MODULAR BUILDINGS - Albion Sections

MODULAR BUILDINGSwww.albionsections.co.uk

R A I S I N G Y O U R E X P E C T A T I O N S

October 2018 Revision 1

Welcome to Albion Sections Ltd structural solutions for modular buildings.This booklet includes section sizes and typical details for both single storey and double storey modular buildings.

Single storey solution:Full structural calculations are available separately (on request) for the single storey modular frame comprising floor and roof cassette and corner columns. This standard design considers wind loadings which are limited to the areas shown on the attached map. It is also assumed the site is at least 2km from the sea and that the site altitude is no greater than 120m.

Corner columns, although sized, are not supplied by Albion Sections.

Two storey solution:Three solutions are provided for the first floor beam; nested solution, compound solution and single beam solution. Full details of each are provided.

These beams are designed to support the temporary roof of the lower module and first floor loadings from the upper module (floor imposed loading limited to 3kN/m2). In this case, Albion Sections Ltd do not consider wind or side sway loadings which must be considered by the client’s structural engineer.

In all cases above, the client’s structural engineer must approve and incorporate Albion Sections Ltd calculations within their design package.

01 Introduction

02 Single storey module

03 Two storey – Nested beams solution (limited to 9.6m long unit).

04 Two storey – Composite beams solution (limited to 9.6m long unit).

05 Two storey – Non composite beam solution (limited to 7.2m long unit).

06 Two storey – Composite beams solution (for module lengths greater than 9.6m and up to 12m)

07 Standard modular connections

08 Non Standard Modular Connections

09 Non Standard Floor Cassette Connections

10 Standard roof cassette inset connections

11 Standard roof cassette flush connections

12 Albion standard punchings available to modular building profiles.

13 Map showing limiting location parameters for single storey frame

Introduction Contents

Minimum stiff bearing on intermediate pads200mm (packing by others)

top flg

lip

btm flg

depththickness

Assumed Construction :Roof: 12mm plywood + membrane+ Insulationor composite panel. Lightweightceiling.Floor: 18mm plywood & insulationWalls : Timber studding, metalouter sheet, plasterboard lining.

Wind LoadingsTo BS EN 1991-1-4:2005Vb, map < = 25m/sAltitude < = 120mDistance to sea > = 2km

All column base plates arerequired to be bolted to concretepad foundation. Standard detailavailable.

Lifting of Module:Modules are required to be lifted, by crane, via "D" shackles screwed into column cap plates. Temporarysupport or bracing may be required.

Columns 100 x 100 x 6.3 SHS(NOT suppliedby Albion Sections Ltd)

End Brace Frame100 x 65 x 5 RHS fully weldedto columns. Alternative end bracemethods may be discussed with manufacturer.

Joist Sections

Width of ModuleImposed Load

kN/m2Joist Centres Section

3m 3 600 C165631316

3m 5 400 C165631616

3.6m 3 600 C165631320

3.6m 5 400 C165631320 Ground Floor Side Skirt Sections and maximum pad centres

Width ofModule

ImposedLoad kN/m2

SectionMaximum Pad

Centres3m 3 C1781007330 3.2m

3m 5 C1781007330 2.4m

3.6m 3 C1781007330 3.2m

3.6m 5 C1781007330 2.4m

ModuleLength

ModuleWidth

Depth Top Flg Btm Flg Top Lip Thickness

9.6m 3m & 3.6m 330 75 65 25 312m 3m 400 100 80 25 312m 3.6m 450 90 85 25 3

Purlins3m wide module - C12516 @ 1.22m centres3.6m wide module - C14613 @ 1.22m centres`

Joists installed in facing pairs with tie bar at mid span

Roof Side Beam Dimensions:

Module Height3m

Module Length 9.6m

or 12m

(overall columns)

Module Width

3m or 3.6m

(overall columns)

Depth to baseplateto be confirmed Intermediate pads

(see below)

Material Specification:-Cold roll formed steelsections, manufacturedfrom Pre-Hot DippedGalvanized Mild SteelBSEN10346:2015, GradeS450 with a Z275galvanized coating. Thecoating has an averagethickness of 20 micronseach side.

Single Storey Module

Albion Sections Ltd2 Albion Road, West Bromwich, West Midlands, B70 8BD

ContactTel: 0121 553 1877 Email: [email protected]

TitleSingle Storey Module 02

Design Parameters for 9.6m SpanFirst Floor/Roof Beam

Assumed Construction at 1st floor :-22mm plywood flooring +lightweight insulationRoof membrane on 12mm plywoodLightweight ceiling

Imposed First Floor Load =3.0kN/m2

Albion Sections Ltd. Structuraldesign is limited to gravity loadsonly. All other considerations byclient's structural engineer. AlbionSections Ltd design must beaccepted and approved by theclient's structural engineer andincorporated into the overallmodule design.

