Modular Home Office Residential Container with Flat Pack
Modular Home Office Residential Container with Flat Pack are sectional prefabricated buildings, or houses, that consist of multiple sections called modules. "Modular" is a method of construction differing from other methods (e.g. "stick-built" and other methods such as off-site construction). The modules are six sided boxes constructed in an exterior (sometimes, remote) facility, then delivered to their intended site of use. Using a crane, the modules are set onto the building's foundation and joined together to make a single building. The modules can be placed side-by-side, end-to-end, or stacked, allowing a wide variety of configurations and styles in the building layout.
Modular Prefabricated buildings, also called prefabricated buildings, differ from mobile homes, which are also called manufactured homes, in two ways. First, modular prefabricated building/homes do not have axles or a frame, meaning that they are typically transported to their site by means of flat-bed trucks. Secondly, modular prefabricated buildings must conform to all local building codes for their proposed use, while mobile homes, made in the United States, are required to conform to federal codes governed by HUD (U.S. Department of Housing and Urban Development).[1] There are some residential modular prefabricated buildings that are built on a steel frame (referred to as on-frame modular) that do meet local building codes and are considered modular homes, rather than mobile homes.
1.Technical Data
Technical characteristics of containers type elements for the modular prefabricated building
(1)ISO standard dimensions of 20 feet STANDARD containers-optionally 10 up to 30 feet
(2)length=6.058 mm (optionally 3.048 - 9.100 mm)
width=2.438 mm (optionally 3.000 mm)
(3)exterior height=2.591 mm (optionally 2.791 mm or 3100 mm)
(4)inner height = 2.300 mm (optionally 2.500 mm or 2800 mm)
container construction difference
ZINCED metal profyles 3 mm connected with scres
container painting
(1)option: on customer wish in RAL color
(2)option: painted on customer wish in RAL color
container floor opening for forklift
(1)without forklift pockets
(2)option: with forklift pockets for containers up to 7.335 mm
(3)holes distance 1.506mm
container roof construction
container exterior wall and side panels
(1)50 mm poliurethane panel, externally micro-corrugated RAL 9002
internally smooth RAL 9010 (white)
(2)option: 60 mm mineral wool, both side plastificated in RAL 9002
(3)option: 60 mm mineral wool, both side plastificated in RAL 9002, internally enriched chipboard 100 WHITE010 (white)
(4)option: 80 mm poliurethane panel, both side plasticated steel plate RAL 9010 (white)
(5)option: 100 mm poliurethane panel, both side plasticated steel plate RAL 9010 (white)
(6)option: 100 mm mineral wool, both side plasticated steel plate RAL 9010 (white)
(7)option: 120 mm mineral wool, both side plasticated steel plate RAL 9010 (white)
container exterior and inner walls
PVC with polyurethane filling 40 mm, clear opening 79/202 cm
container windows and doors
(1)option: windows without shutters
(2)option: windows with shutters
container isolation, coefficient of thermal resistance
floor - U = 0,37 W / m2k
roof - U = 0,39 W /m2k
wall panels - U = 0,41 W /m2k
windows - U = 2,40 W / m2k
Flat Pack Containerized Modular House Solution
Individual KXD container modules
They are assembled in KXD factory production from KXD manufactured elements. They come to the market as finished product as residential or office space equipped with or without equipment. Individual container modules are used as a single objects as bungalows, dormitories, offices, warehouses, shops, workshops and a built MODULE for the construction of various shapes and purposes.
dimensions and weights
container location preparation
container handling and lifting
option: Forklift for lifting containers up to 7.3 m in lenght if container has forklift holes
container electric installations
Illustration of singel module for multi-storey modular house
Insight into the modular house
Wide application for Containerized Modular House Solution:
Modular Houses may be used for long-term, temporary or permanent facilities, such as construction camps, schools and classrooms, civilian, and industrial facilities.[2] Modular buildings are used in remote and rural areas where conventional construction may not be reasonable or possible.Other uses have included churches, health care facilities, sales and retail offices, fast food restaurants and cruise ship construction. They can also be used in areas that have weather concerns, such as hurricanes.
