Development of pre-cast composite structural system

(SMART frame) and the embedded energy efficiency

Won-Kee Hong
1
Ji-Hun Kim
1*
Seon-Chee Park
1
Hyo-Jin Ko
1
JeongTai Kim
1


1
Department of Architectural Engineering, Kyung Hee University, Yongin 446-701,Korea

*Corresponding Author: J. H. Kim (ruleein@khu.ac.kr)



Abstract

The precast structural systems demonstrate outstanding economy compared to steel structures,
but the construction speed is not as fast as steel constructions, preventing precast structural
systems from being used widely. This is because it is difficult to install beams for lateral
braces during erection.This paper presents pre-cast composite structural system(SMART
frame) consisting ofpre-cast concrete, wide flange steeland reinforcement. This structural
system is proposed for easy and simple connections of column-beam units to beam unit to
form lateral braces during erection. Vertical steel sections with brackets are inserted in
between pre-cast columns at joint level. The tree shaped column-beam units are lifted in sites
to be assembled with steel sections inserted at both ends of pre-cast beam units. The
introduction of steel section both in column-beam and beam units helps precast frames to be
erected as similarly as steel frames providing proper lateral resisting frame to prevent lateral
instability during erection. The hybrid construction basedpre-cast composite frames
introduced in this paper adds the economy of precast concrete structures with steel erection
speed. This paper also presents the embedded energy efficiency of the proposed pre-cast
concrete frames based on the hybrid characteristics in terms of both structures and
constructions.


Keywords: SMART frame, energy efficiency, column-beam unit, pre-cast composite
structural system

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1. Introduction

Both the structural performance and constructability of the joints of precast composite
structure is one of the importantaspects for design.
Jurkiewiez et al. studied a new connection device based on horizontal shear connectors,
eliminating the need for welding. The resulting steelconcrete composite beam was subjected
to a static bending test [1].
Hajjar demonstrated the benefits of the composite systems relative to more common systems
by comparing the performance characteristics of the beams when subjected to service and
ultimate loads [2].
In this study, the areas of structure, materials and construction are investigated as a hybrid
characteristic to provide versatileprecast composite structural systems.Precast composite
structural systems proposed in this paper (SMART frame; hereinafter referred to as SF)
consist of precast concrete, wide flange steel and reinforcement. SFseparated and
manufactured at low moment locations as shown in Figs. 1 and 2 enables to assemble several
floors of frames by one lifting.
The precast structures cannot be erected as fast as the erection of steel frames due to the
difficulties of the installation of beams for lateral braces during erection. In order for precast
frames to be erected as similarly as steel frames requires proper lateral resisting frame to prevent
lateral instability during erection.As shown in Fig 5 wide flange section isused to provide
connections between precast column-beam and beam units for the erection of precast frames.

Fig 2.Column-Beam unit separated at low
bending moment(Lateral Loads)
Fig 1.Column-Beam unit separated at low
bending moment(Vertical loads)
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2. Principles of SMARTframe

2.1Column-beam unit and beam unit
Figure 3 illustrates a column-beam unit. For fast, convenient lifting and construction, steel
plates and wide flange steels are inserted between precast columns.The horizontal steel
member attached to wide flange steels are connected to steels installed at each ends of
composite beams. Figure 4 shows a composite beam unit with embedded steels at both ends
of beam. Every 2 or 3-story columns are erected and connected to beams. As shown in Fig 6,
using steel sections for erection eliminates the need of construction of slabs for upwards
construction similarly to steel frame erections. The construction of slabs will follow without
jeopardizing the lateral stability of the frame.
The precast column-beam unit (column tree) separated at locations of low moment due to
vertical and lateral loads is manufactured, then lifted and connected to beams through steel
sections. The connection at these low moment locations reduces stresses for safe and fast
connections against both vertical and lateral loads. The weight of the column/unit is designed
as light as possible at this separation.











Fig 5.Assembly of Column-Beam and Beam unit
Bracket (Wide Flange Steel)
Precast Concrete
Fig 3.Column-Beam unit
Fig 4.Beam unit
Steel Plate
Wide Flange Steel
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2.2Distinct Features & Advantages of SF
Precast structures cannot be erected as fast as the erection of steel frames due to the
difficulties in installing beams for lateral braces during erection.As shown in Fig. 6, SF
presented in this paper does not have to wait for the construction of slabs.
The SF proposed in this study is a hybrid composite structural system that adopted only the
advantages of both steel frame structure and precast concrete structure.The presented hybrid
construction method of precast structural systems makes it possible to erect precast concrete
frames as similarly as steel frame systems with the same construction speed.The SF provides
three types of hybrid characteristics. Structural, material and construction hybrid function
makes SF suitable and economic. The SF enables the erection of frames as fast as possible
and as economic as concrete, as well. During erection stage, composite beams act as wind
braces against horizontal load during the erection process before the slab is poured.














