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Blast resistant modular buildings for the petroleum and chemical processing industries
Abstract
There exists a need for blast resistant yet portable buildings to protect personnel temporarily assigned duties within explosively hazardous areas. Blast resistant portable buildings (BRPBs) are a valuable asset for protection of temporarily assigned personnel involved in activities located near potential explosion sites. Portable. Stackable and modular. Blast designed and ductile. Several companies have designed products to meet this need. Blast resistant portable buildings are the size of a typical office trailer; however, they may be installed in a variety of configurations and floor plans. The buildings are similar in design and construction to steel shipping containers but they are larger in scale, are much stronger, and are intended to be occupied within hazardous areas. Typical siting issues for modular buildings involve blast related requirements, process related requirements and conventional loading requirements. Examples of these requirements include: Sliding and overturning during blast response. Positive pressure and forced ventilation requirements. Seismic and wind loading. This paper describes blast performance, structural siting issues, and presents different applications of blast resistant modular buildings that have been installed at various facilities.
... Fireproofing measures with three layers of gypsum boards can safeguard the columns and ensure a 3-hour fire-resistance rating. The fireproofing measure with a layer of gypsum board and mineral wool experienced early gypsum board failure and a smaller rating [21]. ...
... It will also help us determine the areas of failure and what can be done to reduce the failure of the modules. With increasing attention given to high-density urban areas and limited working spaces, modular prefabrication can act as an excellent replacement for conventional buildings [21]. ...
Structures known as modular buildings are made in factories and then moved to construction sites, where they are assembled. The efficacy of modular structures under many uncertainties has to be thoroughly investigated as demand rises; fire is one such uncertainty. The purpose of this study is to ascertain how high temperature affects the components of modular constructions. In the current study, hollow steel columns and beams were taken into account as components of a modular construction. Using ABAQUS, several situations were examined depending on the span length to determine the important locations of the members. Experimental research was conducted on the critical regions identified by the analysis, and the results were contrasted with those of the analysis. A high-temperature localized heating furnace was used for the experimental testing. The findings demonstrated that for spans of 250 mm and 500 mm, the central area of the beams was essential, and the load-carrying capacity was six times less than that of heating at the extremities of the beams. Similar to the beams, columns exhibited less fluctuation than the beams and were weaker in the bottom area when exposed to high temperature. When compared to other places, the capacity was reduced by 1.1 times, and in Case 1, the capacity reduction with regard to loading was 1.68 times greater.
... In unique application scenarios, they serve other structural purposes. They serve as protection against blast/fire [10,11], or they are cantilevered [1] or suspended [12] for special architectural effects. Intrinsic differences in structural terms exist between a modular building structure and a steel moment-resisting-frame (MRF) system. ...
... In addition to the aforementioned general design issues, specialized modules perform better to achieve certain specific design objectives. Blast-proof modules should prevent sliding and overturn while satisfying the requirements of pressure and forced ventilation [10]. In blast protection, LP and SU play less important roles than connections and MS do. ...
Prefabricated 3D modules are widely adopted in building construction for better quality, lower demand on labor and construction space, faster construction, and less emission. Various types of modular structures and connections have been tested and are commercially available. A large number of actual applications demonstrate that the structural system of a modular building can be flexibly organized to suit for the topmost utility architecturally. However, in terms of the stability of the structural system, the role of prefabricated modules widely varies. A systematic summary and categorization of different structural stability systems and layout patterns, especially in multi-story modular buildings where load sharing and transfer between the units are necessary, has yet to be made. This paper provides a state-of-the-art review which focuses on four major structural aspects, e.g., module connection, individual module structure, layout pattern, and additional stability unit. Recommended combinations of structural parts of the system are provided. Nonlinear static or pushover analysis is carried out with the numerical model based on available experimental data to demonstrate the roles of individual modules and additional stability units on system stability. A rating procedure for the modular structural system is proposed to briefly evaluate several aspects of the multi-story modular building structures. Trends in design and usage of modular structure systems are presented using examples of 20 unique applications.
... Modular buildings may be subjected to blast load from several sources including chemical / industrial / terrorist explosion. They are therefore used in industry to protect personnel [96][97][98] where they are referred to as blast resistant modules (BRM) or blast resistant portable buildings (BRPB) (Fig. 7). Steel modules have a primary steel frame with walls formed by infill between roof and floor. ...
... (L) One storey BRM building[96], (M) Two storey BRM building[96], (R) Stacked BRPB complex[97] ...
Prefabrication by off-site manufacturing leads to a reduced overall construction schedule, improved quality, and reduced resource wastage. Modular building is therefore increasingly popular and promoted. With the recent promotion a number of relevant studies have been completed, however, a review of the design, construction, and performance of modular buildings under different loading conditions is lacking. This paper presents a state-of-the-art review of modular building structures. First, structural forms and construction materials are presented as a brief introduction to the modular structures. Modular building is shown to refer not to a single structure type, but a variety of structural systems and materials. These modular structures might perform differently to similar traditional structures and the structural performance is highly dependent on inter- and intra-module connections. The structural response of modules to different hazards is then considered, followed by the current design practice and methodology. As a currently developing area there is great potential for innovation in modular structures and several key research areas are identified for further work.
