K block manual draft rev2

KOTO

Energy Efficient High Speed Industrialized Building System

RESIDENTIAL WALLING MANUAL No. 2 Date of issue: 1.1.2011

DRAFT - NOT FOR CIRCULATION © KOTO Corporation 2011 - all rights reserved

CONTENTS E Page 1

INTRODUCTION

…. 2

2

K-BLOCK

…2

3

KOTO SYSTEM

….2

4

APPLICATION OF MANUAL

.....3

5

CONSTRUCTION PROCESS

…. 5

6

DESIGN

7

8

9 10 11 12

PROPERTIES

6.1

Basis

.....6

6.2

Material Properties

….6

6.3

Column Section

....6

6.4

Column Bending Capacity

.....7

6.5

Column Racking Capacity

.....8

6.6

Column Compression Capacity

.....8

WIND LOADS

....8

7.1

Malaysia

…8

7.2

Australia

…8

DESIGN PROCEEDURE

....10

8.1

Column Bending

.....10

8.2

Racking

….15

8.3

Column Compression

.....15

8.4

Free Standing Walls and Fences

….16

ROOF CONNECTION THERMAL INSULATION ENVIRONMENTAL CONTRIBUTION FIRE RATING

....17 ....18 ....18 ....18

This manual has been prepared by Ron Marshall B.E.,M.Eng.Sc on behalf of Koto Corp for use by Building Designers. The information provided in this publication is intended as general guidance only and is not a substitute for the services of professional consultants on particular projects. The manual is subject to regular updates and designers should check they have the latest version. (DRAFT ONLY ) Contact email: globalsolutions@kotocorp.com 1

1 INTRODUCTION This design manual has been prepared for guidance in the design of reinforced concrete column and beam Residential buildings using KOTO permanent formwork and infill walls.

While construction using K-Blocks is applicable to all buildings, the design tables included in this manual are for residential buildings up to 5 stories high with floor to ceiling height of up to 3.6m and subjected to wind speed of up to 60 m/s.

The preferred foundation is a K-Pod Raft and the preferred suspended slab is K-Rib lightweight floor. The full economies and efficiencies of the KOTO system are only realized when the building is designed using all KOTO components for foundation, floors, walls and roof.

2

THE K-BLOCK

The K-Block consists of 170mm thick panel of light weight material with precision cut 100mm by 200mm cores at 300mm centers.

The blocks are pre-coated with fibre-mesh composite coating. K-Blocks provide permanent formwork for reinforced concrete columns and beams and then act as infill walls between those colums and beams. concrete columns and beams and then act as infill walls between those columns.

600mm

200mm 100mm up to 6m long

200mm 100mm 200mm 50mm

35mm 100mm 170mm

2

3 KOTO SYSTEM

Starter bars in floors K-Floor Panels Colums formed by filling hollow cores

reinforced lintels K-Block Walls

K-Pod Foundation

WALLS & COLUMNS

Refer to K-Pod, K-Floor and K-Roof Manuals for information about foundations, suspended slabs and roofing

3

4 APPLICATION OF MANUAL The designs in this manual have been carried out on the following basis:a. Foundation and floors have sufficient strength and stiffness to provide rigid support for all KOTO columns. b. Roofs and floors have adequate stiffness to distribute racking forces to the bracing walls. Otherwise cross bracing must be used. c. The roof is anchored into the bond beam or ring-beam, with connections designed to resist uplift and lateral forces. d. Vertical wall reinforcement provides tie-down to the roof to resist uplift. e. 400mm starter bars extending from the floors provide anchorage for the KOTO columns. f. The columns are all connected into a slab or a bond-beam at the top. g. The roof is properly anchored to the bond beams. h. Concrete columns provide the bending strength to resist wind pressure on the face of the wall by spanning vertically between floors and between a floor and roof. i. A column is located at the end of all walls and at the edge of all openings. j. The column at the edge of an opening is designed to also carry the wind load from the opening. k. Lintels over openings provide vertical strength to carry wind loads and are extended to columns and tied to the bond beam by reinforced cores. l. Columns act to resist the racking forces by acting as restrained vertical beams between floors and between a floor and the roof.

(ring beam)

column each side of openings

4

PlateFigure dimensions Roof fixing as required 4.1 Walland layout

N12 Bars top & bottom 200mm

Columns

BOND BEAM / RING BEAM

LINTEL Figure 4.2 Wall details

5

2 rods in wall

382.5 470 300

2 rods in buttress

End of K-Block removed to link filled cores

Figure 4.3 Opening edge details

6

5 CONSTRUCTION PROCESS The houses are constructed generally in the following way: 1. Foundations are poured with starter bars cast in to align with and lap with vertical reinforcement.