Construction process for modular house
Modular components are typically constructed indoors on assembly lines. Modules' construction may take as little as ten days but more often one to three months. Completed modules are transported to the building site and assembled by a crane.[4] Placement of the modules may take from several hours to several days.
Manufacturing considerations
The entire process of modular construction places significance on the design stage. This is where practices such as Design for Manufacture and Assembly (DfMA) are used to ensure that assembly tolerances are controlled throughout manufacture and assembly on site. It is vital that there is enough allowance in the design to allow the assembly to take up any "slack" or misalignment of components. The use of advanced CAD systems, 3D printing and manufacturing control systems are important for modular construction to be successful.[5] This is quite unlike on-site construction where the tradesman can often make the part to suit any particular installation.
Advantages of modular house
Modular buildings are argued to have advantages over conventional buildings, for a variety of reasons.
- Speed of construction/faster return on investment. Modular construction allows for the building and the site work to be completed simultaneously. According to some materials, this can reduce the overall completion schedule by as much as 50%.
- Indoor construction. Assembly is independent of weather, which can increase work efficiency and avoids damaged building material.
- Ability to service remote locations. Particularly in countries in which potential markets may be located far from industrial centers, such as Australia, there can be much higher costs to build a site-built house in a remote area or an area experiencing a construction boom such as mining towns.[citation needed]
- Low waste. With the same plans being constantly built, the manufacturer has records of exactly what quantity of materials are needed for a given job. While waste from a site-built dwelling may typically fill several large dumpsters, construction of a modular dwelling generates much less waste.
- Environmentally friendly construction process. Modular construction reduces waste and site disturbance compared to site-built structures.[citation needed]
- Flexibility. One can continually add to a modular building, including creating high rises.[6]
Generally speaking, our Steel structure warehouse/workshop are categorized as below:
(1) Simple Steel Structure Workshop
|
| Main structure |
Single span: L -shorter than 18m, H -lower than 6m |
| Maintenance system |
Roof |
Colored steel sheet with 50mm glass wool insulation |
| Wall |
Colored steel sheet |
| Door |
Simple steel rolling shutter (within 10m2) |
| Window |
Very few |
| Usage |
Warehouse, workshop |
| Standard and suitable market |
Africa, Middle-East, South America (no snow, wind load below 0.4kn/m2) |
| |
(2) Standard Steel Structure Workshop
|
| Main structure |
Single span: L -shorter than 24m, H -lower than 8m |
| Maintenance system |
Roof |
Colored steel sheet with 50mm glass wool insulation |
| Wall |
Colored steel sheet or 50mm EPS sandwich board |
| Door |
Wind resistance rolling door(within 15m2) |
| Window |
Alu. Alloy (can use with skylight) |
| Usage |
Warehouse, workshop, shopping mall, exhibition hall, super market |
| Standard and suitable market |
Snow loading below 0.5kn,wind loading below 0.5kn/m2 |
| |
3) Coastal (high wind speed) Steel Structure Workshop
|
| Main structure |
Single span: L -shorter than 18m, H -lower than 6m |
| Maintenance system |
Roof |
Colored steel sheet with 50mm glass wool insulation |
| Wall |
Colored steel sheet or 50mm EPS sandwich board |
| Door |
Wind resistance rolling door (within 15m2) |
| Window |
Alu. Alloy (can use with skylight) |
| Usage |
Warehouse, workshop, shopping mall, exhibition hall, super market |
| Standard and suitable market |
Coastal areas (snow loading below 0.7kn, wind load below 1.2kn/m2) |
| |
(4) Cold Region (heavy snow) Steel Structure Workshop
|
| Main structure |