... Due to the plastic collapse of the front wall and the permanent plastic deformation of other components, the module could not meet safety standards. Thus, the module was reinforced with an aluminium panel wall system filled with crushed stones to prevent plastic failure and enhance safety [208,209]. A blast test was then performed, and it was recognised that the protection did not cause a collapse. ...
Prefabricated volumetric modular steel construction (PFVMSC) has a sustainable behaviour that reduces construction time, waste resources, and onsite workload, resulting in improved quality, faster, safer, and more environmentally sustainable construction. This gradually encourages its adaptation to modern urbanisation as an acceptable alternative to traditional construction in multi-storey structures. The structural instability is not noticeable in low-rise buildings and low seismic zones, so PFVMSC is frequently used. However, lateral loads from winds and earthquakes in high seismic zones significantly impact high rise modular steel building (MSB) since the building's height rises. Thus, PFVMSC's applicability to high-rise engineering projects is hampered by a lack of information about high-rise structures' stability due to extreme multidirectional forces. Therefore, this research summarises key technical issues related to the structural stability and robust performance of multi-storey PFVMS structures. Because of the study's versatility, the module classification is briefly introduced to PFVMSC, followed by a structural system discussion. The structural response of the stability systems and recent connection advancements, on which the multidirectional structural stability of multi-storey PFVMS buildings is highly dependent, is discussed in detail. It was accompanied by a summary of the associated challenges, structural requirements, a research evaluation of recent advancements and associated performance studies that can significantly improve multi-level vertical stacking and multidirectional force transmission. Despite increased research into PFVMSC's structural performance, a thorough understanding of the subject has yet to be gained, posing a threat to its continued prevalence in multi-storey buildings and areas where hazardous events may occur. As a result of this development, numerous significant research sectors have proposed expanding the use of PFVMSC on a multi-storey level.
... Overall, modularisation research offers insights into methods for modelling, modularising, and optimising architectural designs while considering the manufacturing, transportation, and on-site assembly. There is significant existing research that investigates different types of modular systems [12][13][14][15], assembly of modules and connections [16][17][18][19][20][21], structural stability [22][23][24][25], sustainability of prefabricated construction [26][27][28][29][30][31][32][33][34], performance of modular buildings under different load types and extreme conditions [35][36][37][38][39][40][41][42], and optimisation of modular manufacturing [43][44][45][46][47]. However, there is negligible existing research that investigates the feasibility of automating and optimising the modularisation design process of light-weight structures [48,49]. ...
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The construction industry is currently undergoing an increasing demand to boost productivity and improve system efficiencies. Clients are demanding increasingly more customised products at a more competitive cost, speed, and quality. Yet current design systems and existing literature largely overlook the use of automated decision-making tools for supporting mass-customisation for prefabricated buildings. To address this gap, a method for using automated tools to optimise the modularisation of prefabricated lightweight structures is investigated. This study's primary contributions include a multi-variable Modularisation Index, which offers a novel framework for characterising the "optimal" solution, and a recursive Slack-distribution algorithm, which offers a novel method for modularising customised architectural designs. The core insight is that an optimal modularisation solution may be found using a Greedy algorithm. This involves incrementally adjusting the internal module boundaries from the initial solution, and evaluating each viable solution using the proposed Modularisation Index. The Index considers functions of cost, speed, and quality that are weighted according to client preferences. The system outputs the top three highest scoring modularisation solutions which may then be examined by the builder. Overall, the proposed method performs equal to or better than experts for 90% of cases. The Index and modularisation algorithm hence offer useful tools for automating and optimising prefabricated construction, with further opportunity for optimising architectural designs.
... Additionally, the blast resistance capacity is also [61] important for protecting personnel from buildings when they are working in hazardous areas. The additional design considerations for blast resistance can greatly reduce the risk to employees in modular buildings [76]. A study on the fire performance of blind bolted composite beam to column joints demonstrated satisfactory performance without any bolt shank fracture or bolt pull-out failure [77]. ...
Modular construction offers faster and safer manufacturing, better predictability to completion time, superior quality, less workers on site, less resource wastage, and a more environmentally friendly solution than the conventional construction process. Despite having several advantages of modular construction, the private sector still relies heavily on the traditional on-site construction method. To understand the scientific reason behind this situation, this paper critically reviews the recent developments, performances, challenges and future opportunities of modular buildings. Modular constructions are extensively used for low-rise buildings and further attracts strong interest for multi-storey building structures. Prefabricated modules demonstrated satisfactory performance under static, dynamic impact, cyclic, seismic, blast, fire and long-term sustained loading, and offer environmental, economic and social benefits. The acceptance and application of modular construction will further spread with the development of design guidelines, more skilled workers, addressing handing and transportation difficulties, and the development of novel interlocking connections between modules. Recently, composite materials demonstrated high potential to manufacture prefabricated building modules. In Australia, it is expected that modular construction will increase from the current stage of 3% to 5-10% by year 2030.
