This paper describes the application of Profiled Steel Sheet Dry Board (PSSDB) system as innovative lightweight composite school classroom modules

Awang, Hanizam

Nordin, Norhaiza

Wan Badaruzzaman, Wan Hamidon

English

This paper describes the application of Profiled Steel Sheet Dry Board (PSSDB)

system as innovative lightweight composite school classroom modules. The structural

composite panel system consists of profiled steel sheet attached to the dry board via

mechanical self drilling and self tapping screws. Compared to traditional building systems and

materials, the PSSDB system eliminates the used of conventional timber formworks, columns

and roof trusses in buildings. Besides, the proposed system has many advantages such as it

is lightweight, making construction less labour-orientated, shorter construction time, materials

optimisation, and provides better finished products. The proposed panel system falls under

the Industrialised Building System (IBS) category since all the structural panel components

are manufactured in a factory, transported and assembled into a structure or building with

minimal additional site work. The system was successfully implemented in two school

classroom modules at Sekolah Kebangsaan Telok Mas, Melaka, Malaysia

Repository@USM

 COMPLETE APPLICATION OF PROFILED STEEL SHEETING DRY BOARD SYSTEM AS SCHOOL CLASSROOM MODULES  1Hanizam Awang, 2Norhaiza Nordin, 3Wan Hamidon Wan Badaruzzaman 1Universiti Sains Malaysia, 2Universiti Malaysia Pahang, 3Universiti Kebangsaan Malaysia 1hanizam@usm.my, 2nhza@yahoo.com, 3whamidon@vlsi.eng.ukm.my   ABSTRACT: This paper describes the application of Profiled Steel Sheet Dry Board (PSSDB) system as innovative lightweight composite school classroom modules. The structural composite panel system consists of profiled steel sheet attached to the dry board via mechanical self drilling and self tapping screws. Compared to traditional building systems and materials, the PSSDB system eliminates the used of conventional timber formworks, columns and roof trusses in buildings. Besides, the proposed system has many advantages such as it is lightweight, making construction less labour-orientated, shorter construction time, materials optimisation, and provides better finished products. The proposed panel system falls under the Industrialised Building System (IBS) category since all the structural panel components are manufactured in a factory, transported and assembled into a structure or building with minimal additional site work. The system was successfully implemented in two school classroom modules at Sekolah Kebangsaan Telok Mas, Melaka, Malaysia.  Keywords: Profiled steel sheet, Dry board, Industrialised building system, School classroom modules.  1. INTRODUCTION In 2007, the government of Malaysia has announced an additional allocation of RM 2.6 billion for the development of education in rural areas (Jamdi, 2007). This is a boost to the grand Education Development Master Plan 2006-2010 (KPM, 2006) which has also proposed to build 5,138 classrooms under the Upgrading Rural Education Development programme in Sabah and Sarawak. The Minister of Education has also reiterated that schools which have limited space and are under enrolled in rural areas will use the cabin concept for the construction of their new computer labs (Habibah, 2007). In fact, the Ministry of Education (MOE) has already embarked on new rural school modules based on the cabin concept that has recently been tendered out for bidding by contractors for the state of Sabah. As part of the initiative related to the above needs, an Industrialised Building System (IBS), namely the Profiled Steel Sheeting Dry Board System (PSSDB) developed at Universiti Kebangsaan Malaysia has been utilised in a pilot project to build two temporary classrooms for Sekolah Kebangsaan Telok Mas, Melaka. This paper will discuss the salient features of the project.  2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)432 The PSSDB system is a lightweight composite system consisting of profiled steel sheet connected to dry boards by self drilling and self tapping screws. The screws play an important role in transferring the shear force between the dry board and profiled steel sheeting, thus resulting in composite action between the two components. The performance of a connection depends on the type of screw, profiled steel sheet and dry board used, and also on the spacing of the screws which together determine the degree of composite action and the stiffness of the structural composite system. The panel results in a strong and efficient composite structural system which can be assembled to virtually numerous sizes and strength combinations. The original concept of PSSDB system was first introduced by Wright and Evans (1986) as a replacement to existing timber joist floor. Figure 1 shows the typical composition of PSSDB system.           