Affordable housing,usually called prefabricated affordable home/house,is a kind of housing soluton that uses light structural steel as main frame,insulated panels for wall and roof cladding and bolted structure.Affordable housing has wide applications in temporary housing situation like construction labor camp,disaster relief area and lower income people considering its advantages of fast installation,cost-saving,sturdy structure and environtent friendly.
I.Affordable housing model design and plans
Affordable housing could be in various models whether in single story or multi-story,or different function rooms(bedroom,kitchen,living room,dining room,bathroom,storage room etc) based on the clients' requests.Many people may concern about the look of a affordable housing.But there could be different options for the affordable house look like coupled slope,hipped roof and even multi-slope roof.What's more,your affordable house could be even equipped with veranda,fences or posts.To sum up,a prefabricated affordable house could be in different forms just like a traditional brick or concrete house.
II.Components of a house.
The components of a affordable house mainly encompass the main frames,wall and roof panels,ceilings,doors and windows and other necessary accessories.
(1)MAIN FRAME
For a house that would be built up in less windy area
,we could use the rectangle hollow section as structural column and beam.If the house would be built up in gale area,it is better that we use the H section steel.
About the surface treatment of the structural steel members,KXD provides anti-corrosive gray painted and galvanized.
(2)Wall and Roof Panel System
Prefabricated affordable houses adopt plug-in system which uses the U channel to accommodate the wall panel.For the roof,the panel could be directly fixed upon the roof structure by bolts.
About the wall and roof panel options,the most commonly used is sandwich panel which includes EPS,Fiberglas wool,Rockwool and PU.The thickness of sandwich panel is 50mm,75mm,100mm and 150mm.The followings are the differences of sandwich panel in the affordable houses:
A:EPS sandwich panel:EPS sandwich panel is commonly used for prefab house wall and roof(ceiling) panel.Considering its light density(8kg/m³,10kg/m³and 12kg/m³ options) and its non-fire proof property,EPS sandwich panel house is applicable for less windy area and the owner who has lower fire-proof requirements for the house.
B:Fiberglass/Rock wool sandwich panel:Fiberglass or rock wool sandwich panel also could be used for the wall system and roof(ceiling) panel.With its fire-proof(rock wool has the highest level of fire-proof even better fiberglass wool),thermal insulation an higher density(60kg/m³)properties,the fiberglass or rock wool sandwich panel house could be used in gale weather area What's more,if the customer has specific request for fire-proof condition,fiberglass or rock wool would be a good option.
C:PU sandwich panel has strong and stable structure itself and non-deformable ability due to its comprehensive higher density which could withstand >6.7KPa wind pressure and >400J impact strength.Hence PU panel for house has good wind uplift resistance capability. It is also ideal for gale or strong wind areas even in cyclone situation to use PU sandwich panel house.Like the EPS and fiberglass wool,PU panel also is used for house wall and roof(ceiling) panel.And PU panel is also fire-proof.
Besides the thermal insulated sandwich panel,KXD also provide the
Cement foam and Stone Chip Coated Steel Roof Tiles.
EPS cement panel refers to a novelty in efficiency and lightweight panel reinforced with fiber cement or calcium silicate, and also filled with cement, polyethylene, ceramics, coal ashes as main material.This product can replace the red brick, brick Clay, hollow brick, mixed sandwich, gypsum blocks, perlite and perlite porous plate and other building materials, which is widely applicable in various types of wall building solutions, such as banks, offices, hospitals, schools, hotels etc. .
Regular Size:
Width: 610 mm
Thickness: 60 mm, 75 mm, 90 mm, 100 mm, 120 mm, 150 mm, 180 mm
Length: 2,270 mm, 3,000 mm (the length of the panel can be measured with the unlimited of 3,000 mm.)
Supporting installation materials cement foam panel:
(3)Ceilings,trim and other accessories.
For the ceiling,there is sandwich panel ceiling,gypsum board ceiling and PVC ceiling.Also our house is equipped with baseboards,trims and other accessories.
(4)Doors,windows and interior fittings
| Doors |
steel wood door |
sandwich panel |
security door |
bathroom door |
| Interior fittins |
ceramic tiles |
toilet |
wash basin |
shower unit |
| Material List For Prefabricated House |
| Main Steel Frame |
| Steel column |
Fabricated by Q235 or Q345 Steel, 80*80 or 100*100 or 120*120 or 150*150 Square Tube, alkyd paiting, two primary painting, two finish painting. |
| Triangular Steel structure roof |
Fabricated by Q235 or Q345 Steel, C80, C100, C120, C140 Section steel, alkyd paiting, two primary painting, two finish painting. |
| Roof Purlin |
Fabricated by Q235 Steel, C80, C100, C120, C140 Section steel, alkyd paiting, two primary painting, two finish painting. |
| Ordinary bolt |
4.8S, Galvanized |
| Roof and Wall |
| Roof Panel |
A: Insulated Steel Sandwich Panel wall
(1) Panel width: 950mm;
(2) Thickness: 50-1200mm.
(3) Powder coated Color steel on both sides: 0.4mm/0.5mm/0.6mm
B: Insulation: Polystyrene, Rockwool, Fiber Glass or Polyurethane
(1) Density of Rockwool: 120Kg/m3
(2) Density of Polystyrene: 12Kg/m3, 16KG/M3 20KG/M3
(3) Density of Polyurethane: 40Kg/m3
(4) Density of Fiber Glass:40Kg/m3, 60Kg/m3 |
| Wall Panel |
A: Insulated Steel Sandwich Panel wall
(1) Panel width: 950mm;
(2) Thickness: 50-1200mm.
