EOI

EOI - Proposed Medium Cost Apartments Project at Kasarani Nairobi, Kenya 10 November 2011

Light Steel Framing Solutions Manazil Steel Framing

Table of ContentsChapter 1 - Company ProfileSECTION 1.1 Genesis Manazil Steel Framing (BJG) Chapter 2 - Proposed Solution SECTION 2.1 Green Technology SECTION 2.2 Project References SECTION 2.3 Experience - Emerging Economies (UAE) SECTION 2.4 Design considerations (walls, floor, roof) Chapter 3 - Technical Information SECTION 3.1 Overview of cold formed steel framing SECTION 3.2 Codes and standards SECTION 3.3 Precast v.s Light Steel Comparison SECTION 3.4 Advantages of the Proposed Technology

Genesis Manazil Steel Framing

SECTION 1.1

Manufacturing Company: Manazil Steel Framing Factory LLC

Contracting Company: Gulf Genesis General Contracting LLC, Parent Company: Manazil- Bin Jabr Group

Manazil Steel Framing LLC (“Manazil”), an industry leader through the Middles East in “green” structural building technologies using light steel in the residential, commercial and institutional construction markets, established in December 2007 its production facility, Manazil Steel Framing Factory in Abu Dhabi.

Manazil is an affiliated company of Bin Jabr Group, an Emirati conglomerate active in various industries throughout the world. Manazil is the exclusive provider of Genesis Canadian building systems in the Middle East, Africa and Central and South Asia.

The company has a Qatari branch under the name Manazil Co. Qatar, which oversees all company’s operations in the state of Qatar. In addition to building villas, office spaces, government buildings locally, Manazil has recently started to export steel structures to neighbouring countries such as Iran and Afghanistan to build houses and schools in earthquake affected areas.

The Manazil manufacturing plant, located in the industrial zone of ICAD, produces light steel panelled structures using the Genesis turn-key solution, which includes leading-edge software, industrial equipment, hardware, processes and engineering services (“Genesis Solution”).

Genesis light steel structural technology, an energy efficient, environmentally friendly building alternative, is well suited to the hot climates of the UAE. The Genesis Solution utilizes a cavity wall design that incorporates air barriers, vapour barriers and insulation materials in order for its structures to improve energy efficiency, as opposed to the use of a single material, such as concrete, which does not conserve energy as well as buildings with a cavity wall design. By using light steel, less energy is consumed in order to bring the temperature down to a comfortable level.

Manazil is contracted to build large family style villas which can be constructed with speed, cost-effectiveness and efficiency, an improvement on the traditional concrete building methods often used in Uganda.

For additional information about the Company, visit www.genesismanazil.com

http://www.genesismanazil.com/�

Build with the Global Green Building Experts

Green Light Steel Structural SolutionsGenesis Manazil Steel Framing

Social and Health

No harmful emission, corrosion or mold

Non-combustible and non-organic

Safe for seismic, wind, and heavy rains

Vapor control and thermal performance

Environmental

Environmentally responsible material

Long life cycle

Infinite recyclability

Limited waste (1 to 10 ratio compared to lumber)

Superior energy efficiency

Aligned with government initiatives (LEED)

Business

Faster deliveries

Turnkey integration efficiencies

Reduced delays from weather

No multi-trade/supply coordination

Accelerated deliveries

Safe, clean and accessible jobsites

Better Quality

Controlled workmanship and consistent dimensions

High strength and durable product (protective coating)

Longer spans, increased design flexibility

No shrinking, warping and cracking

Wide range of architectures and finishing options

Cost Effective

Off-site manufacturing accuracy and predictability

Low skill requirement for structure assembly and finish

Reduced after sales service, call backs and repairs

Low maintenance costs and high resale value

Steel commodity readily available and competitive

Waste disposal, clean-up, and removal reduced

Low contractor’s risk insurance costs

Light stress on foundations, cranes, and contractors

Limited material stock for suppliers and contractors

One-stop accountability resulting in on-time and on-budget deliveries

Genesis Manazil Steel Framing has gained unique light-steel Framing (LSF) technical and execution expertise in United Arab Emirates based on the Genesis Technology Platform. Starting from the architectural drawings all the way to inspecting the finished LSF structure, Genesis Manazil delivers complete turnkey solutions to cost-conscious real estate developers and construction companies eager to join the Green Building movement.

Structural Engineering Services: our dedicated team of professional structural engineers, framing designers and technologists bring the experience and the specialized skills required to engage in any type of structural and non-structural projects using LSF products according to local building codes and requirements.

Manufacturing Services: a state-of-the-art and lean industrial operation located in Abu Dhabi with advanced material handling, cold roll forming, automated framing and sheathing assembly equipment produces on-demand accurate and consistent LSF joist, wall, truss and floor systems in a 100% quality controlled environment.

Logistics Services: a live (web-based) and just-in-time management of product inventories on-site and off-site gives instantaneous access to status of any roof, floor, and wall systems pre-fabricated and pre-bundled in sequence for installation of a specific project.

Installation Services: experienced and efficient site crews, supervisors and professional engineers are committed and available to ensure the structure gets erected and inspected on-time and with the highest quality standards.

Project management Services: dedicated resources to each project manage continuously all the services described above to ensure all the customer deliverables are met within the agreed budget at all times. Our professional project managers are the focal points from the onset of any project including the contractual phase so communication is transparent and effective during the complete project.

A Turnkey Approach to Green Building Structures

Light-Steel Structural Systems Benefits

Residential, Institutional, and Commercial Projects of up to 8 Storeys

Effective and Seamless Project Integration

A Proven and Cost Effective Process

REDUCER

EC

YC L E R E U

SE

Structural Design and Fabrication Drawings for all Structral Elements

Wall / Floor / Roof Panels Production & Delivery

On-site Installation

Day 5

Final Inspection

Proj

ect M

anag

emen

t 1

2

3

4

A Comprehensive Portfolio of Engineered Structural SystemsThanks to its unique and wide capabilities, Genesis Manazil Steel Framing can engineer, manufacture and deliver a building structure for any residential, commercial and institutional building project and can consequently achieve any design architecture with the desired comfort for the occupants. The innovative and smart Genesis Manazil Green Systems provide a complete realm of solutions for floor, roof and wall applications meeting or exceeding the International specifications for fire, sound and thermal ratings.