Figure 1.  Typical PSSDB system  The study of the behaviour of PSSDB floor, wall and roof system was done by Wan Badaruzzaman (1994), Wan Badaruzzaman et al. (1996), Wan Badaruzzaman and Wright (1998), Ahmed (1999), Ahmed et al. (2000), Benayoune et al. (2000), Ahmed et al. (2001), Akhand (2001), Wan Badaruzzaman et al. (2003), Shodiq (2004), Ahmed and Wan Badaruzzaman (2003, 2005), Hamzah (2005), Rahmadi (2005), Awang and Wan Badaruzzaman (2007), and Awang (2008).   The research works conducted show that the system can be used practically as a flooring system (as it was originally intended) as well as load bearing wall and roof systems. Various commercial projects have already implemented the system such as at the 5-star Hyatt Hotel in Kota Kinabalu, Sabah in 1997, UiTM Dry board Self-tapping screw Steel sheeting 2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)433 Tower, Shah Alam in 1997, UKM Bangunan Wawasan, exhibition gallery and solar house at UKM as well as a private house in Bangi (Wan Badaruzzaman et al., 2001).   2.  THE ADVANTAGES OF THE SYSTEM The PSSDB system has many advantages compared to traditional systems. According to Wan Badaruzzaman and Wright (1998), some advantages of the PSSDB system can be listed as below: i. PSSDB is relatively very light as evidenced in Table 1 below:  Table 1: Weight of floor panel with varying dry board thicknesses Thickness of  Profiled Steel Sheet, Peva 45 (mm) Thickness of  Dry Board, Cemboard (mm) Weight of 1 m x 2.4 m PSSDB panel (kg) 16 67.2 18 73.2  0.8 20 79.2  ii. The overall span to depth ratio obtained from previous investigation (Wright et al., 1989 and Wan Badaruzzaman and Evans, 1994) is 30 in comparison to one of approximately 16 for the traditional timber floor. It was shown that the PSSDB system could be designed to be 100 mm less deep than the traditional timber joist flooring system for a 4 m span floor carrying domestic loading. iii. The construction procedure is simple. It doesn’t require temporary formwork or propping. Therefore, it can be erected quickly by unskilled labour, hence cost saving. iv. The system is easily transportable due to its lightweight. It can be stacked on top of each other during transportation. v. Renovation work involving PSSDB panels is much easier to handle. vi. For roofing system, it will posses a significant advantage of doing away with the internal bracing of normal roof truss construction and therefore creating additional living space.   2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)434 Most importantly, according to Badir & Razali (1999), this system falls under the concept of Industrialised Building System (IBS). The IBS is a methodology whereby the local construction industry is driven and encouraged towards the production and utilisation of pre-fabricated and mass produced building components off-sites in factories or controlled environment, to be transported and installed rapidly at the sites (Rahmadi et al. 2002). In terms of the environmental aspects, the PSSDB system is environmentally friendly as there is no wastage of construction materials. The panels could also be insulated to make them sound and heat proof.   3. THE SCHOOL CLASSROOM MODULES The school classroom modules shown below (Figure 2) has been built based on PSSDB IBS and has been implemented for the first time at Sekolah Kebangsaan Telok Mas, Melaka, Malaysia. The total area of the each classroom module is approximately 105 m2.       a. 3D view    b. Front elevation  2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)435     c. Side elevation    d. Rear elevation Figure 2: Classroom modules   Three types of structural panel members utilising the PSSDB system for the modules are the floor, wall and roof panels. The materials used for the modules are listed in detail in Table 2.   Table 2: Details of the individual panel materials Structure Panel Profiled steel sheet  Dry board Connectors  Type Thickness (mm) Type Thickness (mm) Type Length (mm) Floor Peva 45 0.8 Cemboard 18 MK self drilling screws 32  Wall Cliplock CL660 0.48 Primaflex 6 (inner) and 9 (outer) Powerdrive DX-RW 25 Roof Cliplock CL660 0.48 Primaflex 9 Powerdrive DX-RW 25 2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)436 3.1 Floor The floor panel is constructed out of a single skin Cemboard (dry board) connected to Peva 45 (profiled steel sheet). Cemboard conveniently forms the flat walking surface of the floor. The panel thickness is only about 65 mm which is much less than that of the typical concrete slab.  