off-Site Prefabricated Modular Steel Structure Construction for House

• Customization: Available
• Quality Management System: ISO9001
• Color Reference: Ral
• Model NO.: MS-023
• Construction Period: 7 Days
• Life Cycle: 20 Years
• Project Management: One-Stop Solution
• Transport Package: Ocean Freight/Flat Pack
• Specification: 6055*2435mm
• Trademark: KXD
• Origin: China
• HS Code: 9406900090
• Production Capacity: 300 Sets

Product Description

Off-site Prefabricated Modular Construction for Homes

The modular unit or container is designed as a light solid construction consisting of floor and roof frames and corner profiles. The system enables compounding of individual containers in longitudinal and transverse directions without limits. It also enables compounding of containers in 2 floors in height (ground floor + first floor), or in 3 floors in height for warehousing of these containers (ground floor + 2 floor). Wainscots of the container are made of light insulation panels and offer pleasant climate in the interior due to their building and physical properties.
Dimensions and Tare (ISO Standard 1161)

1. External length 20'/ (inner length) 20′: 6.055m/(5.851m)
2. External width/ (inner width): 2.435m/(2.231m)
3. External height/inner height: 2.790m/(2.510m)
4. Tare: 1950 Kg
5. 

(1)Steel Framework

Material::cold formed steel profiles in a thickness of 3 to 4mm (bottom rails).
 
Surface working::shot blasting, epoxy ground coat in a thickness of 30 μm, final vinyl acrylic coat in a thickness of 60-70 μm.
 
Fittings:8 corner fittings (dimensions according to ISO standard 1161), rainwater pipe in the roof framework, plate thickness of 10mm excluding top corner fittings of the top kit of each bundle (20mm thickness)
 
Forklift openings:openings for fork-lift pockets in the floor framework, dim 88*250mm in a distance of 1700 mm

(2)Floor Composition

External wainscot:flat galvanized steel sheet metal in a thickness of 0.5mm.
 
Insulation filling: noncombustible mineral wool in a thickness of 100 mm among hollow steel transverse supports. Mineral wool density:50 Kg/m³
 
Steam blockade: PE foil in a thickness of 80 μm

 
Cement board:
CCA boards (Cellulose Fiber Cement Board, Autoclaved)
in a thickness of 18 mm Density: 1500Kg/ m³
 
Reaction to Fire Classification:A1 certified ISO EN 13501
 
PVC flooring covering in a thickness of 1.5mm
 
Permitted loading: 4 .5 KN/m2 or 6 KN/m2 (reinforced under-structure)
K value: 0.45 W/ m2K
 
R value (Thermal Resistance) = 2.2 m2K/W

(3)Ceiling Composition

(50mm sandwich mineral wool panel)
External wainscot: 1.6 mm thick corrugated "ISO" roof,CORTEN made,and shot blasted&painted.
Steam blockade:PE foil in a thickness of 80μm
Insulation filling:noncombustible mineral wool in a thickness of 50 mm among 30X50X2 mm steel square bars. Mineral wool density: 50 Kg/ m3
Ceiling made of 50 mm thick mineral wool sandwich panels screwed to the steel beams of the roof frame. Sandwich panel composition:
Meteor water outlet: 4 each of PVC rainwater pipes, diameter 50mm in corner pillars
K value: 0.45 W/ m²K
R value (Thermal Resistance) = 2.2 m²K/W
Galvanized and painted steel sheet metal on both sides. Steel thickness: 0.5mm, white color
 
Insulation filling: mineral wool in a thickness of 60mm, density 120 Kg/m3
 
Permitted loading (standard roof) : 2.1 KN/m2

(4)Facade Walls

Sandwich mineral wool
Side panels' width:1140mm; total panel thickness: 60mm.
Five panels fit into the long side and two panels fit into the short side of
container and they are fully interchangeable
Composition:
External wainscot:
Galvanized and painted steel sheet metal in a thickness of 0.5mm, white
color
Insulation filling:
Mineral wool in a thickness of 60mm
Inner wainscot:
Galvanized and painted steel sheet metal in a thickness of 0.5mm, white color.
Permitted loading: 100 kg/m²
Mineral wool density: 120 Kg/m³
K value: 0.71 W/ m2K
Fire rating: 36 minutes according to GB 12955-91 and 20 minutes according to BS 476

(5)Doors

External Aluminum door. Single fold, 40mm thick, made of:

1. a frame in pre painted aluminum
2. hot galvanized and pre painted steel sheets (inside and outside)
3. insulated with PL (polystyrene)
4. Net opening dimensions: 820 x 1985 mm; furnished with a handle lock with 3 keys.

Composition:

1. External frame: galvanized and painted steel profiles, thickness 0.7 mm
2. External and internal wainscot: galvanized and painted steel sheet metal in a
   thickness of 0.7mm.
3. Equipped with 3 hinges, lock and anti-burglary flange
4. Insulation filling: non-combustible mineral wool in a thickness of 50mm.
5. Mineral wool density: 60 Kg/m3

Windows
Made of PVC, white color, with dimensions 800 to 900 mm× 1100 to 1200mm,

1. glazed with double layer glass in a thickness of 4/15/4mm, with "tilt & swing"
2. Mechanism with aluminum made rolling shutters

