Total Steel Project Performance - BDC University

Total Steel Project Performance

Construction Process Improvement through Progressive Steel Joist and Metal Decking Design

Continuing Education Commitment

New Millennium Building Systems AND/OR Building Design + Construction is/are Registered Provider[s] of professional development hours (PDHs), GBCI and American Institute of Architects Continuing

Education System (AIA/CES) courses. Credit earned on completion of this program will be reported according to rules set forth by those organization. Certificates of Completion for all attendees are available on request.

This program is registered with [NAME ORGS] and the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

Learning Objectives

After viewing and listening to this continuing-education module, you should be able to:

•! Recognize and understand the steel construction process through progressive steel joist and metal decking design and implementation.

•! Describe key elements and challenges of joist related total-project performance including cascading costs, cost assessment and the RFI process.

•! List the fundamentals of engineering for total-project cost accountability including tonnage reduction, deeper analysis of MEP, ESFR and joist-and-decking system

design and implementation practices.

•! Discuss the features and benefits of building-information modeling (BIM) based project collaboration for structural steel projects.

Course Outline

I. Defining Progressive Steel Joist Design

II. Engineering for Total Project Cost Accountability

a. Basic approaches to reduce tonnage

b. Deeper analyses for greater cost accountability

c. Metal decking design considerations

III. Cost-Accountable Architectural Design

IV. Taking the Project Owner’s Point of View

V. Frequently Asked Questions

VI. Your Questions (and Answers)

I. Defining Progressive Steel Joist Design

•! The structural steel package is vital to successful management of the construction process.

•! Steel delivery, design and/or detailing can produce significant costs and broadly impact project success.

•! Process improvements can provide significant advantages to building team, benefiting owners and developers.

Cascading Cost Effect

CLASHES

REWORK

PROJECT DELAY

BACK CHARGES

CONTINGENCY EROSION

OCCUPANCY INCOME LOSS

Cost Reduction – Value-Added Engineering

Manufacturing Warehousing Material Trucking Staging Erection

VA

LU

E-A

DD

ED

E

NG

INE

ER

ING

Total Cost Assessment

COST AREAS POTENTIAL SAVINGS CASE STUDY

Materials 3% - 10% and up $1.3 million (9.7%)

Transportation 5% - 10% $ 6,726 (8.3%)

Project Handling $10 per ton $ 1,700 (0.1% total)

Design Errors $ 6,360 per error $ 6,360 (0.5% total)

Lost Occupancy Varies $ 3,000 / week

Logistics Varies

Storage Varies

Erection 10% and up $ 60,000

Addendums Varies

TOTAL SAVINGS $ 1,377,786.00

The Broken RFI Process

•! Current process is dysfunctional.

•! Need for tighter collaboration between subs / suppliers.

•! Structural drawings up to 40% incomplete

•! Dimensions not shown

•! RFIs used for documenting and defending

•! Clashes with MEP and project delays

•! Costly contingency fees

The RFI process should be …

… a tool for fostering communication,

aiding in prevention of extra costs.

Top Fabricator Complaint: The Indecision Loop

?

?

? ?

?

?

? ?

?

?

?

?

?

?

?

?

?

?

? ?

SUPPLIER

II. Engineering for Total Project Cost Accountability

a.! Basic approaches to reduce tonnage

b.! Deeper analyses for greater cost accountability

c.! Metal decking design considerations

a. Basic Approaches to Reduce Tonnage

Rule of Thumb for Material Efficiency

•! Average $1,000 savings per ton removed from steel package

•! Ways to save tonnage include:

1. Reorient the framing

Can save 0.25 lbs./ft. or $0.50 per sq. ft.

2. Updated diagram load data

Expedites metal-deck fastening

Economy Table Tool

Maximizing Deck Capacity

Generic intro and illustration needed. Chris to help?

Space Joists to Maximize Deck Capacity

Cost Reduction: Joist Spacing

12.2% WEIGHT REDUCTION

22% ERECTION SAVINGS

17.2% WEIGHT REDUCTION

Load / Foot Joist Standard Joist

Design Collaboration – Delaney Warehouse

Standard Design Building (B22 Deck)

Girders are 47’-6”, 58” Deep, 10 Panels Based on 5’-0” o.c. Joists

500’ x 950’

44LH09 44LH09 30K11 30K11 30K11 30K10 30K10 30K10 30K10

40LH 40LH 30K 30K 30K 30K 30K 30K 30K

300/180 300/180 300/180 300/180 300/180 300/180 300/180 300/180 300/180

Revised Design Building (B22 Deck)

Joists Respaced at 5’-11 1/4” o.c.

Results – Delaney Warehouse

Standard Design Revised Design SAVINGS

Total Tons 926.77 848.23 tons 78.54 tons

8.47%

Total Pieces 1841 1571 Pieces 270 pieces

14.66%

Total Cost $1,282,000 $1,157,117 $124,883

9.74%

Design Out Costs – Cooper Tire Mfg.