3. Analysis on Energy Efficiency

Energy efficiency during the construction of SF suggested in this study is analyzed based on
the applicationof SF to apartment buildings.The construction periods required for SF
construction was compared with the conventional bearing wall construction[3]. The
Framework construction period of 40~50% of the total constructionperiodwas saved when
using SF for the construction.

3.1Existing Wall Apartment Building Process
As shown in Table 1, the basic framework unit of conventional wall apartment buildings is a
single floor and its process lasts for 7 days. Main processes flow in the following
order:Marking Wall rebar work Installation of wall form Installation of Slab form
Slab rebar work Cleaning& pouring [4].


Fig 6.Construction of Steel, Precast Concrete and SF
Critical Path
Upwards construction
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Table 1.Process of bearing wall[5]
Process 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day
Marking






Wall rebar work






Installation of wall form






Installation of slab form






Slab rebar work






Slab electrical
& Mechanical component






Cleaning and pouring







3.2 SF-Based Construction of Apartment Building Process
Table 2 and Fig 7 show the construction process of SF.The SF column-beam units are
manufactured as 3-strory column unit and erected as one cycle. The main processes of the
first floor work lasts for 4 days consists of:Marking Core wall rebar work/form installation
Installation of column-beam units/beam-units Installation of Deck plates/joint form
Slab rebar work Cleaning& pouring. The second and third floors skip installation of
column-beam units, so they require 3 days.
Fig 7.Construction process of SF
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Table 2.Process of SF
Process
1-Floor 2-Floor 3-Floor
1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 7 Day 8 Day 9 Day 10 Day
Core Wall rebar work



Installation of
Core wall form



Installation of
Column-Beam unit



Installation of Beam unit



Installation of deck plate



Installation of joint form



Slab rebar work



Slab electrical
& Mechanical component



Cleaning and pouring





3.3 Comparison & Analysis of Framework Construction
In general, the basic framework unit for bearing apartment buildings is a single floor and 7
days are needed per floor to complete. 3 days out of 7 days are for wall and slab form works.
This implies that form works which are highly affected by workers skill and operation type
greatly impacts the overall framework period [6]. On the other hand, SF utilizes 3-story
column-beam units, so its basic work unit shall be 3 stories that last for 10 days. The
construction of precast concrete composite frames reduces the amount of formworks,
securing continuity of frameworks that ultimately reduces the construction period. Table 3
presents the calculated construction period that is required for 30-story apartment housing to
compare the bearing wall types and SF types. Based on working days, the conventional wall
apartment buildings require 210 days, yet when SF is applied 100 days are required. This
represents that SF framework constructionperiod is reduced for 52.4% compared to that
applied with the bearing wall type.



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Table 3.Comparison analysis of construction period
Structural Type
Construction Period
Ratio
Typical Floor Apartment Building(30-story)
Bearing Wall 7 Days /1Floor 210 Days 100.0%
SMART frame 10 Days /3Floors 100 Days 47.6%


3.4 Expectations on the Reduction of Construction Period
As SFis applied to apartment buildings, the amount of forms used is reduced, decreasing the
amount of wastes generated. Energy consumption to treat these wastes has been also reduced.
A continuous construction process that does not become critical path is realized which
enables efficient operation of tower canes, concrete pump cars and forklifts. This reduces
CO
2
emission resulting from energy to run equipments and also from operating those
equipments [7, 8]. The steels selectively embedded in the beam units largely contribute to
resisting bending moment efficiently, improving the structural efficiency of materials [9, 10].
SF members are applied to satisfy structural performance, reducing floor heights and material
quantity [11]. Table 4 demonstrates the quantity compared with that of the typical bearing
wall apartment buildings showing reduction in concrete of 38.7% and in steel materials of
10.04%. Energy consumption due to use of concrete and steel material can be reduced and
higher reduction effect is anticipated as apartments get taller [12].


