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LOAD CARRYING CAPACITY OF DRY FLOOR PANEL SYSTEM TE CHEI YEAN UNIVERSITI TEKNOLOGI MALAYSIA
LOAD CARRYING CAPACITY OF DRY FLOOR
PANEL SYSTEM
TE CHEI YEAN
UNIVERSITI TEKNOLOGI MALAYSIA
iii
ACKNOWLEDGEMENT
I would like to thank all the parties who have given the co-operation to me in
writing this project report. I am sincerely greatful to my supervisor, Dr. Redzuan
Abdullah for his continuous support and guidance in this project. He has set a high
standard for the conduct of this study and his valuable suggestions and guidance have
provided me the motivation needed to complete this project report. I would like to thank
Dr Koh Heng Boon for giving me valuable advice and opinions.
Besides, I thank my family and friends for their supports and encouragement. Their
encouragement provided the often-needed motivation and inspirations for me to push
through the hard times. Last but not least, I thank to my dearest Mr EK Lim for his
continued support and concern throughout in this project report preparation. I would
also like to acknowledge the contributions of those who have helped either directly or
indirectly in the completion of this project.
iv
ABSTRACT
This paper describes the application of finite element modelling to study structural
performances of a dry floor system, consisting of plywood attached to top layer of
profiled steel sheet by self-drilling, self-tapping screws connector. Parametric study was
carried out by using various profiled steel sheet thickness, plywood thickness and
different geometry of profiled steel sheet. The preliminary FE model was validated
using experimental study. Parametric studies showed 96.72% increased in flexural
stiffness when the thickness of profiled steel sheet was changed from 0.8mm to 1.8mm.
The increment of plywood thickness from 9.5mm to 25mm has increased flexural
stiffness of the slab up to 23.00% in a quadratic form. Different geometry of profiled
steel sheet affects the load carrying capacity of the proposed dry floor panel where SDP
gives 1.42 to 1.49 higher in flexural stiffness per 1 unit area of steel compared with
PEVA. This means SDP profile will give more economical design compared with
PEVA profile. A theoretical formula was proposed to predict the flexural strength of the
slab. Moment capacity predicted from FE analysis preformed 1.06 safety factor over
theoretical formula and 1.40 over experimental results. FE analysis had indicated high
degree of accuracy and revealed that the prediction moment capacity using FE analysis
and theoretical formula are conservative and safe for design purpose.It can be concluded
that the proposed dry floor panel has a great potential to be exploited as alternative
flooring system.
Keywords: Profiled steel sheet; dry flooring system; composite panel
v
ABSTRAK
Kertas kerja ini membincangkan penggunaan kaedah permodelan unsur
terhingga untuk mengkaji kelakuan struktur sistem lantai kering. Cadangan sistem lantai
kering ini terdiri daripada papan lapis disambungkan ke atas plat keluli berprofil secara
mekanikal mudah dengan mengunakan skru. Kajian parameter melingkungi kesan
ketebalan plat keluli berprofil, kesan ketebalan papan lapis and kesan bentuk geometri
yang berbeza ke atas keupayaan galas beban sistem lantai kering. Analisis permodelan
pertama diselaraskan dengan keputusan eksperimen. Daripada kajian parameter dengan
analisis unsur terhingga, kesan ketebalan plat keluli berprofil menunjukkan pertambahan
sebanyak 96.72% dari segi kekuatan lenturan apabila tebal plat keluli berprofil bertukar
dari 0.8mm ke 1.8mm. Manakala kesan ketebalan papan lapis hanya menunjukkan
pertambahan sebanyak 23% apabila tebal papan lapis bertukar dari 9.5mm ke 25mm.
