PROPOSED DESIGN OF 4-STOREY MULTI-PURPOSE

MODULAR BUILDING

INTRODUCTION

Building construction can be a very difficult and tiring process, with

complications ranging from extreme weather conditions, to work at excessive height and

with limited access. Indeed, the common construction process are well known and

documented, and are accounted for with a number of ways designed to make the work

smarter and safer, as well as to avoid risks while in the construction. As years pass by,

modular building components have supported the bringing of construction process

indoors in an industrialized manner so that it will be one of the most efficient and

effective ways to improve building operations.

The basic concept in constructing a modular building substantially utilizes offsite

construction and assembly in lieu for potentially more challenging onsite construction

methods. It is essentially a construction method where individual modules or volumes are

constructed offsite, stand alone, transported to the site and are then assembled together

onsite to make up a larger structure. Modules are 60% to 90% completed off-site in a

controlled factory environment, and transported and assembled at the final building site.

This can comprise the whole building or equally likely non-core building components

such as rooms, corridors, and common areas with the help of precast component or

concrete. Modular construction exploited the advantages of factory assembly to a great

 2

extent, with the idea of having greater resultant benefit to the project of creating a

modular building.

A model of triangle of time, cost and quality is needed for the construction to be

successful. Any construction project can achieve all three of the objectives in the triangle,

but not with equal results. For example, if an owner wants high quality and speedy

delivery, then he is expected to pay more. Likewise, if lower cost and faster delivery are

required, the quality will decrease. With that, modular construction has advantages to

each of these pillars based on the modular process as compared to conventional, on-site

construction (Gibb, 1999; Hutchings, 1996; Smith, 2010).

Indeed, if modular construction is effective at improving construction projects

through each of these pillars, it should be at least considered, for every construction

project. The question is, why is modular construction not used more prolifically if it

really provides documented benefits to owners, designers, and builders?

Statement of the Problem

Generally, what would be the aim of the research to be conducted?

Specifically, the study aims to answer the following questions:

1. What would be the role of the researchers in finishing the research?

2. What would be analyzed in the structure?

3. What would be the expected output of the study?

4. What would be the contribution of the study in the near future?

 3

Objectives of the Study

Generally, this study was conducted in order to design and analyse a 4-storey

modular apartment building with the help of computer-aided design and structural

software.

Specifically, the study aimed to:

1. Apply the skills and knowledge of the researchers in terms of analyzing and

designing structures which they learned as civil engineering students;

2. Analyze the stability and safety of the structure;

3. Provide architectural plans, structural plans, and cost estimate with construction

specifications and produce a presentation of the analyzed data and structural plan;

4. Produce a manuscript that will serve as a reference for future studies related to

structure design.

Significance of the Study

The significance of the study was to provide a better knowledge of using

modularization as an alternative method in construction, as well as some aspects of their

structural behavior and stability. The study helped develop the authors’ ability in

designing and analyzing the plan of a four-story multi-purpose modular building with the
 4

use of this method to make up the building. It can also be used as a guide and reference

for those who plan to conduct or improved related study.

Time and Place of the Study

The study was conducted at Cavite State University, Indang, Cavite from April

2017 to March 2018.

Scope and Limitations

The general scope of the study was to design a plan of a multi-purpose modular

building and provide its structural analysis using modularization as the method. It does

not include the real construction of the said infrastructure, making it only a proposal. This

was also limited to the preparation of architectural plans and structural plans, excluding

electrical, plumbing and waste disposal design of the building. Furthermore, computation

of its cost estimate with construction specification, and evaluation of the stability of the

whole structure were included in the study. An analyzed data was given in the said study.

Definition of Terms

Modular. A method of construction where module sections are constructed at an

offsite or remote facility, then delivered to the intended site of use.

Construction. All on-site work done in the site preparation, excavation,

foundation, assembly of all the components and installation of utilities, machineries and

equipment of buildings/structures.

Dead Loads. Gravity loads of constant magnitudes and fixed positions that act

permanently on the structure. Weights of permanent equipment, such as heating and air-

conditioning systems, are usually obtained from the manufacturer (NSCP, 2010).
 5

Live Loads. Loads produced by the use and occupancy of the building or other

structure and do not include dead load, construction load or environmental loads such as

wind load, earthquake load and fluid load (NSCP, 2010).

Building Loads. The magnitudes of building design live loads are usually

specified in building codes. Live loads for buildings are usually specified as uniformly

distributed surface loads in pounds per square foot or kilopascals.

Wind loads. Are produced by the flow of wind around structures. It varies in

proportion to the distance from the base of the structure, peak wind speed, type of terrain,

importance factor, and side of building and roof slope.

Steel Frame. A building technique with a "skeleton frame" of

vertical steel columns and horizontal I-beams, constructed in a rectangular grid to support

the floors, roof and walls of a building which are all attached to the frame.

ISO. International Standardization Organization.

NSCP. National Structural Code of the Philippines.

Bolted Connections. A type of connection that is widely used in almost every

mechanical and structural system due to the added flexibility of assembly and

disassembly of sub-systems for inspection, replacement, and routine maintenance.

Claddings. Materials that are used to apply over another to provide a skin or layer

and to provide a degree of thermal insulation and weather resistance.

Gratings. A regularly spaced collection of identical elements and are made from

materials like steel, aluminium and fiberglass.

 6

REVIEW OF RELATED LITERATURE

Modular Building

Based on the study worked by Prajjwal Paudel, Sagar Dulal, Madan Bhandar and

Amit Kumar Tomar, a modular building is constructed by light steel frame to sandwich

panels for the building envelope materials, as a standard module for space series

combination of components, the bolt connection, and the new concept of environmental

protection economic activities in the modular building. The prefabricated components are

brought to the site and erected using building block type construction. Work is never

delayed by curing time or missing materials and can be completed for 30 to 45 working

days.