2. First course of K-blocks are placed over the starter bars and glued in place.

3. Subsequent blocks are glued as they are placed.

4. Fiberglass reinforced joints between blocks are grouted flush.

5. All reinforcement is placed in position in the cores and roof anchors placed into bond-beam location.

6. Columns, lintels and bond-beams are concret filled.

7. The roofing system is connected to the bond-beams.

8. Additional fiberglass mech is installed as required and KOTO wall coating completed.

7. Additional fibreglass mesh is installed as required and the KOTO wall coating completed.

Figure 5.1 Assembly process

With all cores filled, K-Block walls can take loads to 5 stories at W60

7

6 DESIGN PROPERTIES 6.1 Basis The structure consists of reinforced concrete columns cast in the hollow cores of K-blocks.

The columns are calculated to resist wind loads on the face of the wall and the in-plane shear from racking forces on the overall building.

For multi-level buildings the compressive strength of these columns needs to be checked for vertial loads.

For single story houses the external walls usually carry the bracing loads but where house walls exceed 10m in length, internal bracing walls need to be used.

Because of the light-weight nature of a KOTO house, in low earthquake areas racking from earthquake loads will be less than those from wind loads and hence may be ignored.

In areas with high seismic risk, the racking forces from earthquake loading will need to be calculated and if greater than the wind load, the columns designed for these forces.

6.2 Material Properties The design tables in this manual are based on materials with the following properties: Mass of fully concreted KOTO wall  Characteristic Compressive Strength of concrete  Yield Strength of reinforcement For “Y” bars

w = 1.8 kN/m f’c = 30 MPa f sy = 455 MPa

2

NOTE: While the design tables in this manual have been calculated using “Y” bars with fsy = 455 MPa , section properties have also been included for “N” bars of f sy = 500 MPa for locations where they available.

6.3 Column Details The standard 200 mm x 100 mm column has sufficient strength for most buildings. In high wind speed locations and very high walls it may be necessary to increase the face loading strength by adding a buttress to some of the columns.

8

Standard Column

Buttress Colum

6.4 Column Bending Capacity The bending capacity of columns subject to face loads is given in TABLE 6.1.

They have been calculated using the formula: Moment Capacity

 0.6 Ast f sy  M u  f sy Ast d 1  f c' b d  

TABLE  6.1 Bending capacity of columns Column type

Moment capacity per column (kNm) Reinforcement grade & size Yield strength of Yield strength of reinforcement reinforcement fsy = 455 MPa fsy = 500 MPa Y10 Y12 N10 N12 1.84 2.16 1.99 2.16

12.2

17.2

13.4

18.8

9

6.5 Column Racking Capacity The racking capacity of columns given in table 6.2 is based on the columns being rotationally fixed at the base by the floor and at the top by either a concrete floor or a reinforced bond-beam. The values do not take account of compression and are hence conservative for lower floors of a building.

TABLE 6.2 Racking capacity of columns Column detail

6.6

Wall height (mm)

Racking strength per column (kN) Reinforcement grade & size Yield strength of Yield strength of reinforcement reinforcement fsy = 455 MPa fsy = 500 MPa

2400

Y10 3.4

Y12 4.8

Y16 8.4

N10 3.7

N12 5.3

N16 9.1

2700

23.0

4.2

7.3

3.3

4.6

8.0

3000

2.6

3.8

6.5

2.9

4.1

7.1

3600

2.1

3.1

5.3

2.4

3.4

5.8

Column Compressive Strength

The compressive strength of columns given in TABLE 6.3 is based on the formula given in BS8110:N  0.3*(T  1.2*e  2*ea ) * f c' The minimum value of e has been taken as e = 20 mm. (This is conservative for a wall 100 mm wide when compared to other codes which give the  of e as = T/20 for internal walls and T/20 for external walls, ie minimum value  e =5 mm and 17 mm respectively)

10

TABLE 6.3 Compressive strength of columns Column detail Wall height Compressive strength (mm) Per column Per meter with all (kN/column) cores filled (kN/m) 2400 90 300 2700 78 260 3000 64 213 100 3600 32 106

7 WIND LOADS Wind forces are calculated as the wind pressure on an effective exposed area.

The wind pressure is derived from the wind speed appropriate for the location, building height and terrain, multiplied by the Pressure coefficient for the building element. Hence the wind pressures can vary for each individual building. The design wind pressure given in table 7.1 has been obtained by applying the load factor of 1.5

Malaysia For Malaysia, the base wind speed is 33.5 m/s inland and 22.5 m/s on the coastal strip.