Profil SDP lebih kuat sebanyak factor 1.42 ke 1.49 berbanding profil PEVA dari segi
kekuatan lenturan per unit keluasan profil . Ini menunjukkan geometri SDP
menonjolkan rekabentuk yang lebih ekonomi. Keupayaan moment kapasiti yang
berdasarkan analisis unsur terhingga mensyorkan faktor 1.06 berbanding dengan
keupayaan moment kapasiti yang dikira melalui penggunaan formula teori bahan
elastik; dan faktor sebanyak 1.40 berbanding dengan keupayaan moment kapasiti yang
dikira berdasarkan keputusan eksperimen. Analisis penggunaan unsur terhingga
menunjukkan nilai ketetapan yang tinggi. Secara bandingan dengan keputusan
eksperimen, anggaran moment kapasiti mengunakan kaedah unsur terhingga dan
formula teori bahan adalah selamat digunakan dalam proses rekabentuk. Sebagai
kesimpulan, cadangan sistem papak kering mempunyai potensi yang tinggi
diesploitasikan sebagai alternatif sistem lantai konvensional sekarang.
vi
Kata Kekunci: Plat keluli berprofil; lantai kering; komposit
TABLE OF CONTENTS CHAPTER SUBJECT PAGE
DECLARATION ii
ACKNOWLEDGEMENT iii ABSTRACT iv ABSTRAK v TABLE OF CONTENTS vi LIST OF FIGURES ix LIST OF TABLES xii LIST OF SYMBOLS xiii LIST OF APPENDICES xiv CHAPTER 1 INTRODUCTION
1.1 Current Development of Construction
Technology in Malaysia 1
1.2 Problem Statement 4
1.3 Aim and Objectives 4
1.4 Scope of research 5
CHAPTER 2 LITERATURE RIVIEW
2.1 Overview of Dry Floor System 6
2.1.1 W.H. Baruzzaman et al (2003) 8
2.1.2 E.Ahmed, W.H. Baruzzaman and H.D. Wright (2002) 9
vii
2.1.3 E.Ahmed, W.H. Baruzzaman and H.D. Wright (2000) 10
2.2 The Proposed Dry Floor System –
Profile Steel Sheeting Plywood System 11
2.3 Profiled Steel Sheet 13
2.3.1 Property of Material 14
2.4 Laminated Plywood 16
2.5 Nonlinear Analysis
20
2.5.1 Geometrically Nonlinear Analysis 20
2.5.2 Nonlinear Boundary Conditions 22
2.5.3 Materially Nonlinear Analysis 23
CHAPTER 3 METHODOLOGY
3.1 Introduction 24
3.2 Experimental Study of the Profile Steel Sheeting Plywood
(PSSP) Dry Floor Panel 25
3.2.1 Experimental Dry Floor Panel Specimen Design 26
3.2.2 Loading and Instrumentation 27
3.2.3 Test Observation and Results 28
3.2.4 Failure Mode 29
3.3 Preliminary FE Model 30
3.3.1 Modelling of Profiled Steel Sheeting 30
3.3.2 Modelling of Plywood 34
3.3.3 Modelling of Connector 35
3.3.4 Boundary Condition 36
3.3.5 Nonlinear Analysis Control 37
viii
CHAPTER 4 RESULTS AND DISCUSSION
4.1 Introduction 40
4.2 Preliminary Model Results 40
4.2.1 Load-Deflection Behaviour 43
4.2.2 Von Misses Stress Contour 44
4.2.3 Stress – Strain Diagram 46
4.3 Discussion on Results of Preliminary Model 47
4.4 Results and Discussion on Parametric Study 50
4.4.1 Effects of Thickness of Profiled Steel Sheet 51
4.4.2 Effects of Thickness of Plywood 53
4.4.3 Effect of Different Geometric Profile of
Profiled Steel Sheet 55
4.5 Moment Capacity of Proposed Dry Floor Panel 58
CHAPTER 5 CONCLUSIONS AND RECOMMENDATIONS
5.1 Conclusions 60
5.2 Recommendations 62
REFERENCES 63
APPENDIX A1-A5 66
ix
LIST OF FIGURES
FIGURE NO. DESCRIPTIONS PAGE
2.1 Structural component of BCCFP panel system developed
by W.H.Baharuzzman(1994) 7
2.2 Modified Bondek II profiled steel sheet (W.H.Baharuzzman, 2003) 14
2.3 Steelon Deck Plate SDP-51 geometrical dimensions 15
2.4 Graph of stress-strain of plywood (Curry and Hearmon, 1974) 18
2.5 Illustration of geometrically nonlinear behaviour of two simple
structures 21
2.6 Illustration of nonlinear boundary condition of a simple structure 22
3.1 Cross section dimension of profiled steel sheet type of SDP-51 26
3.2 Cross section dimension of profiled steel sheet type of PEVA 26
3.3 Location of transducer on plan view 28
3.4 Typical load-deflection responses at the centre position of the
panel 29
x
3.5 Finite Element idealization of model SDP 08S18P 31
3.6 Comparison between actual and modelling illustration 32
3.7 Input of profiled steel sheet as thick shell element (QTS4) in
LUSAS Modeller Softwore 32
