3. lsfb for multistorey buildings_jbarnard

SASFA IS A DIVISION

OF

November 2013

Light Steel Frame Building in SA Taking LSFB to the next level

John Barnard, SASFA

2

Steel Workshop, November 2013

Introduction to LSFB

Manufacturing and Building Process

Pros and cons of LSFB

Approvals by authorities

SASFA & the RSA industry

Multi-storey building projects

Eastgate

Novo Warehouse, Paarl

Zambezi Mall

Villa Mall

Riverwalk Office Park

Pan African Games Village, Maputo

Questions?

Agenda

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The Manufacturing and Building Process

What is LSFB, and what does it offer? Light steel frame building systems consist of

cold formed sections

manufactured using high strength, thin gauge galvanised steel sheet

integrated design and manufacturing facilities

optimally designed to provide required structural strength

used for roof trusses, walls and

suspended floors

LSFB has been used for decades and is

growing in popularity worldwide,

especially in the US, UK and Australia.

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1. Introduction

LSF used for wall

panels, floor joists

and roof trusses

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1. Architects building plans are copied into CAD/CAM building system design facility.

Structural design automatically carried

out.

Bill of quantities and costing.

2. Design facility is linked to roll profiling

machine. Sections are produced to the

exact required lengths, holes punched,

and each section marked. In the correct

sequence for assembly.

No wastage.

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3. Trusses and wall panels are assembled in the

factory, using steel rivets or screws in pre-

punched holes.

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Frames are strapped together

for each building project. Note

the pre-punched holes in the

sections for services, and the

cross-bracing.

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4. Frames and trusses are delivered to

site, where the floor slab has been cast,

and power floated.

Erection of the wall frames and roof

trusses takes place within 2 to 3 days.

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5. Services (electricity and

water) are installed using pre-

punched holes in the studs.

Note no cutting and chasing of

brick walls!

6. A vapour permeable

membrane is fixed to frames of

all exterior walls.

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7. Exterior panels erected, and

fastened to steel frame.

Also used for multi-storey

buildings. Note shear panels.

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Fibre blanket

insulation is

installed in the

wall cavity

created by the

light steel

frame.

Insulation

requirements

are designed to

suit the

geographic

climate zone of

the building.

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6. After installation of insulation in the wall

cavity, interior dry wall panels and ceilings are fixed to steel frames using self-drilling screws.

Joints are rendered using tape and filler to

obtain a perfect finish.

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1.2 The Manufacturing and Building Process

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1.2 The Manufacturing and Building Process

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Advantages Quality, cost-efficiency & sustainability

Quality:

Tried & tested US, Europe, Australia

Complies with the rational design requirements of the SA NBR.

Structurally sound - each structure is signed off by an engineer.

Only quality certified materials are to be used.

Can accommodate imperfect foundation conditions, sloping sites.

Frames are normally assembled under controlled factory conditions

Thermal insulation superior to double skin brick walls.

Industry association (SASFA) quality and code compliance monitor.

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Advantages Quality, cost-efficiency & sustainability Cost-efficiency:

Fast

Dimensionally accurate everything fits

Minimal wastage and rework

Durable steel inside building envelope has a predicted life of > 100 years

Light weight logistical and handling costs reduced

Energy efficient range of insulation options

Flexibility can be built in stages, alterations

Additional (~ 4%) floor space

Installation of services

Predictable - accurate costing

Earlier occupation

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Minimal scrap / waste

Logistical cost advantage

Energy efficient - insulation

Embodied energy (MJ/m)

Operational energy CSIR research

Materials recycled / recyclable

Site water use


Sustainability

Advantages Quality, cost-efficiency & sustainability

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Challenges

Mindset of home-owners

Walls bullet-proof?

Break in through walls?

Numbers of competent LSF builders

Current tough market conditions

Supply chain is developing

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Approvals by authorities

All buildings must comply with the National Building Regulations

Three alternative routes:

Prescriptive requirements (conventional building),

Agrment certification, or

Rational design

Engineer (competent person) takes responsibility

Submits his rational design

Ensures building is erected to specification

Signs off

Plan approvals

NHBRC, enrolment

Local authorities

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SASFA

Southern African Light Steel Frame Building Association

Why an Association?