Structural & Partition Wall Systems

Curtain Walls Shear Walls Non-Load Bearing Walls Sound Proof Walls Insulated Walls

Structural Floor Systems

Sound Rated Floor PanelsFire Rated Floor PanelsiSPAN Joist System iSPAN Joist System Fire Rated iSPAN Joist System Composite

Complex TrussesScissor TrussesParallel Chord TrussesCommon Truss Jack/Mansard Truss

Structural Roof Systems

MEMBER

Solutions

Fiber Glass Insulation

Cement board

Vapour Barrier

Cement board

EPS

75 mm Concrete with Welded Wire Mesh Reinforcement

Metal Deck

Fiber Glass Insulation

Cement /Gypsum Board

Cold-Formed Steel Joist

Built-Up Roof Assembly

Metal Deck / Plywood

Cold-Formed Steel Roof Truss (Flat or Sloped)

WA

LL S

OLU

TIO

NFL

OO

R SO

LUTI

ON

ROO

F SO

LUTI

ON

Villa Models

300 SERIES

450 SERIES

500 SERIES

By Using Framebuilder™ software, Genesis Manazil can generate any type of building with high degree of accuracy.

Genesis Manazil Green Systems are continuously improved based on a philosophy of on-going innovation, and a clear focus on using the most site-friendly methods of construction. Smart product features are embedded in the systems not only to provide an enhanced assembly experience to all trades but

also to accelerate the erection of any building up to 8-storey high. The accuracy and quality of the products combined with a perfect logistic coordination yield into unbeatable delivery schedules, exceeding any traditional construction expectations.

Unbeatable Delivery Schedule

Starting the Foundation

Installation Commences

Panels Arrive

Assembly Continues

1

3

2

4

Engineering Inspects

Install Insulation Materials

Finished house is ready

Structure complete

Apply External Finishing

5

7

9

6

8

Genesis Manazil Steel F

ra

min

g

READY

Gen

es

is Manazil Steel Fram

ing

Light steel structures provides full flexibility in terms of building envelope giving Manazil Steel Framing’s customers the advantage to get the panelized systems insulated and finished on site. Genesis® Green Systems offer a variety of pre-engineered options for sound, thermal and fire insulation combined with finish fascias so the occupant’s comfort and exterior preference can be met.

Pre-insulated Systems Ready for Finishing

Sheathing Products

Roof Finish Options* Wall Finish Options*

Insulation Products

OSB

Densglass™

EPS Insulation

Blueskin

Plywood

Drywall / Concrete Board

XPS Insulation

Fiberglass Insulation

Substrate/Sheathing Options Finish Options

Slope Roofs

OSB

Asphalt shinglesCedar ShakeStanding Seam/Metal/CopperClay/Slate/Concrete Tiles

Plywood

Structural Insulated Panel (SIP)

Metal Deck

Flat Roofs

OSB

Asphalt MoppedFelt SystemGreen RoofBallastEPDM/PVC/TPO/CSPECool Roof (white acrylic)

Plywood

Structural Insulated Panel (SIP)

Metal Deck

EPS/EPDM built-up rubber membrane

Standing Seam

Floors

OSB CarpetCeramic Tiles / MarbleTraditional Hardwood / BambooEngineered Wood / LaminateVCTPolished Concrete

Plywood

Metal Deck & Concrete

Metal Deck

Walls

Rigid BrickEIFSSidingStuccoHardi Plank Siding

OSB or Plywood or Bamboo

Densglass

*Sample finish options only.

Genesis Manazil Steel Framing Can Build a Wide Range of Projects up to 8 Storeys using Genesis® Structural Systems

RESIDENTIAL

GOVERNMENTAL OFFICES

INSTITUTIONAL AND COMMERCIAL

Governmental Approvals

Location Map

Carrefour

چنيسيس منازل للهياكل الحديدية

Genesis Manazil Steel Framing

P.O. Box 29396 ICAD, Musaffah, Abu Dhabi, UAE

phone: 02-550 2265email: [email protected]

www.genesismanazil.com

MUSAFFAH INDUSTRIAL AREA

Green Technology

SECTION 2.1

Assessment of embodied carbon for steel

frame construction

A comparison of Genesis steel frame system versus standard

concrete construction in the Masdar development

Revision Description Date Issued by Reviewed by

V1 1st Draft 15 May 09 Jane Hersey Ben Gill

V2 2nd Draft 26th June 09 Jane Hersey

BioRegional Development Group

BedZED Centre

24 Helios Road

Wallington

Surrey SM6 7BZ

Tel : 020 8404 4880

Fax : 020 8404 4893

Email : [email protected]

Website : www.bioregional.com

Comparison of embodied carbon in construction

of lightweight steel frame versus concrete frame

BioRegional 3 of 12

Contents

Background and Objectives ............................................................................................................. 4

Summary of environmental benefits of Genesis system .................................................................. 4

Our Approach .................................................................................................................................. 4

Raw data for model ..........................................................................................................................5

Results..............................................................................................................................................7

Conclusions ....................................................................................................................................12



4 of 12 BioRegional

Background and Objectives

Genesis Worldwide is a leading provider of structural light steel framing technologies. Light steel

frames are an alternative construction system to the use of structural concrete frames. Genesis

Worldwide has done some initial analysis of their system and state that there are significant

environmental benefits to the use of their steel frame system over and above the alternatives of

concrete frames.

Genesis world wide have been in discussions with Masdar about the use of the Genesis system as an

option for their Masdar City development. This flagship development in the United Arab Emirates will

be the world’s first zero-carbon, zero-waste, car-free city.

The purpose of this study is to assess the environmental benefits in terms of the carbon emissions

associated with the construction systems. A comparison has been done using the Masdar Villas as an

example, comparing the use of the steel frame versus a concrete frame construction.