Using Appendix A – Simplified procedure – Malaysian Standard MS 1553:2002 Code of practice on wind loading for building structure, the Terrain/height multiplier can be taken as 0.91 for houses up to 5m high, 1.00 up to 10m high and 1.08 up to 20m high, the pressure coefficient for a wall as 1.1 ( used for checking the strength the wall) and for the building as 1.3 (used for calculating the racking forces).

Using these factors, the design pressures are as shown in TABLE 7.1 TABLE 7.1 Design wind pressure for Malaysia Basic wind speed (m/s)

32.5 Zone ll 33.5 Zone l

Building Terrain- Building height height design multiplier wind up to speed (m) (m/s) 5 10 20 5 10 20

0.91 1.00 1.08 0.91 1.00 1.08

29.5 32.5 35.1 30.5 33.5 36.2

Base wind pressure (kPa)

0.53 0.65 0.75 0.57 0.69 0.80

Design wind pressure (kPa) Pressure Pressure coefficient for coefficient for face load on racking load wall on house (Cpe-Cpi = 1.1) (Cpe-Cpi =1.3) 0.98 1.26 0.98 1.26 1.23 1.46 0.98 1.26 1.14 1.34 1.32 1.56

11

Australia For Australia the wind speed varies substantially across the country. The wind loading code for houses AS 1140.4 gives simplified wind speed and pressure coefficients for various locations. Using these factors, the design pressure is as shown in TABLE 7.2.

TABLE 7.2 Design wind pressure for Australia Wind Speed Wind (m/s) class

33 41 50 60 70

8

N2 N3 N4 N5 N6

Non-cyclonic area Cyclonic area Design wind pressure, p wind Design wind pressure, p (kPa) class (kPa) Pressure Pressure Pressure Pressure coefficient coefficient for coefficient coefficient for for face racking load for face load racking load on load on wall on house on wall house (Cpe-Cpi = (Cpe-Cpi (Cpe-Cpi = (Cpe-Cpi =1.35) 1.0) =1.35) 1.35) 0.98 1.32 1.51 2.03 C1 2.03 2.03 2.25 3.03 C2 3.03 3.03 3.24 4.37 C3 4.37 4.37 4.41 5.95 C4 5.95 5.95

DESIGN PROCEEDURE

8.1 COLUMN BENDING Columns are designed to resist wind loads on the face of the wall. The effective exposed area on a column is the sum of half the distances to the adjacent column on either side (effective width W e), times the height of the wall (H). The wind load is the wind pressure times the effective exposed area (pW eH). Where there is an opening, the wind load on the opening is transferred to the side of the opening and the effective width is then taken to the centerline of the opening.

Effective width supported by a column

The maximum width of wall that a column can support is determined by equating the imposed bending moment from the wind pressure (Mwind) to the resistance moment (M*) of that column.

12

The maximum spacing between columns in TABLE 8.1 has been taken as equal to the supported width.

The imposed bending moment from the wind load on the face of a column is given

pW e H 2 for a freestanding wall, 2 pW e H 2 for a column spanning between floor and roof  9

M wind 

byand

M wind

 

Bending moments

M wind  M*

Equating bending moments:-

Maximum width carried by column:-

2M * For a cantilever pH 2 9M *  for a column spanning between floor and roof pH 2

 W e  and

We

 The design moment capacity (M*) of columns is given in TABLE 6.1.



Using the width of wall (including openings) that a column can carry, column spacing, and opening sizes have been calculated for various wind pressures. Column spacing for various wall heights and pressures are given in TABLE 8.1 to 8.4 as follows: Step 1: Determine the wind pressure on the wall (refer section 7) Step 2: For the required wind pressure and wall height, determine the maximum column spacing and reinforcement from TABLE 8.1. For very high walls, Use buttress spaced as shown in TABLE 8.2 Step 3: For each opening check in TABLE 8.3 whether the width exceeds the maximum allowable width Where the width of an openings exceeds the allowable opening, strengthen the edge of that opening by either placing a second column next to the opening or strengthening the edge using a buttress.