Further study shows that it can also lower the total cost of the project by 12

percent as compare to the traditionally build house using traditional materials such as

CHB (Concrete Hollow Blocks). It also includes the study on steel structures and pre-

fabricated structures, analysis and research on the quality, strength, environment friendly,

costing and the comparison between the traditional buildings and pre-fabricated

buildings. This aims to introduce and to provide more knowledge about modular house to

educate the market and to address the concern of every sector of the society especially the

depressed areas of the society for a beautiful, stable and affordable shelter.

Design Considerations
 7

Most design considerations for non-loadbearing wall panels must also be

considered in the analysis of loadbearing wall panels. According to the Precast Concrete

Institute (PCI), the design and structural behaviour of exterior architectural precast

concrete bearing-wall panels is dependent upon the panel shape and configuration, and

they should consider the following:

Gravity loads and the transfer of these loads to the foundation. Vertical (gravity)

loads are parallel to the plane of the wall at an eccentricity influenced by the geometry of

the wall, location of the load, and manufacturing and erection tolerances.

Magnitude and distribution of lateral loads, both wind and seismic, and the means

for resisting these loads using shear walls and floor diaphragms. Loads in the horizontal

direction may be both parallel to and perpendicular to the plane of the wall. For typical

precast concrete structures, improved redundancy and ductility are achieved by

connecting members into a load path to the lateral force-resisting system, which must be

continuous to the foundation.

Location of joints to control volume-change movements due to concrete creep,

shrinkage, and seasonal temperature changes.

Connection concepts and types of connections required to resist the various applied

loads. In some cases, local practice may suggest one type of connection over another,

such as the use of bolts rather than welds. All connections need to be accessible and allow

for tolerances and adjustment.

 8

Tolerances required for the structure with regard to production and erection for

both precast concrete units and connections, including tolerances for interfacing of

different materials.

Specific design requirements during the construction that may control designs,

such as site accessibility.

Joints Connection

A wide variety of connection hardware and devices is used in the precast concrete

industry including:

Headed Concrete Anchors (studs) are round bars with an integral head. These are

typically welded to plates to provide anchorage to the plate.

Steel Shapes including wide flanges, structural tubes, channels, plates, and angles.
Reinforcing Bars are typically welded to steel sections to provide anchorage to the

steel.
Reinforcing Bar Couplers are typically proprietary devices for connecting reinforcing

bars at a joint. Manufacturers of these devices can provide technical information.

Deformed Bar Anchors are similar in configuration to deformed reinforcing bars and

are welded to steel shapes to provide anchorage similar to headed concrete anchors.
Bolts and Threaded Connectors are used in many precast concrete connections. Use

of ASTM A36 or A307 bolts is typical. Use of high-strength ASTM A325 and A490 is

usually not required.

Specialty Inserts are available from many manufacturers of these devices. They

include standard threaded inserts, coil threaded inserts, and slotted inserts that provide for

tolerances and field adjustment.

 9

Bearing Pads are used predominantly for structural applications to support beams,

double tees, and similar components. Use of random fiber-oriented bearing pads (ROF) is

recommended.

Types of Modules and their Specifications

According to Lawson, 2007, there are different types of modules used in modular

construction. These are:

Corner-supported modules. Modules may be designed to provide fully open

sides by transfer of loads to the corner posts. This is achieved by bending of the

deep longitudinal edge beams. The framework of the module is often in the form

of hot rolled steel members, such as Square Hollow Section (SHS) columns and

Parallel Flange Channel (PFC) edge beams, bolted together. A shallower PFC

section may be used to support the ceiling, but in all cases, the combined depth of

the edge beams is greater than for 4-sided modules. The stability of the building

generally relies on a separate bracing system in the form of X-bracing in the

separating walls. For this reason, fully open-ended modules are not often used for

buildings more than three story’s high.

Smaller modules up to 5.5 m length may be manufactured by re-

orientating the floor and ceiling joists to run longitudinally, as in Figure 2. The

joists may be of lattice form to facilitate integration of services.

 10

Figure 2: Open-sided module using

longitudinally spanning lattice joists

Open-sided modules

comprise a primary steel framework and the longitudinal edge beams supporting

the floor cassette. These beams are typically 300 to 450 mm deep, depending on

the span, which typically is 5 to 8 m. Some systems use heavy cold formed

sections, and others use hot rolled steel sections, such as PFC. The combined

depth of the edge beams, the ceiling and floor can be as high as 600 to 800 mm.

Design flexibility is provided by the open-sided modules. Their width is typically

3 to 3.6 m, and rooms of 6 to 12 m width can be created by combining modules.

Four-Sided Modules. Modules may be designed to transfer loads continuously

through their longitudinal walls. In this form of construction, modules are

manufactured with four closed sides to create cellular-type spaces. The maximum

width of the module that is suitable for transportation and installation limits the

cellular space that is provided. The modules are designed for the combined

vertical load of the modules above and in-plane loads due to wind action. As for

the technical details, modules are manufactured from a series of 2D-panels,

beginning with the floor cassette, to which the four wall panels and ceiling panel

are attached. The walls transfer vertical loads and therefore the longitudinal walls
 11

of the upper module are designed to sit on the walls of the module below. An

example of this type of module is illustrated in Figure 1. Modules are essentially

4-sided volumetric units with openings in their ends for windows and doors. Their

external width is limited by transportation requirements to approximately 4 m (3

to 3.6 m is the typical internal module width for most applications). The module

length is typically 6 to 10 m.

Figure 3: Details of 4-sided modules showing recessed corners with

additional angle sections

Partially Open-Sided Modules. These modules can be designed with partially

open sides by introduction of corner and intermediate posts and by using a stiff

continuous edge beam in the floor cassette. The maximum width of opening is

limited by the bending resistance and stiffness of the edge member in the floor

cassette. Additional intermediate posts are usually Square Hollow Sections of

small cross-section, so that they can fit within the wall width.

