RESEARCH
on
the APPLICATION of CONCRETE
STEEL PANELS in
CONSTRUCTION SYSTEM
COMPOSITE BUILDING
by
GEORGE
SZEPESI
Bachelor of Architecture, University
of Houston
(1975)
SUBMITTED IN PARTIAL FULFILLMENT
OF THE REQUIREMENTS
FOR THE
DEGREE OF
MASTER
OF ARCHITECTURE IN ADVANCED
STUDIES
at the
MASSACHUSETS
INSTITUTE OF TECHNOLOGY
1978
MAY,
GEORGE
Signature of
SZEP4S3T
1978
.1
Author............%I*
Department
of
......
........
Architecture,
May 1978
Certified by.
Thesis Supervisor
Acceptedb
Julian BeinartA
byC............................
Chairman,
Rotth
MASSACHUSETTS INSTITUTE
OF TECHNOLOGY
AUG1 0 19,7&UIBRARIES
Department Committee
a
L1.0
ck,
L,,
/v%& e--%%& co), t4-*-X
e,
/bt4L~LL
Z~brn.
~
L~4~Y&~L
acknowledgments
Beatriz Lapp
Fundacion Gran Mariscal de Ayacucho
Waclaw Zalewski
and to all those who believe in technology
Copyright
A
George Szepesi
1978
contents
Preface
6
A need for
Existing
housing building
Description
Illustrations
7
industrialization
of the system
systems
8
10
11
preface
This work is an investigation into the possibility
of using cold formed steel sections as formwork,
where concrete is
poured and placed. Once the
concrete is cured, it becomes
the finished product;
a concrete panel with metal edges.
The cold formed steel
sections behave as partial
reinforcement necessary to supplement additional
steel
rods or mesh.
The methodology applied in
down to definition
this
research breaks
of the problem, an analysis
of existing construction methods, and finally a
presentation of an alternative solution.
The solution is a Composite building System.
Application and reduction on costs were key
considerations in
the developement of this
work.
The sole purpose for the work done was to offer
a
feasible alternative to the construction industry,
minimizing
6
labor
and time.
a need for industrialization
Right now, more than ever before, the correct
Alarming increases of the number of tenants under
understanding of the concept of industrialization
one roof, where single families
in architecture is paramount.
not the solution.
With the increasing population explosion, infant
mortality reduced to minimum figures plus an
production and even automation for the more
dwelled before, is
The use of induizial methods at all stages of
augment on the life span, there is a housing deficit
escalating
to astronomi-cal magnitudes.
It is imperative to state from the very beginning
technically advanced countries is one way to
alleviate the otherwise uncontrollable housing
nigthmare.
Developing industrialization is the rational panacea
that a need for housing should not mean new slums
or poorly designed and built
buildings;
Industrialization as a viable alternative should
also mean designing above the mimimum quality
The concept of industrialized
housing today should
emphasize quality, fair price and code compliance.
standards for human living.
The knowledge of fast and good should be one word,
one principle.
Different actions have been taken by the government
in
all
countries; Federal, state
and local
agencies
desperatelYtrying to cope with this macroproblem
are issueing
new legislations,
renovations of either
change of zonings,
old or run down existing
urban areas, but these have not been sufficient
measurements to cope with the
demand of housing.
7
existing housing building systems
construction
understood today as industrialized
Industrialization could be defined as a process by
What is
which the same identical components are fabricated;
methods is only an actual and revised version of the
requiring minimum of time to manufacture them on a line
old knowledge of putting
In
systems are being used in
Many building
countries.
different
There are numerous modern methods of
production in construction and housing edification but
for
categories would best suit
identifiable
one: load bearing walls, either
internal
this
not all
industrialized
systems (on line
production)
the components are factory produced; which means
components produced under a roof at a distance from the
choosen site requiring some use of transportantion.
Sometimes there are particular reasons why components
three
purposes, basically
classification
buildings together.
assembling.
production for later
analysis:
external or
are
to be produced in situ, adjacent to the fu-ture
assemble spot.
(crosswalls),
two: frame structures, composed by post & beam
with panel infill
or slab
three: box concept with all
its
a
column,
Industrialized housing systems
can be of low, medium or
high degree of technology.
variables.
On line production is accepted as very efficient, mainly
Applications, costs and time investment are always.
due to standartization and fast manufacturing with
top considerations on any industrialized method
a minimum time.
of construction.
Any industrialized
Building systems have first, an alphabet of elements
method is
proved succesfull
and components; Second, production characteristics;
then becomes a key factor
Third, materials plus performance; Fourth, transportation
manufacture the components as well as time required to
requirements and fifth,
erection and assemblage.
Various degrees of technology for the production of
components in
8
building
when it achieves the lowest number of components. This
architecture
for time investment; Time to
assemble them.
Simplicity is the name of the game.
have always been in
existence, therefor, the concept of industrialization
All shapes of components and sizes are being fabricated
in the construction business is not a new one.
for the market also an endless combination of joints
and materials are used.
The same ones are not necessarily to be found on both
sizes simultaneously. Large components have less con
Steel and reinforced concrete are basic materials used in
connections or joints
the prefabrication of components, although the same
flexibility in the arrangement requiring large and
materials are used on conventional types of architecture.
costly cranes.
Steel has a linear characteristic while concrete has a plane
Components that are small in sizedo not require heavy
characteristic.
with fast
assemblage, but lack
equipment for erection on one hand, and they allow high
flexibility
(multidirectinal). On the other hand, small
Steel as a structural element is capable of becoming a
components have more joints, reduce the speed of erection
beam, column or joist, found in the market as sheets or as
and increase precision, requiring
more tolerances.
angles, channels, tees, zees and rails. Steel rebars and
cables once placed inside the concrete becomes the
reinforcement of it.
