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Progress Report No 2 Progress Report No. 2 Project ID: 3751 Project Type: Engineering Project Title: USE OF COLD FORMED STEEL IN RESIDENTIAL HOUSING Principal Investigator: EGYPT: Dr Metwally Abu-Hamd, Cairo University USA: Dr Benjamin Schafer, Johns Hopkins University Affiliation: EGYPT: Professor of Steel Structures, Faculty of Engineering, Cairo University. USA: Chairman, Civil Engineering Dept., Johns Hopkins University Project Start Date: October 16, 2011 Project End Date: October 15, 2013 Project Duration: Two years Reporting period: From: January 16, 2011 To: October 15, 2012 Date of submission: October 15, 2012 Signature of Principal Investigators: Egypt P.I. U.S. P.I. Prof Dr Metwally Abu-Hamd Prof Dr Ben Schaffer

Progress Report No - Department of Civil Engineering progress...2.5 Environmental impact and sustainability assessment (covered in this report) 2.6 Sensitivity analysis (scheduled

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  • Progress Report No 2

    Progress Report No. 2

    Project ID: 3751 Project Type: Engineering Project Title: USE OF COLD FORMED STEEL IN RESIDENTIAL HOUSING Principal Investigator: EGYPT: Dr Metwally Abu-Hamd, Cairo University

    USA: Dr Benjamin Schafer, Johns Hopkins University

    Affiliation: EGYPT: Professor of Steel Structures, Faculty of Engineering,

    Cairo University.

    USA: Chairman, Civil Engineering Dept., Johns Hopkins University

    Project Start Date: October 16, 2011

    Project End Date: October 15, 2013

    Project Duration: Two years

    Reporting period: From: January 16, 2011

    To: October 15, 2012

    Date of submission: October 15, 2012

    Signature of Principal Investigators:

    Egypt P.I. U.S. P.I.

    Prof Dr Metwally Abu-Hamd Prof Dr Ben Schaffer

  • Progress Report No 2

    1. Objectives of the reporting period, as given in the submitted grant application: Research Activity No.2: Building Archetypes Study A building archetype study has been executed considering the following key steps: (Numbers refer to Gantt chart in original proposal):

    2.1 Selection of rural and urban locations for archetype homes (Already covered in first progress report)

    2.2 Design and cost analysis of traditional concrete framing in Egypt (covered in this report)

    2.3 Design and cost analysis of conventional cold formed steel framing (covered in this report)

    2.4 Design and cost analysis of dual system cold formed steel framing (scheduled to be covered in next reports)

    2.5 Environmental impact and sustainability assessment (covered in this report)

    2.6 Sensitivity analysis (scheduled to be covered in next reports) 2. Former achievements through this contract: Item no. 2.1 of the building archetype study, i.e., selection of archetype homes, has been covered in the first progress report covering the first three months period from

    16/10/2011 to 15/1/2012. Based on the findings of that report, four archetypes were

    selected from the National Housing project models to represent Egyptian archetypes.

    These models are characterized by small flat areas typically used for affordable

    housing provided by the government to help low and medium income citizens. Two

    more archetypes with bigger flat areas were added to the original selections to include

    archetypes used by higher income citizens. Accordingly, the following archetype

    design matrix has been developed:

  • Progress Report No 2

    No. RC

    Design Steel Design System

    Skeletal Load

    Bearing Novel 1 63 m2 Model I 1.1 1.2 1.3 1.3 6 Floors @ 4 flatsx63 m2

    2 63 m2 Model II 2.1 2.2 2.3 2.3 6 Floors @ 6 flatsx63 m2

    3 80 m2 Model 3.1 3.2 3.3 3.3 6 Floors @ 4 flatsx80 m2

    4 100 m2 Model 3.1 3.2 3.3 3.3

    Five Floors @ 4 flatsx100 m2

    Gantt Chart Execution Period M3-M6

    M6-M12 M6-M12 M13-M18

    Additional Models to Substitute US Wood Models:

    No. RC Design

    Steel Design System

    Skeletal Load

    Bearing Novel 5 80 m2 Model 5.1 5.2 5.3 5.3 6 Floors @ 4 flatsx63 m2

    6 100 m2 Model 6.1 6.2 6.3 6.3 6 Floors @ 6 flatsx63 m2

    Gantt Chart Execution Period M3-M6

    M6-M12 M6-M12 M13-M18

  • Progress Report No 2

    3. Technical/Scientific Accomplishment/Activities

    a) Task no. 2.2 Task Title: Design and cost analysis of traditional concrete framing in Egypt

    Duration: Three Month (M4 to M6)

    Objective(s): Design and cost analysis of selected building archetypes using

    conventional reinforced concrete framing based on Egyptian Design Specifications for

    loads and design

    Narrative Description of actual accomplishments:

    i) Design of traditional concrete framing:

    The following reinforced concrete home archetypes have been designed:

    1- Model 1 comprising a six-story building having four 63 m2 flats in each story.

    2- Model 2 comprising a six-story building having six 63 m2 flats in each story.

    3- Model 3 comprising a six story building having six 42 m2 flats in each story.

    4- Model 4 comprising a three-story family home with a floor area of 76 m2.

    All models were assumed to have a conventional skeletal reinforced concrete

    construction comprising a 10 cm RC floor slab supported on RC beams and columns.

    Exterior and interior walls are made of bricks.

    The design was performed using the following Egyptian Codes:

    1- Egyptian code of practice for calculation of loads and forces on structures

    2011.

    2- Egyptian code of practice for the LRFD Design of Reinforced Concrete

    Structures 202 2008.

    Detailed design calculations of these four buildings are given in Appendix A1.

    Based on these design calculations, the following concrete and reinforcing steel

    quantities have been determined:

  • Progress Report No 2

    Model 1: (63 m2-4 flats)

    Floor Area =

    280.53 m2

    No. of floors 6 Quantity (m3)

    Reinfor. Steel (ton)

    m3 Conc./m2

    kg steel/ m2

    steel/conc (kg/m3)

    Plain Concrete Footing 147.39 ------ 0.09

    R. Concrete Footings 112.68 6.00 0.07 3.57 53.26

    Columns /story 12.33 3.01 0.04 10.73 244.34 Slab & Beams/

    story 43.77 3.93 0.16 14.01 89.79

    Total 449.25 12.94 0.27 28.31

    Model 2: 63 m2-6 flats

    Floor Area = 400 m2

    No. of floors 6 (m3 ) concrete

    Reinfor. Steel (ton)

    m3 Conc./m2

    kg steel/ m2

    Steel/conc (kg/m3)

    Plain Concrete Footing 180.51 ------ 0.07

    R. Concrete Footings 248.97 13.97 0.10 5.36 56.10

    Columns /story 20.15 4.99 0.05 11.49 247.52 Slab & Beams/

    story 68.01 6.14 0.16 14.15 90.26

    Total 777.92 80.72 0.30 31.00

  • Progress Report No 2

    Model 3: 42 m2-4 flats

    Floor Area 197.50 m2

    No. of floors 6 Concrete m3

    Reinfor. Steel (ton)

    m3 Conc./

    m2

    kg steel/ m2

    steel/ conc

    (kg/m3) Plain Concrete

    Footing 153.68 ------ 0.13

    R. Concrete Footings 113.05 6.93 0.10 5.85 61.29

    Columns /story 11.69 2.44 0.06 12.38 209.20 Slab & Beams/

    story 36.93 3.05 0.19 15.42 82.48

    Total 404.76 39.87 0.34 33.65

    Model 4: EBNI BETAK Model: 76 m2 / 3 floors

    Floor Area = 76.09 m2

    No. of floors 3 Concrete

    Reinfor. Steel (ton)

    m3 Conc./

    m2

    kg steel/ m2

    Steel/ conc

    (kg/m3) Plain Concrete

    Footing 12.05 ------ 0.05

    R. Concrete Footings 15.43 1.59 0.07 6.97 103.05

    Columns /story 3.80 0.95 0.05 12.50 250.26 Slab & Beams/

    story 13.21 1.62 0.17 21.24 122.32

    Total 66.47 9.29 0.29 40.71

    The a.m. quantities shall be used next in research activity no. 2.5 to compare

    conventional RC construction against proposed cold formed steel construction from

    the view points of environmental impact and sustainability assessment.

  • Progress Report No 2

    ii) Cost Analysis of traditional concrete framing:

    1- Cost Break of Concrete Construction:

  • Progress Report No 2

    2- Cost Break Down of Concrete Production:

    Cost Calculations: 1.Batch plant

    1.1. Fixed Costs

    1.1.1.Renting Cost a. Renting cost= 450,000LE/year

    b. Total renting cost in the 2 years = 450,000*2= 900,000 LE

    1.1.2. Initial Cost c. Transportation Cost= 22,000LE

    d. Erection Cost= 70,000LE

    1.1.3. Dismantling Cost = 30,000LE

    Total fixed cost= 900,000+22,000+70,000+30,000= 1022000 LE

    Cost per m3= 1022000/85560= 12 LE/m3

    1.2. Variable Costs

    1.2.1 Labours

    Batch Plant Operators cost= 20LE/hr

    Batch plant produces 30m3/hr

    Operator cost= 20/30= 0.667 LE/m3

    1.2.2 Carpentry crew Productivity of a carpentry crew in columns= 2m3/d

    Cost= 130LE/day = 70LE/m3

    Productivity of carpentry crew in slabs= 1.3m3/d

    Cost = 130LE/day = 100LE/m3

    Productivity of carpentry crew in raft foundation= 2m3/d

    Cost= 70LE/m3

  • Progress Report No 2

    1.2.3 Steel fixing Crew Productivity in columns= 3m3/d

    Cost= 150LE/d = 50LE/m3

    Productivity is slabs= 2.5m3/d

    Cost= 60LE/m3

    Productivity in raft foundation= 3m3/d

    Cost= 50LE/m3

    2. Materials Cost

    2.1. For Reinforced concrete

    Aggregate: 69 LE/m3

    Sand: 30 LE/m3 Cement: number of bags needed in one m3 of concrete is 8 bags. The

    cost of one bag is 26.65 LE. The total cost of cement is 26.65*8=

    213.2 LE/m3

    Admixtures: 8 LE/m3

    Steel Reinforcement cost = 4525 LE/ton

    1 m3 of concrete requires about 90 to 110 KG of steel reinforcement

    (Average of 100KG)

    Cost of steel reinforcement= 452.5 LE/m3

    Total cost of 1 m3= 69+30+213.2+8+452.5=772.7 LE/m3

    Thus the total cost of the 85,560m3 of Concrete= 772.7*82505=63,751,613.5 LE

    Average cost for formwork =18LE/m3 (columns and walls)