Summary of environmental benefits of Genesis system

• Reduction in required cement

• Major reduction in required steel compared to other steel systems

• Eliminates waste from framing activities

• Major reduction in shipping energy

• Produced in local factories, with benefits to the local economy

• Steel allows full deconstructability and reuse

Our Approach

In order to analyse the embodied carbon of a construction, we have collected data on the quantities of

steel and concrete used in the two construction systems. Data has been provided by Genesis

Worldwide and Masdar. We collected information on the product specifications, quantity of materials

used in construction and source of material.

To calculate the embodied carbon of the construction system, the data was input into a spreadsheet

to calculate the mass of materials. Conversion factors are used to calculate the embodied carbon of

each material taken from best practice sources; namely data from Bath University (2006/8). In

addition to the carbon embodied in the materials as assessment has been done on the impact of

freight transport.



BioRegional 5 of 12

Raw data for model

Masdar branded villas material quantity comparison

Reinforced Concrete Version CFS + Str. Steel Version

Concrete

(m^3)

Reinforcement

Steel (kg) Steel (kg)

Concrete

(m^3)

Reinforcement

Steel (kg) Steel

Unit

Type

Total

Area

(m^2) Total per

m^2 Total

per

m^2 Total

per

m^2

Total

Self

Weight

(kg/m^2) Total per

m^2 Total

per

m^2 Total

per

m^2

Total

Self

Weight

(kg/m^2)

Total

Concrete

Reduction

(%)

Total

Structural

Framing

Self

Weight

Reduction

(%)

2 Bed 238 96 0.40 7250 30.46 1246 5.24 1003.76 6 0.03 1485 6.24 16657 69.99 136.73 94% 86%

3 Bed 271 102 0.38 8100 29.89 1338 4.94 938.15 7 0.03 1653 6.10 18669 68.89 136.98 93% 85%

4 Bed 382 144 0.38 11400 29.84 2688 7.04 941.59 10 0.03 2414 6.32 28554 74.75 143.90 93% 85%

5 Bed 456 178 0.39 13710 30.07 2938 6.44 973.35 13 0.03 2745 6.02 30853 67.66 142.10 93% 85%

Average 337 130 0.39 10115 30.07 2053 5.91 964.21 9 0.03 2074 6.17 23683 70.32 139.93 93% 85%

Calculation method and assumptions1

1. General

1.1 Podium slab, foundation and level 1 framing remains concrete and the same thickness for both version. Therefore in calculations above considered

only above podium slab

1.2 Density of concrete is 2,400 kg per m3

1 All these assumptions have been provided by Genesis



6 of 12 BioRegional

2. Reinforced Concrete Version

2.1 Concrete volume includes:

a. Load bearing concrete walls and columns

b. All other perimeter walls

c. Floor and roof slab

2.2 Reinforcement steel has been calculated with following assumptions:

a. For concrete walls 70 kg per each m^3 concrete

b. For floor and roof 1 way slabs 90 kg per each m^3 concrete

2.3 Steel quantity includes:

a. Hot rolled steel framing at cantilevered section

b. Interior non load bearing partition walls (assumed as cold formed steel walls)

3. Cold Formed Steel + Structural Steel Version

3.1 Concrete volume includes:

a. Concrete floor over metal deck at level 2 floor

3.2 Reinforcement steel quantity includes:

a. Metal deck and reinforcement mesh at level 2 floor

b. Metal deck at roof level

3.3 Steel quantity includes:

a. Hot rolled and cold formed steel framing for super structure above podium slab including non load bearing partition walls



BioRegional 7 of 12

Results

The embodied carbon emissions of a building are attributed to the manufacture of materials, their

transport and assembly on site, maintenance and replacement, disassembly and decomposition.

Burning fossil fuels is responsible for most CO2 production however some will be due to converting

limestone into cement for example, which also releases fossilised stores of carbon.

The data below details the embodied carbon of the construction of the Masdar villas.

Materials

Key assumptions

The steel used in the main frame was assumed to be general steel with a typical UK recycled content,

resulting in an embodied carbon figure of 1.77kgCO2/kg. It may be possible for higher levels of

recycled steel to be sourced. However, since all steel is recycled anyway it is not considered

appropriate to allocate credit for higher levels of recycled material, as this just reduced the recycled

content, and increases carbon emissions elsewhere.

Table 1: Conversion factors for concrete (Bath, ICE data)

Concrete (RC40) Kg CO2 per kg material

CEM 1 0.169

25% flyash 0.132

50% flyash 0.096

Assessment of materials with 50% flyash concrete mix

The Masdar development is aiming to achieve very high environmental standards, and as a result will

be using concrete with a high flyash content which provides a low embodied carbon content.

However, potential savings have also been assessed against a no flyash content concrete in order to

show the more likely scenario in another development.

Reinforced Concrete Version, 50% flyash

Embodied carbon 204 tonnes CO2

Material

component Quantity

Material

density Mass kgCO2/kg

Embodied

carbon

Concrete 520 m3 2,400 kg/m3 1,248,000 kg 0.096 119,808

Reinforcement steel 40,460 kg 40,460 kg 1.710 69,187

Structural steel 8,210 kg 8,210 kg 1.770 14,532

TOTAL 1,296,670 kg 203,526 kgCO2



8 of 12 BioRegional

Genesis light weight steel version, 50% flyash


Material component Quantity Material


Embodied

carbon

Concrete 36 m3 2,400 kg/m3 86,400 kg 0.096 8,294



TOTAL 189,430 kg 190,160 kgCO2

Assessment of materials with 0% flyash concrete mix

Reinforced Concrete Version, 0% flyash


Material

component Quantity

Material


Embodied

carbon

Concrete 520 m3 2,400 kg/m3 1,248,000 kg 0.169 210,912



TOTAL 1,296,670 kg 294,811 kgCO2

Genesis light weight steel version, 0% flyash


Material component Quantity Material


Embodied

carbon

Concrete 36 m3 2,400 kg/m3 86,400 kg 0.169 14,602



TOTAL 189,430 kg 196,467 kgCO2

50% flyash concrete 0% flyash concrete

Total embodied

carbon

Embodied

carbon by area

(Kg CO2 per m2)

Total embodied

carbon

Embodied

carbon by area

(Kg CO2 per m2)

Reinforced Concrete Version 204 tonnes CO2 151 295 tonnes CO2 219

Genesis light weight steel 190 tonnes CO2 141 196 tonnes CO2 146

Percentage saving 7% 33%



BioRegional 9 of 12

The results show that there are significant embodied carbon savings from the use of the Genesis steel

frame system. The savings for the 50% flyash mix are 7% overall, which is perhaps not as significant as

might be expected. This is because steel has a very high embodied carbon footprint per tonne

compared to concrete and the concrete that is being used in Masdar already has a relative low impact.