(5)Electrical Installations

1. Standard: UK Specification
2. Voltage: 220 V, 50 Hz single phase
3. Network connections: suitable-connection plug/socket, 3-5 poles 32 A +, 220V ~ mounted on the top frame in upper corners of a shorter side wall
4. Inner distribution system: cables of suitable dimensions (6, 2.5, 1.5 mm2 for 220 voltage, flush-mounted.
5. Protection: protective current switch (40 A +/2E/4E-0,03A), automatic fuses (C-characteristics) of suitable power (6A, 10A, 16A, 20A)
6. Earthing: galvanized connector with a steel plate of dimensions 30x80mm welded on the bottom frame
7. Fittings:
8. Electric distribution box - 1×40A+/2E/4E-0.03A (protective current switch), 1×10A & 2×16A as standard lay out (automatic fuses)
9. Double fluorescent lights 2×36W 220V- 2 each Philips IP 65 rated
10. Option: "PRC" neon lights IP 65 rated
11. Low level flush-mounted illuminated double sockets 220 V/110 V - 3 each
12. Low level flush mounted illuminated double socket 220V/110V with double SUB port - 1 each
13. Flush-mounted switches 220 V/110 V - 1 each

(6)Possibilities of Container Mounting

1. On a flat solid surface (asphalt, concrete,)
2. On point foundations (concrete cubes, dimensions 30/30/30cm, 6 pc/20' container)
3. On band foundations (concrete band, 30cm wide, on the container circumference)
4. Certification: Dimensions, weight, payload and stacking are RINA certified. Certificates available for components.
5. Delivery: Containers can be delivered assembled or individually - in kits 648 mm high.4 kits can be bundled in packages 2591 mm high (ISO
   dimensions)
6. Remark: Rights to technical changes are reserved.

Technical characteristics of containers type elements

ISO standard dimensions of 20 feet EUROSTANDARD and STANDARD containers - optionally 10 up to 30 feet

lenght = 6.058 mm (optionally 3.048 - 9.100 mm)

width = 2.438 mm (optionally 3.000 mm)

exterior height = 2.591 mm (optionally 2.791 mm or 3100 mm)

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

option: on customer wish in RAL color

option: painted on customer wish in RAL color

 

container floor

 

container floor opening for forklift

without forklift pockets

option: with forklift pockets for containers up to 7.335 mm

holes distance 1.506mm

 

container roof construction

 

container exterior wall and side panels

50 mm poliurethane panel, externally microcorrugated RAL 9002

internally smooth RAL 9010 (white)

option: 60 mm mineral wool, bothside plastificated in RAL 9002

option: 60 mm mineral wool, bothside plastificated in RAL 9002, internally enriched chipboard 100 WHITE010 (white)

option: 80 mm poliurethane panel, bothside plasticated steel plate RAL 9010 (white)

option: 100 mm poliurethane panel, bothside plasticated steel plate RAL 9010 (white)

option: 100 mm mineral wool, bothside plasticated steel plate RAL 9010 (white)

option: 120 mm mineral wool, bothside 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

option: windows without shutters

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

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
 

Process, fabrication and quality control standard on welding groove/beveling of steel structure
1. Purpose
To ensure the welding quality, meeting up the technical requirements of welded members and improve the standardization of our fabrication, we specially formulate this regulation.
2. Application scope
This manual apply for the design, fabricate and inspection of groove joint in terms of manual arc welding, CO2 arch welding, mixed gas arch welding, submerged arc welding and electroslag welding.
3. Design of welding groove
3.1 Key points on design welding groove:
In order to obtain quality groove, it is necessary to choose appropriate form of groove. The option of groove mainly depends on the thickness of base metal, welding method and craftsmanship requirements.The followings are the factors we need to consider:

1. minimize the amount of filler metal
2. easy for beveling
3. in convenience for welding operation and slag removal
4. After welding stress and deformation should be as small as possible

3.2 Groove direction:
We will consider the following factors for the groove direction:
A)in favor of welding process and removing slag and leave enough space for welding process on the fusion face
B)minimize the times of flip-flop during welding
C)way of fit-up in actual welding

3.3. Regulation on groove direction of members:

3.3.1 Butt welding on H section rafter/column (when CJP-complete joint penetration and single side fusion is required)
1) When there is no welding backing, the groove orientation on flange plates should be same and falls on the direction in favor of welding on web plats(same rules apply for the PJP situation). Please refer to illustration 1

2)When there is welding backing, we require the groove direction being outward for the flange plates(opposite direction for web plates) and still falls on the direction in favor of welding on web plates. Please refer to illustration 2
3)Butt-welding on construction site:we require all the grooves should be bevelled on the upper rafter/column when it comes to bolt connection for web plates(see illustration 3). For the scenario of welding on web plates, please refer to the illustration 4.
3.3.2 Box column(groove on itself).See illustration 5
4. Welding groove form
4.1. Mark on form and size of welding joint groove:
Example: Shielded metal arch welding, complete joint penetration, butt welding, I shape groove, welding backing and single side weld would be marked MC-BI-BS1
4.2. For the mark of welding method and penetration type, please see the following chart 1.
Chart 1 Mark on welding method and penetration type

Mark	Welding method	Penetration type
MC	Shielded metal arch welding	CJP-complete joint penetration
MP		PJP-partial joint penetration
GC	Shielded arch welding Self-shielded arc welding	CJP-complete joint penetration
GP		PJP-partial joint penetration
SC	Submerged arc welding	CJP-complete joint penetration
SP		PJP-partial joint penetration
SL	Electroslag welding

 4.3. For the mark of single, double side welding and backing material type, please see the following chart 2
Chart 2 Single/double side welding and backing material type mark

Backing material type		Single/double side welding
Mark	Material	Mark	Single/double side welding
BS	Metal backing	1	Single side welding
BF	Other backing	2	Double side welding

4.4. Mark on each part size of groove, see chart 3.
Chart 3 Size mark on groove

Mark	Size of each part on groove
t	Thickness of welding plate(mm)
b	Groove root gap or gap between two members(mm)
h	Groove depth(mm)
p	Groove roof face(mm)
α	Groove angle(º)