    Average cost for formwork = 22LE/m3 (slabs)

    2.2 For plain concrete

    Aggregate: 69 LE/m3

    Sand: 30 LE/m3

    Cement: number of bags needed in one m3 of concrete is 5 bags. The cost

    of one bag is 26.65 LE. The total cost of cement is 26.65*5= 133.25 LE/m3

    Admixtures: 7LE/m3

  • Progress Report No 2

    Form work: 10LE/m3

    Total cost of 1 m3= 69+30+133.25+7+10= 249.25 LE/m3

    Thus the total cost of the 85,560m3 of Concrete= 249.25*3055=761,458.75 LE

    3. Equipment Truck mixer cost= 25 LE/hr (Capacity of 10m3)

    Truck mixer cost= 2.5LE/m3

    Pump Cost= 60 LE/hr

    In columns and cores the pump would pour 12 m3/hr,

    Where in beams and slabs it would pour about 22 m3/hr

    Therefore for its cost on slabs= 60/22= 2.73 LE/m3,

    And cost on columns and cores = 60/12= 5 LE/m3

    Tower crane rental cost is about 800 LE/day

    Cost per m3= 30 LE/m3

    Vibrator Purchase cost = 1700 LE

    Required 2 vibrators for the whole project

    Cost of vibrators= (2*1700)/85650) = 0.04 LE/hr

    Total Cost for Plain Concrete=12+ 249.25+70+2.5+2.73+0.04+0.667= 337.2 LE/m3

    Total Cost for Reinforced concrete for raft foundation= 12+772.7

    +20+70+50+2.5+2.73+0.04+0.667+30= 960.637 LE/m3

    Total Cost for Reinforced concrete for columns & Cores= 12+772.7

    +18+70+50+2.5+5+0.04+0.667+30=960.907LE/m3

    Total Cost for Reinforced concrete for Slabs=

    12+772.7+23+70+50+2.5+2.73+0.04+0.667+30= 963.637 LE/m3

    Assuming Site overheads, General overheads& Contingencies are about 25% Total Cost for Plain Concrete= 337.2 LE/m3 * 1.25= 421.5 LE/m3 Total Cost for Reinforced concrete for raft foundation= 960.637 LE/m3* 1.25= 1200.79625 LE/m3 Total Cost for Reinforced concrete for columns & Cores= 960.907LE/m3* 1.25=

    1201.13375 LE/m3 Total Cost for Reinforced concrete for Slabs= 963.637 LE/m3* 1.25= 1204.54625 LE/m3

  • Progress Report No 2

    b) Task no. 2.3 Task Title: Design and cost analysis of conventional cold formed steel framing Duration: Six Month (M6 to M12)

    Objectives: Design and cost analysis of selected building archetypes using

    conventional cold formed steel framing.

    Narrative Description of Actual Accomplishments:

    i) Design of conventional cold formed framing:

    In this Task, the structural design of the selected home archetypes using conventional

    cold formed steel construction was performed. The following design assumptions

    were used:

    1- Glass fiber reinforced concrete (GRC) panels are used for floors and walls.

    These panels, in addition to having considerably lighter weights, are pre-cast in

    the factory and transported to site ready for fast erection.

    2- Two structural systems have been used: one using skeletal framing solution

    and the second using wall bearing framing solution.

    3- The design was performed using the International accepted American Iron and

    Steel Institute (AISI) code for cold formed steel design. This code was used

    instead of the not so highly developed Egyptian code.

    Detailed sample design calculations of the structural analysis and design are given in

    Appendix A2 for the skeletal system (for Models 63x3 and 80 m2) and in Appendix A3

    for the wall bearing system (for models 63x4, 63x6, and 80 m2). Based on these

    calculations the following quantities have been calculated:

  • Progress Report No 2

    I) Results for Skeletal Systems:

    1- Model 63x4 with Floor Area = 280 m2

    Item Quantity Steel Wt. / m2 %

    Plain Concrete Footing (m3) 40 ----

    Reinforced. Concrete (m3) 40 ----

    Floor Beams (ton) 27.773 16.53

    Columns (ton) 18.032 10.733

    Bracings (ton) 2.158 1.285

    Misc.(10 %) (ton) 4.796 2.855

    Total Steel Wt. 52.759 31.40

    2- Model 63x6 with Floor Area = 400 m2

    Item Quantity Steel Wt. / m2 %

    Plain Concrete Footing (m3) 58

    Reinforced. Concrete (m3) 55

    Floor Beams (ton) 41 17.08

    Columns (ton) 24 10

    Bracings (ton) 3 1.25

    Misc.(10 %) (ton) 6.8 2.83

    Total Steel Wt. 74.8 31.16

  • Progress Report No 2

    3- Model 80x4 with Floor Area = 365 m2

    Item Quantity Steel Wt. / m2 %

    Plain Concrete Footing (m3) 52

    Reinforced. Concrete (m3) 53

    Floor Beams (ton) 35.893 16.389

    Columns (ton) 27.731 12.662

    Bracings (ton) 2.582 1.18

    Misc.(10 %) (ton) 6.62 3.023

    Total Steel Wt. 72.826 33.253

    4- Model 100x4 with Floor Area = 460 m2

    Item Quantity Steel Wt. kg/ m2 %

    Plain Concrete Footing (m3) 65

    Reinforced. Concrete (m3) 66

    Floor Beams (ton) 45.520 16.142

    Columns (ton) 34.096 12.091

    Bracings (ton) 2.924 1.037

    Misc.(10 %) (ton) 8.254 2.927

    Total Steel Wt. 90.794 32.20

  • Progress Report No 2

    II) Results for Wall Bearing Systems:

    1- Model 63x4 with Floor Area = 280 m2

    Item Quantity (ton)

    Steel Wt. / m2 %

    Plain Concrete Footing (m3) 40 ----

    Reinforced. Concrete (m3) 40 ----

    Floor Beams (ton) 12.915 7.688

    Studs (ton) 13.26 7.893

    Bracings (ton) 14.43 8.589

    Misc.(10 %) (ton) 4.06 2.417

    Total Steel Wt. 44.667 26.587

    2- Model 63x6 with Floor Area = 400 m2

    Item Quantity (ton)

    Steel Wt. / m2 %

    Plain Concrete Footing (m3) 60

    Reinforced. Concrete (m3) 60

    Floor Beams (ton) 20.685 8.618

    Columns (ton) 17.64 7.35

    Bracings (ton) 16.275 6.781

    Misc.(10 %) (ton) 5.46 2.275

    Total Steel Wt. 60.06 25.025

  • Progress Report No 2

    3- Model 80x4 with Floor Area = 365 m2

    Item Quantity (ton)

    Steel Wt. / m2 %

    Plain Concrete Footing (m3) 55

    Reinforced. Concrete (m3) 55

    Floor Beams (ton) 17.783 8.12

    Columns (ton) 16.545 7.555

    Bracings (ton) 18.289 8.35

    Misc.(10 %) (ton) 5.261 3.023

    Total Steel Wt. 57.876 26.427

    The a.m. quantities shall be used next in research activity no. 2.5 to compare

    conventional RC construction against proposed cold formed steel construction from

    the view points of environmental impact and sustainability assessment.

    III) Cost Analysis of Conventional Cold Formed Framing:

    Unlike reinforced concrete construction, there are very few producers of cold formed

    steel sections in Egypt. Therefore the production cost was not calculated similar to

    concrete but rather taken from the producers as follows:

    1- Material Cost of un-galvanized steel = 5000 LE /ton

    2- Material Cost of painted steel = 6000 LE /ton

    3- Material Cost of galvanized steel = 7000 LE/ton

    The cost of transportation, fabrication and erection is estimated at 1000 LE/ton.

    An additional 15 % is added to cover contractor's profit. Accordingly the final cost is

    calculated as follows:

    1- Final Cost of un-galvanized steel = 6900 LE /ton

    2- Final Cost of painted steel = 8050 LE /ton

    3- Final Cost of galvanized steel = 9200 LE/ton

  • Progress Report No 2

    c) Task no. 2.5 Task Title: Environmental impact and sustainability assessment. Duration: Six Month (M6 to M12)

    Objectives: Existing sustainability tools will be utilized to assess the environmental

    impact of various home archetypes.

    Narrative Description of actual accomplishments:

    5.2.1 Sustainability

    Figure 2.5.1: The Three Pillars of Sustainability

    Environmental, economic, and social concerns are often described as the triple bottom line of sustainability and sustainable development (Figure 2.5.1). Any attempt toward true improvement in sustainability must consider all three pillars, not just one or two. The term sustainable development can be described as enhancing quality of life and thus allowing people to live in a healthy environment and improve social, economic and environmental conditions for present and future generations. Since the world commission on environment and development (WCED), entitled Our Common Future (1987), sustainable development has gained much attention in all nations and a report was published which called for a strategy that united development and the environment and which also made a declaration describing sustainable development as meeting the needs of the present without compromising the ability of future generations to meet their own needs. Improving social, economic and environmental indicators of sustainable development are drawing attention to the construction industry. In order to overcome the increasing

  • Progress Report No 2

    concern of todays resource depletion and to address environmental considerations in both developed and developing countries, life cycle assessment (LCA) can be applied to decision making in order to improve sustainability in the construction industry. Life cycle assessment is a valuable tool through which designers, policy-makers, and consumers can understand how to lower the environmental impact of any structure. LCA deals mainly with the environmental aspect of a products impact, and it is difficult or impossible to incorporate economic and social concerns in most cases. While cost can sometimes be quantified in impact assessment, it is not normally part of a life cycle inventory. Social issues are extremely broad and usually too qualitative to put in an LCA model; only those factors that can be quantified, such as a carcinogenic emissions impact on human cancer rates, can be considered in impact assessment. Therefore, LCA presents only a partial picture of how a product may impact sustainability concerns from a truly holistic viewpoint. An environmental assessment of the performance of a building, a roadway, or any other object properly spans the entire life cycle. Limiting such an assessment to one phase of the life cycle can lead to conclusions and actions that are poorly informed. Products and services have impacts throughout their life, beginning with raw materials extraction and product manufacturing, continuing through construction, operation and maintenance, and finally ending with a waste management strategy. Conventional environmental assessments often overlook one or more of these phases, leading to incomplete results and inadequate conclusions. Life cycle assessment (LCA) can be used to evaluate all phases of the life cycle, providing a comprehensive analysis of the environmental burden of building construction and operation. An LCA presents an accurate estimate of the quantities and timing of environmental impacts. It therefore provides a solid basis for identifying the benefits of changes in the construction of a building or its operation. The assessment of alternatives can yield a direction (more or less usage of a specific material or system) and order-of-magnitude estimate of the impact of a given change. Such assessments can form an unbiased comparison of alternative design strategies, and directional ideas for environmental improvements. For buildings, these strategies may include greater use of thermal insulation or location of concrete in a way that maximizes its heat-storage characteristics. 5.2.2 Life Cycle Assessment of Structures Construction materials constitute a major percentage of the resources humans use today. It is estimated that approximately 75% of all material consumption in the United States consisted of construction materials, and this number does not even include industrial minerals such as the cement that goes into concrete (Figure 3). Despite the fact that material consumption has grown much faster in the rest of the world than in the United States, the US still consumed approximately one- third of the worlds materials in 1995, or 2.8 billion metric tons. That corresponds to at least 2.1 billion metric tons of construction materials in the US alone, and only 8% of these materials were considered renewable. The World watch Institute estimates that world building

  • Progress Report No 2

    construction is responsible for 40% of the stone, sand, and gravel, 40% of the energy, and 16% of the water used globally. Buildings consume half of the European Unions the total energy and emit half its annual carbon dioxide production throughout their life cycles. Although steel is a largely recyclable resource, it comes with high energy requirements. Construction materials such as concrete are more difficult to recycle, and as essentially nonrenewable resources they contribute more to total material consumption.