When we compare the savings from the steel frame system compared to typical 0% flyash concrete

the embodied carbon is 33% lower than the concrete structure. Both of these examples show that the

steel frame system delivers a significant reduction in embodied carbon emissions in materials.

Water

Water in the UAE is generally produced through desalination meaning that the water has a high

embodied energy. Water made using reverse osmosis is responsible for 1.78kg CO2 per m32 , which is

over six times more embodied carbon than typical European water.

The steel framing system by reducing the quantity of concrete also reduces the quantity of water used.

However, an assessment of the high embodied carbon in the water needed for this development

shows that in this context it has little overall effect on the embodied carbon of the whole construction.

However, there are still environmental benefits from this reduction in water consumption in an area

with water scarcity.

Transport

The table below illustrates the impacts of the transport of the materials and the key assumptions

regarding mode and source. The steel framed system saves 7 tonnes of CO2 from freight based on this

system, or 51%. It should be noted though that the impact of the reinforced concrete version is

heavily dependent on where the aggregate is sourced, and therefore without accurate data on this

there is significant uncertainty in the figure.

Reinforced Concrete Version

STRUCTURAL 14 tonnes CO2

Material

component Mass Source Mode Distance Tonne-km

kgCO2

/tonne

-km

Transport

emissions

kgCO2

Cement

186,667 kg UAE Road 60 km 11,200 0.163

1,829

Aggregate

960,000 kg UAE Road 60 km 57,600 0.163

9,406

Reinforcement

steel 40,460 kg Egypt Shipping 5,499 km 222,473 0.011

2,447

Structural steel 8,210 kg Egypt Shipping 5,499 km 45,143 0.011 497

2 WWF, (2007). Making water Desalination: option or distraction for a thirsty world?



10 of 12 BioRegional

Genesis light weight steel version

STRUCTURAL: 7 tonnes CO2

Material

component Mass Source Mode Distance Tonne-km

kgCO2

/tonne

-km

Transport

emissions

Cement 12,923 kg UAE Road 60 km 775 0.163 127

Aggregate 66,462 kg UAE Road 60 km 3,988 0.163 651

Reinforcement

steel 8,297 kg Egypt Shipping 5,499 km 45,622 0.011 502

Structural steel 94,733 kg Egypt Shipping 5,499 km 520,898 0.011 5,730

Total carbon emissions

The table below shows the embodied carbon savings from the Genesis steel frame system compared

with 50% flyash concrete are 10% overall, when both transport and materials are taken into account.

However, when compared to a standard concrete the savings are 34%. This saving is due to the

reduction in mass of concrete required using the light weight steel frame system.


Embodied carbon

Reinforced

Concrete Version

Genesis light

weight steel

version

Reinforced

Concrete

Version

Genesis light

weight steel

version

Material 204 190 295 196

Transport 14 7 14 7

TOTAL 217.9 197.2 309.0 203.5

Per square metre

(Kg CO2 per m2) 162 146 229 151

Percentage reduction 10% 34%

End of life assessment

Steel is such a high value material that when a building has come to the end of its life and is being

taken down the structural steel would nearly always be recovered and recycled. Reinforcement steel

is also now often recovered from the concrete for recycling. Concrete cannot be recycled in the same

way, and is generally either landfilled or crushed then used as an aggregate replacement. This is a

downcycling of the material which results in a material of lower value and quality.



BioRegional 11 of 12

Using Simapro lifecycle assessment software a basic screening was completed using generic data

from the Ecoinvent library. This is a different dataset than used for the rest of this report, in order to

enable an assessment of the contribution of the waste disposal route of the construction materials to

the carbon footprint. The recycling and downcycling of the construction materials would contribute

another 1% to 3% of the total carbon footprint.

The preferred route for waste disposal is to deconstruct and reuse the structural steel as this provides

an avoidance of burden from the use of primary and secondary steel. An analysis was done assuming

that 50% of the structural steel could be recovered and reused in another project. The results are

shown in the table below.


Embodied carbon

Reinforced

Concrete Version

Genesis light

weight steel

version

Reinforced

Concrete

Version

Genesis light

weight steel

version

Material 204 190 295 196

Transport 14 7 14 7

Reuse discount -7 -84 -7 -84

TOTAL 211 113 302 120

Percentage reduction 46% 60%

The results show that if the steel can be reused in this way the avoided burdens are significant. In the

case of the Masdar development with 50% flyash concrete there is a 46% reduction compared to the

concrete structure.

Gaps in the analysis

There are a number of issues that this study has not been able to address, but which will have impacts

on the embodied carbon in these results. It is felt that the results in this study may be an

underestimate of the savings that could be achieved through the steel framing system. Items that are

not included due to lack of data are:

• The model includes the reduced quantity of concrete required in the steel frame

construction. However, it is possible that the lightweight steel structure may enable an

even higher proportion of fly ash to be used in the concrete mix due to the reduced

strength requirements (leading to a lower impact concrete).

• The Genesis factory in UAE is powered by zero carbon energy. The data available for

embodied carbon in steel is based on typical manufacturing conditions and therefore the

impact of the lightweight steel frame would be lower than is stated here.

• There may be scope to design a lighter-weight ground slab and foundations in the case of

the steel frame construction.