13

Step 3 Where there is a double opening, check in TABLE 8.4 whether the width exceeds the maximum allowable sum. Where the sum of the widths of the openings exceeds that allowable, strengthen the pier between the openings.

TABLE 8.1 Maximum spacing of columns - wall subject to face wind load Maximum spacing of columns “S“ (mm) Wall height (mm) 2400 2700 3000 3600 2-Y10 0.98 2700 2100 1800 1200 1.14 2400 1800 1500 900 1.32 2100 1500 1200 900 1.5 1800 1500 1200 600 2.2 1200 900 600 300 3.2 600 600 300 300 4.4 600 300 300 2-Y12 0.98 3000 2700 2100 1500 1.14 2700 2100 1800 1200 1.32 2400 1800 1500 900 1.5 2100 1500 1200 900 2.2 1500 1200 900 600 3.2 900 600 600 300 4.4 600 600 300 300 NOTE this table does not apply to internal wall

Wall detail

Wind Pressure (kPa)

TABLE 8.2 Maximum spacing of buttress columns - wall subject to face wind load Wall detail

Wind Pressure (kPa)

2-Y10 each face

0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5 2.2 3.2 4.4

2-Y12 each face

Maximum spacing of columns “S“ (mm) Wall height (mm) 5000 6000 7000 3000 3000 2100 3000 2700 1800 3000 2100 1500 2700 1800 1500 1800 1200 900 1200 900 600 900 600 300 3000 3000 3000 3000 3000 2700 3000 3000 2400 3000 2700 2100 2700 1800 1200 1800 1200 900 1200 900 600

14

TABLE 8.3 Maximum openings in wall Wall detail

Wind Speed (m/s)

2-Y10

0.98 1.14 1.32 1.5 2.2 3.2 4.4

Maximum opening width “O” (m) Wall height (mm) 2400 2700 3000 3600 2800 2100 1500 900 2100 1800 1200 900 1800 1200 900 600 1500 1200 900 600 900 600 600 600 -

2-Y12

0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5

2700 2700 2400 2100 1200 900 600 2700 2700 2700 2700

2400 2100 1800 1500 900 600 2700 2700 2700 2100

1800 1500 1500 1200 600 2700 2400 2100 1800

1200 1200 900 600 1800 1500 1200 900

2.2

1800

1200

900

-

3.2

1200

600

-

-

4.4

-

-

-

-

2-Y10

2-Y12

4-Y10

0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5

2700 2700 2700 2700 2400 1500 900 2700 2700 2700 2700

2700 2700 2700 2700 1800 900 600 2700 2700 2700 2700

2700 2700 2700 2100 1200 600 2700 2700 2700 2700

2400 1800 1500 1200 600 2700 2700 2700 2700

2.2

2700

2700

2700

2700

3.2

2700

2700

2700

2700

2700

2700

2700

4.4

2700

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TABLE 8.4 Selection of pier Wall detail

Wind Speed (m/s)

400 2-Y10

0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5

Maximum sum of openings “O1 + O2” (m) Wall height (mm) 2400 2700 3000 3600 5400 4200 3000 2100 4500 3600 2700 1800 3900 3000 2400 1200 3000 2400 1800 1200 1800 1500 1200 1200 5600 4800 3600 2400 5600 4200 3000 2100 4800 3600 2700 1800 3900 3000 2400 1500 2400 1500 1200 1500 1200 1200 5400 5400 5400 3300 5400 5400 4500 2700 5400 4800 3600 2100 5400 4100 3000 1800

2.2 3.2 4.4 0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5 2.2 3.2 4.4

3300 1800 5400 5400 5400 5400 4800 3000 1800 5400 5400 5400 5400 5400 5400 5400 5400 5400 5400 5400 5400 5400 5400

2-Y12

2-Y10

2-Y12

4-Y10

4-Y12

2400 1200 5400 5400 5400 5400 3300 1800 1200 5400 5400 5400 5400 5400 5400 5100 5400 5400 5400 5400 5400 5400 5400

1500 5400 5400 5400 4500 2400 1500 5400 5400 5400 5400 5400 5400 3900 5400 5400 5400 5400 5400 5400 5400

4800 3900 3300 2700 1500 5400 5400 5400 5400 5400 3600 5400 5400 5400 5400 5400 5400 3600

16

8.2 Racking Design The Racking load on a building is the wind pressure multiplied by the effective exposed area. The effective exposed area can be taken as the building width times the height from the centre of the lower story to the top of the building. For an upper story of the building, the effective exposed area can be taken as the building width times the height from the centre of the wall at that story level to the top of the building.