The compression resistance of the corner or internal posts controls the

maximum height of the building, but 6 to 8 storeys can be achieved, as for fully
 12

modular construction. Additional edge beams are required for wider openings; the

beams can be bolted to the posts. Modules can also be re-orientated at the internal

posts to permit design of more flexible building forms.

Stair Modules. Modular stairs may be designed as fully modular units and by

their nature, generally comprise landings and half landings with two flights of
Figure 4: Use of mid-side post to provide intermediate support to the side of
a module

stairs. The landings and half landings are supported by longitudinal walls with

additional angles or Square Hollow Section (SHS) members to provide local

strengthening, if necessary. Modular stairs may be used in buildings using fully

modular construction up to 4 storeys in height. For the technical details, the stair

modules rely for their stability on a base and top, which leads to use of a false

landing. The walls may require additional strengthening members at the half and

full-landing positions. The open top and base of the wall may also be strengthened

by a T, L or similar members to transfer out of plane loads to the landing. The

stairs can be fully or partially finished before delivery to site. SHS posts and

bracing can be introduced in the walls to provide for overall stability. Details of a

typical light steel modular stair system, showing use of a 'false' landing to provide
 13

stability at the roof of the module, are shown in Figure 28. Alternatively, the

framework of the stair module may be made as a primary steel structure, in which

case, the light steel walls act as infills.

Figure 5: Detail of light steel modular stair system showing use of a “false”
landing to modules

Technical Design Issues

Stability and Structural Integrity. Overall stability is provided by the modules

themselves, or by an external structure. Robustness is provided by the ties

between the modules; and tying action when one module is notionally removed. A

minimum tying force equivalent to half the loaded weight of the module is

normally assumed (minimum value of 30 kN).

Cladding. Various forms of cladding may be used, such as:

• Brickwork, generally in-situ

 14

• Metallic fascia

• Insulated render

• Board materials.

Typical details of various cladding systems which satisfy current thermal

regulations are implemented. Lightweight cladding can be pre-attached to the

modules to eliminate the requirement for scaffolding.

Acoustic Performance. The double layer floor and ceiling, and pairs of

separating

walls, achieve excellent airborne and impact sound reductions. The off-site

manufacture and quality control also ensures that all aspects of the building

physics performance are more reliable. Airborne sound reductions of over 63 dB,

or 52 dB (with low frequency correction factor), are achieved. These are up 5 to

10 dB better than in Part E of the Building Regulations. Impact sound

transmissions are also low (< 30 dB). In some applications, a concrete screed can

be introduced, although this adds to the floor weight.

Thermal Insulation. Thermal insulation is characterised by the heat loss per m2

of the façade or roof (its U-value). Low U-values of 0.2 W/m2°C and excellent

air-tightness can be achieved by the cladding details, meeting Part L of the

Building Regulations. External insulation boards are normally placed on site.

Fire Resistance. Fire resistance is provided by multiple layers of fire resisting

boards (Type F to BS EN 520), assisted by mineral wool placed between the C

sections. Two 15 mm thick fire resisting plasterboard layers internally plus 100
 15

mm thick mineral wool achieves a fire resistance of 90 min. Outer sheathing

boards also assist in preventing passage of smoke into the cavity between the

modules. Regular cavity barriers in the form of mineral wool ‘socks’ in metal

gauze are provided horizontally and vertically.

Dimensional Planning of the Modular Building

Cladding. Brickwork design is based on a standard unit of 225 mm width and 75

mm depth. Therefore, it may be important to design a floor-floor depth to a

multiple of 75 mm in order to avoid non-standard coursing of bricks. The multiple

of 225 mm in horizontal brickwork coursing width is more difficult to achieve in

terms of the module width and the window size. At corners and brickwork returns,

a variable width cavity may be detailed. Other types of cladding, such as clay tiles

or metallic finishes, have their own dimensional requirements, but generally they

can be designed and manufactured to fit with window dimensions etc. Many types

of lightweight cladding can be pre-attached to the modules, but it is generally

necessary to install a cover piece over the joints between the modules on site, to

cater for geometrical tolerances and misalignments.

Standardization of Planning Grid. Standardization of the planning grid is

important at the scheme design stage, as the planning grid will be controlled

mainly by other building components and fitments. A dimensional unit of 300 mm

may be adopted as standard for vertical and horizontal dimensions, reducing to

150 mm as a second level for vertical dimensions, i.e. a multiple of either 2 or 4

bricks. Typical dimensions for modular building are illustrated in Table 1.Typical

Figure 6: Typical wall and floor/ceiling dimensions

 16

wall and floor dimensions are illustrated in Figure 38, although actual dimensions

are system-specific. For planning, a combined wall width of 300 mm may be

used. External walls are detailed according to the type of cladding. Again, a 300-

mm total wall width may be adopted as a guide for most cladding materials. The

actual width will vary between 200 mm for insulated render and board materials

to 320 mm for brickwork.

Table 1: Typical dimensions for planning in modular construction

Internal Walls. Internal walls may be designed for a standard 300 mm face-face

overall width, incorporating the various boards and insulation. The gap between
 17

the walls is a variable, depending on the number and thickness of boards and size

of the wall studs. In practice, most modular systems lead to total wall widths in

the range of 250 – 300 mm.

Floor Zone. Floors and ceilings in modular construction are deeper than in more

traditional construction. In most cases, 450 mm may be adopted as a standard for

the floor-ceiling dimension, although many systems provide shallower depths. A

floor and ceiling zone of 300 or 375 mm is feasible in some systems and aligns

with brick coursing. The details of a corner supported module are illustrated in

Figure 7. In most cases, a standard overall floor and ceiling depth of 600 mm may

be used. The gap between the floor and ceiling is a variable depending on the

number of boards and the joist size. Actual dimensions of the modules will be less

than these planning dimensions to allow for gaps (by up to 50 mm for walls, and

up to 150 mm for floors).