Reinforcing concrete
can be presented either as a
structural component or as a non structural one. As a
structural
component it can be foundation, column,.wall,
beam, floor and roof; and also non structural, like partitions
and parapets. Concrete is an extremely flexible material
because of its own properties, capable of generating the
infills.
The size and number of components gives the potential
capacity
for more or less flexibility on any building
system.
For a better understanding of large or small components
it is is important to recognize the advantages and the
disadvantages.
9
description of the systein proposed
All
the goals and objectives defined from
The
marriage of both
materials was
the
equipment.
the beginning of the research to visualize
answer to the advantages,of them
If
an alternative,
individually. Needless to say
of the concrete panels,
have been mentioned.
can be sumarized thusly, the
the
of components,
They
fewer number
better.
performance of one is
other and viceversa.
that the
enhanced by the
in
the
be
the
is
The final solution responds well to the
This concept is belived valuable if the
It
potencial for assembling is
particular
arrives
almost
'to
one
universal
component,
which
the walls,
floors and roof for housing
once
The system
cold
is
nothing
formed steel
realized.
assembled, creates
units.
but,
section
and only,
Because of the interaction of elements the
called a composite one.
space.
Also it
tissue
for
also
concrete
serves
asthe
panel.
definitive
reinforces
frame
can configurate
provides all
housing
the necessary
proyects.
This new system
Two concrete panels facing each other
make the walls for
the building.
the
for
saves
flexibility
as fastening elements are
adopted because they are fast, inexpensive
and a minimum technology..
keeps
The
The
size
of
physical
size
the
panel
space
was
also
was established
requirements
developed
as a possible
and complete
were met.
for
total
time
to the
total
adaptability. The
simplified
structural
which makes
allows
to a maximum but
stability.
investment from production
final
assembling is shortened.
after
The
remembering human
substitute
material,
component lighter. It
design has been
force
10
using.the basic concrete
variation,
all the components needed to enclose a
line
the
is
to observe how this
system,
minimizing tolerances and offering a clean
Nuts and bolts
but
interesting
Concrete panels with this new metal edge
can be connected easily during erection,
together become a load bearing wall panel.
only
manufacturing
dry joint.
a
concrete infill. these two elements once
Incorporation of steel,not
the
a metal joist
floor and roof components.
panel and little
used as formwork
functioning also as structure with
system is
during
embedded on the concrete, the result will
need,
it
factory,
heavy
And last
but
not
permanent quality
least
it
shelter.
provides
a
illustrations
13
Basic wall panel B.W.P.,structural
15
Floor
17
Alphabet
19
Assembling the system components
21
Four B.W.P.,with conector. It is a sandwich system
Two B.W.P. facing each other beconles a load bearing wall
panel,structural
component
component
of components
23
Typical four B.W.P. conecting with two floor panels
25
Same as 23,
27
same as 23, view from the side
29
Same as 23, view from the top
31
B.W.P. sandwich, allowing any desired width
33
Four B.W.P. intercepted by
vertical
section
two B.W.P.,from opposite
directions
Orthogonal geometry
35
Four B.W.P. intercepted by one
37
B.W.P. sandwiches being intercepted
Allowing electrical conduits and plumbing
B.W.P.
sandwich from the side
39
B.W.P.
41
View of different components assembled
43
Various conditions of joints with conectors
45
Interior walls and partitions. Derivations from B.W.P.
horizontal section
47
Interior
typical corner condition
walls and partitions
with conectors
49
Same as 47
51
Floor panel cut at required length. Accept shafts
Vertical section
53
All
mechanicals, plumbing,and electrical
55
Vertical section through entire
57
Fenestrations. Windows and doors
59
Different finishes
61
Planning
guide.
for plumbing
are inside floors and B.W.P.
building
System matrix
II
12
basic wall panel
B. WP
Physical and structural
Dimensions:
Depth
properties.
6
cm.
Length
300
cm.
Width
120
cm.
2
Net area:
3.6 mts
Composition:
Concrete.
Normal or ligth
weight
Steel. Cold formed
L section
0.01 cm.
Reinforcing bars.
Rods
o
0 *;i;
Steel plate
14 x 24 x 31
Finish product:
All different exterior and interior
concrete textures.
All colors, with concrete pigments.
Paint.
Description of the wall panel.
It is factory produced and
transported to the site.
Two (B.W.P.),facing each other and
joint together make a 15 cm. structural
sandwich; It becomes a load bearing
wall.
There are different gap possibilities
between the two (B.W.P.), according to
requirements.
The panels are assembled in situ.
They are conected while erection
special
conectors,and fastened
nuts and bolts.
with
using
14
floor panel
Physical and structural
Dimensions:
Net area:
proporties.
Depth
3.6
Composition:
6 cm.
26 cm. with joist incorporated
Length
300
600
cm. minimum
cm. maximum
Width
120
cm.
mts. 2
4.32
2
ats
;
5.76 mts
Concrete.
Normal or ligth
2
;
2
7.2 mets
weight
Steel. Cold formed
L section
0.01 cm.
Reinforcing bars.
Rods
0
joist
&
Steel angle
6 x
Steel
Finish product:
4 x
k
All different floor coverings.
Vinyl and carpet.
Description of the floor panel.
It is factory produced and
transported to the site.
Same floor conectors are used to
conect them simultaneously to the
wall panels.
The panel accept perforations at
any place. All floor panels are
assembled in situ and fastened
with nuts and bolts.
The
same (B.V.P.)
The
floor panel. It is the
a joist
is
used to manufacture
embedded in the
(B.W.P.) with
concrete.
16
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