    Figure 2.5.2: Raw materials consumed in the United States The construction and maintenance of buildings is responsible for the majority of materials consumption in the United States. The operation of buildings is currently responsible for about 40% of national annual energy usage and about 70% of national electricity consumption (EIA 2003). In recent years, environmental concerns have come to the fore. The exponential growth of the U.S. Green Building Council over the last decade symbolizes the growing concern to reduce the environmental impacts of buildings. The steady increase of CO2 levels in the atmosphere due to anthropogenic activity and increasing consensus among scientists of the likely relation of human emissions to changes in climate has led to consideration and implementation of policies to reduce consumption of fossil fuels and associated emission of greenhouse gases. In the U.S., experts in the government, industry and academia recognize that improved performance of buildings is financially attractive when compared with increased use of renewable, low-carbon energy sources.

  • Progress Report No 2

    Because of numerous innovations reducing energy use during the operational phase of a building, the embodied energy due to a buildings materials and construction is becoming a larger percentage of a buildings total energy over its lifetime. Therefore, it is essential to investigate the embodied energy of structures and determine ways to reduce this energy in the same way operational energy has already been reduced. This could be accomplished by changing the structural system of the building to use different or fewer construction materials. Life cycle assessment is an essential tool to help civil and structural engineers understand how they can contribute to lowering the embodied energy of any structure. The potential for paradigm shifts in structural design due to the lessons learned from LCA could be significant. 5.2.2. Conceptual basis of life cycle assessment Life cycle assessment (LCA) is a methodology for evaluating the environmental impact of processes and products (goods and services) during their life cycle from cradle to grave. LCA has been used in the building sector since 1990 and is an important tool for assessing buildings. The description of the LCA methodology is based on the International standards of series ISO 14040 and consists of four distinct analytical steps: defining the goal and scope, creating the inventory, assessing the impact and finally interpreting the results.

    Figure 2.5.3: Stages of Life Cycle Assessment (ISO 2006a)

    The LCA approach to quantifying environmental impact is formalized by the International Organization for Standardization (ISO) 14040 series. Notable documents in this series are ISO 14040:2006 Principles and Framework and ISO 14044:2006 Requirements and Guidelines (ISO 2006a; ISO 2006b), which together outline fundamental concepts relevant to developing and conducting an LCA study. The ISO standards break the LCA framework into four stages: goal and scope definition, inventory analysis, impact assessment and interpretation.

  • Progress Report No 2

    Figure 2.5.3 depicts these stages, their relationship and potential applications. As described by ISO, the stages include the following activities: 1. Goal and scope definition describes the plan for conducting an LCA. The goal defines the intended application, the reasons for conducting a study, the intended audience, and the dissemination of the final product. The scope provides the approach to meet the stated goals, including defining the functional unit(s), system boundaries, impact assessment methodology, and other relevant parameters. 2. Inventory analysis describes and quantifies the inputs and outputs of each process that falls within the scope. This is the key organizational step in the LCA process, where the data and process relationships are established. Within the inventory analysis, the life cycle is broken down into phases (e.g., pre-use, use, end-of-life), which are further organized into processes (e.g., materials flows, transportation distances). On the lowest level, these processes contain data on inputs (i.e., material and energy consumption) and outputs (i.e., products, emissions and wastes). The life cycle inventory then sums up all inputs and all outputs that cross the defined system boundary. In an ideal case, the inventory contains only elementary flows (flows taken from or released into the environment without further transformation) such as resources, emissions or waste energy. Inventory analysis results can then be summed over all processes to determine the total emissions over the life cycle. 3. Impact assessment uses impact categories to quantify the environmental damages based on the inventory data. For instance, the impact category global warming potential characterizes carbon dioxide, methane, nitrous oxide and other greenhouse gases through their warming potential, commonly expressed in carbon dioxide equivalents, or CO2e. 4. Interpretation synthesizes the results from the inventory analysis and/or impact assessment stages in order to draw defensible conclusions. This stage allows the LCA practitioner to make recommendations to decision-makers in the context of assessment uncertainties and assumptions. 5.2.3 LCA Tools Various LCA tools have been developed and made available for use in environmental assessment. These tools have been classified according to three levels. Level 3 is called Whole building assessment framework or systems and consists of methodologies such as BREEAM (UK), LEED (USA), SEDA (Aus); level 2 is titled Whole building design decision or decision support tools and uses LISA (Aus), Ecoquantum (NL), Envest (UK), ATHENA (Canada), BEE (FIN); finally level 1 is for product comparison tools and includes Gabi (GER), SimaPro (NL), TEAM (Fra) LCAiT (SE). Some databases used for environmental evaluation are: CML, DEAM TM, Ecoinvent Data, GaBi 4 Professional, IO-database for Denmark 1999, Simapro database, the Boustead Model 5.0 and US Life cycle inventory database. It is observed that previous tools and databases vary according to users, application, data, geographical location and scope. The data represents conditions in industrialized countries. Data from developing and emerging countries, however, is still lacking. For

  • Progress Report No 2

    example the use of European and American database may not lead to correct decisions in developing countries. 5.2.4 Athena Impact Estimator a) Description of Software

    The Athena Impact Estimator is a whole building, life cycle based environmental assessment tool that lets building designers, product specifiers and policy analysts compare the relative environmental effects or trade-offs across alternative building design solutions at the conceptual design stage. Some of the Impact Estimators specific features include:

    the ability to model the buildings complete structure and envelope (claddings, insulation, gypsum wall board, and roofing and window systems over 1200 possible assembly combinations) over the expected life of a building; the ability to model maintenance and replacement life cycle effects based on building type, location and a user defined expected life for the building; a regionally sensitive calculator to convert operating energy to primary energy and emissions to allow users to compare embodied and operating energy environmental effects over the buildings life (requires a separate estimate of operating energy as an input);

    an "end-of-life" module, which simulates demolition energy and final disposition of the materials incorporated in a building; a context sensitive help facility in place of a users manual; and, the capability to model both Canadian and US regional locations.

    Impact Estimator results are presented in various ways and levels of detail to meet the needs of different types of users. A researcher wanting detail can see the results by specific energy forms or waste substances, by life cycle stage and by assembly type. An architect may only be interested in tabular or graphical displays of summary measures or characterizations by building assembly and for the total design. The Impact Estimator also allows the user to make direct comparisons among alternative designs on an absolute basis, on a per unit area basis or on a relative basis where one design is selected as the baseline project. In North America, the Athena Impact Estimator for Buildings is the only software tool that evaluates whole buildings and assemblies based on internationally recognized life cycle assessment (LCA) methodology. Using the Estimator, architects, engineers and others can easily assess and compare the environmental implications of industrial, institutional, commercial and residential designsboth for new buildings and major renovations. Where relevant, the software also distinguishes between owneroccupied and rental facilities. The Estimator puts the environment on equal footing with other more traditional design criteria at the conceptual stage of a project. It incorporates Athenas own widely

  • Progress Report No 2

    acclaimed building material life cycle inventory databases as well as those contained in the US LCI database (www.nrel.gov/lci). It is capable of simulating over 1,200 different assembly combinations and is applicable to 95% of the building stock in North America. With the addition of Los Angeles and Seattle in version 4.1, seismic effects have been added to the structural calculations for projects in Los Angeles, Seattle and Vancouver. The Estimator takes into account the environmental impacts of:

    Material manufacturing, including resource extraction and recycled content Related transportation On-site construction Regional variation in energy use, transportation and other factors Building type and assumed lifespan Maintenance, repair and replacement effects Demolition and end-of-life disposition Operating energy emissions and pre-combustion effects

    Although the Estimator doesnt include an operating energy simulation capability, it does allow users to enter the results of a simulation in order to compute the fuel cycle burdens and factor them into the overall results. Although LCA is a complex process, the Estimator has been designed for ease of use. The first step is to enter required information such as geographic location (the system allows users to select from specific Canadian and US regions as well as a US national average), expected building life and occupancy type, and, if desired, optional information such as annual operating energy by fuel type. b) Software Input/Output:

    Preset dialog boxes prompt users to describe the different assembliesby requesting the geometry, live load of a floor assembly and envelope attributes, for examplethat together form a conceptual building design. The Estimator then instantly provides cradletograve implications in terms of: Absolute Values:

    Energy total and primary energy consumed Air Emissions Water Emissions Land Emissions Ecologically Weighted Resource Use

    http://www.nrel.gov/lci

  • Progress Report No 2

    or Summary Measures:

    Fossil Fuel Consumption Acidification Potential Global Warming Potential Human Health Criteria Ozone Depletion Potential Smog Potential Eutrophication Potential

    Detailed LCA Results: Results from an individual design can be seen in summary tables and graphs by assembly group and life cycle stage. Detailed tables and graphs show individual energy use by type or form of energy and emissions by individual substance for both the assembly group and life cycle stage breakouts.

    Make Flexible Comparison of Alternate Building Designs: Accommodating up to five comparisons at once, the Estimator allows users to change the design, substitute materials, and make sidebyside comparisons for any one or all of the environmental impact indicators. Or compare the new building design to one you did last year. You can also compare similar projects with different floor areas on a unit floor area basis. The Estimator can perform as many as five project comparisons at a time.