Figure 7: Detail of corner supported module

Attachment Points. Generic forms of attachment uses angles at the corners of

modules. SHS provide the highest compressive resistance and may be used as the
 18

corner posts for open-sided modules. However, although these sections are

compact, their connections can be more complex. Access holes of 50 mm

minimum diameter in the SHS allow bolts to be inserted through end plates to

provide for vertical and horizontal attachments.

Attachments between modules are made in both horizontal and vertical directions,

primarily to transfer in-plane forces, but also for structured integrity.

Figure 8: Corner posts using hot rolled steel angles

Figure 9: Corner post using SHS or special sections

Steel Frame Structures

Steel frame is a building technique with a "skeleton frame" of

vertical steel columns and horizontal I-beams, constructed in a rectangular grid to support
 19

the floors, roof and walls of a building which are all attached to the frame. The

development of this technique made the construction of the skyscraper possible.

Bolted Steel Construction

A type of steel construction in which steel fabricators produce finished and

painted steel components, which are then shipped to the site and simply bolted in place.

This is the preferred method of steel construction, as the bulk of the fabrication can be

done in workshops, with the right machinery, lighting, and work conditions. The size of

the components is governed by the size of the truck or trailer they are shipped in, usually

with a max length of 6m (20ft) for normal trucks or 12m (40ft) for long trailers. Since the

only work to be done at site is lifting the steel members into place (with cranes) and

bolting, the work at site is tremendously fast. Pre-engineered buildings are an example of

bolted steel construction that is designed, fabricated, shipped and erected by one

company to the owner.

Connections in Modular Building

The behavior of connections in analysis and design of buildings should

particularly be taken into account in detail because of their effects on the distribution of

internal forces and on structural deformations Their behavior can be defined depending

on strength, stiffness and deformation capacity. The connections are critical components

of structural systems and also in modular buildings.

Unlike conventional construction, modular buildings have additional interior

connections, which further add to the complexity. The behavior of multi-story modular
 20

construction under lateral loading is still not well-understood because of the complexities

of modular connections.

The modules are attached to each other or to other structural systems to form a

complete modular building. The connections between modules transfer the applied

lateral forces to the group of modules. The connections also ensure the stability and

robustness of the assembly of modules in modular construction.

Connection between modules in 4-sided modules. For the vertical loads, it is

transferred through the module walls. In lateral loads, it is by the bracing or

diaphragm action of the board materials.

Connection between modules in open-sided modules. The vertical loads are

transferred by the columns and edge beams. The column-to-column connections

ensure bending resistance. In lateral loads, it is through the bracing system and

sheeting. The column-to-beam connection makes some lateral stiffness possible

and can provide stability to modules in low-rise building.

Beam-to-stringer connections in light steel modules. The connection consists of

directly welding the members to each other. This connection is a shear

connection, which is assumed not to transfer bending moment.

Connections between corridor cassette and modules. On the lateral loads, it is

transferred by the corridor the braced system or core. The beams ensure vertical

support to the corridor and provide additional stiffness to improve the rigidity of

longitudinal sides of the open-sided modules. The connection does not ensure

vertical support to the corridor and just transfer shear forces.

Connections between modules and structural components in frame unit

system. Properties of the system are not considered dependent on the modules.
 21

The connection between the frame and the modules must be strong enough to

transfer gravity loads although modules do not bear any loads except their own

gravity loads. A diaphragm system should be taken into account for the

integration of modules and frame in the system.

Modeling in Modular Building

Light steel sections are widely used in modular construction because of their

efficiency and lighter weight. Light steel framing in modular buildings is limited due to

its range of applications; use of hot-rolled steel posts or beams in heavily loaded

structures is more suitable and efficient.

The lateral loads are reversible, braces are subjected to both compression and

tension; consequently, they are mostly designed according to compression requirements.

The braces are designed resisting the horizontal shear in axial compression and tension.

The floors having the diaphragm effect may be identified as horizontal resisting system

against lateral forces. The diaphragm behavior is an important aspect for transferring

wind or seismic loads.

A typical story detail of the modular building consists of a set of columns, a floor

and a ceiling framing. A gap between floor beam and ceiling beam, and the diagonal

braces provides lateral stability in modular buildings. Lateral loads are transferred

through the bracing elements via the horizontal connection between the modules and then

to the foundation via the vertical connections.

Evaluation of the Connections

 22

Vertical (Column-to-Column) Connection. Splice connections should be

designed to allow for the transfer of stress resultants existing in the joint, with due

allowance for second order effects, imperfections and load eccentricities. The

connections must provide strength and continuity of stiffness in both axes of the

columns. Splice column connections should be generally used in the locations

performing lower buckling strength. The splice column connections consist of

welding of base plates of upper module columns to cap plates of lower module

columns in modular building. Cap and base plates are welded on site to each

other. Only the outer faces of the columns can have access to welding in these

connections.

Module-to-Module Connection. These connections are used to join to modules

horizontally. The module-to-module connection (horizontal connection)

consisting of field bolting of clip angles that are shop-welded to the flange of

floor beams. The connections between modules transfer in-plane forces and

provide the structural integrity and robustness.

Edge Beam-to-Column Connection. This connection between the column and

edge beam makes some lateral stiffness possible and can provide stability to

modules in low-rise buildings. The connection between edge beams and column

are generally designed as a moment-resisting connection. This type of moment-

resisting connection can be designed as the main stabilization system for modular

buildings.

Beam-to-Stringer Connection. This connection consists of directly welding of

the stringer to the web of the beam.

 23

Use of Light Steel Framing in Modular Construction

Components

Building portions that are shop assembled prior to shipment to site are commonly

referenced as prefabricated. The smaller steel buildings tend to be prefabricated or simple

enough to be constructed by anyone. Prefabrication offers the benefits of being less costly

than traditional methods and is more environmentally friendly since no waste is produced

on-site (Benefits of Steel Buildings, 2015). The larger steel buildings require skilled

construction workers, such as ironworkers, to ensure proper and safe assembly

(Armstrong, 2011).