The panel is also light enough to be lifted by two persons and can be stacked and delivered to the construction site with ease. This is especially beneficial for construction in remote areas where the basic infrastructure is limited and inaccessible to the use of crane and other heavy machineries. The floor panel size is 2400 mm x 1000 mm with screw spacing of 200 mm and is designed as simply supported. Figure 3 below shows a typical cross section of PSSDB floor panel.          Figure 3: The cross section of a floor panel           Figure 4: Two workers lifting a 2.4 m PSSDB floor panel  3.2 Wall The wall panel is constructed out of a double skin Primaflex (dry board) attached to a central core of CL660 (profiled steel sheet). The width of the wall panel is 660 mm. Figure 5 below shows a typical PSSDB wall panel with window opening. The lengths (heights) are however varied according to the tapered height of the wall.  1 m 2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)437  Figure 5: Double skin wall panel with window openings  3.2 Roof Based on the original concept of the system, the application of the PSSDB system has been extended to form a new concept of roofing system. The new approach will eliminate the roof trusses normally required in traditional roof structures. There are many advantages of the PSSDB roof system when compared to traditional forms of pitched roof structures in small and medium sized buildings which normally would involve the use of either a purlin and rafter or a trussed rafter system. This clearly arises due the load bearing capacity of the PSSDB system and due to it is made of more durable materials. The roof system was designed to cater for a dead load of 0.31 kN/m2 and an imposed load of 0.25 kN/m2. Two sizes of panels were involved; 750 mm wide x 2000 mm length (14 nos) and 750 mm wide x 4000 mm length (28 nos) and the screw spacing is 100 mm. Table 2 shows the details of the individual components and Figure 6 shows the PSSDB panel system for the roof.          Figure 6(a). Reversed position of proposed PSSDB roof panel   Ajiya CL 660 Rockwool Dry board 9 mm Self drilling screw 2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)438  Figure 6(b) Proposed PSSDB roof panel  4.   PREPARATION AND CONSTRUCTION PROCESS  The site was cleared and prepared prior to the beginning of the installation of the modules. The footing was constructed out of normal reinforced concrete. All modules were prefabricated in the factory as shown in Figure 7.  The erection process started with the placement of the floor after construction of the floor beam has been completed. After all the floor panels have been placed, the wall panels are installed one after another. Finally, the roof panels were installed into position. Figures 8 (a-d) show the processes of erection of the modules, while Figure 9 shows the completed modules. The whole construction process was completed in a timely manner with minimal material wastage, less site materials, neater and safer site condition and better quality control.    Figure 7.  Stacks of PSSDB panels at the construction site   Rockwool Dry board 9 mm Self drilling screw Top layer Ajiya CL 660 2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)439       Figure 8(a). Construction of footing        Figure 8(b). Erection of floor panel    Figure 8(c). The propped wall and laid floor panels  Figure 8(d). Erection of roof panels  2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)440     Figure 9: Completed classroom modules 5. CONCLUSION This paper has described the application of Profiled Steel Sheet Dry Board (PSSDB) system as a structural component in constructing innovative lightweight composite school classroom modules. The system has many advantages. It was successfully implemented in two school classroom modules at Sekolah Kebangsaan Telok Mas, Melaka, Malaysia. The described application manifests the potential of the PSSDB system to be implemented as a complete IBS in the construction of buildings.   6. REFERENCES  Ahmad, E., (1999). Behaviour of profiled steel sheet dry board folded plate structure. PhD Thesis. Universiti Kebangsaan Malaysia.  