Interested parties, early 2006

Needed a forum for industry to

develop and set standards

monitor quality

coordinate industry development

Funding: major material suppliers

Steel

Fibre cement board

Gypsum board

Insulation

Formed as division of SA Institute of Steel Construction

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SASFA

Mission : To develop and grow the Southern African and export markets for Light Steel Frame Building.

Vision : SASFA strives to realise the following

LSFB is established as a high quality, energy efficient, cost effective and preferred method of building in Southern Africa, for

low rise residential and non-residential buildings.

Light steel frames constitute a significant export industry.

Goal : To capture 10% of all new low rise building projects in South Africa, including additions and alterations.

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SASFA

Milestones achieved

SASFA established as the industry representative association. Major material suppliers as founder members.

Website established. More than 1000 visits / month.

SASFA Code for low rise Light Steel Frame Building published, replaced by SANS 517.

Training course for LSFB erection established. Australian input.

Code training courses presented, major centres. Overseas speakers.

Course for building inspectors.

Obtained support from the NHBRC and the major banks bonds.

Publicity: 3 - 4 media articles per month. Building exhibitions.

Quality checklist compiled.

Accreditation Scheme drafted, being implemented.

Accepted as Associate Member of NASH, LSK (Europe) and SFA (USA).

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SASFA

SASFA Company Membership

Member category Oct-13

Major material supplier 6

Other material, component and equipment suppliers 6

Manufacturers of Light Steel Frame Building Systems

Large (>1000t / yr) 14

Other (

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Industry capacity

Current profiling capacity in m floor area / yr :

trusses => 1.8 million m systems => 2.7 million m

LSF Manufacturing facilities RSA Jun-13

Profilers Number 35

Profiling machines Number 67

Profiling capacity 106 lin m/yr 58

103 t ons/yr 59

Products manufactured

trusses only % of t ot al 25%

full LSFB systems % of t ot al 75%

Capacity of SASFA members % of total 80%

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Whats happening?

Hazy Crest, Pta North

5 Sept 06

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Whats happening?

Double storey house, Johannesburg

Office building, Durban airport

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Whats happening?

Offices inside

industrial building,

Durban

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Whats happening?

College building, Durban

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Whats happening?

Trusses, school

buildings for GDE

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Whats happening?

Vaal Dam

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Whats happening? Action cricket hall, Pretoria

2300 sq m, 7kg/sq m

Tiled roof, 12,5m span

Industrial building,

26m span

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Whats happening?

Antigua Estate,

Amanzimtoti

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Whats happening?

House in Macaneta, Mozambique.

MB Construction.

Zivania Village, GDS

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Whats happening?

Bela Bela house

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Whats happening?

Xanadu Eco Village, Hartebeespoort Dam

Multi-storey applications

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Eastgate extensions, Bedfordview

Novo Packhouse, Paarl

Zambezi Mall, Pretoria

Villa Mall, Irene

Riverwalk Office Park

Athletes Village, Maputo

Multi-storey applications : Eastgate extensions

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Multi-storey applications : Eastgate extensions

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Built on top of parking area mass saving essential 4000 sq m of walls, up to 10m high

MDS Architects

Grinaker LTA

Vela SBS / Browndeck

Multi-storey applications : Novo Packhouse, Paarl

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Johan Wessels Architect

Main contractor: Murray & Roberts Construction Western Cape

LSF supplier and erector: Light Frame Homes

Multi-storey applications : Zambezi Mall, Pretoria

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Osglo Architects

Steel supplier: MiTek / Razorbill


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Multi-storey applications : Villa Mall

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Osglo Pretoria, Architects

Light steel frame supplier and erector: GDS

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External walls

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External wall detail

15mm FS gypsum board Light steel track

EPS fastener

90mm thick 20kg/m EPS board

1.0mm G550 Z275 stud

2 x 4mm layers of proprietary

render with embedded fibre

mesh EIFS

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Internal wall detail

15 mm FS gypsum board 0.8 mm G550 Z275 stud

Staggered joint finished with 2 layers

of proprietary render with embedded

mesh

15 mm FS gypsum board

0.8 mm G550

Z275 stud

Steel door frame Bottom track

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Alternative building methods ...