    Interpreting Impact Estimator Results: As output, the Impact Estimator produces a detailed life cycle inventory for an entered design. It also generates a set of summary impact indicators in graphical and tabular form based on US EPAs Tool for the Reduction and Assessment of Chemical and Other Environmental Impacts (the US Environmental Protection Agencys TRACI - Tool for the Reduction and Assessment of Chemical and other environmental Impacts) life cycle impact indicator methodology (2007 version).

    c) Environmental Impact:

    The Athena Impact Estimator software calculates the environmental impact based on the following environmental measures:

    1. global warming potential 2. acidification potential 3. ozone depletion 4. smog 5. fossil fuel consumption 6. aquatic eutrophication potential 7. human health criteria air-mobile 8. total primary energy

  • Progress Report No 2

    These eight environmental measures are described briefly as follows:

    1- Global Warming Potential (GWP) Global warming potential is a reference measure. The methodology and science behind the GWP calculation can be considered one of the most accepted LCIA categories. GWP will be expressed on an equivalency basis relative to CO2 in kg or tonnes CO2 equivalent. Carbon dioxide is the common reference standard for global warming or greenhouse gas effects. All other greenhouse gases are referred to as having a "CO2 equivalence effect" which is simply a multiple of the greenhouse potential (heat trapping capability) of carbon dioxide. This effect has a time horizon due to the atmospheric reactivity or stability of the various contributing gases over time. As yet, no consensus has been reached among policy makers about the most appropriate time horizon for greenhouse gas calculations. The International Panel on Climate Change100-year time horizon figures have been used here as a basis for the equivalence index: CO2 Equivalent kg = CO2 kg + (CH4 kg x 23) + (N2O kg x 300) While greenhouse gas emissions are largely a function of energy combustion, some products also emit greenhouse gases during the processing of raw materials. Process emissions often go unaccounted for due to the complexity associated with modelling manufacturing process stages. One example where process CO2 emissions are significant is in the production of cement (calcination of limestone). Because the Impact Estimator uses data developed by a detailed life cycle modelling approach, all relevant process emissions of greenhouse gases are included in the resultant global warming potential index.

    2- Acidification Potential (AP) Acidification is a more regional rather than global impact effecting human health when high concentrations of NOx and SO2 are attained. The AP of an air or water emission is calculated on the basis of its H+ equivalence effect on a mass basis.

    3- Ozone Depletion Potential (ODP) Stratospheric ozone depletion potential accounts for impacts related to the reduction of the protective ozone layer within the stratosphere caused by emissions of ozone depleting substances (CFCs, HFCs, and halons). The ozone depletion potential of each of the contributing substances is characterized relative to CFC-11, with the final impact indicator indicating mass (e.g., kg) of equivalent CFC-11.

    4- Photochemical Ozone Formation Potential (Smog) Under certain climatic conditions, air emissions from industry and transportation can be trapped at ground level where, in the presence of sunlight, they produce photochemical smog, a symptom of photochemical ozone creation potential (POCP). While ozone is not emitted directly, it is a product of interactions of volatile organic compounds (VOCs) and nitrogen oxides (NOx). The smog indicator is expressed on a mass of equivalent O3 basis.

  • Progress Report No 2

    5- Fossil Fuel Consumption Fossil Fuel Consumption is reported in mega-joules (MJ). Embodied Fossil Fuel Consumption includes all energy, direct and indirect, used to transform or transport raw materials into products and buildings, including inherent energy contained in raw or feedstock materials that are also used as common energy sources. (For example, natural gas used as a raw material in the production of various plastic (polymer) resins.) In addition, the Impact Estimator captures the indirect energy use associated with processing, transporting, converting and delivering fuel and energy plus the operating energy.

    6- Aquatic Eutrophication Potential Eutrophication is the fertilization of surface waters by nutrients that were previously scarce. When a previously scarce or limiting nutrient is added to a water body it leads to the proliferation of aquatic photosynthetic plant life. This may lead to a chain of further consequences ranging from foul odours to the death of fish. The calculated result is expressed on an equivalent mass of nitrogen (N) basis.

    7- Human Health (HH) Criteria Air-Mobile Particulate matter of various sizes (PM10 and PM2.5) have a considerable impact on human health. The EPA has identified "particulates" (from diesel fuel combustion) as the number one cause of human health deterioration due to its impact on the human respiratory system asthma, bronchitis, acute pulmonary disease, etc. It should be mentioned that particulates are an important environmental output of plywood product production and need to be traced and addressed. The Institute used TRACIs "Human Health Particulates from Mobile Sources" characterization factor, on an equivalent PM10 basis, in our final set of impact indicators.

    8- Total Primary Energy Consumption Although not presented in the summary measure table, Total Primary Energy Consumption is reported in mega-joules (MJ) at the bottom of the Energy Consumption absolute value table. Embodied primary energy includes all energy, direct and indirect, used to transform or transport raw materials into products and buildings, including inherent energy contained in raw or feedstock materials that are also used as common energy sources. (For example, natural gas used as a raw material in the production of various plastic (polymer) resins.) In addition, the Impact Estimator captures the indirect energy use associated with processing, transporting, converting and delivering fuel and energy and energy plus the operating energy. 5.2.5 Application to the Present Project In order to assess the environmental impact of the cold formed steel systems proposed in this project, a life cycle assessment has been performed using the Athena Impact estimator to:

    1- Calculate the environmental measures of different designs. 2- Compare the environmental impact of traditional concrete construction and

    proposed cold formed steel construction.

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    The LCA methodology used in this study is as follows: i- Goal This study compares different construction systems for a range of building types in order to benchmark cold formed steel residential building systems in relation to other traditional concrete building systems. ii- Scope The reference flow of this LCA is one buildings structure and shell over a 60-year lifetime, which is a conventional analysis period of building LCAs. The functional unit is the useable area for each building type. All buildings are finished to the same degree with only the structural systems differing. The system boundary is defined as cradle-to-grave. The life cycle of the buildings is broken into three phases: pre-use, use, and end-of-life (Figure 2.5.4). The pre-use phase is the cradle-to-site portion, from raw material extraction to manufacturing and processing and finally, transportation from the factory to the job site. No specific data could be obtained for the operating energy in Egypt so that this item was not included in the assessment. The end-of-life phase assumes total demolition of the building. The majority of the material is sent to a landfill while steel is recycled. Additionally, half of the demolished concrete is assumed to be recycled into aggregate. The term 'embodied refers to the emissions associated with materials and their disposal throughout the life cycle of the building. The term 'operating refers only to the energy and emissions associated with the operation of the building throughout the use phase.

    Figure 2.5.4 Building LCA system boundary used in this study The bill of material used to calculate the environmental impacts are as follows:

  • Progress Report No 2

    Bill of Materials for Reinforced Concrete Design

    Bill of Materials for Cold Formed Steel Design

    iii- Inventory Analysis

    The inventory analysis already included in the Athena software was used in the

    study.

    iv- Impact Assessment The results of applying Athena Environmental Impact Estimator to the present project

    are shown next. Graphical presentations of the results clearly show that the proposed

    steel construction has considerably less environmental impact than the traditional

    concrete construction.

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    a) Comparison of Environmental Impact Measures by Life Cycle Stages:

    1- Global Warming Potential

    2- Acidification Potential

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    3- Ozone Depletion Potential

    4- Smog Potential

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    5- Fossil Fuel Consumption

    6- Aquatic Eutrophication Potential

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    7- Human Health Criteria Air-Mobile

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    b) Comparison of Environmental Impact Measures by Assembly Groups

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    c) Embodied Energy Consumption Absolute Value Chart By Life Cycle Stages

    Project Concrete Design model 63x4

    Embodied Energy Consumption Absolute Value Chart By Life Cycle Stages

    Project Cold Formed Steel Deign model 63x4

  • Progress Report No 2

  • Progress Report No 2

    3.4 Deliverables:

    1- Publications: The work performed in the project so far has resulted in the following publications:

    1- M. Abu-Hamd, Buckling Strength of Axially Loaded Cold Formed Built-Up I-

    Sections, accepted for publication in the 2013 Annual Stability Conference of

    the Structural Stability Research Council.

    2- J. Batista-Abreu, M. Abu-Hamd, L. Vieira, Jr., B.W. Schafer, State-of-the-art

    Review: accepted for presentation in the Fire Performance of Cold-Formed

    Steel, ASCE Structures Congress 2013.

    2- Workshop: In order to raise the level of awareness and increase the body of knowledge of cold

    formed steel construction in the society, we intend to organize a two-day workshop

    on the subject. The speakers in the workshop include members of both teams from

    Egypt and USA, in addition to six experts from the American Iron and Steel Institute

    (AISI). The workshop announcement and proposed program are shown below:

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    Egypt-US Workshop on Use of Light Steel Framing in Residential Buildings

    Cairo University (Egypt), in conjunction with the Johns Hopkins University (USA) is organizing a two-day workshop on the use of light steel framing in residential buildings. The workshop aims at creating awareness and spreading knowledge on LSF resources and capabilities in the society. Location: Faculty of Engineering, Cairo University, Egypt Date: December 9,10 / 2012 Format: 1- Key Note Lectures 2- Panel Discussions 3- Industrial Exhibition Speakers:

    1- Ben Schafer, Professor and Chair, Civil Engineering Dept, Johns Hopkins University, USA, Vice Chairman of the Structural Stability Research Council, Active Member in developing design specifications of Cold-Formed Steel Structural Members. Developer of CUFSM software.

    2- Don Allen, Senior Engineer & Marketing at DSi Engineeering, Former Technical Director

    at the Steel Framing Alliance, the Steel Stud Manufacture Association and the Cold Formed Steel Engineers Institute, USA.

    3- George Richards, Principal at Borm Associates, Inc., USA

    4- Maged Hanna, Associate Professor, National Housing and Building Research Center,

    Egypt

    5- Metwally Abu-Hamd, Professor of Steel Structures, Cairo University, Egypt.

    6- Mohammed Badr, Professor of Steel Structures, Housing and Building Research Center, Egypt.

    7- Nabil AbdelRahman, Chairman of the Cold Formed Steel Engineers Institute, Director

    of Engineering at The Steel Network, USA

    8- Nader ElHajj, Director at FrameCad Solutions, Former Director at NAHB Research Center, USA.