12 of 12 BioRegional

• This analysis does not include any assessment of the in-use energy demand and how this

may be affected by the use of the Genesis steel frame system. The Masdar development

is in an arid climate where night time temperature exceeds a comfortable room

temperature throughout most of the year. This means that thermal mass has a negative

impact on the temperature in housing. The Genesis steel frame system reduces thermal

mass and therefore will enable a reduction in energy demand for cooling in the homes

compared to the proposed construction method.

Conclusions

This assessment shows that at Masdar there would be significant savings of 10% in the carbon

emissions associated with the Genesis construction system using light weight steel frames compared

to concrete frames of 50% flyash content. It can also be seen that these savings are much larger (34%)

when comparing to a standard concrete mix.

An examination of the end of life options for these buildings has shown that reuse of the structural

steel can have an even greater impact on the potential savings from this system. Embodied carbon

savings could be increased to 46% in the case of Masdar if half of the steel is reused. A key

recommendation therefore must be that planning for deconstruction and reuse is one of the most

important factors in reducing the embodied carbon footprint of construction.

However, it is also important to note that this is a fairly limited study, focusing just on a few

components of the system. Also, the available data is based on average UK economy and there may

be significant differences in the UAE. In order to fully examine the potential savings a more detailed

life cycle assessment would be required.

Given more time, and a greater level of data, Simapro could be used to create a more detailed life

cycle assessment of these two construction systems.

Project References 500+ Projects were built using the Genesis Light Steel system around the World with over 1.5 million m2 of covered space.

SECTION 2.2

6 Commercial

Forest Manor SchoolProject Category Commercial

Project Type Public School

City Toronto

Province/State Ontario

Country Canada

Storey 2 storey

Qty 1

Square Meter 2,700

Year 2009

Solutions WallsFloorRoof

7 Commercial

Cantebury GardensProject Category Commercial

Project Type Care Facilities

City Peterborough


Country Canada

Storey 4

Qty 1

Square Meter 11,700

Year 2007

Solutions WallsFloorPanel

8 Commecial

Esfahan Primary SchoolProject Category Commercial

Project Type Primary School

City Esfahan

Province/State

Country Iran

Storey 1

Qty 1

Square Meter 560

Year 2007

Solutions Walls, Floors, Roof

9 Commercial

Bold Oaks EstatesProject Category Commercial

Project Type Retail

City Bolton


Country Canada

Storey 1

Qty 7

Square Meter 125

Year 2006

Solutions Roof (Trusses)

10 Commercial

Homewood SuitesProject Category Commercial

Project Type Hotels / Resorts

City Burlington


Country Canada

Storey 6

Qty 1

Square Meter 16,000

Year 2005

Solutions Roof (Panelized)

11 Commercial

Trinity SchoolProject Category Commercial

Project Type Secondary School

City Collingwood


Country Canada

Storey 2

Qty 2

Square Meter 2,300

Year 2004

Solutions WallsFloor (Panelized)Roof (Panelized)

12 Commercial

Eagle’s Nest Golf ClubProject Category Commercial

Project Type Restaurants / Retail

City Vaughan


Country Canada

Storey 2

Qty 1

Square Meter 450

Year 2003

Solutions WallsRoof (Trusses)

13 Residential

Leopard Lane DevelopmentProject Category Residential

Project Type Condominiums

City Vaughan


Country Canada

Storey 3

Qty 1

Square Meter 1,200

Year 2009

Solutions WallsRoof (Panelized)

14 Residential

Dinskaya TownhomesProject Category Residential

Project Type Townhouses

City krasnodar

Province/State krasnodar Region

Country Russia

Storey 4

Qty 8

Square Meter 2,400

Year 2009


15 Residential

Clairlea Gardens - Stacked Town HomesProject Category Residential


City Toronto


Country Canada

Storey 4

Qty 112

Square Meter 11,800

Year 2005


16 Residential

Boardwalk TownhousesProject Category Residential


City Toronto


Country Canada

Storey 4

Qty 8

Square Meter 2,200

Year 2005


17 Residential

Arrowhead TownhomesProject Category Residential


City Collingwood


Country Canada

Storey 4

Qty 38

Square Meter 10,000

Year 2005


18 Residential

Gardens At QueenProject Category Residential


City Toronto


Country Canada

Storey 4

Qty 174

Square Meter 13,500

Year 2004


19 Residential

Jarvis MansionsProject Category Residential

Project Type Condominiums

City Toronto


Country Canada

Storey 3

Qty 1

Square Meter 2,500

Year 2004


Experience - Emerging Economy (UAE)

SECTION 2.3

ProjectLocationSolution

Villas for Fahad Matooq Al Hossani

Residential - 3 VillasPlot No 67B, Sector No26, Khalifa City A, Abu Dhabi, UAETurnkey


Trinity Villa

Sample VillaICAD 1, Mussaffah, UAETurnkey


Villa for Rukaya Al Muhairy

Residential VillaPlot No 12, Al Baheya, Abu DhabiTurnkey


Villa for Bader Said Al Murekhi

Residential - 2 VillasPlot No 72, Sector NoW52, Al Mushref, Abu Dhabi, UAETurnkey


Villas for Ali Abdullah Al Mansuri

Residential - 2 VillasPlot No 40, Sector No13, Khalifa City A, Abu Dhabi, UAETurnkey


Villas for Nasser Al Reyami

Residential – 3 VillasPlot No 117, Sector Z-5, Mohamed Bin Zayed, Abu Dhabi, UAESteel only


Masdar 1A Ancillary Buildings

Commercial - InstituteMasdar City, Abu Dhabi, UAERoof / Floor Solution


CID (Criminal Investigation Division)

Commercial - OfficeAbu Dhabi Police, 27th - Airport St, Abu Dhabi, UAETurnkey


Majlis for Shafi Al Bajash

Residential - MajlisKhobar, Saudi ArabiaCore and Shell


Service Block for Nasser Al Reyami

Residential - 2 Service BlocksPlot No 117, Sector Z-5, Mohamed Bin Zayed, Abu Dhabi, UAESteel only


Majlis for Faraj Al Mansori

Residential - MajlisPlot NO. 103, Sector 11, Khalifa A, Abu Dhabi, UAE Turnkey


Service Block for Abo Baker Obeid

Residential - Service BlockShamkha City, Shamkha 10, Plot No 35, Abu Dhabi, UAECore and Shell


Al Kahf General Cont. EST.

