SRT251: CONSTRUCTION AND STRUCTURES

1. Next Home Previous SRT251: CONSTRUCTION AND STRUCTURES PROJECT 1: WAREHOUSE AND OFFICE COMPLEX Fiona Allpress: 300138121 Jamie Ifrah: 300173659 Steven Kymantas: 300175956 Adam Wood: 300182771 Stephen Young: 300150037

2. Next Home Previous Contents (home) WAREHOUSE: • Span Table: PG 4 • Concrete for Slab: PG 5,6,7 • Footing System for Slab: PG 8 • Grid System for Warehouse: PG 9 • Portal Frames: PG10, 11, 12, 13 • Portal, Bracing and bolt specification: PG 14 • Examples of Portal Frames: PG 15, 16 • Envelop System: Tilt-up: PG 17, 18 • Roof Structure: PG 19 • Roof Cladding: PG 20 • Guttering System: PG 21 • Roller Doors and Exits: PG 22 • Figure 1: PG 23 • Layout of Warehouse: PG 24 • Sketches: PG 25, 26 • Site Layout: PG 27 • Warehouse Section: PG 28 SHOWROOM: • Concrete Slab for Showroom: PG 30 • Grid System & Layout for Showroom: PG 31 • Portal Frame for Showroom: PG 32 • Portal, Bracing and bolt specification: PG 33 • Examples of Showrooms: PG 34, 35 • Envelop System: Tilt-up: PG 36 • Roof Cladding & Guttering System: PG 37 • Showroom Finish: PG 38 • Showroom Section: PG 39 REFERENCES

3. WAREHOUSE

4. Next Home Previous Span Table

5. Next Home Previous Concrete for Slab Reinforced concrete: Reinforced concrete combines concrete and some form of reinforcement into a composite whole. Concrete has high compressive strength but low tensile strength. Steel has very high tensile strength. By combining steel and concrete into composite material we are taking advantage of steel’s high tensile strength and concrete’s compressive strength. Retaining walls: Retaining walls likened to vertical beam fixed at one end. Soil or other material being retained causes wall to act as cantilever. The footing of the wall tends to bend or distort as load is applied. Reinforcement should be distributed to resist these stresses. Joints in concrete construction: Joints can be of two general types: • Those which allow no relative movement of concrete on either side of them. • Those which allow relative movement. It is recommended that joints allow relative movement. They are named according to type of movement they allow… Contraction joints: allow concrete to shrink away from plane of the joint while restraining relative movement in other directions. Expansion joints: separate two faces sufficiently to allow expansion towards the plane of the joint. This also allows contraction but prevents movement in other directions. Isolation joints: completely separates two faces and allows complete freedom of relative movement.

6. Next Home Previous Concrete for Slab Location of joints: Contraction joints should be located where severest concentrations of tensile stresses resulting from shrinkage of the concrete are expected to occur. For example, in large areas of pavement or slab on ground. Spacing of contraction joints generally dictated by designer or supervising engineer, however, 5 to 6m can be used as a guide. Large areas of concrete should be divided into approximately square bays by means of contraction joints. Joints must be spaced sufficiently close together to prevent shrinkage cracks from occurring between successive joints. Expansion joints create a gap between two surfaces so as to allow expansion of concrete into the gap. The gap is usually filled with compressible filler, e.g. rubber, plastic, cork or mastic. All relative movement in the plane of joint is prevented. Expansion joints most expensive type of joint to make. An increase in concrete’s temperature will generally increase the concrete’s length, e.g. temperature rise of 10C. in a 10 metre length of unrestrained concrete will result in an expansion of about 1mm. Under Australian climatic conditions normal maximum temperature differential through a year doesn’t exceed about 40C. Therefore thermal movements at a joint wouldn’t exceed 10mm. per 25 m. of concrete. Thus if decided to place expansion joints at 25m. intervals, they must be sufficiently wide enough to allow for 10mm. movement. If joint made 15mm. wide at average temperature, should be filled with material capable of being compressed to 10mm. thickness and of expanding to 20mm. thickness. Spacing of expansion joints is design consideration. Building rarely exceed 30m. in length without introduction of either an expansion or an isolating joint into floors, columns and beams.

7. Next Home Previous Concrete for Slab Class of concrete: Normal class of concrete is intended to cover the needs of the majority of domestic, commercial, industrial and institutional building projects. Normal class concrete has a strength grade chosen from N20, N25, N32, N40 or N50. Slump required at point of delivery chosen from 40, 60, 80 or 100mm. Maximum nominal size of coarse aggregate chosen from 10, 14 or 20mm.