There are five main types of structural components that make up a steel frame -

tension members, compression members, bending members, combined force members

and their connections. Tension members are usually found as web and chord members in

trusses and open web steel joists. Ideally tension members carry tensile forces, or pulling

forces, only and its end connections are assumed to be pinned. Pin connections prevent

any moment (rotation) or shear forces from being applied to the member. Compression

members are also considered as columns, struts, or posts. They are vertical members or

web and chord members in trusses and joists that are in compression or being squished.

Bending members are also known as beams, girders, joists, spandrels, purlins, lintels, and

girts. Each of these members have their own structural application, but typically bending

members will carry bending moments and shear forces as primary loads and axial forces
 24

and torsion as secondary loads. Combined force members are commonly known as beam-

columns and are subjected to bending and axial compression. Connections are what bring

the entire building together. They join these members together and must ensure that they

function together as one unit (Geschwindner, 2008).

Structural Steel

Structural steel is a category of steel used as a construction material for making

structural steel shapes. A structural steel shape is a profile, formed with a specific cross

section and following certain standards for chemical composition and mechanical

properties. Structural steel shapes, sizes, composition, strengths, storage practices, etc.,

are regulated by standards in most industrialized countries.

Characteristics. Structural steel differs from concrete in its attributed compressive

strength as well as tensile strength (Handbook of Structural Engineering, 1997).

Strength. Having high strength, stiffness, toughness, and ductile properties,

structural steel is one of the most commonly used materials in commercial and industrial

building construction.

Constructability. Structural steel can be developed into nearly any shape, which

are either bolted or welded together in construction. Structural steel can be erected as

soon as the materials are delivered on site, whereas concrete must be cured at least 1–2

weeks after pouring before construction can continue, making steel a schedule-friendly

construction material.

Fire resistance. Steel is inherently a noncombustible material. However, when

heated to temperatures seen in a fire scenario, the strength and stiffness of the material is
 25

significantly reduced. The International Building Code requires steel be enveloped in

sufficient fire-resistant materials, increasing overall cost of steel structure buildings

Corrosion. Steel, when in contact with water, can corrode, creating a potentially

dangerous structure. Measures must be taken in structural steel construction to prevent

any lifetime corrosion. The steel can be painted, providing water resistance. Also, the fire

resistance material used to envelope steel is commonly water resistant (Chen, 2005).

Mold. With the propagation of mold and mildew in residential buildings, using

steel minimizes these infestations. Mold needs moist, porous material to grow. Steel studs

do not have those problems (Armstrong, 2014).

Structural Load

Structural loads or actions are focuses, deformations, or accelerations applied to a

structure or its components. Loads cause stresses, deformations, and displacements in

structures. Assessment of their effects is carried out by the methods of structural analysis.

Excess load or overloading may cause structural failure, and hence such possibility

should be neither considered in the design nor strictly controlled.

Dead Loads. Consist of the weight of all materials of construction incorporated

into the building or other structure, including but not limited to walls, floors, roofs,

ceilings, stairways, built-in partitions, finishes, cladding and other similarly incorporated

architectural and structural items and fixed services equipment, including the weight of

cranes.

Live Loads. Shall be the maximum loads expected by the intended use or

occupancy but in no case shall be less than the loads required. Live load used in this
 26

study is 6 KPa for stores according to NSCP 2010 Minimum Uniform and Concentrated

Live Loads (NSCP, 2010).

Wind load. Horizontal load caused by the movement of air relative to earth. Wind

load is required to be considered in design especially when the heath of the building

exceeds two times the dimension transverse to the exposed wind surface.

Laying Foundation for Modular Building

Footings. For the footing, identification of the building loads each of the location

must be supported by the building loads to be placed.

If the loads at the columns are much higher, it will require larger footings. Footings are

typically constructed with concrete. The base of the footing must be on undisturbed soil

and extend to the frost line or bedrock (Brosius, 2001). It may require a soil investigation

to be performed to determine soil characteristics and values. These values are compared

to the loads imposed by the structure and the beams are sized to distribute the loads

evenly. Poured-in-place grade beams will then be placed. Typically, the grade beam is

finished at an elevation even or slightly above the surrounding soil. This allows the

building modules to be pulled onto the prepared foundation then blocked with pre-cast

blocks. The site is prepared by digging trenches at least 12″ deep or below the ground

line, where applicable, placing reinforcement steel and finally pouring minimum 3000 psi

concrete.

Anchorage. Most modular building construction use a system with steel straps

secured to the frame that transports the structure. These straps are connected to an auger
 27

that is embedded into the soil (Brosius, 2001). The manufacturer's blocking point plan

will provide suggested tie-down locations, which are based on the capacity of the ground

anchors and wind speed design of the building. Proper design and installation of the

anchoring system provide safety and durability through the effective transfer of wind

loads to the ground. A design based on local conditions would be included with the

footing design.

Site Work. The manufacturer will provide instructions for completion of the

building on-site. Other considerations would be the final electrical and plumbing

connections. On a temporary installation, the crawl space must be ventilated in

accordance with the local building code. Proper ventilation will prevent the build-up of

moisture that could affect the durability of the building as well as the indoor air quality

(Brosius, 2001). The area under the building should be elevated enough to prevent the

accumulation of standing water in the crawl space area. All site work, including the

footing and anchorage installation, is under the jurisdiction of the local building

department, who will issue the appropriate permits and perform the installation

inspections.

Permanent Installation. These designs generally use a foundation wall around

the perimeter of the building and could include a basement. Anchorage would be

provided through attachment to the wall (Brosius, 2001). Column supports at the mating

lines would still be required per the manufacturer's recommendations. All other code

considerations would be addressed by the design.