Residential - MajlisAl Falah, Falah 5, Block number 50, Abu Dhabi, UAECore and Shell


Balcony for Abdullah Al Qubaisy

Extension - BalconyPlot No 42, Sector W46-02, Mushref, Abu Dhabi, UAETurnkey


Roof addition - Farm Villa

Addition – Sloped RoofAl Zayed City, Dubai, UAERoof Solution


AUD Police-Traffic Institute

Commercial - OfficeAl Ain, UAETurnkey


Labour Camp for Onsite Construction

Commercial - Labour CampKabul, Afghanistan Steel Only

Design Considerations

SECTION 2.4

Wall Solutions

• Supply and installation of 152mm exterior wall panels, with engineered light-steel framing at 406mm on center, complete with 12.mm Cement Board at exterior with 25mm EPS and 18mm Cement Board at interior side in preparation for wall finishing application as indicated by exterior and interior finish, including but not limited to the engineered window and door openings and pre-punched holes at standard locations. See figure 1 for typical proposed exterior wall panel.

• Supply and installation of 92mm structural interior wall panels, with engineered light-steel framing at 406mm on center, complete with 18mm Cement Board at each side in preparation for wall finishing application as indicated by interior finish. Interior load-bearing wall panels to be positioned at predetermined/pre-approved locations within the structure to satisfy Genesis® engineering requirements. Panels include engineered door openings and pre-punched holes at standard locations. See figure 2 for typical proposed interior wall panel.

Figure 1 (a) Plan view of typical exterior/interior wall Figure 1 (b) 3D view of typical exterior/interior wall

EXTERIOR WALL CONFIGURATION:

• RENDER +PAINT • 12mm CEMENT BOARD • 25mm EPS Thermal Resistance • VAPOR BARRIER R 4 m2.K/W • 152mm METAL STUD @ 406 o/c • 50mm ROCKWOOL Sound Transition Class • 18mm CEMENT BOARD STC ≥ 50 • RENDER + PAINT

INTERIOR WALL CONFIGURATION:

• RENDER +PAINT • 18mm CEMENT BOARD • 92mm METAL STUD @ 406 o/c Sound Transition Class • 50mm ROCKWOOL STC ≥ 50 • 18mm CEMENT BOARD • RENDER + PAINT

Floor Solutions

• Supply and installation of 254mm or 305mm structural floor panels, with engineered light-steel floor joists at 406mm on center, complete with site installed galvanized metal deck sheathing with welded wire mesh and concrete, engineered / framed stair openings and pre-punched holes at standard locations. See figure 2 for typical floor panel.

• Floor panels to include integrated engineered transfer elements, web stiffeners and bridging.

Figure 2 (a) Section of typical floor assembly

WITH FALSE CEILING WITHOUT FALSE CEILING

FLOOR CONFIGURATION

• CERAMIC TILE • MORTAR • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 50mm ROCKWOOL • METAL CEILING FRAME • 12.5mm CEMENT BOARD • RENDER + PAINT

FLOOR CONFIGURATION

• CERAMIC TILE • MORTAR • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 50mm ROCKWOOL • 12.5mm CEMENT BOARD • RENDER + PAINT

Figure 2 (b) 3D view of typical Floor

Sound Transition Class

STC 50

Roof Solutions

Flat Roof

• Supply and installation of 254mm or 305mm structural roof panels, with engineered light-steel floor joists at 406mm on center, complete with site installed metal deck sheathing with welded wire mesh and concrete. See figure 3 for typical roof panel.

• Roof panels are flat and do not accommodate drainage. Figure 3 (a) Section of typical flat roof assembly WITH FALSE CEILING WITHOUT FALSE CEILING

ROOF CONFIGURATION

• 300x300 TERRAZZO TILE • GROUT WITH WATER PROOF MORTAR • 30mm THICK CEMENT SAND SCREED • 1000 GAUGE POLYTHENE SHEET • WATER PROOF MEMBRANE • 50mm THICK FOAM CONCRETE TO SLOPE • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 100mm ROCKWOOL • VAPOR BARRIER • METAL CEILING FRAME • 12.5mm CEMENT BOARD • RENDER + PAINT

ROOF CONFIGURATION

• 300x300 TERRAZZO TILE • GROUT WITH WATER PROOF MORTAR • 30mm THICK CEMENT SAND SCREED • 1000 GAUGE POLYTHENE SHEET • WATER PROOF MEMBRANE • 50mm THICK FOAM CONCRETE TO SLOPE • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 100mm ROCKWOOL • VAPOR BARRIER • 12.5mm CEMENT BOARD • RENDER + PAINT

Thermal Resistance R 3.9 m2.K/W

Sound Transition Class STC 50

Figure 3 (b) 3D view of typical flat roof

Sloped Roof

• Supply and installation of cold formed steel structural sloped roof trusses, at 610mm on center, complete with site installed 12.5mm plywood sheathing to receive clay tile finish. See figure 4 for typical roof panel.

• Supply and install all required bracing.

Figure 4 Section of typical sloped roof assembly

SLOPED ROOF ASSEMBLY

• CLAY TILE • 12mm PLYWOOD • STEEL TRUSS @ 610 o/c

Overview of cold formed steel framing

SECTION 3.1

Overview of Cold Formed Steel Framing

Although "Steel" may conjure up images of a heavy, cumbersome material for construction, steel studs

from coated sheet steel products are just the opposite. Steel studs offer a strong, accurate,

dimensionally stable and durable framing system, and are ideal for residential construction.

Residential steel framing members were originally designed as a substitute for wood framing. However,

they are now being manufactured in systems, which reflect the superior strength and consistency of

steel. The variety of available steel shapes, strengths and sizes has expanded beyond that of standard

lumber, and this versatility offers the advantage of savings in both material cost and time while

delivering a consistently high quality product.

