Derek Duhon W0378788 Derek.Duhon-2@selu.edu

SteelFabrication & Erection

ofBelle Chasse Primary

SchoolSite Location:

Belle Chasse, LA

ET-493Final Proposal

Spring 2015Instructor: Chris Koutsougeras

Advisor: Edward Rode’

Table of ContentsPage

Abstract ………………………………………………………..3

Purpose…………………...…………………………………….4

Introduction…………………………………………………….4

o Why use steel?..................................................................4o Steel Design Process…………………………………….4o Steel Fabrication Process………………………………..5o Steel Erection Process………………………………......6

Deliverables …………………………………………………....7

o Site Analysis ……………………………………………7o Structural Shapes Analysis..…………………………..7-9o Load Cases…………………………………………….10o Pre-K Interior Signage Floor Plan…….. ……………..11o Enlarged Classroom Floor Plan……………………….12o Code Regulations Analysis………..…………………..13o Cost Analysis………………………………………….14

References ……………………………………………………15

Spring 2015 Semester Timeline ……………………………...16

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Abstract

This senior design project will exercise the knowledge and skills obtained from the Construction Engineering program at Southeastern Louisiana University. The Belle Chasse Primary School steel fabrication and erection process will theoretically be completed. The pre-design: Design Phase, Site Analysis, Structural Analysis and Code Requirements will be completed during the Spring 2015 semester. Followed by the Fall of 2015 covering the pre-construction phase: Construction Drawings, Building Schedule, and Cost Estimate.

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Purpose

The purpose of this project is to demonstrate a complete construction process using all aspects of construction. This project will show the skills and abilities learned from the Construction Engineering Program.

IntroductionWHY USE STEEL?

Steel has many advantages when compared to other structural materials such as concrete, timber, plastics and the new composite materials.

Advantages of Steel: Does not wrap or twist – unlike wood. Does not substantially expand and contract with the weather - unlike wood. Does not need time to cure and is immediately at full strength – unlike concrete. Steel is versatile, having more strength with less weight. Steel can be erected in most weather conditions. Steel is of uniform quality with proven durability. Steel has low life cycle costs. Steel is the most recycled material in the United States, being 100% recyclable.

STEEL DESIGN PROCESS The architects, along with the property owner, produce a general layout of the

building known as preliminary drawings. These drawings are then used to finalize the design of the structural framework. The structural engineer is qualified to make the concept come true by determining what needs to be done in order to satisfy the architect’s requirements. After the architecture of the building is finalized, the design of the framework – beams, columns, bracing, etc. – starts with engineering calculations. The structural engineer calculates the behavior of steel with reference to: various building codes, including the recommendations and codes of the American Institute of Steel Construction (AISC). These codes are used in both computer and hand calculations to produce the structural design of the building.

Categorizing structural steel design framework into three areas: Main Members- may include beams, columns, trusses, and girders. These members

are the skeleton of the framework and are the primary members that carry the loads of the structure. Meaning – this part of the structure is the main source of support.

Secondary Members- may include bracing, stairs, and decking. These members are designed to carry a specific load. Meaning – a brace may be added to produce extra support in the area of a load, reducing the size of a member.

Connections- are joints or nodes of structural elements used to transfer forces between structural elements or members. The connections ensure that at the point where the structural members meet, sufficient steel area exists to resist the stresses at that point such as – axial loads (compression and tension), bending moments, and torsional loading (torque).

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STEEL FABRICATION PROCESSFabrication is the process of cutting, burning, welding, drilling, grinding, punching,

bending and generally producing the steel detail pieces shown on the detail drawings. The traditional process of fabricating steel is systematic, using many laborers, demanding specific attention to detail. This involves layout of the cuts, moving the beam from the drill line to the bandsaw to the coping station. This can be a long process and is prone to error.

Modern day technologies have created a plasma cutting system that has revolutionized the structural steel fabrication process. The advanced CNC robotic high-definition plasma cutting system is called the PythonX. The process takes place as follows: the beam is loaded onto the infeed conveyor along with loading a part file from AutoCAD or other detailing software into the computer system. PythonX calculates the cutting path and sequence, moves the beam into position, and starts making all the needed cuts and features. It starts at one end of the beam and works to the other end, making all the cuts in one pass.

Compared to traditional machines, PythonX is proven to: Less floor space is needed More time efficient processing Offers complete fabricating capability at a cheaper price

PythonX replaces these machines: Beam Drill Line Bandsaw Angle Line Plate/Bar Line Coping Machine Marking Machine Small Burning Machine

`PythonX: “CNC Plasma Cutting System,” http://www.pythonx.com, Copyright ©2007-2013 Burlington Automation Corp.

After the fabrication of the steel process is complete, the members are transported to the field to be unloaded, sorted, and temporarily stored until the erections process begins.

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STEEL ERECTION PROCESSErection is the process of connecting the fabricated members in the field on the site

of the project. Generally columns are erected first, since they are the most critical element of the structure, by giving the main support to the trusses, beams, bracing and other miscellaneous steel. Column base plates are connected to the foundation using anchor bolts that are placed in the concrete, by the foundation contractor. The location of the anchor bolts in the foundation must match exactly to the pattern of the boltholes in the base plate of the column, to ensure the exact final elevation of the structure. (Shown in figure 1 below).

Figure 1.Commonly, after the erection of the columns, comes the trusses and the major

girders, then beams, bracing, stairs and other miscellaneous steel. The erection process is usually divided into phases based on the anticipated movements of the cranes. The fabricator and erector should coordinate the job in these same phases so that the erector has the necessary steel for each phase without delay. The next step is the plum and bolt process that consist of placing the steel assemblies in their proper location, aligning them and temporally bolting them in place. Safety cable handrails allow ironworkers to move freely from one area to another without interruptions (Shown in figure 2 below). The decking crew follows by placing corrugated bent plate on structural frame that will later be cast-in-place by concrete to form a slab for each floor.