 28

METHODOLOGY

Gathering of Important Information

All the important data such as formulas in the structural design and cost

estimating of materials were gathered through reading books of National Structural Code

of the Philippines 2015 (NSCP 2015), Reinforced Concrete Design (USD), Simplified

Steel Design of Besavilla, Association of Structural Engineers of the Philippines Steel

Handbook (ASEP), and Simplified Construction Estimate. The researchers interviewed

some professional and technical persons who were knowledgeable to the structural design

on the study that was conducted. Other references related to modular building and

construction were included to the study.

Structural Parameters

Dead and live load for minimum uniform and concentrated loads (see Appendix

Table 1) for the function of each modules; yield strength of non-pre-stressed

reinforcement for structural members; minimum yield stress of structural steel;

compressive strength of concrete; unit weight of concrete; soil bearing capacity;

reduction and bending factor; and modulus of elasticity was obtained from the latest

National Structural Code of the Philippines.

 29

Preparation of Architectural Design

The architectural plan of the four-storey multi-purpose modular building was

based on an existing plan of a building. The researchers used the Computer Aided

Drafting Device (CADD) in making and preparing the plans and layouts of the modular

building as well as the development plan of the site. They have also used the Google

Sketch Up software to show the perspective of the said building.

Preparation of Structural Design

The authors developed the structural plan of the four-storey multi-purpose

modular building through the aid of a computer software commonly known as Structural

Aided Analysis and Design (STAAD PRO v8i SelectSeries5) which provided the shear,

reaction, moment and axial forces. The software helped the researchers to simplify

complex situations and lengthy computations. The most economical section used was

based on the computed results.

As for the technical information and other considerations in designing was based

on the National Structure Code of the Philippines (NSCP 2015). Other books including

Simplified Steel Design by Besavilla and Reinforced Concrete Design served as a

reference in designing the structural members of the building.

Design Computations and Analysis

Structural Design

Design of Base Plate

1. Design the column and the Footing or pedestal area.

 30

2. Compute the allowable concrete bearing stress fc’. If the base plate is as

large as pedestal, it should have the case of ‘full support area’ and n on

footing it should have “on less than area”.

P
3. Find the base plate area, A=
Fp
P
4. Determine the actual stress, f a= . Check the bearing strength, if f a >
A

Fa, it is correct.
5. Compute for the required base plate thickness
N−0.59 d B−0.8 bf
m= ; n=
2 2
6. Use the largest value of m or n to compute the cantilever bending moment

in a unit strip width of the base plate.

7. Find the base plate thickness based on an allowable bending stress.

t2
Fb=0.75fy. If a unit width in the length m or n is used in the section is
6

and equating allowable stress Fb to the actual thickness t is t=2 n

Design of Isolated Footing

√ fp
Fy
.

1. The values of ultimate moment (Mu) and ultimate axial load was adopted

from STAAD.

2. Compute critical load.

Pu=φPn

3. Assume weight of footing to range from 6% to 8% of service load.

Weight of footing=0.08 Pc

4. Compute Total load.

P=Pc+weight of footing
 31

5. Compute the required area of footing.

Total load
required area=
Soil Bearing Capacity

6. Use a bigger size than the required area.

7. Compute the ultimate soil pressure.

e=( Mu
Pu )

Pu 6e
q=
B 2 (
1±
B )
8. Compute depth of footing “d” by punching shear which occurs at a

distance d/2 from the face of the column.

a. Compute allowable value of punching shear.

2 √ f c'
Vc= 1+( βc ) 6

Where:

long side of column

βc=
short side of column

1
Vc=
3
√ f c'

Use whichever is lesser.

b. Compute the average ultimate soil pressure.

max . q+ min. q
Ave . q=
2

c. Compute the value of “d” by equating the actual punching shear to

allowable punching shear.

Vu
Vn= ( Actual )
φ bo d
 32

C
d +¿
Where
L2−( ¿¿ 2 ]
Vu=qu¿

bo d =( d +c )( 4 )( d )

φ=0.85

Vu
Vc=
φ bo d

Check “d” in beam shear.:

Pu
qu=
A

1
Vc= √ fc ' bd
6

Vu=∅ Vc

9. Check “d” in bending.

Mu=qu ( L )( x ) ( 2x )
Mu=φb d 2 f c ' ω ( 1−0.59 ω )

ωf c '
ρ=
fy

10. Compare ρ to ρ min :

1.4
ρmin =
fy

if ρ< ρmin ;use ρ= ρmin

11. Compute steel area requirement.

As=ρbd

12. Compute the required development length was computed.

 33

0.02 A b fy
Req . Ld=
√ f c'
Where: Ab = area of one bar

Min. Ld=0.06 d b fy∨300 mm

13. Actual weight of footing was rechecked by using the following formulas:

Total depth of footing=d +70+1.5 d b

Wt . of footing=( B 2) ( Total depth )( 2.4 )( 9.81 )

Design of Anchor Bolts

1. Given the moment in the STAAD analysis, use the summation of moment

at the base of anchor bolts.

2. Get the moment M that group of anchor bolts could carry.
3. Assume size of anchor bolts to obtain its total number.
4. Using formula d= AsFt , the diameter of the bolt can be computed.
5. Compute the embedded length using:
0.1( Ab) fy
Ld= ∨Ld =0.00058 ( bd ) fy
√ fc '

Design of Steel Beam.

1. Compute the loads to be supported by the beam;

2. Select a section from the steel handbook;

3. Check whether the section is compact or non-compact;

bf 170
< ; compact section , use Fb=0.66 Fy
2 t Fy

bf 170
> ; non−compact section ,use Fb=0.6 Fy
2 t Fy
 34

4. Compute the moment considering the weight of the beam;

5. Check if the section is safe in bending

M
F=
Sx

6. Repeat the procedure with a different section when failed.

Design of Steel Column

1. Assume a trial section and note from the table of properties both of the

cross-sectional area and section modulus.

2. Compute the slenderness ratio KL/r being the unsupported length of the

column.
3. Compute fa,

[ ]
2
KL
F a = 1−
3 ( )
r Fy
2
2C c F.S.