C1781007330 side skirt

Floor Decking

C1656316 @ 600 c/c

Temporary roof covering

Purlins to suit client's roofarrangement

Beams to suit client'sceiling arrangement

Nested beam :-450 x 95 x 3mm unlipped channel over440 x 90 x 18 x 3mm lipped channel

9600 maximum(overall columns)

3000 max(overall columns)

Section "A-A"For Nested Beams

Column designNOT by Albion SectionsLtd.

No bolted connectionsrequired between floor

beam & roof beam

A

A

Roof Construction asAlbion Standard SingleStorey Module

Ground Floor Constructionas Albion Single Storey Module

Albion Standard 400 deepRoof Beam Connection(6 bolt)

Material Specification:-Cold roll formed steel sections, manufacturedfrom Pre-Hot Dipped Galvanized Mild SteelBSEN10346:2015, Grade S450 with a Z275galvanized coating. The coating has an averagethickness of 20 microns each side.

Module Units: 9.6 Span First Floor Beams - Nested Scheme



TitleModule Units: 9.6m span first floor beams - Nested Scheme 03



A

A

Column designNOT by Albion Sections Ltd.

Design Parametersfor 9.6m Span FirstFloor/Roof Beam

AssumedConstruction at 1stfloor :-22mm plywoodflooring + lightweightinsulationRoof membrane on12mm plywoodLightweight ceiling

Imposed First FloorLoad = 3.0kN/m2

Albion Sections Ltd.Structural design is limited togravity loads only. All otherconsiderations by client'sstructural engineer. AlbionSections Ltd design must beaccepted and approved bythe client's structuralengineer and incorporatedinto the overallmodule design.

Material Specification:-Cold roll formed steel sections,manufactured from Pre-Hot DippedGalvanized Mild Steel BSEN10346:2015,Grade S450 with a Z275 galvanizedcoating. The coating has an averagethickness of 20 microns each side.

Floor Decking

Temp. roof

C1781007330

440 x 90 x 18 x 3mm

Purlins to suitclient's roofarrangement

beams to suit client'sceiling arrangement

Section "A-A"Composite Beams

Roof Construction asAlbion Standard Single

Storey Module


B


M20 Class 8.8bolts with washers

to head and nut

Compound Bolt Postions based on M20 (8.8) bolt

2 @ 680

2 @ 680

2 @ 930 1580 2 @ 9301580

9600

View on Arrow B showing required centres of bolts

Module Units: 9.6 Span First Floor Beams - Composite Section



TitleModule Units: 9.6m span first floor beams - Composite Section 04



A

A


Design Parametersfor 7.2m Span FirstFloor/Roof Beam



Albion Sections Ltd.Structural design islimited to gravityloads only. All otherconsiderations byclient's structuralengineer. AlbionSections Ltd designmust be acceptedand approved by theclient's structuralengineer andincorporated into theoverallmodule design.

Floor Decking

Temp. roof

C1781007330

440 x 90 x 18 x 3mm



Section "A-A"Non - Composite Beams



Module Units: 7.2 Span First Floor Beam



TitleModule Units: 7.2m span First Floor Beam 05



A

A


Design Parametersfor 12m Span FirstFloor/Roof Beam



Albion Sections Ltd.Structural design is limited togravity loads only. All otherconsiderations by client'sstructural engineer. AlbionSections Ltd design must beaccepted and approved bythe client's structuralengineer and incorporatedinto the overallmodule design.


Floor Decking

Temp. roof

C 350 x 100 x 25 x 3.2mm

450 x 100 x 25 x 3.2mm



Section "A-A"Composite Beams

Roof Construction asAlbion Standard Single

Storey Module


B

Beam to column connectiondetails to be agreed withmanufacturer

M20 Class 8.8bolts with washers

to head and nut

2 @ 550

2 @ 550

2 @ 700

2 @ 700

2 @ 970 2 @ 9701560 1560

12000

Compound Bolt Postions based on M20 (8.8) bolt

View on Arrow B showing required centres of bolts

Two Storey – Composite Beams Solution (for Module Lengths greater than 9.6M and up to 12M)



TitleTwo storey – Composite beams solution (for module lengths greater than 9.6m and up to 12m) 06