Ahmed, E. and Wan Badaruzzaman, W.H., (2003). Finite Element Prediction of the Behavior of Profiled Steel Sheet Dry Board Folded Plate Structures – An Improved Model, International Journal of Engineering, Transaction B: Applications, 16(1), pp. 21-32.  Ahmed, E. and Wan Badaruzzaman, W.H., (2005). Finite Element Prediction on the Applicability of Profiled Steel Sheet Dry Board Structural Composite System as a Disaster Relief Shelter, Journal of Construction and Building Materials, 19(4), pp. 285-295.  Ahmed, E., Wan Badaruzzaman W.H. and Wright, H.D., (2000). Experimental and Finite Element Study of Profiled Steel Sheet Dry Board Folded Plate Structures, Thin-Walled Structures 38(2), pp. 125-143.  Ahmed, E., Wan Badaruzzaman, W.H., Rashid, A.K. and Taib, K.A., (2001). Analysis and experiments of a composite folded plate roof structures. Proceeding of Construction Technology Conference, pp. 39-50.  Akhand, A.M., (2001). Nonlinear finite element modeling and partial plastic analysis of composite profiled steel sheeting dry board continuous floor. PhD Thesis. Universiti Kebangsaan Malaysia.  Awang, H., (2008). Development of profiled steel sheeting dry board (PSSDB) roof panel system. PhD Thesis. Universiti Kebangsaan Malaysia. 2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)441  Awang, H. and Wan Badaruzzaman, W.H., (2007). Development of profiled steel sheet dry board (PSSDB) roofing system. Proceeding of International Conference on Built Environment, Penang.  Badir, Y.F. and Razali, A.K., 1999. Theory of classification & Badir-Razali building systems classification. IJM JURUTERA.  Habibah Omar (2007). Konsep kabin sekolah pedalaman, kurang murid. Utusan Malaysia, 11 April.    Hamzah, S.H., (2005). Kelakuan struktur dinding sistem komposit keluli berprofil papan kering (PSSDB) dengan bukaan. PhD Thesis. Universiti Kebangsaan Malaysia.  Jamdi Nasir (2007). Tambahan RM2.6b dilulus -- Tingkatkan mutu, prasarana pendidikan luar bandar – PM. Utusan Malaysia, 16 Februari.    Kementerian Pelajaran Malaysia (2006). Plan Induk Pembangunan Pendidikan 2006-2010. Rancangan Malaysia ke 9. Bab 7: Merapatkan Jurang Pendidikan.   Rahmadi, A.P., (2005). Sistem bangunan berindustri berasaskan sistem panel komposit kepingan keluli berprofil papan kering. PhD Thesis. Universiti Kebangsaan Malaysia.  Rahmadi, A.P., Wan Badaruzzaman, W.H., Zain, M.F.M., Rashid, A.K., Ismail, A., Yusof, K., Osman, S.M. and Shodiq, H., (2002). Profiled steel sheeting/ dry board (PSSDB) Industrialised Building System. Proceeding of 2nd World Engineering Congress 2, pp. 413-416.  Shodiq, H.M., (2004). Prestasi sistem baru lantai keluli berprofil papan kering dengan isian konkrit. PhD Thesis. Universiti Kebangsaan Malaysia.  Wan Badaruzzaman, W.H., (1994). The behaviour of profiled sheet/dryboard system. PhD Thesis, University of Wales.  Wan Badaruzzaman, W.H., Ahmed, E. and Rashid A.K., (1996). Out-of plane bending stiffness along the major axis of profiled steel sheet dryboard composite floor panels. Jurnal Kejuruteraan, 8, pp. 79-95.  Wan Badaruzzaman, W.H. and  Evans, H.R., (1994). Profiled steel sheeting/ dry board system as an alternative to existing traditional systems. Proceeding of the 1st International Conference ICAST, pp. 139-145.  Wan Badaruzzaman, W.H. and  Wright, H.D., (1998). Lightweight  thin walled profiled steel sheeting/ dry board (PSSDB) composite flooring system. Proceeding of International Conference on Thin-Walled Structures. pp. 355-365.  Wan Badaruzzaman, W.H., Akhand, A.M., Shodiq, H.M., Khalim, A.R. and Taib, T.A. (2001). Development and application of composite profiled steel sheeting dry board floor system. Proceeding of Construction Technology Conference. pp 29-37.  2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)442 Wan Badaruzzaman, W.H., Zain, M.F.M., Akhand, A.M., and Ahmed, E., (2003). Dry board as load bearing element in the profiled steel sheet dry board floor panel system - structural performance and applications, Journal of Construction and Building Materials 17, pp 289-297.  Wright, H.D. and Evans, H.R., (1986). Profiled steel sheeting for the replacement of timber flooring in building renovation. SERC Grant GR/D/76875. United Kingdom.  Wright, H.D., Evans, H.R. and Burt, C.A., (1989). Profiled steel sheet/ dry boarding composite floors. The Structural Engineer 67: 7, pp. 114-129.                                          2nd INTERNATIONAL CONFERENCE ON BUILT ENVIRONMENT IN DEVELOPING COUNTRIES (ICBEDC 2008)443

Complete Application Of Profiled Steel Sheeting Dry Board System As School Classroom Modules

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