3
L L
5
F . S .= +
r
3
−
r () ()
3 8 C c 8 C 3c

P fa
f a= ; , the allowable stress by using a column formula.
A Fa

4. Multiply fa, found in the third step by the area of the column cross section.

This gives the allowable load on the trial column section.

fa Cmf b
+ ≤ 1.0
Fa fa
(
1− ' F b
Fe )
 35

M1
Cm=0.6−0.4 ( ) M2
>0.4

5. Compute the allowable load with the design load

6
1.03 x 10
F e' =
KL 2
( )r

Design of Floor Joist.

1. Compute the maximum moment considering the live load only;

( LiveLoad ) ( spacing of joist ) ( L2 )

M ¿=
8

Compute the section modulus

M
S=
Fb

2. Select a section from the steel handbook using S;

3. Compute the moment considering the weight of the beam;

4. Check if the section is safe in bending

M
F=
Sx

Repeat the procedure with a different section when failed.

Design of Ceiling Joist.

5. Compute the maximum moment considering the live load only;

( LiveLoad ) ( spacing of joist ) ( L2 )

M ¿=
8
 36

Compute the section modulus

M
S=
Fb

6. Select a section from the steel handbook using S;

7. Compute the moment considering the weight of the beam;

8. Check if the section is safe in bending

M
F=
Sx

Repeat the procedure with a different section when failed.

Preparation of Cost Estimate

The quantity of materials was computed based on the Simplified Construction

Estimate by Max B. Fajardo.

Concrete Works

Footing

1. Determine the volume of the slab.

Volume = thickness x width x length

2. Determine the class mixture of the concrete by defining the concrete

proportion to be used.

3. Determine the quantity of cement (bags), sand (cu.m.) and gravel

(cu.m.) by multiplying the corresponding factor.

Main Reinforcement

Footing
 37

1. Determine the length of one cut reinforcing bar.

2. Determine the total number of cut bars in one footing.

3. Determine the total number of cut bars for all the footing of the same

type/category by multiplying the total number of cut bars for one

footing to the total number of footing.

4. Find the total length of the computed quantity of cut bars by

i. multiplying the quantity to indicated length of

individual cut bars.
5. Determine the length of commercial reinforcing steel bar to be used.

6. Determine the quantity of commercial reinforcing steel bars by

dividing the computed total length of steel reinforcement by the length

of commercial steel reinforcement to be used.

Steel Components

The steel beam, steel column, bolts and other steel components will be

estimated through direct counting method. The number of each components will be based

according to the plan. The cost of each components will be based on their price on the

market.
 38

RESULTS AND DISCUSSION

Gathering of Important Information

The technical information such as dead loads, live loads, seismic load, and

uniform load for floor depending on its function, wind load and load combination used

were taken from the National Structural Code of the Philippines (NSCP 2015).

The gathered data includes the criteria based on the computation of beams, floor

joists, steel columns, and concrete column footings. The following data were considered:

specified yield strength of reinforcements was Fy=275 MPa for column footings;

specified minimum yield stress of structural steel was Fy=250 MPa for steel columns,

steel beams, floor joists; specified compressive strength of concrete was fc’=21 MPa; the

unit weight of concrete was γ=2400 kg/m3; the soil bearing capacity used was 150 kPa;

the reduction factor was ϕ=0.90 for bending and ϕ=0.85 for shear; and the modulus of

elasticity was E=200000 MPa.

Reference and civil engineering books such as the Association of Structural

Engineers of the Philippines Steel Handbook (ASEP), Reinforced Concrete Design,

Simplified Steel Design and design projects of former civil engineering students were

used as references on the different design computations.

 39

The Structural Aided Analysis and Design (STAAD pro v8i SELECTseries5)

software was used to determine the factored axial load (Pu), ultimate shear (Vu) and

ultimate moment (Mu) which were used in designing the section of structural members.

Development Plan

To visualize the development plan, the authors included building perspective (see

Appendix Figure 1) and the development plan of the main building of the four-storey

modular building.

Included in the architectural plans were module arrangement plans (see Appendix

Figure 4-7), floor plans (see Appendix Figures 8-11), roof plans (see Appendix Figure

12), elevations (see Appendix Figures 13-16), and section (see Appendix Figure 17) of

the proposed modular building.

Structural plan includes structural frames which were used in design analysis and

foundation plan. The details of beam, column, footing and floor joist were also prepared.

In determining which structural frame to use, the researchers considered which

part is the most critical that carried most the load. The building floor framing layout was

done after computing the design of the structural members.

Architectural design was based on an existing plan of a building. Architectural

parameters were cross reference to the National Building Code of the Philippines.

The preparation of architectural plan and detailed plans of structural members was

done through Computer Aided Drafting Device (CADD) and Google Sketch Up.

Analysis of Individual Structural Members

 40

The analysis of individual structural members was obtained with the aid of

STAAD software and the results of the members was taken. Based on the analysis output,

safe sections and needed reinforcement were determined and the result is stated below.

Design Computation and Analysis

Design of beam. The design of tie beam member no. 6742 with a length of 12

meters and the section was found as compact. The allowable and actual stress was

computed, and the section used was W12 x65 Steel. For the design of mid beam, the

section obtained was the same with tie beam, that was W12 x 65 Steel. The section

obtained for both top and roof beam was the same and the section used was W8 x 48

Steel.

The section obtained for floor joists spaced 300 mm on centers was LC

65x30x15x12.0.

The section obtained for ceiling joists spaced 300 mm on centers was LC LR

50x40x12.0.

Design of column. The columns were designed on ultimate moment and shear

taken from STAAD Analysis Results. The effective length factor used was 1.0 conform

with the AISC specifications where both ends are pin-connected (rotation free and

translation fixed).

The column was designed and determined to have a large axial load and small

moment. The slenderness ratio was computed and said to be an intermediate column. The

design of column having a height of 3 meters, the ultimate axial load was 333.009 kN and
 41

the ultimate moment was 95.87 kNm. The section obtained was 300 mm x 300 mm and

reinforced with 4-16 mm diameter vertical bars.