3.8 Eccentricity definitions in a thick shell element 33
3.9 Screw connectors were modelled as a joint element with no
rotational stiffness in Lusas Modeller Software 36
3.10 Support definition in the proposed FE modelling 37
3.11 Nonlinear analysis controls in the proposed FE modelling 39
4.1 Conversion of point load to uniform distributed area load 41
4.2 Deformed shape of the proposed dry floor system under load 43
4.3 Comparison between experimental and FE analysis for flexural
Load-deflection behaviour for model SDP0.8PLY18P 44
4.4 Contour diagram of the Von Misses stress during load factor 0.2.
Critical stress were prorogated from point of applied line load 45
4.5 Contour diagram of the Von Misses stress during load factor 0.9 46
4.6 Yield stress strain diagram of the proposed model of a point in the
mid span 47
4.7 Elastic behaviour of the experimental and FE model 49
4.8 Flexural load-deflection behaviour of the proposed dry floor system
with different thickness of profiled steel sheet. 52
4.9 Load increments at 18mm deflection for different profiled steel sheet
thickness. 52
4.10 Flexural load-deflection behaviour of the proposed dry floor system
xi
with different thickness of plywood 54
4.11 Comparison load carrying capacity for variable profiled steel sheet
and plywood thickness 55
4.12 Geometry dimensions for Model SDP and PEVA 56
4.13 Equivalent area loads per 1 unit effective second moment plotted
against deflection 57
xii
LIST OF TABLES
TABLE NO. DESCRIPTIONS PAGE
Table 1.1 5 major systems promoting in IBS system in Malaysia
Construction industry. (Economic Planning Unit, Prime
Minister’s Department, 2003) 2
Table 2.1 Test Speciment 8
Table 2.2 Properties of Bondek II profiled steel sheet 15
Table 2.3 Properties of SDP-51 profiled steel sheet 15
Table 3.1 The proposed test program carried out by Mohd Hanif (2006) 25
Table 3.2 Steel Properties used in FE model 33
Table 3.3 Elastic-plastic Strain for Plywood Material used in FE Model 34
Table 4.1 Flexural stiffness value for various thickness of profiled steel
sheet in elastic 53
Table 4.2 Flexural stiffness values for various thickness of plywood
in elastic region 54
Table 4.3 Section properties for different type of profiled steel sheet 56
Table 4.4 Comparison flexural stiffness (kN/m2/m4) for two different
xiii
geometry profile of profiled steel sheet type PEVA and SDP 57
Table 4.5 Moment capacity of dry floor panel for various thicknesses
of profiled steel sheet. 59
LIST OF SYMBOLS
SYMBOL DESCRIPTIONS
mm
N/mm2
kNm
kN/m2
MPa
f
z
I
E
I’
t
-
-
-
-
-
-
-
-
-
-
-
Milimeter
Newton/ milimeter square
kiloNewton meter
kiloNewton/ meter square
Mega Pascal
Mode of rupture
distance from neutral axis
second moment of area of each element
modulus of elasticity of each element
second moment of area of the full cross-section
total thickness of steel sheet
xiv
LIST OF APPENDICES
APPENDIX DESCRIPTIONS PAGE
A.1 Calculation Bending Moment Capacity based on Elastic Section Properties for Model of specimen SDP 08S18P 66
A.2 Calculation Bending Moment Capacity based
on Elastic Section Properties for Model of specimen SDP 10S18P 69
A.3 Calculation Bending Moment Capacity based on Elastic Section Properties for Model of specimen SDP 12S18P 72
A.4 Calculation Bending Moment Capacity based on Elastic Section Properties for Model of specimen SDP 15S18P 75
A.5 Calculation Bending Moment Capacity based on Elastic Section Properties for Model of specimen SDP 18S18P 78
CHAPTER 1
INTRODUCTION
1.1 Current Development of Construction Technology in Malaysia
The construction industry plays a big role in Malaysia’s development and is
expected to be a major contributor towards the realisation of Vision 2020. Thus, as
envisaged in the Third Outline Perspective Plan (OPP3) 2001-2010, the industry is
expected to grow at 6.6% per annum and contribute 3.1% to the GDP in the year 2010
(Shahrul Nizar Shaari and Elias Ismail, 2003). Unfortunately, local construction industry