(3) Powder coated Color steel on both sides: 0.4mm/0.5mm/0.6mm
B: Insulation: Polystyrene, Rockwool, Fiber Glass or Polyurethane
(1) Density of Rockwool: 120Kg/m3
(2) Density of Polystyrene: 12Kg/m3, 16KG/M3 20KG/M3
(3) Density of Polyurethane: 40Kg/m3
(4) Density of Fiber Glass:40Kg/m3, 60Kg/m3 |
| Edge Cover |
0.4mm galvanized color steel , angle Alu. |
| Fasteners & Accessoreis |
Nails\glue ect |
| Ceiling&Flooring |
| Ceiling |
6mm gypsum board,with steel keel |
| Plywood |
18mm film faced plywood |
| Floor feather |
1.5mm PVC floor leather |
| Door and window |
| Door |
(1) External door: Single open door. Insulated with opening dimension 950*2100mm, furnished with lock with 3keys.
(2) Inner door: Single open door. Insulated steel door. |
| Window |
4mm glass PVC window witn flying screem |
| Electrical System |
| Electric Cable |
(1) Three diferent color.
(2) Lighting: 2.5m m2.
(3) Air condition: 4.0mm2.
(4) BV cable, solid core. |
| PVC Wire Channel |
PVC wire channel |
| Lights |
Double tube fluorescent lamp, 220V,50-60HZ |
| Switches |
Single Switch, with junction box |
| Socket |
16A five hole univesal socket. |
| Power Distribution Cabinet |
Box+breakers+earth leakage protective device |
| Water&Plumbing system(choose) |
| Water drain pipe |
(1) PPR pipe, dim 16-20mm, connection fittings are made of copper, life span over 10 years.
(2) Exhaust fan or air exchange hole, size 250mm*250mm made of steel or PVC |
| Sanitary ware |
(1) Western Close tool: ceramic, with pipes and installation fittings
(2) Urinal: ceramic, with pipes and installation fittings
(3) Wash basin: ceramic, with post, faucet, pipes and installation fittings
(4) Shower head, Shower base, Water mixture |
| Plumbing System and Rain Water Drainage System as per building design |
| No. |
Sort |
Name |
Specification |
| 1 |
Specification |
length |
No limited |
| 2 |
Width |
Less than 11m |
| 3 |
Wall height |
2600mm/2800mm |
| 4 |
Clear height |
2600mm/2800mm |
| 5 |
Roof slope |
15° |
| 6 |
Standard accessory |
Wall board |
75mm thickness double color-steel sandwich panel with polystyrene foam inside. Heat Insulated coefficient is 0.041w/m.k. Heat transfer coefficient is 0.546w/ m².k. |
| 7 |
False ceiling |
75mm thickness double color-steel sandwich panel with polystyrene foam inside. Heat Insulated coefficient is 0.041w/m.k. Heat transfer coefficient is 0.546w/ m².k. |
| 8 |
Roof board |
color steel corrugated sheet, 0.5mm thickness |
| 9 |
Outside door |
Security door, single door with dimensions of 900*2100mm, furnished with a handle lock with 3keys. Doorframe is made of 1.2mm steel, and door is made of 0.7 mm steel, 90mm thick rock wool insulation foam. |
| 10 |
Inside door |
SIP, single door with dimensions of 750*2000mm, furnished with a cylinder lock with 3keys. Doorframe is made of aluminum, 50mm thick EPS insulation foam. |
| 11 |
Window(W-1) |
PVC, white color, with dimensions of 1200*1200mm, glazed with glass in a thickness of 5mm, two bay fixed, and two bay sliding, supplied with fly screen. |
| 12 |
Window(W-2) |
PVC, white color, with dimensions 500*500mm, glazed with glass in a thickness of 5mm, casement opening, supplied with fly screen. |
| 13 |
Channel |
Galvanized Steel Plain Sheet press moulding Material: Q235. Painted |
| 14 |
Post |
Square steel tube Material: Q235. Painted |
| 15 |
Purline |
Square steel tube Material: Q235. Painted |
| 16 |
Roof truss |
Square steel tube Material: Q235. Painted |
| 17 |
Decoration and connection |
color steel sheet, 0.35mm thickness |
| 18 |
Option |
Decorative floor |
PVC, laminated or ceramic tile |
| 19 |
Drainage system |
Provided plan, design and construction |
| 20 |
Electric system |
Provided plan, design and construction |
| 21 |
Technical parameter |
Bearing load |
30kg/m2 |
| 22 |
Wind pressure: |
0.45KN/M2 |
| 23 |
Fire proof |
B2 grade |
| 24 |
Resistant temperature |
-20 ºC to 50ºC |
| |
|
|
|
| No. |
Item |
Material |
| 1 |
steel stucture |
mainly sqaure tube, under grey powder varnish |
| 2 |
wall |
EPS Steel sandwich panel |
| 3 |
roof |
EPS Steel sandwich panel |
| 4 |
Window |
PVC sliding window |
| 5 |
Door |
sandwich panel composited door |
| |
|
|
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:
- minimize the amount of filler metal
- easy for beveling
- in convenience for welding operation and slag removal
- 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) |
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