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Internal and external finishes

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Advantages of LSF walling

Reduced dead loads on structure

Savings in structural concrete

Logistics

Speed of construction

Water consumption

Time & cost savings

Energy savings

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Reduced dead loads:

Mass of a double leaf masonry wall, plastered both sides: 450 kg / m

LSF internal wall 30 LSF external wall 35

Area external walls 23 000 m

Area internal walls 50 000 m

Mass saving (load reduction) : 31 000t


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Reduced dead loads:

The lower mass of the walls, made the use of coffer slabs, spanning 8.5m,

possible. Used less concrete than 350mm solid slabs, saved time.

mass saving 48 000 tons

The lower mass of the walls & slabs resulted in reduced section columns,

using less concrete.


All the above savings made the use of 1.2m diameter piles possible, in lieu

of 1.5m piles.



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Logistics

Walls: transport of 31 000t less materials than for masonry

construction, at 20t / load 1550 fewer truck loads

Rubble removal:

Inherent in wet trades : 10% breakages and wastage using LSF walling reduces rubble removal by 3 900t

195 fewer truck loads.

Concrete:

Saving of 114 000t (49 500 m) of concrete 8 260 fewer concrete trucks

Total reduction of 10 000 truck loads


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Site water consumption

i) Water requirement for mortar and plaster : 24 l / m wall area

=> Water saving = 73 000 m x 24 l

= 1,75 million litres

ii) Water requirement for concrete: 180 / m

=> Water saving = 114 000 m x 180 l / m

= 6.53 million litres

Total water saving : 8.28 million litres


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Time and cost savings

Erection of internal & external walls : saving 60% on time for

masonry construction

Mass reduction of LSF => use of special coffer slab

=> 25% saving in RC construction

time period


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Professional team comments:

Structural engineer we will definitely use LSF walling again in the future

Architect a huge success! It is faster, more energy efficient, cleaner, and it facilitates hassle free

changes to the floor plan at a later refurbishment

stage a real advantage in the retail space market.


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Riverwalk Office Park, Pretoria

EIFS

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Office building, Pretoria

Architect: Boogertmann

LSF erection: GDS

LSF supply: Vela SBS

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Progress Photograph

Moambique: December 3, 2010

Progress Photograph

Moambique: May 11, 2011

Progress Photograph

Moambique: August 10, 2011

Progress Photograph

Moambique: August 25, 2011

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Questions?

John Barnard

[email protected]

083 468 1410

www.sasfa.co.za

VSE

C

P.M

. -

Heritage Walk

Baltimore, Maryland

5-story loadbearing CFS with Hollowcore Planks

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Hotel, Carlsbad, California

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Dormitories at Cal Poly

San Luis Obispo, California

Condominiums in Mercer Island, Washington

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114 Senior residences, 1000 2000 s.f. each: 5 stories CFS on concrete podium.

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Hotel in Central Ohio

Podium: All structural steel

Walls: CFS

Floors: CFS joists

Roof: CFS trusses

Lateral Mixed: Tilt-up concrete stair and elevator towers; CFS shearwalls sheathed with sheet steel

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Ohio Hotel

February 20, 2007

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Ohio Hotel

February 23, 2007

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Ohio Hotel

February 26, 2007

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Ohio Hotel

March 16, 2007

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Ohio Hotel

March 30, 2007

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Ohio Hotel

April 13, 2007

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Ohio Hotel

April 26, 2007

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Ohio Hotel

May 11, 2007

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Ohio Hotel

May 18, 2007

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Ohio Hotel

June 1, 2007

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Ohio Hotel

June 15, 2007

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Ohio Hotel

June 29, 2007

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Ohio Hotel

July 20, 2007

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Ohio Hotel

August 3, 2007

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Ohio Hotel

August 17, 2007

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Ohio Hotel

September 12, 2007

95 Ohio Hotel

March 30, 2007

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Ohio Hotel

June 15, 2007

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Ohio Hotel

July 20, 2007

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Ohio Hotel

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Ohio Hotel

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Ohio Hotel

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Ohio Hotel

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Ohio Hotel

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Ohio Hotel

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Ohio Hotel

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Ohio Hotel

3. lsfb for multistorey buildings_jbarnard

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