technology still dominated by conventional cast in-situ reinforced concrete system,
which is very labour-intensive method. The reasons why local construction player
would not opt for alternative methods are caused by the followings factors:
a) Lack of knowledge in alternative construction technique resulting in
fear and avoidance.
b) Cheap rates and abundant supply of labours sourced from
neighbouring countries.
c) Failure of local players to have proper technology transfer – resulting
in problems during production and installation.
d) High prices of systems caused by high set-up costs, low demand and
designs originally meant for in-situ construction.
2
Nevertheless, the cheap labour and huge supply of labour in the local
construction industry would not last forever and a disruption of the supply would
generate huge problems to the industry; as experience in 2002. Also, besides increasing
the outflow of Ringgit to foreign economies, dependency on foreign labours also brings
about negative impact to the nation, socially and culturally.
Because of this, it is important for local industry players to begin sourcing
alternatives to labour-intensive construction methods. Instead of “builder” the
contractors should be functioning as “assemblers” at sites. CIDB actively promoting the
usage of new technologies know as “Industrialised Building System” (IBS).
IBS can be defined as products, systems and techniques used in making
construction less labour- orientated, faster as well as quality controlled. It generally
involves prefabricated products – factory manufactured elements that are transported to
the construction sites and erected. IBS can be structurally divided into 5 major groups:
Table 1.1: 5 major systems promoting in IBS system in Malaysia construction industry
(Economic Planning Unit, Prime Minister’s Department, 2003)
Group 1:
Precast Concrete Framing,
Panel and Box Systems
The most common IBS are the precast concrete
elements, precast concrete columns, beams, slabs
walls, “3-D” components ( e.g. balconies, staircases,
toilets, lift chambers, refuse chambers), lightweight
precast concrete, as well as permanent concrete
formworks.
Group 2:
Steel Formwork Systems
Considered as one of the “low-level” or the “least
prefabricated” IBS as the systems generally involve
site casting. Thus, the question of the structural
3
quality control still arises. Nevertheless, these
systems, tunnel forms, tilt-up systems, beams and
columns moulding forms, a dn permanent steel
formwork (metal decks) do offer high quality
finishes and fast construction with less site labour
and material requirement.
Group 3:
Steel Framing Systems
Commonly used with precast concrete, slabs, steels
columns and beams have always been the popular
choice and used extensively in the fast-track
construction of skyscrapers. Recent development in
these types of IBS includes the increased usage of
light steel trusses cocsisting of cost-effective
profiled cold-formed channels and steel portal frame
systems as an alternative to the heavier traditional
hot-rolled sections.
Group 4:
Timber Framing Systems
Among the products listed in this category are
timber building frames and timber roof trusses.
Group 5:
Brickwork Systems
The construction method of suing the conventional
bricks has been revolutionised by the development
and usage of interlocking concrete masonry units
(CMU) abd lighlight concrete blocks. The tedious
and time-consuming traditional brick-laying tasks
are greatly simplified by the usage of these effective
alternative solutions
The main benefits offered by the usage of these systems are:
a) High quality of finished products and minimal wastages due to factory-
controlled prefabrication environment.
b) Elimination of conventional timber formworks and great reduction of props
through the usage of prefabricated elements or system formwork for site casting.