Single span: L -shorter than 18m, H -lower than 6m |
| Maintenance system |
Roof |
EPS/rock wool/PU sandwich board |
| Wall |
EPS/rock wool/PU sandwich board |
| Door |
PU foamed rolling door |
| Window |
Alu. Alloy, Hollow glass |
| Usage |
Warehouse, workshop, shopping mall, exhibition hall, super market |
| Standard and suitable market |
Cold regions such as Norway, Russian, North Canada, Finland, Iceland, Greenland, Sweden, etc. (snow loads below 3kn, wind load below 1KN/M2) |
| |
(5) Steel Structure Workshop with Crane (5T, 10T, 20T)
|
| Main structure |
Single span: L -shorter than 20m, H -lower than 10m |
| Maintenance system |
Roof |
Colored steel sheet with 50mm glass wool insulation |
| Wall |
Colored steel sheet or sandwich board |
| Door |
Wind resistance rolling door (within 15m2) |
| Window |
Alu. Alloy (can use with skylight) |
| Usage |
Warehouse, workshop |
| Standard and suitable market |
Snow 0.5kn, wind load below 0.5kn/m2 |
| |
| Name |
steel structure hangar |
| Standard |
GB |
| Main Material |
| Main frame |
Q 235 &Q345 |
| Bracing |
Angel and round pipe |
| Purlin |
C or Z section steel |
| Connection |
Normal bolts and High strength bolt |
| Roof panel |
Corrugated steel sheet or EPS, Glass wool, Rockwool, PU, etc sandwich panel |
| Wall panel |
Corrugated steel sheet or EPS, Glass wool, Rockwool, PU, etc sandwich panel |
| Accessories |
Skylight belts, Ventilators, Down pipe, Out gutter |
| Windows |
Aluminum window/PVC sliding window |
| Doors |
Sliding door;Rolling up door;Folding tip-up door;PVC door |
| Surface |
Hot dip galvanize or Painted |
| Packing |
Main frame packed in 40FT container, maintenance packed in 40HQ container |
| Main market |
North America, South America, Eastern Europe, Southeast Asia, |
| Africa, Oceania, Mid East, Eastern Asia, Western Europe |
Specifications
Name |
Steel Structural |
Dimensions |
Length |
H beam:4000-15000mm |
Thickness: |
web plate:6-32mm
wing plate:6-40mm |
Height |
200-1200mm |
Color |
according to customers |
|
|
Advantages |
1. design according to customers' requirements |
2. manufacture under complete quality control system---ISO9001 |
3. Fast construction and easy installation . |
4. installation with instruction of experienced engineers |
5. Hight quality and low-price . |
6. Wide span , Flexible design , Long using life |
7.Others: environmental protection, stable structure, earthquake resistance, water proofing, and energy conserving. |
| |
Main components |
Main frame |
H beam |
Purlin |
C or Z section steel purlin |
Brace |
Anchor, ordinary, high strength bolt |
Bolt |
Sandwich panel or steel plate |
Roof &wall |
PVC or aluminum alloy door |
Door |
Sliding or rolling door |
Insulation panel |
EPS,XPS,Rock wool , PU sandwich |
Material |
Q235,Q345 China standard steel |
Sheet |
0.5mm or 0.6mm galvanized sheet |
KXD's H Section Manufacturing Equipment and Process
Steel plate cutting→H section assembly→Automatic welding-H section strengthening→Assembly→Manual welding→Shot blasting-Painting→
Storage
I.Steel plate cutting
The H section steel plate should be checked again by the factory and shall be applied under the condition of up to design and specified requirements after checking. Steel plate cutting should be aimed at quality guarantee and material saving. For each process like plate cutting,H type assembly, components assembly and pre-assembly should be carried out by profession setting-out worker precisely on processing surface and assembly sample plates.To guarantee the accuracy of the components'geometrical dimension,tolerance of form and position, angle and contact surface,inspection is necessary by inspector after setting out.In order to ensure the cutting quality,the surface of the ultra-thick plate is subjected to the surface carburizing hardness test before cutting.The CNC cutting equipment is preferred for cutting.The high purity 98.0% acrylic gas and 99.99% liquid oxygen gas are used to guarantee the smoothness and flatness of the cutting surface without notches and slags.The groove is cut by a special imported cutting machine.