    9- Zhanjie Li, Post doctoral fellow, Civil Engineering Dept, Johns Hopkins University, USA

  • Progress Report No 2

    Egypt-US Workshop on

    Use of Light Steel Framing in Residential Buildings Proposed Program

    Day 1:Sunday December 9, 2012 08:30 09:00 Registration 09:00 09:30 Welcome Addresses: 1- President of Cairo University 2- Dean of the Faculty of Engineering 3- Director of STDF Session 1: Application of LSF in Residential Buildings 09:30 10:00 Current Housing Status in Egypt (Metwally) 10:00 11:00 Application of LSF in Residential Building Construction (AISI/IAB) 11:00 11:30 Coffee Break Session 2: Design Resources for LSF Construction 11:30 12:15 Design Codes (Ben) 12:15 13:00 Design Aids and Design Software (Ben/AISI/TSN) 13:00 13:30 Coffee Break Session 3: Design Examples of LSF Residential Buildings 13:30 14:00 Alternative Solutions for floors and walls. (Badr) 14:00 14:30 Design Example A: Wall Bearing Systems (Maged) 14:30 15:00 Design Example B: Skeletal Systems (Metwally) Day 2: Monday December 10, 2012 Session 4: Design Details of LSF Residential Buildings 09:00 09:30 Connections of Cold Formed Members (Ben) 09:30 10:00 Architectural and Services Details (---) 10:00 10:30 Fire Protection (Ben/Ellobody) 10:30 11:00 Acoustic Performance (Maged) 11:00 11:30 Coffee Break Session 5: LSF Construction 11:30 12:00 Sustainability Assessment (Zhanjie) 12:00 12:30 CFS Production Technology (AISI/IAB) 12:30 13:00 LSF Erection Technology (AISI/IAB) 13:00 13:30 Coffee Break Session 6: Implementation of LSF in Egypt 13:30 14:00 Present Capabilities of LSF in Egypt (Alex form/ Energya Steel) 14:00 14:30 Implementation of LSF in Egypt (---) 14:30 15:00 Closing Remarks ____________________________________________________________________________ Faculty of Engineering Cairo University

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    3.5 The Gantt Chart for the reporting period: All the scheduled tasks stated in the Gantt Chart have been executed successfully.

    These tasks are:

    2-1 Selection of rural and urban locations in U.S. and Egypt Done Design and costs analysis of

    2-2 traditional framing (U.S. timber, Egypt concrete) Done 2-3 conventional cold-formed steel framing Done

    2-5 Environmental Impact and Sustainability assessment Done

    A revised version of the Gantt Chart is shown next.

  • Established by the presedential decree number 218 for the year 2007

    Project Title: Use of Cold Formed Steel in Residential HousingProject ID:3751Principle Investigator: Dr Metwally Abu-Hamd (Cairo University, Egypt) & Dr Benjamin Schafer (Johns Hopkins University, USA)Start Date16/10/2011 Activity primarily in the U.S. (JHU)Expected E Two Years Activity primarily in Egypt (Cairo)

    Tasks/ Activities Start End Dur

    atio

    n (D

    ays)

    % C

    ompl

    eted

    Wor

    king

    Day

    s

    Day

    s Com

    plet

    e

    Rem

    aini

    ng D

    ays

    16/10/2012

    1 Research Activity 1: Development of a novel non-proprietary cold-formed steel framing system

    1.1 1-1 Develop Library of Optimal Shapes M1 M12 225+1351.2 1-2 Develop 'dual' system for walls and floors M4 M24 360+2701.3 1-3 Develop home archetype M4 M6 90 Done1.4 1-4 Develop full framing solution for archetype home M10 M18 2701.5 1-5 Demonstrate flexibility of 'dual' framing system M19 M23 1351.6 1-6 Price estimates for building archetypes study M10 M15 1802 Research Activity 2: Building Archetypes Study2.1 2-1 Selection of rural and urban locations in U.S. and Egypt M1 M3 90 Done

    Design and costs analysis of2.2 2-2 traditional framing (U.S. timber, Egpyt concrete) M4 M6 90 Done2.3 2-3 conventional cold-formed steel framing M7 M12 180 Done2.4 2-4 novel 'dual' system cold-formed steel framing M13 M18 1802.5 2-5 Environmental Impact and Sustainability assessment M4 M21 360 Done

    2.6 2-6 Sensitivity Analysis M13 M24 360Final Report

    GANTT Chart

    M1

    M2

    M3

    M4

    (FIR

    ST R

    EPO

    RT

    )M

    5M

    6M

    7M

    8M

    9

    M12

    Science and Technology Development

    M10

    M11

    Science and Technology Development Fund

  • Progress Report No 2

    3.6 The Logical Framework Matrix (LFM): The following LFM activities have been performed:

    4.1. Selection of typical design layouts presently used in residential buildings.

    4.2. Identify locally available construction materials and construction methods.

    4.3. Select the structural systems appropriate to each design location.

    4.5. Assess sustainability and environmental impact of developed designs.

    4.6. Perform detailed comparisons among developed building designs.

    4.7. Analyze results to arrive at appropriate recommendations for different designs Accordingly, all the stated performance indicators have been achieved:

    1- Satisfaction of housing needs

    2- Compliance with local building codes and regulations.

    3- Sustainability of structural systems and construction methods to be executed at

    the specified urban/rural location.

    A revised version of the LFM is presented next.

  • Science and Technology Development Fund

    Science and Technology Development Fund Established by the presidential decree number 218 for the year 2007 Annex 3: Logical Framework Matrix Project Title: Use of Cold Formed Steel in Residential Housing Project ID: 3751 Principle Investigator: Prof Dr Metwally Abu-Hamd (Egypt) & Prof Dr Benjamin Schafer (USA) Activity description Performance Indicators Means of Verification Assumptions

    1- Goal (Overall Objective) Increasing residential housing building capacity by using cold formed steel framing.

    Increase of the share of steel framed buildings in newly built homes up to 30% of the total building market.

    1- Analysis of relevant governmental and private sector statistics.

    2- Market survey of building contractors.

    3- Monitoring of building sector activities

    1- Continued market demand for more residential housing.

    2- Newly developed cold formed steel framing systems shall be more affordable to people and financially profitable to building contractors.

    1. People and building contractors have the ability to use the developed building designs once proven beneficial to both.

  • Science and Technology Development Fund

    Activity Description _____________________________

    2- Project Objectives

    2.1. Development of typical steel framing building systems using locally available cross- sections 2.2. Developing new non-

    proprietary steel framed systems using novel-optimized cross-section shapes and new dual system for load bearing and lateral resistance.

    Performance Indicators _____________________________

    1- Newly built houses implement developed systems.

    2- Construction times are reduced considerably.

    3- Building contractors strongly support the developed systems.

    Means of Verification ______________________________

    1- Monitoring of building sector activities.

    2- Market survey of newly built houses.

    3- Questionnaire in building fairs and workshops.

    Assumptions ___________________________ 1- Locally available materials

    and construction methods produce affordable designs in terms of economic, environmental and sustainability aspects.

    2- Society is made aware of the benefits of the developed systems through successful marketing.

  • Science and Technology Development Fund

    Activity Description _____________________________

    3- Outputs (Results) 3.1. Comparative study between

    reinforced concrete houses and developed typical cold formed steel houses in Egypt.

    3.2. Comparative study between

    wood houses and developed typical cold formed steel houses in USA

    3.3. Comparative study between reinforced concrete houses and newly developed cold formed steel houses in Egypt

    3.4. Comparative study between

    wood houses and newly developed cold formed steel houses in the USA.

    3.5. Building a demonstration

    model of one of the developed designs

    Performance Indicators _____________________________ 1- Newly built houses implement

    developed systems. 2- Construction times are reduced

    considerably. 3- Building contractors strongly

    support the developed systems.

    Means of Verification ______________________________

    1- Monitoring of building sector activities.

    2- Market survey of newly built houses.

    3- Questionnaire in building fairs and workshops.

    Assumptions ___________________________ 1- Newly developed cold

    formed steel framing systems shall be more affordable to people and financially profitable to building contractors.

    2. Building of the demonstration model shall be financed totally by private sector building contractors (see annex 6).

  • Science and Technology Development Fund

    Activity Description _____________________________

    4- Activities (*) 4.1. Selection of typical design layouts presently used in residential buildings. 4.2. Identify locally available construction materials and construction methods. 4.3. Select the structural systems appropriate to each design location. 4.4. Perform structural design and cost analysis of conventional (wood in USA and concrete in Egypt), typical cold formed steel framing, and newly developed steel framing systems. 4.5. Assess sustainability and environmental impact of developed designs. 4.6. Perform detailed comparisons among developed building designs. 4.7. Analyze results to arrive at appropriate recommendations for different design situations.

    Performance Indicators ______________________________

    I. Indicators:(*) i. Satisfaction of housing needs ii. Compliance with local building

    codes and regulations. iii. Sustainability of structural

    systems and construction methods to be executed at the specified urban/rural location.

    II. Means i. At the project stage all the

    required design work shall be performed by the project staff using mostly the available facilities at Cairo University (EGYPT) and Johns Hopkins University (USA).

    ii. At the implementation stage, training courses and workshops shall be arranged to familiarize practicing engineers and building contractors with the developed systems.

    Means of Verification ______________________________

    1- Survey of present residential building trends from building contractor data.

    2- Survey of social housing needs in selected urban and rural locations.

    3- Survey of available construction material resources

    4- Review of developed design against design codes.

    5- Survey of material and labor cost for executing the developed designs.

    Assumptions ___________________________ 1- Availability of typical

    layout designs presently used in residential housing.

    3. Availability of data related to construction material resources and present construction methods.

    4. Existing facilities at Cairo University and Johns Hopkins University are sufficient to perform the needed design work.

    (*) Updates on 16/10/2012: Activities 4.1, 4.2, 4.3, 4.4, and 4.5 have been completed. Activities 4.6 and 4.7 are partially completed. All indicators have been achieved.

  • Progress Report No 2

    3.7 Planning for the next reporting period:

    We plan to continue as scheduled in the Gantt Chart in the following tasks:

    2-4 novel 'dual' system cold-formed steel framing

    2-5 Environmental Impact and Sustainability assessment (more cases to be

    considered)

    2-6 Sensitivity Analysis

    4. The PI evaluation of the progress of the project:

    1- The work executed in the first year went exactly according to the planned

    activities.

    2- All the scheduled tasks have been completed.

    3- The obtained results are very encouraging.

    5. Actual or Expected Problems Encountered and Resolutions

    Description of problems encountered: None

    Description of actions taken to resolve the problems: None

    Description of problems expected in the future: None

    Description of actions proposed to resolve the problems: NA

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    6. Implementing Teams: 6.1 Egypt Team

    1- Prof Dr Metwally Abu-Hamd 2- Prof Dr Mohammed Ragaee badr 3- Dr Maged Tawfick Hanna

    6.2 U.S. Team 1- Prof Dr Ben Schaffer 2- Dr. Li Zhanjie

  • Progress Report No 2

    Appendix 1:

    Design of Reinforced Concrete Archetypes

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    Objective

    This Appendix contains the analysis and design of the conventional RC construction.