Design of footing. The footing was designed on ultimate moment and shear taken

from STAAD Analysis Results. Clear concrete covering used for footing was 75 mm

greater than the minimum covering stated in section 407.8 of NSCP 2010. Allowable soil

pressure used was 150 kN/m2.

The footing at support 1 was designed isolated square footing. The section

obtained was 1.2 m x 1.2 m x 0.3 m with ultimate axial load of 20.583 kN and ultimate

moment of 21.817 kN.m. and was a reinforced with 9-16 mm diameter bars both ways.

The highest computed depth was used.

The footing at support 2 was designed isolated footing. The section obtained was

1.6 m x 1.6 m x 0.3 m with ultimate axial load of 80.416 kN and ultimate moment of

37.551 kN.m and was a reinforced with 12-16 mm diameter bars both ways.

For the actual construction, the technical specification detailed and scheduled in

the study was recommended to use. This was based on design computation analysis and

economically acceptable that would not impair and sacrifice that strength of the building.

Design of connection. For the beam to column connection, the ultimate axial load

of 231.164 kN and the ultimate moment of 248.503 kN-m was considered. The area of

angle plate was computed, and the section used was BA 100 x 100 x 8. The number of

bolts used in the angle plate was 4 -25mm. For the column to column connection, the

ultimate axial load and ultimate moment was based on the columns and the angle plate

was BA 125 x 125 x 10 with 6- 25mm bolts.

 42

Design of baseplate and anchor bolts. The computation of the base plate and

anchor bolts of both the interior and exterior footing was based on the ultimate axial load

and ultimate moment of the steel columns. For the exterior footing, the dimension

obtained based on the loads applied was 415 mm x 215 mm x 15 mm baseplate punch 6 –

25 mm f holes and shop weld plate to column for field erection. It was also checked in

safety for the actual and allowable bearing pressure. For the interior footing, it was

computed, and the results were 350 mm x 150 mm x 5 mm baseplate punch 6 – 25 mm f

holes and shop weld plate to column for field erection.

 43

SUMMARY, CONCLUSIONS AND RECOMMENDATIONS

Summary

The study prepared a proposed plan of a four-storey multi-purpose modular

building with a lot area of 2688 square meters.

The physical development plan included a four-storey commercial complex with

floor area of 762 m2 on the ground floor, second floor, third floor and fourth floor (see

Appendix Table 3).

The architectural plans were composed of perspective, floor plans, elevations, and

the schedule of doors and windows. Electrical and plumbing plans were excluded in the

study.

The architectural plan of the buildings was drawn using Computer Aided Drafting

Device (CADD), while the other member analysis was computed manually.

Technical information was taken from the National Structural Code of the

Philippines (NSCP) 2015 and Association of Structural Engineering of the Philippines

Inc., (ASEP) Handbook. Architectural design considerations were taken through research

and observation of some existing modular building structures within Cavite. Design
 44

project of former civil engineering students was also used as reference in design

computation and comparison of analysis.

The researchers designed the four-storey modular building considering the

building code and steel design computation. In designing the structural member of the

four - storey multi-purpose modular building, a design criteria was considered such as

specified yield strength of non-pre-stressed reinforcement was Fy=275 MPa for beams,

columns, slabs and column footings; specified minimum yield stress of structural steel

was Fy=275 MPa; specified compressive strength of concrete was fc’=21 MPa; the unit

weight of concrete was γ=2400 kg/m3; the soil bearing capacity used was 150 kPa; the

reduction factor was ϕ=0.90 for bending and ϕ=0.85 for shear; and the modulus of

elasticity was 200000 MPa.

Tie beams obtained a section of 304.8 mm x 304.8 mm and was reinforced at start

support with 2-16 mm diameter steel bar at the top and 2-16 mm bar diameter for

anchorage, at end support with 2-16 mm diameter steel bar at the top and 2-16 mm bar

diameter for anchorage, and at middle span with 2-16 mm diameter steel bar at the

bottom and 2-16 mm diameter bar for anchorage. Roof beam obtained section of W 8 x

48 (Wide Flange).

Isolated footing 1 obtained a section of 1.2 m x 1.2 m x 0.3 m and was reinforced

with 9-16 mm diameter bars both ways. Isolated footing 2 obtained a section of 1.6 m x

1.6 m x 0.3 m and was reinforced with 12-16 mm diameter bars both ways.

Conclusions
 45

Based on the study conducted, it was found out that using modular construction

has many advantages compared to traditional construction considering the quality of the

products used to make up the module and its standard specifications. The design of the

modular building also affects the computation of the load distribution as it was designed

differently from the typical concrete structures.

The structural design of the project was done following the procedures for steel

building design and other requirements as per NSCP 2015 standards. Based on the

gathered information, study and investigation, the researchers concluded that the

development and design of the project follow all proper guidelines and procedures in the

development of the modules and of the whole building.

Structural Aided Analysis and Design software and Computer Aided Drafting

software are a great help in analyzing the structural member of the building and

accomplishing the architectural and structural details of the building as well as the site

development.

Based on the studies and computations done, it can be concluded that all the

sections and materials used in the project are safe and economical.

To conclude, the design project will be a better alternative that is good for the

environment and useful enough that will produce a building that meets the client’s needs

within the limitations of government regulations and market standards. Furthermore, the

conduct of the study enhances the knowledge of the authors regarding this type of

construction system and the field of works of civil engineering such as structural and

construction.
 46

Recommendations

Based on the result of the study, the authors recommend a more detailed and

comprehensive analysis and design of the modular building including the per module

analysis and construction system.

It is suggested that the design project be used for its future implementation and to

serve as a reference for future researchers.

Furthermore, the use of modular construction in a proposed building can be used

for its rapid construction and ranges from medium to high rise buildings and is an

alternative with the traditional one.