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Structural Decking: High Rise Buildings and Ibs Adoption

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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.
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