    The following four archetypes are presented:

    1- Model 1 having six storeys each having four 42 m2 flat.

    2- Model 2 having six storeys each having four 63 m2 flat.

    3- Model 3 having six storeys each having six 63 m2 flat.

    4- Model 4 having three storeys each have 75 m2 floor area.

    Building Dimensions

    Archetype 1:

    The building is 6 stories (four flats in each story) each flat is 42m2. The following figures indicate the ground and the typical floor of the archetype.

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    Archetype 2: The building is 6 stories (four flats in each story) each flat is 63m2. The following figures indicate the ground and the typical floor of the archetype.

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    Archetype 3:

    The building is 6 stories (six flats in each story) each flat is 63m2. The following figures indicate the ground and the typical floor of the archetype.

    Archetype 4: The building is 3 stories Ebni betak . The following figures indicate the ground and the typical floor of the archetype.

  • Progress Report No 2

    ASSUMPTION OF THE DESIGN Design Loads :

    1- Dead load - Own weight of slab 10 cm 250 kg/m2

    - Owen weight of Slab 12 cm 300 kg/m2

    - Flooring 150 kg/m2

    - Wall ( brick wall ) 12 cm thick. + 4 cm plaster 300 kg/m2

    - Wall (brick wall ) 25 cm thick. + 4 cm plaster 500 kg/m2

    2- Live load : - Live load ( Residential ) 200 kg/m2

    3- WIND LOAD

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    Wind load and earthquake load are according to Egyptian code of load No. 201 2003

    where :

    - The wind pressure = 70 kg/m2. ( building in Cairo )

    Wind load P

    Ce = Shape factor = 0.8 for inward side, = 0.5 for leeward side

    k = Height factor = 1 for height = 0 -10 m

    = 1.15 for height = 10-20 m

    q = Basic wind pressure = 0.68 KN/m2 corresponds to basic wind speed = 33 m/sec

    4- SEISMIC LOAD

    Total base force = Fb = Sd(TI)* * W/g

    Sd(TI) = Design response spectrum at fundamental period of vibration TI

    = ag *I *S* (2.5/R)* (TC/TI) *

    ag = design acceleration = 0.15 g (Zone (3) acc. to Egypt

    zoning)

    S = Soil class factor = 1.5 for soil class C

    Tc = constant response spectrum period = 0.25 sec for soil class C

    TI = structure period = Ct (H) 3/4 , Ct = 0.085 for steel frames,

    = 0.075 for RC frames.

    H = building height in meters

    W = Total dead load plus 25 % of live loads

    = 1 for TI > 2 TC , otherwise = 0.85

    P = Ce k q (KN/m2)

  • Progress Report No 2

    R = Response modification factor = 5 for Moment Resisting Frames

    Design Codes: - For concrete design :

    - Egyptian code of practice for concrete design, 202 2008 ( LRFD ) .

    Strength - Steel bars : Steel (52) Fy = 3600 Kg/cm2

    - For stirrups : Steel (37) Fy= 2400 kg/cm2

    - Concrete strength fcu = 250 kg/cm2

    Analysis of the archtype

    The analysis of different members was done using the world wide recognized software

    (Sap 2000 V14) and in the following is a graphical presentations of model output data

  • Progress Report No 2

    Analysis of the archtype-1

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    Analysis of the archtype-2

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    Analysis of the archtype-3

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    Analysis of the archtype-4

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    STRUCTURAL DESIGN :

    According to the analysis of the structure system, the design of slab, beams, columns

    and footings is done using both the ACI-318-05 and the Egyptian code of design

    concrete No. 202-2008. The cross section of the concrete skeleton and the

    reinforcement of the slabs, beams and columns, and footings are indicated in the

    following figures.

    Archetype-1

    Reinforcement of the ground floor .

  • Progress Report No 2

    Reinforcement of the typical floor .

  • Progress Report No 2

    Archetype-2

    1.0 DIMENSIONSNOTES

    2.0 MATERIAL SPECIFICATIONS

    BEAM'S REFERENCE

    4. LEGENDEXPOSED COLUMNS OR WALLS ABOVE SLAB.

    SECTION'S REFERENCE

    TOP REBARS

    BOTTOM REBARS

    SLAB THICKNESS

    3.0 GENERAL

    Reinforcement of the typical floor .

  • Progress Report No 2

    2.0 MATERIAL SPECIFICATIONS

    BEAM'S REFERENCE

    4. LEGEND

    EXPOSED COLUMNS OR WALLS ABOVE SLAB.

    SECTION'S REFERENCE

    TOP REBARS

    BOTTOM REBARS

    SLAB THICKNESS

    3.0 GENERAL

    Reinforcement of the typical floor

    1.0 DIMENSIONSNOTES

    2.0 MATERIAL SPECIFICATIONS

    3.0 GENERAL

    COLUMNS OR WALLS

    FOOTINGS REFERENCE

    BOTTOM FOOTING'S LEVEL

    FOUNDATION THICKNESS

    FOOTINGS SCHEDULE

    4. LEGEND

    Foundation of the archtype-2

  • Progress Report No 2

    Archetype-3

    Reinforcement of the typical floor.

  • Progress Report No 2

    Foundation of the archtype-3

  • Progress Report No 2

    Archetype-4

    Reinforcement of the typical floor .

    Estimation of the quantity The quantity of the concrete and the steel bar is shown Tables for each archetype.

    The total quantity of each item of the concrete and steel bar is divided by the area of

    the building to give the quantity of the concrete and steel per square meter of building

    as shown in third and fourth columns. The fifth column indicates the average steel ratio

    of each item of the concrete.

  • Progress Report No 2

    Archetype-1

    Table -1 Summary of the quantity of the concrete and steel bars in the conventional

    structure system ( concrete skeleton and solid slab).

    Area = 197.50 m2

    6 Quantity Reinfor. Steel (ton) m3 Conc./m2kg

    steel/m2steel/conc

    (kg/m3)

    153.68 m3 ------ 0.13

    113.05 m3 6.93 0.10 5.85 61.29

    11.69 m3 2.44 0.06 12.38 209.20

    36.93 m3 3.05 0.19 15.42 82.48

    404.76 m3 39.87 0.34 33.65

    Ceiling

    total

    Type -2 (42 m2-4 flats)

    No. of floors

    Plain concrete

    Reinfor. Concrete for footings

    Columns

    Archtype-2

    Table -2 Summary of the quantity of the concrete and steel bars in the conventional

    structure system ( concrete skeleton and solid slab).

  • Progress Report No 2

    Archetype-3

    Table -3 Summary of the quantity of the concrete and steel bars in the conventional

    structure system ( concrete skeleton and solid slab).

    RC CONVENTIONAL SOLUTION Area = 420 m2

    Item Quantity Unit Cost Cost (LE**)

    P C for Footings(m3) 180.51 400 72205 R C for Footings (m3) 248.97 1200 298768 Skeleton (m3)* 528.95 1400 740530 Brick Walls (m2 /HP) 2604.00 80 208320 Ceramic Flooring (m2 )) 2604.00 75 195300 Total 1,515,123

    (**) $ = 6 LE

    Execution Time= 18 Monthes

    Archetype-4

    Table -4 Summary of the quantity of the concrete and steel bars in the conventional

    structure system ( concrete skeleton and solid slab).

    Area = 76.09 m2

    3 Quantity Reinfor. Steel (ton) m3 Conc./m2kg

    steel/m2Steel/conc

    (kg/m3)

    12.05 m3 ------ 0.05

    15.43 m3 1.59 0.07 6.97 103.05

    3.80 m3 0.95 0.05 12.50 250.26

    13.21 m3 1.62 0.17 21.24 122.32

    66.47 m3 9.29 0.29 40.71

    Ceiling

    Total

    EBNI BETAK Type (76 m2-3 floors)

    No. of floors

    Plain concrete

    Reinfor. Concrete for footings

    Columns

  • Progress Report No 2

    Appendix 2

    Skeletal Cold Formed Framing Design

  • Project Title: USE OF COLD FORMED STEEL IN RESIDENTIAL HOUSING

    STDF Project ID: 3751

    NSF Grant No. : OISE 1103894

    Principal Investigator: EGYPT: Dr Metwally Abu-Hamd

    Professor of Steel Structures,

    Faculty of Engineering,

    Cairo University

    USA: Dr Benjamin Schafer,

    Professor and Chair

    Department of Civil Engineering

    Johns Hopkins University

    Design Calculations for Building Model 63 m2

    By: Metwally Abu-Hamd

    April 2011

  • Table of Contents

    1- Introduction 2- Architectural Drawings 3- Design Loads 4- Structural Drawings 5- STTAD Model and Input File 6- Design of Members 7- Material Take Off

  • 1- Introduction:

    This report contains the structural design calculations of the first Egyptian

    archetype composed of 6-storey building having four-63 m2 flats in each floor.

    The basis for selecting this model is its wide use in the Egyptian National

    Housing Program. The framing plans and elevations of the cold formed steel

    solution were derived from the original architectural drawings after making

    some minor modifications in grid spacing so that the resulting grid line

    arrangement is suitable for the steel solution.

    2- Architectural Drawings: a) Architectural Plan

    b) Architectural Sectional Elevation

  • 3- Design Loads

  • EGYPT- US COLD FORMED STEEL HOUSING PROJECT

    DESIGN LOADS

    REFERNCE STANDARD: EGYPTAIN CODE OF PRACTICE FOR CALCULATION OF LOADS AND FORCES ON STRUCTURES 2011. 1- DEAD LOADS 1.1 Self weight of steel structure according to design using steel weight = 78.5 KN/m3

    1.2 a) Conventional RC Design:

    Floor slab thickness acc. to design using reinforced concrete weight = 25 KN/m3

    b) Egypt Steel Design:

    GRC panels weighing 0.5 KN/m2

    1.3 Wall weights:

    a) Conventional RC Design:

    12 cm Brick wall = 3 KN/m2.

    b) Egypt Steel Design:

    GRC panels weighing 0.5 KN/m2

    1.4 Flooring:

    a) Conventional RC Design:

    Sand + cement + tiles = 1.5 KN/m2.

    b) Egypt Steel Design:

    1 cm screed = 0.25 KN/m2.