The columns must be of sufficient number and strength to resist the total racking force at each level of the building.

TABLE 6.2 gives the design shear resistance for columns when subject to a racking force. The house can be designed for racking by the following:Step 1 Determine the wind pressure and exposed area at the relevent level (refer section 4.3).

Step 2 Calculate the applied racking force in each direction.

Step 3 Add up the total number of columns at that level in each directions and multiply by the racking resistance of each column (from table 4.3) to determine the total racking resistance.

Step 4 Check whether the total resistance exceeds the applied racking force. If not increase the reinforcement or the number of columns. If there are insufficient columns, convert as many internal walls as needed into bracing walls by adding column as required.

8.3 Column Compression The vertical load on a wall is the total dead and live load (with the appropriate load factors applied) that is carried by that wall. There must by sufficient columns in the length of the wall to carry that vertical load.

The column spacing of a load-bearing wall can be calculated by dividing the strength of a column (for the appropriate height) by imposed load per meter.

17

8.4 Free standing walls and fences The spacing of columns required to support a free-standing wall is given in TABLE 8.5. NOTE: The foundation supporting the wall must be of sufficient strength to prevent overturning of the wall.

TABLE 8.5 Maximum spacing of columns in free-standing wall Wall detail

2-Y10

2-Y12

9

Wind Pressure (kPa)

0.98 1.14 1.32 1.5 2.2 3.2 4.4 0.98 1.14 1.32 1.5 2.2 3.2 4.4

Maximum spacing of columns “S“ (mm) Wall height (mm) 900 1200 1500 1800 3000 2400 1500 1200 3000 2100 1200 900 3000 1800 1200 900 3000 1500 900 600 1800 900 600 300 1200 600 300 300 900 600 300 3000 3000 1800 1200 3000 2700 1500 1200 3000 2100 1200 900 3000 1800 1200 900 2400 1200 900 600 1500 900 600 300 1200 600 300 300

ROOF CONNECTIONS

Roof trusses must be connected to the top of the wall to resist both uplift forces and horizontal movement.

In low wind areas this can be achieved by bolting a top plate to the bond beam and then attaching the roof framing to the top plate.

In high wind areas, the truss needs a stronger connection. This can be achieved by the use of truss plates anchored into the bond-beams. The pull out strength of the truss plate in the bond-beam and the strength of the connection to the roof framing must both be checked.

18

Typical details and design capacities are given in the following diagrams:

Alternative Detail for low wind areas:

19

10 THERMAL INSULATION Permanent Thermal Value: K-Block or K-Panel thermal resistance will not diminish over the life span of the building.

K-Panel: K-Panel is designed for Hi-Rise infil panels between columns and beams.

Both K-Block and K-Panel described herein are manufactured as standard building components:75mm thick has an R-value of 2.1 160mm thick has an R-value of 4.5 200mm thick has an R-value of 5.6 300mm thick has an R-value of 8.4 Special thermal applications can be accommodated by changing density, material modification and composite structure.

11 ENVIRONMENTAL CONTRIBUTION: This permanent energy efficient construction system provies a simple solution to reducing loads on power grids in any country and exceeds the performance of conventional construction by a significant amount. i.e. solid concrete has an R-value of .2 12 FIRE RATINGS: The fire retardant properties of the ESP core insulation are non-toxic.

The core material and coatings are not a fuel for fire and the blocks and panels will not spread flame.

The heat of combustion of solid polystyrene polymer is 40, 472kJ/kg; combustion products are carbon dioxide, water, soot (carbon), and to a lesser extent carbon monoxide.

A CSIRO report [Ref (ii)] comments that the toxicity of gases associated with theburning of EPS is no greater than that associated with timber. Extensive research programs have been conducted overseas [Ref(iii)] to determine if thermal decomposition products of EPS present toxicity hazard.

The test results have revealed that the toxicity of the decomposition products appears to be no greater than for wood and decidedly less than other conventional building products, most types of furniture, toys and soft furnishings.

The material itself is self-extinguishing, waterproof and not-bio-degradable, therefore rendering the life span as "permanent".

The polymer modified fibre reinforced mineral coating applied to the facing of K-Block and K-Panel is non-combustible. i(i) P.R. Nicholl and K.G. Martin, 'Toxicity considerations of combustion products from cellular plastics'. (iii) H.Th Hofmann and H. Oettel, Comparative toxicity of thermal decomposition products'.

20