12N

30K 192/117

44G 10.6K 12N 32G 9.7K

Assumed Loads vs. Actual Loads Initial Girders vs. Deeper Girders

68G 58G

Design Out Costs – Cooper Tire Mfg.

12N

30K 269/125

44G 14.8K 12N 32G 13.5K

192/117

10.6K 9.7K

Assumed Loads Assumed Loads vs. Actual Loads

Design Out Costs – Cooper Tire Mfg.

RESULTS

1351.25 tons 1251.29 tons

$1,491,632 $1,405,266

SAVINGS 99.96 tons (7.4%)

$86,366 (5.8%)

b. Deeper Analysis = Greater Cost Analysis

In addition to cost analysis related to materials, transportation, handling and other related elements …

Thoroughly analyze all systems.

- MEP

- ESFR sprinkler systems

… for improved cost analysis

and savings.

MEP Systems – Duct Passage

MEP Clash Prevention for Cost Reduction

Benefits of MEP Coordination for Cost Savings

•! 10-20% cost savings using MEP clash prevention methods

•! Up to 20% cost reduction on steel package with early fabricator involvement

•! Cost reduction opportunities include:

1. Reducing rework.

Minor problems: 0.5% of project cost = $6,360

2. Related costs.

Clashes add to Lost Occupancy, Logistics, Storage, Erection, and Contingency Erosion.

Design Impact of ESFR Sprinkler Systems

Information from ESFR Contractor

•! Branch line locations and branch line O.D.

•! Distance from deck bottom to center of branch line

•! Minimum clearance between branch lines and bridging

Information Supplied by ESFR Manufacturer

Interference? No Problem. Flexibility!

Example - Basic Cost Reduction

Benefits of ESFR Coordination for Cost Savings

•! Project cost savings estimated at ___________

•! Cost reduction opportunities include:

1. Reducing rework.

Minor problems: 0.5% of project cost = $6,360

2. Related costs.

Clashes add to Lost Occupancy, Logistics, Storage, Erection, and Contingency Erosion.

Engineering for Even Greater Cost Accountability

Metal Decking Design Issues

•! Use deeper seats

For R-type extensions there may be savings by increasing the extension seat depths.

•! Designate load and locations

Knowing loads and location of loads on joists will decrease costs.

•! Review the building layout

Try alternatives to framing. Avoid transferring moment through girder seats.

Use Deeper Seats

An example: R-type extensions

Bearing angle: 2 @ 2x2x3/16

2 !”

Top chord: 2 @ 2x2x3/16 Joist weight:

228 lbs

Seat depth

5”

Top chord: 2 @ 1 ! x 1 ! x 1/8 Joist weight:

139 lbs Seat depth

Weight savings:

40%

Bearing angle: 2 @ 1 ! x 1 ! x 1/8

Confirm Loads and Load Locations

An example

40’ span with 250plf total load and two 2000-lb. max loads

Requires 24KSC4 joists …

250 plf

2000 lbs 2000 lbs

Designates 24KSP joists…

250 plf

2000 lbs 2000 lbs

10’0” 10’0”

660 lbs per joist

420 lbs per joist

Weight savings:

36%

Confirm Loads and Load Locations

Top chord extension design

Joist Spacing for Maximum Deck Capacity

Use of “Load Zone” Conditions

Load-zone joist vs. KCS joist: An example

Example: KCS selection is 26KCS4, vs. load-zone joist 26KZ200/100 (A, B)

KCS joist:

Load-zone joist:

660 lbs per joist

420 lbs per joist

Weight savings:

21%

End Moment Connections

•! Increase design efficiency

•! Allow for highly efficient steel allocation

•! Traditional approaches are cost-inefficient!

End Moment Connections

End Moment Connections

Bolted type

Incorporate Girders & Joists into Bracing Schemes

Deeper Analyses: A Case Study

•! Costs reduced in all phases:

Design, delivery, assembly and erection

•! Steel tonnage reduced by 50% plus

•! 20% less manufacturing time

•! 67% less transportation costs – no wide-load

•! Reduced on-site storage

•! 66% reduction in erection labor / crane costs

S.C. Governor’s School for Science & Math

Challenge: Athletic wing over school’s gym area features

three-piece Fink-Truss design.

Deeper Analyses: A Case Study

Cost Preventative Design

Source: Structural Engineering & Design, July 2010.

Deeper Analyses: A Case Study

Joist design: A chain reaction of cost reductions

c. Metal Decking Design Considerations

Deck Gauge and Cost Calculation

Specify special thickness!

Example: For a 5,000 ft2 deck…

20ga standard

490 tons required

21ga special

450 tons required

Saves 40 tons, or $25,000!