8. Footing System for Slab The footing system we have chosen to use is an isolated pad footing system, at the point loads of the columns. The pads are 1000mm by 1000mm by 750mm. Once this has been achieved we will then poor a 150mm thick slab with 300mm by 300mm edge beams running around the exterior of the building. This will be poured so the finished height of the slab is at the same level as the pad footings. 150 300 750 1000 300 40,000

9. Next Home Previous Grid System for Warehouse 8000 40,000 8000 40,000

10. Next Home Previous Portal Frames A Portal Frame is a ‘continuous rigid frame with a restrained joint between the stanchion and beam’ (Jeremy Ham’s lecture notes; lecture 1). They provide an efficient structural solution to long span construction. There are the three types of portal frame construction: • 3-pinned portal, • 2-pinned and • Rigid base portal 3-pin portal frames have three pin joints. Two at each of the supports and one at ‘crown.’ 2-pin frame has 2 pin joints at the supports. In Two and Three pinned frames, the portal frame is supported at ground level with a pin joint, therefore ‘rotational’ forces don’t have to be resisted in the footing. Bending moments are transmitted vertically into the ground, reducing footing size but as a consequence have a heavier frame. All joints in rigid baseportal frames are restrained. This system requires good foundations and is used to span smaller distances compared with pinned construction. This inturn leads to greater volumes of concrete required in the footing; hence adding to the cost of the foundation. Rigid frames have lower bending moments than Two and Three pinned frames resulting in rigid frames being lighter and footings being heavier. Source: Jeremy Ham’s lecture notes

11. Next Home Previous A Portal Frame Purlins Rafter/ beam Knee joint Girts Stanchion/ column Base Pad footing Source: Jeremy Ham’s Lecture notes.

12. Next Home Previous A Portal Frame Source: Jeremy Ham’s Lecture notes.

13. Next Home Previous Portal Frames(continued) Portal Frames are most commonly used in • warehouses, • factory buildings, • large span storage buildings, and • heavy industrial process plant structures When a beam in a portal frame is loaded it deforms elastically. The top flange of the beam goes into compression, whilst the bottom flange goes into tension. Such deformation would result in columns spreading at base if there was no lateral restraint. Footings resist this spreading and in doing so carry bending moments as well as axial loads. Columns also act in bending as connections between footings and columns, and columns and beams are rigid. Roof members generally have low pitched rafters or horizontal beams that are connected to a stanchion with a rigid joint. Roof pitches between 5 and 10 degrees are preferred in portal frame construction. These pitches are suitable for any continuous length steel sheet profiles and this factor outweighs superior structural action of higher pitch roofs, which have additional sheeting costs. The most popular portal frame system is the ‘column and truss system.’ On a ‘cost’ basis, the simplicity of a portal frame results it in being the cheaper option for spans less than 45 metres. For our requirements, this seems to be the most viable option. Source: http://www.ul.ie/%7Egaughran/Gildea/page8.htm

14. Next Home Previous Portal, Bracing and Bolt Specifications We have chosen to use a rigid base portal since it is ideal for smaller spans as well as it allowing us to use smaller sized members. The size of our portal frame columns are 530UB92.4 The size of our portal frame beams are 460UB82.1 The size of our girts are 180x75x5.0 CC The bracing specification is 30mm Rod Bracing (See sketches for bracing layout). The size of bolts used as M-20 specification. Image: Bunnings Warehouse Waurn Ponds. Shows bracing above an opening

15. Next Home Previous Examples of Portal Frames Image: Bunnings Warehouse Waurn Ponds. Shows Flange for beam section. Image: Bunnings Warehouse Waurn Ponds. Shows layout of warehouse.

16. Next Home Previous Examples of Portal Frames Purlins Services through flange Rafter Column Girt Corrugated Sheet Image: Colerain Warehouse Separation St. Image: KD Stewart centre Waurn Ponds.

17. Next Home Previous Envelop System: Tilt-up Concrete Tilt up concrete construction is an economic & attractive alternative to the traditional construction methods such as corrugated iron. It has a versatile design and is extremely quick to construct. By using a Tilt-up systems it helps ensure durability, with maintenance only required every 6 years with a new coat of paint. Panel connections can be installed during initial construction to make panel detachment & relocation easy. Tilt-up concrete is ‘virtually’ impenetrable due to the thickness and strength of panels, which proves a ‘positive’ with the use of folk lifts in our warehouse. It is a first choice for fire resistance as a 6.5” wall will have a fire rating of 4 hours; this inturn results in cheaper insurance for the client. Slabs are casted on-site and after curing, are lifted or ‘tilted’ with crane & set on the concrete foundations. The roof structure, once constructed, is anchored to walls. After removal of panel braces, grout is applied at base of panels and all vertical joints are caulked. When determining the size crane to use it’s best to let the crane company decide this, based on the size and weight of the panels. http://www.tilt-up.org/construc/faq-general.htm

