Modular Construction: Using Composites

Nor Azrin bin Nor Azman1, Martyn Jones2a and Rayven Jay2b

Introduction
A building built using modular construction method requires the building elements, known as modules, to be prefabricated in a controlled environment, and away from the main
construction site[1]. The modules are made out of steel, and once completed, they will need to be transported back to the main construction site for assembly process. Unlike
conventional construction, this method proved to be very efficient in highly congested areas as it will help to minimize economic disruption due to the chaotic construction
works and the transportation of hazardous materials[2].
A prefab building module adds approximately 16000kg of mass onto a typical 15000kg lorry. Transportation of modules from manufacturing plant to the construction site
directly relates to fuel cost In general, fuel cost depends on 3 factors; the distance one has to travel, current fuel price and vehicle fuel consumption[3]. Studies have shown the
fuel consumption is proportionate to vehicle weight, where the amount of fuel increases as the vehicle increases and vice versa.
At the construction site, the modules are attached together to create a larger living space. Attachment of the modules can be made from side-to-side, top-to-bottom, and
front-to-back sequence, depending on the specification. However, this method of attachment adds unnecessary columns in between the two modules, which sectioned the area.
Therefore, it reduces the available living space and limits its applications.

The Problem
Logistics
o Transportation of heavy prefabricated modules from
manufacturing plant to main site using haulage vehicle put a
high price on fuel consumption.
Available Living Space
o The method of joining two modules to create larger living space
adds undesirable columns in the middle that sectioned the area,
and therefore reduced the available living space.

Challenges
Building Codes
o Building codes available are for metallic structure, but none for
polymer composite structures
Structural Integrity
o Removal of supporting columns led to excessive deflection of
floor beams
o Floor beam structure need to meet at least the minimum Factor of
Safety requirement governed by building codes.

Figure 1 shows the comparison between steel and composite beams weight in kilograms

Solution
Substitute metallic with composite materials
Building codes
o Apply limit state design for steel structure from Eurocode for base
line
o Use Eurocomp by Fiberline as guidelines for recommended limits
Structural integrity (using FEA)
o Deflection of composite beams must be <= L/360
o Factor of Safety shall be >= 2

Future Work
Multiple load cases
o Wind loading
o Seismic load
Environmental effect on composite
o Fatigue
o Fluids
o Weathering
o Temperature
o Fire and Flammability

Composite joining methods

o Adhesive
o Mechanical Joining
(fastener)
o Adhesive + Mechanical
Joining Combination
o Co-Curing Process
o Stitching/Z-Pinning

Figure 2 shows the deflection of steel and composite beams that lies within the recommended 34mm
limit by Eurocomp

References
[1] Mike Riley and Alison Cotgrave, Construction Technology 2:
Industrial and Commercial Building, Surrey:Palgrave Macmillan,
2014.
[2] Benjamin Beerman and Romeo Garcia, Prefabricated Steel
Bridge Systems: Final
Report, U.S. Department of
Transportation [Online], Available:
htps://www.fhwa.dot.gov/bridge/prefab/psbsreport02.cfm
[Accessed
5 October 2015]
[3] RACQ, Measuring Fuel Consumption, RACQ [Online].
Available: http://www.racq.com.au/cars-and-driving/cars/owning- andmaintaining-a-car/fuelsavingtips/measuring-fuelconsumption [Accessed 5 October 2015]

210, Jalan Tuanku Ahmad, Kampung Gong Kapas, 21100 Kuala Terengganu, Terengganu,
Malaysia;
2a
Glyndwr University Wrexham, Plas Coch, Mold Road, Wrexham, Wales, LL11 2AW;
2b
STRAND Aerospace (M) Sdn Bhd, PJ Trade Centre, 8, Jalan PJU 8/8a, Damansara Perdana,
47820 Petaling Jaya, Selangor, Malaysia.
1

Email: 0339975@gmail.com, martyn.jones@glyndwr.ac.uk, and rayven.jay@strandeng.com.my

Figure 3 compares the Factor of Safety(FoS) between the baseline beam model (steel) with composites
beam models (carbon and glass fiber), where the recommended FoS limit by Eurocomp is 2.

Acknowledgements
This study is partly supervised by STRAND Aerospace (M) Sdn Bhd (STRAND),
under Professional Development Center program organized by MARA, STRAND
and Glyndwr University.