    2- LIVE LOAD 2.1 On floor areas = 2 KN/m2

    2-2 On stairs, corridors, kitchens and bathrooms = 3 KN/m2

    3- WIND LOAD

    Wind load P

    P = Ce k q (KN/m2)

  • Egypt-US Cold Formed Steel Housing Project

    Ce = Shape factor = 0.8 for inward side, = 0.5 for leeward side

    k = Height factor = 1 for height = 0 -10 m

    = 1.15 for height = 10-20 m

    q = Basic wind pressure = 0.68 KN/m2 corresponds to basic wind speed = 33 m/sec

    4- SEISMIC LOAD

    Total base force = Fb = Sd(TI)* * W/g

    Sd(TI) = Design response spectrum at fundamental period of vibration TI

    = ag *I *S* (2.5/R)* (TC/TI) *

    ag = design acceleration = 0.15 g (Zone (3) acc. to Egypt zoning)

    S = Soil class factor = 1.5 for soil class C

    Tc = constant response spectrum period = 0.25 sec for soil class C

    TI = structure period = Ct (H) 3/4 , Ct = 0.085 for steel frames,

    = 0.075 for RC frames.

    H = building height in meters

    W = Total dead load plus 25 % of live loads

    = 1 for TI > 2 TC , otherwise = 0.85

    R = Response modification factor = 5 for Moment Resisting Frames

    = 4.5 for Braced Frames

    . Important Note: Fb represents the FACTORED load in LRFD and to be divided by 1.4 in ASD.

  • 4- Structural Drawings

  • 5- STAAD Model and Input File

    The building has been modeled using STTAD PRO software as a 3-D

    structure comprising rigid frames in the east-west direction and braced

    frames in the north-south direction. In order to keep the model as

    simple as possible, the interior joists in each floor were not included

    although their weight has been considered. The cross sections of all

    members were defined in a user provided table according to STAAD

    PRO format. The software was used to obtain the structural analysis

    results only.

  • STAAD SPACE START JOB INFORMATION ENGINEER DATE 20-Oct-11 END JOB INFORMATION INPUT WIDTH 79 UNIT MMS MTON JOINT COORDINATES 1 0 0 0; 2 0 0 3930; 3 0 0 6550; 4 0 0 9200; 5 0 0 11210; 6 0 0 14560; 7 3350 0 0; 8 3350 0 3930; 9 3350 0 7860; 10 3350 0 11210; 11 3350 0 14560; 12 6700 0 0; 13 6700 0 3930; 14 6700 0 7860; 15 6700 0 11210; 16 6700 0 14560; 17 8700 0 930; 18 8700 0 3930; 19 10050 0 7860; 20 10050 0 11210; 21 10050 0 14560; 22 11400 0 930; 23 11400 0 3930; 24 13400 0 0; 25 13400 0 3930; 26 13400 0 7860; 27 13400 0 11210; 28 13400 0 14560; 29 16750 0 0; 30 16750 0 3930; 31 16750 0 7860; 32 16750 0 11210; 33 16750 0 14560; 34 20100 0 0; 35 20100 0 3930; 36 20100 0 6550; 37 20100 0 9200; 38 20100 0 11210; 39 20100 0 14560; 40 0 3000 0; 41 0 3000 3930; 42 0 3000 6550; 43 0 3000 9200; 44 0 3000 11210; 45 0 3000 14560; 46 2150.01 3000 6550; 47 2150.01 3000 9200; 48 3350 3000 0; 49 3350 3000 3930; 50 3350 3000 6550; 51 3350 3000 7860; 52 3350 3000 9200; 53 3350 3000 11210; 54 3350 3000 14560; 55 6700 3000 0; 56 6700 3000 928.999; 57 6700 3000 3930; 58 6700 3000 7860; 59 6700 3000 11210; 60 6700 3000 14560; 61 8700 3000 928.999; 62 8700 3000 3930; 63 8700 3000 7860; 64 10050 3000 7860; 65 10050 3000 11210; 66 10050 3000 14560; 67 11400 3000 928.999; 68 11400 3000 3930; 69 11400 3000 7860; 70 13400 3000 0; 71 13400 3000 928.999; 72 13400 3000 3930; 73 13400 3000 7860; 74 13400 3000 11210; 75 13400 3000 14560; 76 16750 3000 0; 77 16750 3000 3930; 78 16750 3000 6550; 79 16750 3000 7860; 80 16750 3000 9200; 81 16750 3000 11210; 82 16750 3000 14560; 83 17950 3000 6550; 84 17950 3000 9200; 85 20100 3000 0; 86 20100 3000 3930; 87 20100 3000 6550; 88 20100 3000 9200; 89 20100 3000 11210; 90 20100 3000 14560; 91 0 6000 0; 92 0 6000 6550; 93 0 6000 9200; 94 0 6000 11210; 95 0 6000 14560; 96 1.01863e-006 6000 3930; 97 2150.01 6000 6550; 98 2150.01 6000 9200; 99 3350 6000 0; 100 3350 6000 3930; 101 3350 6000 6550; 102 3350 6000 7860; 103 3350 6000 9200; 104 3350 6000 11210; 105 3350 6000 14560; 106 6700 6000 0; 107 6700 6000 928.999; 108 6700 6000 3930; 109 6700 6000 7860; 110 6700 6000 11210; 111 6700 6000 14560; 112 8700 6000 928.999; 113 8700 6000 3930; 114 8700 6000 7860; 115 10050 6000 7860; 116 10050 6000 11210; 117 10050 6000 14560; 118 11400 6000 928.999; 119 11400 6000 3930; 120 11400 6000 7860; 121 13400 6000 0; 122 13400 6000 928.999; 123 13400 6000 3930; 124 13400 6000 7860; 125 13400 6000 11210; 126 13400 6000 14560; 127 16750 6000 0; 128 16750 6000 3930; 129 16750 6000 6550; 130 16750 6000 7860; 131 16750 6000 9200; 132 16750 6000 11210; 133 16750 6000 14560; 134 17950 6000 6550; 135 17950 6000 9200; 136 20100 6000 0; 137 20100 6000 3930; 138 20100 6000 6550; 139 20100 6000 9200; 140 20100 6000 11210; 141 20100 6000 14560; 142 0 9000 0; 143 0 9000 6550; 144 0 9000 9200; 145 0 9000 11210; 146 0 9000 14560; 147 1.01863e-006 9000 3930; 148 2150.01 9000 6550; 149 2150.01 9000 9200; 150 3350 9000 0; 151 3350 9000 3930; 152 3350 9000 6550; 153 3350 9000 7860; 154 3350 9000 9200; 155 3350 9000 11210; 156 3350 9000 14560; 157 6700 9000 0; 158 6700 9000 928.999; 159 6700 9000 3930; 160 6700 9000 7860;

  • 161 6700 9000 11210; 162 6700 9000 14560; 163 8700 9000 928.999; 164 8700 9000 3930; 165 8700 9000 7860; 166 10050 9000 7860; 167 10050 9000 11210; 168 10050 9000 14560; 169 11400 9000 928.999; 170 11400 9000 3930; 171 11400 9000 7860; 172 13400 9000 0; 173 13400 9000 928.999; 174 13400 9000 3930; 175 13400 9000 7860; 176 13400 9000 11210; 177 13400 9000 14560; 178 16750 9000 0; 179 16750 9000 3930; 180 16750 9000 6550; 181 16750 9000 7860; 182 16750 9000 9200; 183 16750 9000 11210; 184 16750 9000 14560; 185 17950 9000 6550; 186 17950 9000 9200; 187 20100 9000 0; 188 20100 9000 3930; 189 20100 9000 6550; 190 20100 9000 9200; 191 20100 9000 11210; 192 20100 9000 14560; 193 0 12000 0; 194 0 12000 6550; 195 0 12000 9200; 196 0 12000 11210; 197 0 12000 14560; 198 1.01863e-006 12000 3930; 199 2150.01 12000 6550; 200 2150.01 12000 9200; 201 3350 12000 0; 202 3350 12000 3930; 203 3350 12000 6550; 204 3350 12000 7860; 205 3350 12000 9200; 206 3350 12000 11210; 207 3350 12000 14560; 208 6700 12000 0; 209 6700 12000 928.999; 210 6700 12000 3930; 211 6700 12000 7860; 212 6700 12000 11210; 213 6700 12000 14560; 214 8700 12000 928.999; 215 8700 12000 3930; 216 8700 12000 7860; 217 10050 12000 7860; 218 10050 12000 11210; 219 10050 12000 14560; 220 11400 12000 928.999; 221 11400 12000 3930; 222 11400 12000 7860; 223 13400 12000 0; 224 13400 12000 928.999; 225 13400 12000 3930; 226 13400 12000 7860; 227 13400 12000 11210; 228 13400 12000 14560; 229 16750 12000 0; 230 16750 12000 3930; 231 16750 12000 6550; 232 16750 12000 7860; 233 16750 12000 9200; 234 16750 12000 11210; 235 16750 12000 14560; 236 17950 12000 6550; 237 17950 12000 9200; 238 20100 12000 0; 239 20100 12000 3930; 240 20100 12000 6550; 241 20100 12000 9200; 242 20100 12000 11210; 243 20100 12000 14560; 244 0 15000 0; 245 0 15000 6550; 246 0 15000 9200; 247 0 15000 11210; 248 0 15000 14560; 249 1.01863e-006 15000 3930; 250 2150.01 15000 6550; 251 2150.01 15000 9200; 252 3350 15000 0; 253 3350 15000 3930; 254 3350 15000 6550; 255 3350 15000 7860; 256 3350 15000 9200; 257 3350 15000 11210; 258 3350 15000 14560; 259 6700 15000 0; 260 6700 15000 928.999; 261 6700 15000 3930; 262 6700 15000 7860; 263 6700 15000 11210; 264 6700 15000 14560; 265 8700 15000 928.999; 266 8700 15000 3930; 267 8700 15000 7860; 268 10050 15000 7860; 269 10050 15000 11210; 270 10050 15000 14560; 271 11400 15000 928.999; 272 11400 15000 3930; 273 11400 15000 7860; 274 13400 15000 0; 275 13400 15000 928.999; 276 13400 15000 3930; 277 13400 15000 7860; 278 13400 15000 11210; 279 13400 15000 14560; 280 16750 15000 0; 281 16750 15000 3930; 282 16750 15000 6550; 283 16750 15000 7860; 284 16750 15000 9200; 285 16750 15000 11210; 286 16750 15000 14560; 287 17950 15000 6550; 288 17950 15000 9200; 289 20100 15000 0; 290 20100 15000 3930; 291 20100 15000 6550; 292 20100 15000 9200; 293 20100 15000 11210; 294 20100 15000 14560; 295 0 18000 0; 296 0 18000 6550; 297 0 18000 9200; 298 0 18000 11210; 299 0 18000 14560; 300 1.01863e-006 18000 3930; 301 2150.01 18000 6550; 302 2150.01 18000 9200; 303 3350 18000 0; 304 3350 18000 3930; 305 3350 18000 6550; 306 3350 18000 7860; 307 3350 18000 9200; 308 3350 18000 11210; 309 3350 18000 14560; 310 6700 18000 0; 311 6700 18000 928.999; 312 6700 18000 3930; 313 6700 18000 7860; 314 6700 18000 11210; 315 6700 18000 14560; 316 8700 18000 928.999;