18. Next Home Previous Envelop System: Tilt-up Concrete Expansion can be designed for by detaching and relocating the panels or cutting new openings Tilt up concrete also has excellent sound control through the sound reduction properties of concrete. This is done by the ‘mass’ absorbing the sound rather than ‘letting it through.’ Tilt up is mainly done on the ground, so there is no vertical framework or scaffolding required. There are also less labour crews since no vertical forming, or other costly erection processes are required, thus allowing for a shorter project cycle which presents less prosperous for accidents to occur. Source:http://www.constructionengineers.com/images/BigSouixStop

19. Next Home Previous Roof Structure The roofing system we have opted for is using ‘C’ section purlins. There will be 25 purlins overall, 12 on either side of the pitch and 1 at the joint between both sides. On both sides of the pitch, the first and last purlins will sit in 1 metre from each end, with 10 in between at 1.8 metre centre spacings. These ‘C’ section purlins will be 200mm x 75mm x 6mm, and weigh 15.5 kg/m. Although capable of spanning 12 metres we have these purlins spanning at 8 metres. Source: http://www.fielders.com.au/product.asp?pID=4 Dura Gal channels are high strength cold formed structural sections that are in-line Hot-dip galvanised over a prepared surface, to produce a fully bonded coating with a minimum average coating mass of 100 g/m2. The zinc surface then has a surface conversion coating applied. All channels are coated with a clear polymer over the conversion coat. (note that roof at 10° pitch)

20. Next Home Previous Roof Cladding The roof cladding we have used for this warehouse is Colourbond WideKlip produced by Fielders. The width of the cladding is 760 mm and requires no screws therefore no screw holes. This type of cladding uses a clip system which allows for them to give a watertight guarantee. We chose the lighter of the two choices which was 0.42 BMT in thickness, making the mass 4.55 kg/m2. Below is a picture of the WideKlip. For the natural lighting we have used UV-Stabilised Commercial Grade Reinforced Translucent Roofing, which is an economical product for natural lighting in a large enclosed area. It is also extremely flexible allowing it to meet unique variations of design criteria. Common applications for such a product are things such as commercial and industrial developments, institutional and other projects where long-term high quality lighting is required. We have chosen a thickness of 2.5 mm which makes its mass 3.66 kg/m2. WideKlip FIELDERS Topglass ALSYNITE NZ LIMITED

21. Next Home Previous Guttering System We have chosen to use internal box guttering. The gutters are 150mm X 100mm stainless steel square downpipes at 1800 lengths. Image: Bunnings Warehouse Waurn Ponds. Shows a boxed gutter Source: www.fielders.com

22. Next Home Previous Roller Doors & Exit Doors The type of roller door system we have chosen to use is the ‘industrial slat type shutter. The steel shutter is designed to economically fulfill requirements of the client (us) and can be made to custom size. Sizes for openings range from 900mm x 900mm to 6000mm x 6000mm. For our entrance doors we have opted to use a 6000mm X 6000mm roller door system. For the side access we have chosen a 3000mm X 3000mm roller door setup. We have chosen to have 5 exit doors in our warehouse. By law, it is required that exits are provided at no more than 20 metres from any position in the warehouse. (see Figure 1)

23. Next Home Previous Figure 1. Girt Vertical support above opening Door One Door Two Door Three Door Four Door Five Fire Hydrant Exit Door

24. Next Home Previous Layout of Warehouse door pellet The proposed layout for shelving. We predict that by using a three shelf system we can store between 1100 and 1200 pellets.

25. Next Home Previous Sketches

26. Next Home Previous Sketches Preposed bracing sections of warehouse

27. Next Home Previous Site Layout 4. OFF-STREET CAR PARKING REQUIREMENTS Council’s standards for the number of off-street car parking spaces required with developments are outlined below: Commercial Premises and Offices 1 space per 35m2 of net floor area, plus 1 space for Manager/Caretaker. Industrial Development 1 space per 70m2 of net floor area, with a minimum of 3 spaces per unit. 5.4 Entry and Exit to Site The driveways and on-site arrangements are to be such that vehicles drive in a forward direction entering and leaving the site. 7. OTHER REQUIREMENTS 7.3 Disabled Driver Car Parking A minimum of 1 space per 100 car spaces is to be made available for disabled driver car parking. If less than 100 spaces are provided then at least 1 space is to be made available. This space is to be clearly marked and identified, and provided as close as practicable to shop entrances. The width of the space is to be at least 3.0 metres. 7.4 Loading Bays These shall have dimensions to suit the type of vehicle servicing the development, with absolute minimum dimensions of 6.0 x 3.0m.