4
c) Sturdy and safe platforms provided by the prefabricated elements.
d) Faster completion due to the introduction of components replacing in-situ
construction.
e) Neater, cleaner and safer sites due to reductions of construction debris, site
workers and materials.
f) Lower total construction cot due to all of the above.
1.2 Problem Statement
Recent development of alternative construction system has encouraged studies
on various innovative lightweight composite structural flooring panel systems. One of
the lightweight systems is dry floor panel consisting plywood attached to top layer of profiled
steel sheet by self-drilling, self-tapping screws connector. Two major structural components
of the system, profile steel sheets and plywood are both readily available material in
market and in pre-fabricated form. The new system is introduced to meet IBS concepts,
which is making construction less labour-orientated, faster and better quality control.
1.3 Aim and Objectives
The proposed dry floor system consists of plywood attached to top layer of profiled
steel sheet by self-drilling, self-tapping screws connector. The aim of the study was to
investigate the structural performance of the system using various profiled steel sheet
thickness, plywood thickness and different geometry of profiled steel sheet by using finite
element method. In order to achieve the aim of the study, 4 objectives were set as below:
a) To develop a finite element modeling for dry floor system by using Lusas
Modeller Finite Element Software.
5
b) To perform non-linear FE analysis to determine the behavior and load carrying
capacity of the proposed dry floor system.
c) Parametric study on the effect of the thickness of profiled steel sheet, thickness
of plywood and effect of different geometry of profiled steel sheet on the load carrying
capacity of the proposed system.
d) To compare bending moment capacity obtained from FE analysis and
experimental results with theoretical formula based on elastic section properties.
1.4 Scope of research
The scopes of this study are:
a) The FE model was in 3-Dimensional.
b) Only material non-linearity included in the analysis.
61
a) The load carrying capacity of the proposed dry floor panel increased with the
increment of the profiled steel sheet. The capacity increased as much as 96.72%
when the thickness increased from 0.8mm to 1.8mm.
b) The load carrying capacity of the proposed dry floor panel increased by
thickness of plywood by a value 23% when thickness increased from 9.5mm to
25mm.
c) Load carrying capacity increased linearly with the profiled steel thickness and
plywood thickness. The profiled steel thickness give higher rate of load carrying
capacity compared to the plywood thickness.
d) Different geometry of profiled steel sheet affects the load carrying capacity of
the proposed dry floor panel. SDP profile gives higher flexural stiffness per 1
unit
area of steel section compared to PEVA profile. This means SDP profile will
give more economical design compared with PEVA profiled at same load
carrying capacity.
e) Moment capacity predicted from FE analysis had performed acceptable results
compared with the proposed theoretical formula and experimental results. FE
results with 1.06 times higher than theoretical results indicated high degree of
accuracy of FE analysis. Whilst the average experimental results with 1.4 times
higher than the theoretical results. This revealed that prediction of moment
capacity using FE analysis and theoretical formula are conservative and safe for
design purpose.
62
5.2 Recommendations
Several recommendations are outlined below to improve the study of the
proposed dry floor panel in future:
a) In this study, the geometric profile of the proposed dry floor panel had been
modelled using assembly of 3-D isotropic plates. The 3-D model is much time
consuming. It is recommended that the profiled steel sheet should be modelled as
an equivalent orthotropic plate of uniform thickness in order to reduce
computation time and memory.
b) The effect of connector on the behaviour of proposed panel should be studied
in future. This includes the effect of the spacing of the connectors and the load-
slip relationship, in order to gain better understanding on the interaction between
plywood and profiled steel sheet.
c) The contact condition between profiled steel sheet and plywood should be
taken into consideration in future study. It is suggested that an appropriate
surface contact condition shall be inserted between profiled steel sheet and
plywood by assigning slideline dataset to the required lines or surfaces. It is
expected that the contact condition may contribute to the partial composite
action.
63
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