1035

165

35

330

DE

EP

MA

X

3590305

58m

m P

LT (

or 1

0mm

)

5 30 165 35

3590

359

9

178

deep

sid

e sk

irt

5

8mm

PLT

(or

10m

m)

5 30 120 35

3015

015

030

15

400-

450

dee

p ro

of b

eam

max

3mm web

120 45

25

6

17

32,5

100

7,5

25

100

25

165

or 2

00de

ep fl

oor

beam

3025

8mm thick fin plate4no. Ø18 C'formed holesin roof beam and Ø18c'sunk holes in plate to suitM16 (8.8) c'sunk/rd/hex bolts

Corner Post (NOT toAlbion Sections Ltd Design)

Roof Beam to Corner Post(Roof Beam max 330 deep)

Side Skirt toCorner Post

Section X-X

Section X-X

x x

x x

"Outside"

"Outside"

"Outside"

"Outside"

Roof Beam to CornerPost (400-450mm deep)

Plate orientation same asSection 'X-X'

10mm thick fin plate6No. Ø18 c'formed holes inroof beam and Ø18 c'sunkholes in plate to suit M16(8.8) c'sunk rd hex bolts

Floor beam

190 x 55 x 3mm galv'd L x 150mm long

Floor Beam to Side Skirt

178 x 100 x 73 x 3mmSide Skirt

4No. Ø7 c'sunk holes to suitØ7 Huk Bolts

2No. Ø7 c'sunk holes tosuit Ø7 huk bolts OR 2No.

Ø14 c'forms to suit M12c'sunk bolts (choice by

customer)

Material SpecificationAlbion Sections Ltd profilesand cleats grade S450.Fin plates and SHS boxsections by others.

Standard Modular Connections



Title”Standard” Modular Connections 07



Title”Standard” Floor Cassette Connections 08

Non Standard Modular Connections

100

Flange

6

190 Cleat

1203mmWeb

45 25

C146 Joist

17


10 35

2525

75

125

Cle

at

178

Sid

e S

kirt

2530

Plan on Cleat

3535

75190 x 55 x 3mm thick angle x 125 deepwith 6no. 8 O countersunk holesto suit 7 O HUK Bolts

100Flange

6

190 Cleat

1203mmWeb

45 25

C165 Joist

17


7.5

32.5

2525

100

150

Cle

at

178

Side

Ski

rt

100

2530

Plan on Cleat

32.5

32.5

100

190 x 55 x 3mm thick x 150 deepwith 6no. 8 O countersunk holesto suit 7 O HUK Bolts

Floor Cassette - C145 Joist to Side Skirt Connection

A selection of connections developed to suit manufacturers requirements

Floor Cassette - C165 Joist to Side Skirt Connection

General Note:

These details are shown as standard connecting to a 178mm deep side skirt.

This detail will accommodate varying depths of side skirts to suit manufacturers detail.

Skirt depths ranging from 200 - 400mm are currently provided.

Note:

These details are provided for general information but are subject to a design check for each application



Title”Special” Floor Cassette Connections 09

Non Standard Floor Cassette Connections

85Flange

6

178 Cleat

1083mmWeb

45 25

C165 Joist

20

1020

2525

75125

2530

Plan on Cleat

178 x 55 x 3mm thick x 125 deep220mm deepx 85mm x 65mm x 3mm

with 6no. 8 O countersunk holesto suit 7 O HUK Bolts

65

685

20

20

3mmWeb

10865

45 25

10 2025

2575

125

2530

Plan on Cleat

240mm deepx 85mm x 65mmx 3mm Side Skirt

Cleat:178mm x 55mm x 3mm x 125 long6No 7 O countersunk holesto suit 7 O HUK bolts

C165 Joist

C165 Floor Joist Set 20mm above Side Skirt C165 Joist Set 20mm above Side Skirt 240mm Deep

General Note:

Sides skirts can be up to 400mm deep with joist positioned above or below top flange.