Deck Specifications … and Costs

Decking Gauge & Cost Calculations

Example: Roof project in Shepherdsville, KY 6,056 squares of deck, specified painted 22ga Total weight: 488 tons

Potential cost and ton savings of 23ga Gravity load capacity: 25 psf total 23ga allowable for 3-span @ 5’-6 5/8”

Diaphragm strength required Pattern: Interior: 325 p/f 36/5 - 5 sidelaps Edges: 464 p/f 36/7 - 7 sidelaps

23ga Interior: 330 p/f 36/5 - 8 sidelaps Edges: 465 p/f 36/7 - 10 sidelaps

Total weight and cost savings for 23ga:

Deck: 8%

Joist/deck package: 2%

Decking Span Restrictions

… Watch framing layouts!

Temporary Shoring of Deck

Temporary Deck Shoring

Per ANSI:

1.! Galvanizing must conform to ASTM A653 (A653M) 2.! Uncoated or phosphatized with painted underside

must be applied to steel conforming to A1008 (A1008M) 3.! Finish on steel composite deck must be suitable for

environment of structure.

Decking Finish Considerations

Deck Accessories

Unsupported Accessory Proper Composite Accessory

Decking Accessories Specification

Shear Stud Strong Positioning

3. Cost-Accountable Architectural Design

Expanded Specifications for Special-Profile Steel Joists

Architectural Vision: Detroit Airport

Cost-Accountable Architectural Design: Case Studies

Architectural Vision: Pittsburgh Mills

Cost-Accountable Architectural Design: Case Study

Castellated Beams for Eglin Air Force Base

•! Castellated beam design can achieve

appearance objectives plus functionality.

•! Array of solar panels will generate electricity.

•! Additional engineering steps removed costs and prevent downstream erection costs.

Cost-Accountable Architectural Design: Case Study

4. Taking the Project Owner’s Point of View

Improving the RFI Process

Architect

Fabricator

Contractor

Engineer

Supplier

Digital Steel Joist Design

•! Develop / exchange digital, 3-D

steel joist plans with a (BIM) steel joist design component.

•! Addresses three stages of design:

1. Generic joist object for preliminary design. 2. Use of generic info for detailing- design process. 3. As-built joist BIM object with end conditions, member sizes

•! Joist object imported into BIM model

BIM-Based Project Collaboration

•! Earlier decision-making

•! Works best with sound engineering

•! Complete data transfer & processing

•! Work with suppliers who are BIM-ready

•! Case studies demonstrate the value

!""#$%

&$$"$'"()%

*+(,"-)./0%

1"$23(%

1")/20"#%

1"$23(%

*+($)4.,5+(% 6-"4/5+(%

7"0/58"%*+$)%

+9%%1"$23(%*:/(3"%

•! BIM forces early decision-making

•! Front-load all questions and details

•! Faster approval process

•! Fewer problems lead to more profitable job

BIM-Based Project Collaboration

BIM Capabilities

•! Garbage in = Garbage out

•! BIM = lots of data

•! Users spend time checking

•! But BIG mistakes can happen

•! BIM still demands qualified manual detailing

•! Good detailers > BIM

BIM-Based Project Collaboration

Inputs BIM

Modeling

Detail

Clarification

BOM Created

Steel

Fabrication

BIM allows for complete data transfer and processing

BIM-Based Project Collaboration

BIM-Based Project Collaboration

BIM-Based Project Collaboration

BIM-Based Project Collaboration

The Owner’s Point of View: BIM

BIM-Based Project Collaboration

BIM-Based Project Collaboration

BIM-Based Project Collaboration

BIM-Based Project Collaboration

Project: Target Store, San Clemente, CA

•! Structural package, joists, modeled in 3-D BIM

•! Timeline for shop drawings:

Originally10 weeks …

… to 3.5 weeks

•! BIM goal: Better utilize space around steel for HVAC, electrical

Photo: Ocean County Register

BIM-Based Project Collaboration: A Case Study

Project:

Target Stores

SOURCE: BUILDING DESIGN & CONSTRUCTION, JAN. 2011.

BIM-Based Project Collaboration: A Case Study

“With BIM analysis tools we knew we could reduce conflicts and increase utilization of the space within our box. We

wanted to move beyond that. We wanted to use BIM as a

way to figure out what was in there and then establish that and

build in protocols for how we could start to utilize that space to

reduce the height of our buildings, or maximize the amount of space we have, or minimize the amount of structure put up.”

-!Brad Koland

Group Manager

Structural Engineering, Target

Target on the Effectiveness of BIM

BIM-Based Project Collaboration: A Case Study

Questions and Answers

Total Steel Project Performance

This concludes this registered PDH OR American Institute of Architects Continuing Education Systems Program OR GBCI-registered program

Total Steel Project Performance

Total Steel Project Performance

Construction Process Improvement through Progressive Steel Joist and Metal Decking Design