Equipment name: Portable CNC Fire-cutting machine
Model No.: CNCDG-1530
Application feature: steel plate cutting(5-100mm plate cutting thickness), beveling of the edge.Advantageous in small equipment and easy-to-move. Mainly for cutting regular and irregular small components and beveling of the plate.
Equipment name:Straight flame cutting machine
Model No.:DZCG-4000A
Application feature:steel plate cutting(5-100mm plate cutting thickness),Y flange plate, web plate cutting, effective cutting width: 3200mm
Equipment name:CNC cutting machine
Model No.:CNC-4000C
Application feature:steel plate cutting(5-100mm plate cutting thickness),Y flange plate,web plate and irregular component cutting,effective cutting width: 3200mm
Equipment name: Radial drilling machine
Model No.:Z3050*16/1
Application feature:Maximum drilling diameter φ50mm,Mainly for processing of component bolt-connection holes
Equipment name:Puncher machine
Model No.:JH21-400
Application feature:Maximum stamping pressure-400 ton,Mainly for plate punching, blanking, bending and shallow stretching
Equipment name:Shearing machine
Model No.:Q11Y-25*2500
Application feature:cutting width 2500mm and cutting thickness 3-25mm
II.H section steel assembly
The assembly process is set up on the imported H section production line.4 hydraulic positioning system press firmly against between the upper/lower flange and web plates in position. The adjust the parallelism of the flange plates and perpendicularity between flange and web plates and get them fixed after. The fixing welding should adopt C02 gas shielded welding.
Equipment name:H section steel assembly machine
Model No.:Z20B
Application feature:mainly for H type assembly u,flange width 150-800mm,web height 160-2000 mm
III.Automatic welding
The H section steel members will be hoisted into the gantry-type submerged arc automatic welding machine for welding.The welding process should be carried out in accordance with specified welding sequence and regulation parameters.Preheating, which uses the electrical heaters, is necessary for the ultra-thick plates of components.The set temperature shall be determined based on the specified one.Please see factory welding process documents for detail.
Equipment name: Gantry-type submerged arc automatic welding machine
Model No.:LHA5ZB
Application feature:Mainly for assembly welding of H section steel whose maximum cross section up to 800mm×2000mm
IV.H section steel strengthening machine
H section steel strengthening process: Correction of flange flatness by using H section steel flange plate strengthening machine.Flame-correct the perpendicularity between the H section flange and web plate under special circumstances and then correct the side bending of the H section steel. The flame temperature should be controlled under the range of 600~800ºC.
Equipment name:H section steel strengthening machine
Model No.:YTJ60B
Application feature:Mainly for correcting the deformation of I beam or H section steel flange plate during welding process,flange width 200-1000mm, flange thickness≤60mm, web height≥350mm
Equipment name:H section flange strengthening machine
Model No.: HYJ-800
Application feature:Mainly for correcting the deformation of I beam or H section steel flange plate during welding process,flange width 160-800mm,flange thickness≤40mm,web height≥160mm
V.Simulated assembly of component
1.Get familiar with component shop drawing and technical requirements.
2.The model components need to re-check by related department after making and finalizing of the model components and then to assemble.
3.Accurate mark-up
4.Inspect the component after first assembly.For multi-group components, pre-assembly for the first group and then batch assembly after qualified test.
VI.Manual welding
VII.Shot blasting
Equipment name:10-ramming heads shot blasting machine
Model No.:QH1525
Application feature:Mainly for shot blasting of section steels including H section steel, welded members and steel plate,10 ramming head; Machine entry size:1500Í2500 and member at 1200Í2000 size could pass the machine at once; up to Sa2.5 Grade.
