Hitmi Complex, Doha, Qatar Structural Decking – Picture

LYSAGHT BONDEK II - Jamarat Bridge, Saudi Arabia Structural Decking – Picture

LYSAGHT BONDEK II - Emirates Twin Towers, Dubai, UAE