Figure 2.

The final steps consist of torqueing the bolts once the majority of the structure is erect. The welding crew follows this, being responsible for final welds of all the assemblies in accordance to the erection drawings. These final steps are commonly referred to as “Buttoning-up”, since they are the last of the structural erection activities.

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Deliverables

Site Analysis

Location - The site should be related to major streets or landmarks previously existing. There should be documentation of distances and time from major places.

Proximity - The proximity of neighboring buildings and other obstructions can severely delay the construction process. Zoning of the neighborhood is important including the following: architectural patterns, street lighting, and condition of existing buildings. The immediate surroundings of the site are essential as well. The reaction of the surrounding buildings towards the site and people moving around should be analyzed.

Obstructions - Anything that may interfere with the work site must be removed. This includes overhead obstructions such as trees, power lines, and any other blockades deemed necessary.

Designated work areas - free and clear of any and all obstructions with enough space to physically perform the tasks required in erecting the steel building.

Unloading and staging areas - in close proximity to work areas. The off loading of building materials will coincide with job start date.

Vehicular Traffic Flow - The ability to access the site from the adjacent highway or road for both the construction project along with students and faculty.

Finished slab - Concrete slab is to be free of pits, depressions, and similar obstructions that may hinder the accurate elevation.

Anchor bolts and threads - properly placed and free of concrete. Inspection of anchor bolt setting should be preformed prior to erection. Rejection of anchor bolts will endure additional charges to be made for any and all work required to correct improper anchor bolt settings.

Structural Shapes to be Analyzed

Shapes ASTM Grade FyWide flange shapes A992 50

Channels, angles, plates and bars A36Rectangular (and square)hollow structural sections

A500 B 46 ksi

Steel pipe A53 B 35 ksiHeavy hexagon structural bolts A325

Heavy hexagon nuts A563Hardened washers F436

Anchor Rods and Bolts F1554 36Threaded rods A36

Shapes ASTM Grad KSI

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eWide flange shapes A992 50

Channels

angles

plates

A36

A500 B Fy =

8

Rectangular (and square)hollow structural sections

46 ksi

Steel pipe A53 B Fy = 35 ksi

Heavy hexagon structural bolts A325

Heavy hexagon nuts A563

Hardened washers F436

Anchor Rods and Bolts F1554 36Threaded rods A36

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Load Cases1) 1.4(D + F)2) 1.2(D + F + T) +1.6(L + H) + 0.5(Lr or S or R)3) 1.2D + 1.6(Lr or S or R) + (L or 0.8W)4) 1.2D + 1.6W + L + 0.5(Lr or S or R)5) 1.2D + 1.0E + L + 0.2S6) 0.9D + 1.6W + 1.6H7) 0.9D + 1.0E + 1.6H8.) 1.0D + 1.0L + 1.0E

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Pre-K Interior Signage Floor Plan

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Enlarged Classroom Floor Plan

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Code Regulations Analysis

Building Code: NFPA Life Safety Code, local & state building codes. Structural steel is that work defined in American Institute of Steel Construction

(AISC) "Code of Standard Practice" and as otherwise shown on drawings. This includes fabrication and erection of structural steel work, as shown on drawings including schedules, notes, and details showing size and location of members, typical connections, and types of steel required.

Shop drawings prepared under supervision of a Louisiana Licensed Structural Engineer, including complete details and schedules for fabrication and assembly of structural steel members, procedures, and diagrams.

Include details of cuts, connections, cambers, holes, and other pertinent data. Indicate welds by standard AWS symbols and show size, length, and type of each weld.

All shop drawings used in the field must bear the Architect/Engineer shop drawings review stamp with "No Exceptions Taken" indicated.

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Cost AnalysisPre-K Building Materials Labor Overhead Profit$164,339Structural Steel Cost

$57,518.65 $49,301.70 $24,650.85 $32,867.80

$7,915Anchor Bolts Cost

$2,770.25 $2,374.50 $1,187.25 $1,583.00

$1,940Misc. Fasteners Cost

$679.00 $582.00 $291.00 $388.00

$14,000Engineering Detail Cost

$4,900.00 $4,200.00 $2,100.00 $2,800.00

Total Profit = $37,638.80

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References

Berman, Gary S. "Structural Steel Design Awards Shortlist." Steel Construction 4.2 (2011): 93. Web.

"PythonX CNC Plasma Cutting System Beats Any Beam Drill Line or Coping Machine for Structural Steel Fabrication." PythonX CNC Plasma Cutting System. N.p., n.d. Web. 06 May 2015.

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Spring 2015 Semester Timeline Phase 1

January 19 – 23 Meet with advisor get approval on topic

January 26 – 30 Begin researching information on topic

February 2 – 6 Site Analysis;Begin Proposal Report layout

February 9 – 13 Preliminary Floor Plan Drawings

February 16 – 20 Begin Proposal Presentation layout;Watch the ET 492 Presentations

February 23 – 27 Structural Shape Analysis

March 2 – 6 Structural Shape Analysis Continued

March 9 – 13 Finalize Proposal Presentation & Report

March 16 – 20 Continued

March 23 – 27 Presentation of Initial Proposal

March 30 – April 3 Produce Rough Material Estimate

March 6 – 10 Continued

March 13 – 17 Building Codes

March 20 – 24 Economic Feasibility

March 27 – May 1 Continued

May 2 – 8 Final Presentation

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