Table 4.Comparison analysis of quantities per unit area[13]
Materials
Amount of material per unit area
Reduction Rate(%)
Bearing Wall SMART frame
Concrete(m
3
/m
2
) 0.602 0.369 38.70
Reinforcement(kN/m
2
) 0.528 0.353 -
Steel(kN/m
2
) - 0.122 -
Sum(Reinforcement + Steel) 0.528 0.475 10.04


4. Conclusion
This study proposes a precast composite structural system designed to provide hybrid
functions for structure and constructionareas.The following conclusions are drawn based on
the comparisonof the construction periods of SF-applied apartment building with that of the
existing bearing wall type.

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1) This paper presents hybrid construction method that provides the economy of precast
concrete structures and steel erection speed as well.
2) As a result of analysis on 3-story, 1-cycle process that utilizes 3-story column-beam
units, it requires 10 days for completion. When compared to the existing bearing wall
apartment building in which 1-floor, 1-cycle process lasts for 7 days, framework
construction period can be reduced for 52.4% based on the working days.
3) The amount of concrete and steel used per unit area in SF decreased by 38.7% and
10.04% compared with bearing wall apartment buildings, respectively.

This study introduced the SFproviding hybrid functions in terms of construction and structure.
It was also proved to be energy efficientdue to the reduction of SF construction period
compared with conventional bearing wall apartment buildings. Further investigations of
comprehensive studies regarding SF buildings that affect the overall construction period and
life cycle cost are needed.


Acknowledgements
This work was supported by the National Research Foundation of Korea (NRF) grant funded
by the Korea government (MEST) (No. 2012-0000609).


References

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[2] Hajjar JF: Composite steel and concrete structural systems for seismic engineering; Journal of
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[3]Hong WK, Kim SI, Park SC, Kim JM, Lee SG, Yoon KJ,Kim SK: Composite beam composed of
steel and pre-cast concrete. (Modularized hybrid system, MHS) Part IV: application for multi-
residential housing; Structural Design of Tall and Special Buildings 2010; 19(7): 707-727
[4] Hong SW, Park SH, Kim SW, An JK, Son CB, Lee DJ, Lee MK:Analysis of Construction
Planning and Scheduling in the Mock-up House forPracticality of Long Life
Housing;Architectural Institute of Korea 2009; 25(7):145152
[5] Lee SH, Kim SE, Kim GH, Joo JK, Kim SK:Analysis of structural work scheduling of
GreenFrame; Journal of Korea Institute Building Construction2011;11(3):301309
[6] Han CH, Bang JD: Development of an effective time scheduling mechanism of the structural
framework for the high-rise Apartment Housing focusing on One Cycle time scheduling
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[7] Hong WK, Kim JM, Park SC, Lee SG, Kim SI, Yoon KJ, Kim HC, Kim JT: A new apartment
construction technology with effective CO2 emission reduction capabilities; Energy - The
International Journal 2010; 35(6): 2639-2646
[8] Hong WK, Park SC, Kim JM, Kim SI, Lee SG,Yune DY, Yoon TH, Ryoo BY: Development of
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Capability for CO2 Emissions; Indoor and Built Environment 2010; 19(1): 151-162
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steel and precast concrete. (Modularized hybrid system, MHS) Part I: experimental investigation;
Structural Design of Tall and Special Buildings 2010; 19(3): 275-289
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Author biography
Won-Kee Hong Professor of Department of
Architectural Engineering, College of Engineering,
Kyung Hee University, Yongin 446-701,Korea
E-mail: hongwk@khu.ac.kr
Profile
Professor Hong has more than 30 years of professional experience in structural
engineering. Professor Hong's research interests include a new approach to
construction technologies based on value engineering and composite structures.
He provided many useful solutions to the current structural design and
construction technologies issues. Professor Hong has been conducting the research
that combines structural engineering with construction technologies. He is the
author of numerous papers and patents in this field.
Lately he has started research work in hybrid Composite Frame System at the
Center for Sustainable Healthy Buildings (CSHeB). Especially, Professor Hong
developed the green frame hybrid systems consisting of structural Tee steel beam
(or wide flange steel beam), precast concrete and cast-in-concrete. And now he
is preparing the development of new long-life and eco-friendly multi-residential
housing using this system.
Professor Hong received his master and Ph.D degree from UCLA and he worked
for Englelkirk and Hart, Inc.(USA), Nihhon sekkei(Japan) and Samsung
engineering and construction(Korea) before he joined Kyung Hee University. He
also has professional engineering licence from both Korea and U.S.A.
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