28. Purlins 200 x 75 x 6 ‘C’ sections Rafters ‘C’ sections Girts 180x75x5.0 CC Bracing 30mm rod bracing Reinforced Concrete Slab Slab Thickening 300 wide Pad Footing 1000 X 750d Columns 530UB92.4 Next Home Previous Warehouse Section

29. SHOWROOM

30. Next Home Previous Concrete Slab for Showroom We have chosen to use the same concrete slab system for the showroom. We did this because this system is high in strength and ensures there will be no ground movement or foundation movement.

31. Next Home Previous Grid system and Layout for Showroom

32. Next Home Previous Portal frame for showroom The sizes of the members for the showroom are as follows: -Columns 310UC158 -Beams (bearers) 310UB46.2 -Beams (roof) 310UB46.2 -Floor joists 240mm X 45mm. -WideKlip roofing 10 degrees roof pitch Tasmanian oak wooden strip flooring 19mm thick flooring Second storey floor- For the second storey floor we have decided to use strip, the wood we chose was Jarrah, which is a dark red brown hardwood. The reason we chose this wood was because it is appealing to the eye and it had to be a hardwood, so that it would resist any abrasion to its surface from things like chairs, etc.

33. Next Home Previous Portal, Bracing and Bolt Specifications • We are using the same bracing and bolt specification as the warehouse

34. Next Home Previous Examples of Showrooms Image: Rex Gorrell Ford. Shows the front entrance into the showroom. All ‘glass front.’ Image: Rex Gorrell Ford. Showing alternate entrance into building.

35. Next Home Previous Examples of Showrooms Image: Rex Gorrell Ford. Glass sections Supported by aluminium. Clean view inside Image: Reece Plumbing showroom. Showing large spaning windows leaving plenty of room inside to see.

36. Next Home Previous Envelop System: Tilt-up Concrete We are using the same envelop system for the showroom as the warehouse. We decided this in order to keep the same theme. There are only2 differences, we are using a whole glass front section and for the walls, we decided to use Custom Blue Orb-Lysaght. We have chosen to use frameless glass doors and assemblies, this will allow us to maximise our retail exposure on the ground floor, as this is where the showroom is. We are using toughened glass in panes of 2500mm X 3500mm for the showroom front. The toughened glass can be realised with minimal fixing and support structure. The strength of the glass allows larger clear spans with minimum fixings, the fixings we are using are aluminium patch channel fittings. These are bolted to the concrete slab and the external I-beams. The glass we are using is Pilkington Armourfloat 12mm thick that is toughened safety glass and tinted in accordance with AS2208. Custom Blue Orb-Lysaght is a material which basically looks like corrugated sheeting. This cladding goes on top of the Clayco tilt-up. The Clayco Tilt-up only goes up to a level of 7 metres, but in the section left over from the roof pitch we are using the Custom Blue Orb-Lysaght. The BMT (Bare Metal Thickness) is 0.60 colour bond 4.64 kg/m, the total weight being 6.09 kg/m2. Covers either 608 mm or 762 mm spans, in whatever length required.

37. Next Home Previous Roof Cladding & Guttering System The roof cladding we are using is also the same as the warehouse. This was since there wasn’t any real need to change cladding types. We also can keep the same guttering system. WideKlip FIELDERS Topglass ALSYNITE NZ LIMITED

38. Next Home Previous Showroom Finish For the inner walls of the showroom, we will be creating stud walls in between the columns with 60mm fibreglass insulation and then a 10 mm plasterboard wall. We aren’t setting up where the actual offices will be situated, we are only doing the interior perimeter and facilities such as toilets, kitchens, etc.

39. Toughened Glass in panes of 2500mm X 3500mm Reinforced Concrete Slab Next Home Previous Showroom Section Roof Beams 310UB46.2 Bearers (beams) 310UB46.2 Columns 310UC158 Pad Footing 1000 X 750d Slab Thickening 300 wide

40. Next Home Previous References Lysaght broacher http://www.fielders.com.au/product.asp?pID=4 http://www.tilt-up.org/ http://www.ul.ie/%7Egaughran/Gildea/page8.htm Jeremy Ham’s Lecture notes. www.onesteel.com www.clayco.com www.pikington.com.au