  • 317 8700 18000 3930; 318 8700 18000 7860; 319 10050 18000 7860; 320 10050 18000 11210; 321 10050 18000 14560; 322 11400 18000 928.999; 323 11400 18000 3930; 324 11400 18000 7860; 325 13400 18000 0; 326 13400 18000 928.999; 327 13400 18000 3930; 328 13400 18000 7860; 329 13400 18000 11210; 330 13400 18000 14560; 331 16750 18000 0; 332 16750 18000 3930; 333 16750 18000 6550; 334 16750 18000 7860; 335 16750 18000 9200; 336 16750 18000 11210; 337 16750 18000 14560; 338 17950 18000 6550; 339 17950 18000 9200; 340 20100 18000 0; 341 20100 18000 3930; 342 20100 18000 6550; 343 20100 18000 9200; 344 20100 18000 11210; 345 20100 18000 14560; MEMBER INCIDENCES 1 1 40; 2 1 41; 3 2 41; 4 3 42; 5 4 43; 6 5 44; 7 6 44; 8 6 45; 9 7 48; 10 8 49; 11 9 51; 12 10 53; 13 11 54; 14 12 55; 15 13 57; 16 14 58; 17 15 59; 18 16 60; 19 17 61; 20 18 62; 21 19 64; 22 19 65; 23 20 65; 24 21 66; 25 22 67; 26 23 68; 27 24 70; 28 25 72; 29 26 73; 30 27 74; 31 28 75; 32 29 76; 33 30 77; 34 31 79; 35 32 81; 36 33 82; 37 34 85; 38 34 86; 39 35 86; 40 36 87; 41 37 88; 42 38 89; 43 39 89; 44 39 90; 45 40 41; 46 42 41; 47 44 43; 48 44 45; 49 42 46; 50 43 47; 51 40 48; 52 41 49; 53 44 53; 54 45 54; 55 46 47; 56 46 50; 57 47 52; 58 48 49; 59 49 50; 60 50 51; 61 51 52; 62 52 53; 63 53 54; 64 48 55; 65 49 57; 66 51 58; 67 59 53; 68 54 60; 69 55 56; 70 56 57; 71 57 58; 72 58 59; 73 59 60; 74 56 61; 75 57 62; 76 58 63; 77 59 65; 78 60 66; 79 61 62; 80 62 63; 81 63 64; 82 62 68; 83 64 65; 84 65 66; 85 64 69; 86 67 68; 87 68 69; 88 65 74; 89 66 75; 90 71 67; 91 68 72; 92 69 73; 93 70 71; 94 71 72; 95 72 73; 96 73 74; 97 74 75; 98 76 70; 99 72 77; 100 73 79; 101 81 74; 102 75 82; 103 76 77; 104 77 78; 105 78 79; 106 79 80; 107 81 82; 108 83 78; 109 84 80; 110 83 84; 111 85 76; 112 77 86; 113 81 89; 114 82 90; 115 87 83; 116 88 84; 117 85 86; 118 86 87; 119 88 89; 120 89 90; 121 40 91; 122 41 91; 123 42 92; 124 43 93; 125 44 94; 126 44 95; 127 45 95; 128 41 96; 129 48 99; 130 49 100; 131 51 102; 132 53 104; 133 54 105; 134 55 106; 135 57 108; 136 58 109; 137 59 110; 138 60 111; 139 61 112; 140 62 113; 141 64 115; 142 65 115; 143 65 116; 144 66 117; 145 67 118; 146 68 119; 147 70 121; 148 72 123; 149 73 124; 150 74 125; 151 75 126; 152 76 127; 153 77 128; 154 79 130; 155 81 132; 156 82 133; 157 85 136; 158 86 136; 159 86 137; 160 87 138; 161 88 139; 162 89 140; 163 89 141; 164 90 141; 165 93 94; 166 94 95; 167 91 96; 168 92 96; 169 92 97; 170 93 98; 171 91 99; 172 96 100; 173 94 104; 174 95 105; 175 97 98; 176 97 101; 177 98 103; 178 99 100; 179 100 101; 180 101 102; 181 102 103; 182 103 104; 183 104 105; 184 99 106; 185 100 108; 186 102 109; 187 110 104; 188 105 111; 189 106 107; 190 107 108; 191 108 109; 192 109 110; 193 110 111; 194 107 112; 195 108 113; 196 109 114; 197 110 116; 198 111 117; 199 112 113; 200 113 114; 201 114 115; 202 113 119; 203 115 116; 204 116 117; 205 115 120; 206 118 119; 207 119 120; 208 116 125; 209 117 126; 210 122 118; 211 119 123; 212 120 124; 213 121 122; 214 122 123; 215 123 124; 216 124 125; 217 125 126; 218 127 121; 219 123 128; 220 124 130; 221 132 125; 222 126 133; 223 127 128; 224 128 129; 225 129 130; 226 130 131; 227 131 132; 228 132 133; 229 134 129; 230 135 131; 231 134 135; 232 136 127; 233 128 137; 234 132 140; 235 133 141; 236 138 134; 237 139 135; 238 136 137; 239 137 138; 240 139 140; 241 140 141; 242 91 142; 243 92 143; 244 93 144; 245 94 145; 246 95 145; 247 95 146; 248 91 147; 249 96 147; 250 99 150; 251 100 151; 252 102 153; 253 104 155; 254 105 156; 255 106 157; 256 108 159; 257 109 160; 258 110 161; 259 111 162; 260 112 163; 261 113 164; 262 115 166; 263 115 167; 264 116 167; 265 117 168; 266 118 169; 267 119 170; 268 121 172; 269 123 174; 270 124 175; 271 125 176;

  • 272 126 177; 273 127 178; 274 128 179; 275 130 181; 276 132 183; 277 133 184; 278 136 187; 279 136 188; 280 137 188; 281 138 189; 282 139 190; 283 140 191; 284 141 191; 285 141 192; 286 144 145; 287 145 146; 288 142 147; 289 143 147; 290 143 148; 291 144 149; 292 142 150; 293 147 151; 294 145 155; 295 146 156; 296 148 149; 297 148 152; 298 149 154; 299 150 151; 300 151 152; 301 152 153; 302 153 154; 303 154 155; 304 155 156; 305 150 157; 306 151 159; 307 153 160; 308 161 155; 309 156 162; 310 157 158; 311 158 159; 312 159 160; 313 160 161; 314 161 162; 315 158 163; 316 159 164; 317 160 165; 318 161 167; 319 162 168; 320 163 164; 321 164 165; 322 165 166; 323 164 170; 324 166 167; 325 167 168; 326 166 171; 327 169 170; 328 170 171; 329 167 176; 330 168 177; 331 173 169; 332 170 174; 333 171 175; 334 172 173; 335 173 174; 336 174 175; 337 175 176; 338 176 177; 339 178 172; 340 174 179; 341 175 181; 342 183 176; 343 177 184; 344 178 179; 345 179 180; 346 180 181; 347 181 182; 348 182 183; 349 183 184; 350 185 180; 351 186 182; 352 185 186; 353 187 178; 354 179 188; 355 183 191; 356 184 192; 357 189 185; 358 190 186; 359 187 188; 360 188 189; 361 190 191; 362 191 192; 363 142 193; 364 143 194; 365 144 195; 366 145 196; 367 145 197; 368 146 197; 369 147 193; 370 147 198; 371 150 201; 372 151 202; 373 153 204; 374 155 206; 375 156 207; 376 157 208; 377 159 210; 378 160 211; 379 161 212; 380 162 213; 381 163 214; 382 164 215; 383 166 217; 384 167 217; 385 167 218; 386 168 219; 387 169 220; 388 170 221; 389 172 223; 390 174 225; 391 175 226; 392 176 227; 393 177 228; 394 178 229; 395 179 230; 396 181 232; 397 183 234; 398 184 235; 399 187 238; 400 188 238; 401 188 239; 402 189 240; 403 190 241; 404 191 242; 405 191 243; 406 192 243; 407 195 196; 408 196 197; 409 193 198; 410 194 198; 411 194 199; 412 195 200; 413 193 201; 414 198 202; 415 196 206; 416 197 207; 417 199 200; 418 199 203; 419 200 205; 420 201 202; 421 202 203; 422 203 204; 423 204 205; 424 205 206; 425 206 207; 426 201 208; 427 202 210; 428 204 211; 429 212 206; 430 207 213; 431 208 209; 432 209 210; 433 210 211; 434 211 212; 435 212 213; 436 209 214; 437 210 215; 438 211 216; 439 212 218; 440 213 219; 441 214 215; 442 215 216; 443 216 217; 444 215 221; 445 217 218; 446 218 219; 447 217 222; 448 220 221; 449 221 222; 450 218 227; 451 219 228; 452 224 220; 453 221 225; 454 222 226; 455 223 224; 456 224 225; 457 225 226; 458 226 227; 459 227 228; 460 229 223; 461 225 230; 462 226 232; 463 234 227; 464 228 235; 465 229 230; 466 230 231; 467 231 232; 468 232 233; 469 233 234; 470 234 235; 471 236 231; 472 237 233; 473 236 237; 474 238 229; 475 230 239; 476 234 242; 477 235 243; 478 240 236; 479 241 237; 480 238 239; 481 239 240; 482 241 242; 483 242 243; 484 193 244; 485 194 245; 486 195 246; 487 196 247; 488 197 247; 489 197 248; 490 193 249; 491 198 249; 492 201 252; 493 202 253; 494 204 255; 495 206 257; 496 207 258; 497 208 259; 498 210 261; 499 211 262; 500 212 263; 501 213 264; 502 214 265; 503 215 266; 504 217 268; 505 217 269; 506 218 269; 507 219 270; 508 220 271; 509 221 272; 510 223 274; 511 225 276; 512 226 277; 513 227 278; 514 228 279; 515 229 280; 516 230 281; 517 232 283; 518 234 285; 519 235 286; 520 238 289; 521 238 290; 522 239 290; 523 240 291; 524 241 292; 525 242 293; 526 243 293; 527 243 294; 528 246 247; 529 247 248; 530 244 249; 531 245 249; 532 245 250; 533 246 251; 534 244 252; 535 249 253; 536 247 257; 537 248 258; 538 250 251; 539 250 254; 540 251 256; 541 252 253; 542 253 254; 543 254 255; 544 255 256; 545 256 257; 546 257 258; 547 252 259; 548 253 261; 549