Note:




Title”Standard” Roof Cassette Inset Connections 10

Standard Roof Cassette Inset Connections

C120 Purlin

4No 8 O countersunk holesto suit 7 O HUK bolts

2510mm CLT

PROJECTION

30

7025

255

5

A

A

2 Web3025

View ‘A-A’

Application

Purlin set beneathlip of side skirt

C146 Purlin


2510mm CLT

PROJECTION

30

8525

255

5

A

A

2 Web3025

View ‘A-A’

Application


C165 Purlin


2510mm CLT

PROJECTION

30

105

2525

55

A

A

2 Web3025

View ‘A-A’

Application


120mm Purlin to Roof Beam 146mm Purlin to Roof Beam 165mm Purlin to Roof Beam

65mm x 55mm x 3mm thick angle x 110mm deep

4no. 8 Ø countersunk holes to suit 7 Ø HUK bolts

65mm x 55mm x 3mm thick Angle x135 deep

4No 8 Ø countersunk holes to suit 7 Ø HUK blots

Cleats are attached before despatch using

2No 7mm Ø HUKs

65mm x 55mm x 3mm thick Angle x155 deep

4No 8 Ø countersunk holes to suit 7 Ø HUK blots

Note:




Title”Standard” Roof Cassette Flush Connections 11

Standard Roof Cassette Flush Connections

75Flange

5

97 Cleat

20

117

3mmWeb

20

3015

156080

2530

Plan on Cleat

3060

30

1010

2020

100

clea

t3mm thick notched cleatwith 4no. 8 O countersunk holesto suit 7 O HUK Bolts

Note: Cleat is fixed to the outsideof the web

75Flange

5

3015

156580

3085

30

1010

2020

125

clea

t

97 Cleat

20

117

3mmWeb

20

2530

Plan on Cleat

3mm thick notched cleatwith 4no. 8 O countersunk holesto suit 7 O HUK Bolts

Note: Cleat is fixed to the outsideof the web

Roof Cassette - 120 deep Purlin Tops Level with 330’G’ Section Roof Cassette - 146 deep Purlin Tops Level with 330’G’ Section

Note:


Cleats are attached to purlins before despatch

Albion Standard Punchings Available

Standard round holes (diameter in mm)2, 3, 5, 7, 8, 8.5, 9, 10.5, 12, 14, 16, 17, 18, 19, 22, 25, 26, 28, 30 & 31.75.

Counterformed holes8, 14 & 18mmThis is the clear hole diameter of the counterformed hole, the distorted area is approx 2.5 times greater (critical when counterformed holes are spaced at close centres) .

Slots:Slots tools are restricted to their orientation in the section. In the following, the first dimension is with the length of the section, the second dimension is across the section.

Rounded slots:30 * 7mm7 * 30mm20 * 14mm28 * 14mm21 * 11mm30 * 22mm48 * 18mm

Rectangular slots:14 * 20

Service slot:100 * 50mm

Special restrictions on this slot:May only be punched in material 1.5mm thick or greater.

Only one slot may be formed in the width of the section.

There is no limitation on the number of slots that can be punched longitudinally.

Any series of slots may be positioned anywhere within the width of the section but all slots would be restricted to this position (i.e. slots in different positions in the section width are not possible).

Hexagonal holes:16 HEX 16mm across flats, 19mm across corners.21 HEX 21mm across flats, 24mm across corners.

Flange holes:All of the above apply to flanges as well as webs. Application limited by the width of the actual flange.

Albion Sections Ltd. Punching capability on the Bradbury machine

Restrictions / limitations on punchings:The maximum punch diameter is 31.75mm.Any non-standard punched shape (square, hexagonal) must fit into a circle of this diameter.

On any single member, as well as counterforms, 18mm*48mm slots and service slots, up to three additional different types of punching may be accommodated.

Punchings may be in singles or in pairs and different punchings can be accommodated in the width of the section.

The purchasing of tooling to punch other holes or shapes (although the limit of 31.75mm applies) may be cost effective depending on the quantity.

Manufacture is subject to our inspection and acceptance of final details drawings.



TitleAlbion Standard Punchings available to Modular Building Profiles 12

Standard Modular Design Calculation of Applied Wind Loading

Vb, MAP = 25 m/s or less

ALTITUDE = 120m or less

DISTANCE TO SEA = 2km or more

© 2016 Albion Sections. All Rights Reserved - November 2016

Permission to reproduce extracts from British Standards is granted by BSI Standards Limited (BSI). No other use of this material is permitted. British Standards can be obtained in PDF or hard copy formats from the BSI online shop: www.bsigroup.com/Shop

Albion Sections LtdAlbion RoadWest BromwichWest MidlandsB70 8BD

Main switchboard 0121 553 1877 Fax 0121 525 6122Email [email protected] Website www.albionsections.co.uk

Notes and CalculationsAlbion standard design for single storey modular frameis limited to the shaded area.



TitleAlbion Sections Ltd Standard modular design - Calculation of applied wind loading 13

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MODULAR BUILDINGS - Albion Sections