Environmental and economic concerns have prompted the building industry to research alternative

building materials and methods. This, in addition to its construction benefits and excellent recycling

capabilities, is making steel framing a growing choice for residential construction. This follows the long

time use of steel framing in commercial construction where steel has proven quality and performance

records.

Cold-formed steel has been widely used in buildings, automobiles, equipment, home and office

furniture, utility poles, storage racks, grain bins, highway products, drainage facilities, and bridges. Its

popularity can be attributed to ease of mass production and prefabrication, uniform quality, lightweight

designs, economy in transportation and handling, and quick and simple erection or installation.

In building construction, cold-formed steel products can be classified into three categories: members,

panels, and prefabricated assemblies. Typical cold-formed steel members such as studs, track, purlins,

girts and angles are mainly used for carrying loads while panels and decks constitute useful surfaces

such as floors, roofs and walls, in addition to resisting the in-plane and out-of plane surface loads.

Prefabricated cold-formed steel assemblies include roof trusses, panelized walls or floors, and other

prefabricated structural assemblies. Approximately 40% of the total steel used in building construction is

cold-formed steel. Cold-formed steel possesses a significant market share because of its advantages

over other construction materials and the industry-wide support provided by various organizations that

promote cold-formed steel research and products, including codes and standards development that is

spearheaded by the American Iron and Steel Institute (AISI).

Cold-formed steel has become a competitive building material in the last two decades as a result of

industry-wide efforts. The use of cold-formed steel in the structural system of residential construction

has taken hold in some site building markets but potentially offers far more value to the manufactured

home industry.

References: Canadian Sheet Steel Building Institute

Manufactured Housing Research Alliance

Codes and Standards

SECTION 3.2

Codes & Standards

Cold formed steel framing is fully specified in a wide range of building codes.

Applicable Building Codes

• UBC 1997, Uniform Building Code

• IBC 2009, International Building Code (Adopted by Abu Dhabi Municipality starting Jan 1, 2010)

• NBC 2005, National Building Code

• BS, British Standards

• Eurocode

Design Standards

• CSA S136-07, AISI S100, North American Specification for the Design of Cold Formed Steel

Structural Members

• BS 5950 – 5, Structural use of steel work in building, Structural use of Cold Formed Steel

Members

Manufacturing Standards

• ASTM C645, Standard Specification for Nonstructural Steel Framing Members

• ASTM C955, Standard Specification for Load-Bearing (Transverse and Axial) Steel Studs, Runners

(Tracks), and Bracing or Bridging

Material Standards

• ASTM A653 / A653M - 09a Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or

Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

Or

• ASTM A792 / A792M - 09a Standard Specification for Steel Sheet, 55 % Aluminum-Zinc Alloy-

Coated by the Hot-Dip Process

GENESIS SYSTEM HAS BEEN CERTIFIED BY INTERNATIONAL CODE COUNSIL (ICC) WITH

PRODUCT NUMBER = ESR - 2849

Design Considerations

Engineering Design Scope

• Genesis Manazil SF to provide supplementary “structural design drawings” (for the Genesis®

structure) conforming with International Building Code (IBC) and Local Building Code, sealed by

Professional Engineer in Ontario, Canada.

• Genesis Manazil SF to provide detailed fabrication drawings for wall, floor and roof panels.

• Genesis Manazil SF to provide wall, floor and roof framing layouts, connection and installation detail

drawings prior to on-site installation.

• Genesis Manazil SF to conduct regular site inspections, and provide engineering general review on

Genesis installed products upon substantial completion of work.

Structural Design Considerations

• Structural design of proposed cold formed and hot rolled steel super structure and concrete slab &

foundation shall be performed in accordance to International Building Code (IBC) 2009, British

Standard BS 6399 “Loading for buildings”, British Standard BS 5950 “Structural use of steel work in

building”, British Standard BS 8110 “Structural use of concrete” and applicable local codes.

• All cold formed steel structural materials are confirming with ASTM A-653, structural quality grade 37

(Min. Yield Strength 275 MPa) and feature a galvanized coating of minimum Z-180 (G60).

• Stability of structure under lateral loads (wind & seismic) shall be accommodated by crossed braced

shear walls part of the cold formed steel structure.

• Floor live load deflection shall be limited to L/480 or 20mm, total load deflection shall be limited to

L/250 or 25mm. Horizontal sway of the building shall be limited to H/500, deflection of each storey

shall be limited to h/400.

Self Weight of Each Assembly

Self weight of structural assemblies is as followings:

Exterior / Interior Wall Panels:

Cold formed steel members: 0.10 kPa

Fasteners : 0.05 kPa

Total: 0.15 kPa

Floor Panels:

Concrete with metal deck: 1.5 kPa


Fasteners : 0.05 kPa

Total: 1.9 kPa

Roof Panels:

Concrete with metal deck: 1.5 kPa


Fasteners: 0.05 kPa

Total: 1.9 kPa

Precast v.s. Light Steel Comparison

SECTION 3.3

Precast vs. Cold Formed Steel Framing Comparison

The main specified option for building material for the project is pre-cast concrete system. In which

walls are sandwich panels and floors are 200mm pre-cast slabs. Our proposed solution is a cold-formed

steel framing system. Walls are pre-manufactured panels finished with cement boards at each side and

floors and roof to be pre-manufactured panels with concrete topping and cement board at ceiling side.

Please refer to the below list for comparison between the two options:

DESCRIPTION PRE-CAST SYSTEM COLD-FORMED STEEL FRAMING

Thermal Performance Sandwich wall panel thermal Wall panel thermal

resistance = R 2.2 m2.K/W resistance = R 4.8 m

2.K/W

Fire Resistance Non-Combustible material. Non-Combustible material.

Acoustical Performance STC 50 STC 50

Manufacturing Manufactured at controlled Manufactured at controlled

environment. environment.

Extended production time. Quick production time.

Curing treatment requires Dry Construction, no additional

for hot climate. treatment requires.

Inconsistent surface and panel Dimensionally stable,

dimensions may occur. all panels have consistent

surface and dimensions.