VIII.Painting
The surface of the members should be in even,flat, glossy and full painting without manifest of cracking, peeling and pin holing.The color and coating thickness should also meet design requirements.If there is no certain requirements,the following standards should be followed:thickness is 150μm indoor while 125μm outdoor.The allowable deviation is -25μm.The allowable deviation of dry paint film thickness for each-time painting
Two coats of primer:thickness being40±5μm; Two coats of finish paint:thickness being 60±5μm.
Equipment name:Airless sprayer
Model No.:CPQ9CA
Application feature: Derived capacity:56 L/min,Air consumption:50~1200 L/min.Mainly for surface paint of structural members, Pressure ration: 32:1
Applicable Codes
LATEST INTERNATIONAL CODES COMPLIANCE
A. (GB50009-2012): Load code for the design of building structures
Loads on all buildings are applied in accordance with:
2012 edition of the Load code for the design of building structures
B. (MOHURD): Ministry of Housing and Urban-Rural Development of the People's Republic of China
Manufacturing and Erection tolerances are applied as per:
GB50205-2001 edition Code for acceptance of construction quality of steel structures
C.(MOHURD): Ministry of Housing and Urban-Rural Development of the People's Republic of ChinaHot rolled sections and built up sections are designed in accordance with:
GB50017-2017 Code for design of steel structure
D. CISA - China Iron & Steel Association - Latest Edition
Cold formed members are designed in accordance with:
GB50018-2002 Technical code of cold-formed thin wall steel structures
E. (MOHURD): Ministry of Housing and Urban-Rural Development of the People's Republic of China
Welding is applied in accordance with:
JGJ81-2002 Technical specification for Welding of steel structure of building
F. Surface treatments are applied in accordance with:
GB/T 8923.1 Preparation of steel substrates before application of paints and related products-Visual assessment of surface cleanliness-Part 1: Rust grades and preparation grade of uncoated steel substrates and of steel substrates after overall removal of previous coatings
STRICT DEFLECTION CRITERIA
| Deflection |
Type of structural members |
Deflection Limitation |
| Vertical Deflection |
Portal frame rafter |
Only support corrugated steel sheets roof and cold-formed section purlins |
L/180 |
| If there is ceiling system |
L/240 |
| If there is top running crane |
L/400 |
| Mezzanine floor |
Main beam |
L/400 |
| Secondary beam |
L/250 |
| Purlins |
Only support corrugated steel sheets roof |
L/150 |
| If there is ceiling system |
L/240 |
| Corrugated roof steel sheet |
L/150 |
| Lateral Deflection |
Wall panel |
L/100 |
| Wind columns or wind truss structures |
L/250 |
| Wall beam |
Only support corrugated steel sheet wall |
L/100 |
| Support masonry wall |
L/180 and ≤50mm |
Material Specifications
The material standards for which the building components have been designed as per specifications.
STANDARD MATERIAL SPECIFICATIONS
| Material Specifications |
| No |
Components |
Specifications |
Minimum yield strength |
Applicable Design Code |
| 1 |
Built -up
(Plates) |
GB/T1591-2008 |
Fy = 34.5 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 2 |
Hot Rolled |
Angles |
GB/T3274-2007 |
Fy = 23.5 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
Beams |
GB/T11263-2010 |
Fy = 23.5 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 3 |
Cold Form
|
Galvanized |
GB/T 2518-2008 |
Fy = 45.0 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 4 |
Roof panel/Wall panel
(Zinc) |
GB/T12754-2006 |
Fy = 34.5 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 5 |
Roof panel/Wall panel
(Alu) |
GB/T12754-2006 |
Fy = 34.5 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 6 |
X-Bracing |
Galvanized cable bracing |
GB/T 700-2006 |
Fu = 157 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 7 |
Anchor bolts
|
GB/T 700-2006 |
Fu = 40.0 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 8 |
High strength Bolts |
GB/T 1228-2006 |
Ft = 30.3 kN/cm2
Fu = 72 to 83 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
| 9 |
Machine Bolts
|
GB/T 1228-2006 |
Ft = 13.8 kN/cm2
Fu = 41.0 kN/cm2 |
CISA - China Iron & Steel Association - Latest Edition |
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