Transportation Costly transportation Inexpensive transportation

because of heavy material. due to very light material.

Damage may occur Damage very unlikely occur.

during transportation.

Construction Heavy crane is required for handling Light crane would be adequate to

and installation. handle and install panels. Most

panels can be lifted by two workers.

Inconsistent shell walls, specially Consistent quality of

surface. shell walls.

Limited field adaptability, no future Ability to be modified in field

retrofits can be done. and future retrofits are possible .

DESCRIPTION PRE-CAST SYSTEM COLD-FORMED STEEL FRAMING

Construction All mechanical, electrical and Mechanical, electrical and

plumbing runs have to be through plumbing runs can be easily and

outside of wall and floor panels. quickly run in the wall panels.

Structural slab thickness for roof Structural slab thickness for roof

and floor is 200mm. and floor is 330mm.

Expensive treatment may be required No joints between panels.

for joints between panels.

Time of construction faster than Time of construction is faster

in-situ concrete. than pre-cast construction

Architectural Finish According to design. According to design.

Advantages of Proposed Technology

SECTION 3.4

Advantages of the Proposed ¢ŜŎƘƴƻƭƻƎȅ:

Lightweight - Cold-formed steel components weigh approximately 80% to 90% less than pre-cast concrete, which

means easier handling during construction and transportation.

High-strength and stiffness - As a result of the cold-forming process, cold-formed steel possesses one of the

highest strength-to-weight ratios of any building material. This high strength and stiffness advantage means more

design flexibility, wider spans and better material usage.

Fast and easy erection and installation - Building components made of cold-formed steel can be fabricated with

high accuracy in a plant and then assembled on job sites, which greatly increases erection efficiency and ensures

construction quality.

Dimensionally stable material - Cold-formed steel does not expand or contract with moisture content. In addition,

it does not split or warp as time goes by. Therefore, it is dimensionally stable. Cracked gypsum sheathed walls, nail

head popping and other common problems with wood-framed structures can be virtually eliminated in buildings

with cold-formed steel stud walls.

No formwork needed - The use of cold-formed steel decks eliminates the formwork for pouring concrete floor. In

addition, composite action between the steel deck and concrete increases floor strength and stiffness.

Durable material - Cold-formed steel is durable because it is termite-proof and rot-proof. In addition, galvanized

cold-formed steel products can provide long-term resistance to corrosion.

Economy in transportation and handling - Lightweight cold-formed members or panels are easy to handle and to

transport. In addition, they can be nested and bundled, reducing the required shipping and storage space.

Non-combustible material - Steel is a non-combustible material and will not contribute fuel to the spread of a fire.

This can result in better fire resistance and lower insurance premiums.

Recyclable nature - Steel is North America No. 1 recycled construction material, with a minimum 25% recycled

content. Steel products used in construction are infinitely recyclable, with no degradation in structural

properties. It can be recycled and reused. Steel-framed housing dramatically reduces the amount of trees

consumed for residential construction, thus conserving one of nature's most precious resources.

Sagging – Cold formed steel members provide the strength and stiffness to accommodate heavy floor toppings

without long term sagging or creep.

Electrical & Plumbing Services – Steel framing supplied with pre-punched (aligned) holes in the web of floor joists

and wall studs. The installation of electrical and plumbing services is easily and quickly accomplished when the pre-

punched holes used for running these services.

PRODUCTION AND INSTALLATION CAPACITY

• Production capacity is up to 200,000 m2 of built up area per year (based on 2 shifts)

• Average speed of site installation is 2500 m2 per week (based on 10 x 6 man crews) this can be increased by adding additional crews to site.

• Company employees (within UAE).

• Number of permanent head office employees. (32) • Number of permanent construction site employees. (16) • Number of temporary contractual construction site employees. (16+)

STAFF STRENGTH • Manazil Steel Framing has 32 white collar staff including 6 dedicated Engineers and Detailers in addition to; staff for Financial Management, Administration, Marketing and Executive Management. • Factory and onsite labour capacity is adjusted according to demand as we have an open contract with Sawa’d Human Resources.

ID Task Name Duration

1 Engineering 5 days2 Fabrication 14 days?3 Ground Floor Walls 3 days?4 First Floor Panels 3 days?5 First Floor Walls 3 days?6 Roof Panels 3 days?7 Sloped Roof Trusses 2 days?8 Installation 15 days?9 Ground Floor Walls 3 days?

10 First Floor Panels 3 days?11 Ground Floor Sheathing 3 days?12 First Floor Metal Deck + Concrete 3 days?13 First Floor Walls 3 days?14 Roof Panels 3 days?15 First Floor Sheathing 4 days?16 Roof Metal Deck + Concrete 4 days?

S S M T W T F S S M T W T F S S M T W T F S S M T W TW1 W2 W3 W4

TYPICAL WORK SCHEDULE FOR ONE VILLA(WITH FIVE MEN INSTALLATION CREW)

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Joanna

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This document has been published for the purpose of providing information of a general nature only. Further, no guarantee, warranty, or any other form of assurance is given as to the accuracy, currency or completeness of the information provided. Accordingly, any reliance on, or use, by you of any information contained within this document for any purpose whatsoever shall be entirely at your own risk, and any liability to you is expressly disclaimed to the maximum extent permitted by law.

All Logos are trademarks of Genesis Manazil Steel Framing

Copyright® 2010 Genesis Manazil Steel Framing. Reproduction of any part of this document is prohibited, except with the prior written consent of Genesis Manazil Steel Framing.

Contact Us

Genesis Manazil Steel Framing provides world leading structural solutions, technologies and expertise. Starting from the architectural drawings all the way to inspecting the finished LSF structure, Genesis Manazil Steel Framing delivers complete turnkey solutions to cost-conscious real estate developers and construction companies eager to join the green building revolution.

For more information, please contact us at:

www.genesismanazil.comEmail: [email protected] Phone: 02-550 2265 Fax: 02-550 2265

P.O. Box 29396 ICAD, Musaffah, Abu Dhabi, United Arab Emirates

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