... As a result, there is a growing need for cost effective blast-resistant structures. Recently, blast-resistant steel modular buildings have been recognized as an economical and practical solution to minimize blast effects in petrochemical and military industries, and valuable asset for protection of personnel involved in activities located near potential explosion sites [1]. They can be used as control rooms, operator shelters, offices, labs and guard booths in a wide range of layouts to meet the needs in explosively hazardous areas or areas with potential terror threat. ...
A two-module blast-resistant steel building with overall dimensions of 12 m by 6 m floor plan and 3.4 m height was designed to resisted 80 kPa free field overpressure with 140 microsecond duration. The building was designed to remain within “high damage/response” level when it is anchored to its foundation. The effect of anchored and unanchored or sliding (free-to-slide) foundation on blast performance of structural elements on the wall and roof, foundation loads, building sliding, and building total friction and kinetic energy were investigated using nonlinear dynamic finite element analysis tools. The comparison of analyses results revealed that building foundation reactions and maximum deflection demands for structural members can significantly decrease with unanchored foundation. For unanchored foundation, several friction coefficients (i.e., 0.2, 0.5, and 0.8) for the interaction between the building and its foundation were considered. The analyses results show that the maximum relative deflections of the structural members of the building with unanchored foundation to be between 43% and 120% with an average of 80% of that for the building with anchored foundations. The most significant effect of unanchored foundation on blast performance of the building was the significant decrease in the foundation maximum horizontal reaction, which was approximately 15% to 60% of that for the building with anchored foundation. However, the unanchored foundation had negligible effect on building vertical foundation reactions. The computed maximum sliding displacements were approximately 10 m, 2 m and 0.3 m for the building with unanchored foundation for friction coefficient of 0.2, 0.5, and 0.8, respectively. For the building with unanchored and anchored foundations, both friction energy and kinetic energy versus time plots were very similar for initial stages of the blast loading. The overall results show that providing even limited permissible sliding between blast resistant structures and their foundation can significantly reduce their foundation reactions and improve blast performance of structural members. A controlled-sliding mechanism between blast resistant structures and their foundation with steel cables is recommend to improve blast performance of the structure while limiting maximum sliding within desired permissible limits.
... In these studies, the interactions between the side walls and the frame of container and the integrated container stiffness were not considered. Harrison [12] described antiknock performance of blast resistant portable buildings (BRPBs) and presented different applications that was installed at various facilities. But, the mechanical properties of boundary condition and corrugated sheet were lacked. ...
This paper does some research on the mechanical property of multilayer container structure under high temperature and gives some suggestions on how to make fire protection based on the performance-based fire design. Firstly, using the software of FDS (Fire Dynamics Simulator), the fire background and fire heating release curve are determined. Through the simulation, the actual temperature curves (of the top and bottom temperature curves of the middle, door, and corner position in the container) are obtained and compared with the standard temperature curve of ISO-834. Secondly, using the software of Abaqus, a full scale finite element model of multilayer container structure is established. Two temperature fields under the standard temperature curve of ISO-834 and the actual temperature curve (of the most unfavorable curve of the top temperature curve of the middle position in the container) are obtained, respectively. Thirdly, the thermal-mechanical coupled analysis is carried out for the container structure under the wind loading and temperature field. The research result can be feasible in design and construction of container buildings and provides some references to corresponding specification preparation.
... The foam can be either Extended Polystyrene (EPS), extruded polystyrene foam (XPS) or polyurethane foam (PU), etc. PU coated composite plate was found effective for mitigating impact loading effect and absorbing impact energy [4]. In the petroleum and chemical processing industries, blast resistant modular houses have been used as permanent or temporary structures to protect personnel and instruments in explosively hazardous workplace [5]. The modular houses enveloped by composite structural insulated panels with metal skin can be employed in the petrochemical industry owing to the advantages of being easily assembled, easily moved, lightweight and thermal insulated etc. ...
... In addition, growing concerns over the thread of terrorist activities or accidental explosions such as pipeline and gas explosions as shown inFigure 1 Structural insulated panels (SIPs) are widely used as wall panels in warehouses, factories, prefabricated houses, container houses, modular houses and other industrial and civil buildings. In the petroleum and chemical processing industries, blast resistant modular houses have been used as permanent or temporary structures to protect personnel and instruments (Harrison 2003). The modular houses or normal houses enveloped by structural insulated panels, as shown inFigure 2, have the advantage of easy assembled, easy moved, lightweight and thermal insulated. ...
Off-site construction has been increasingly employed due to its advantages, for instance, improved quality control, reduced skills labour, faster construction time, decreased material wastage and safe working environment. As the most cutting-edge off-site construction, modular buildings have been utilised for residential building, student accommodation, and hotel projects. However, because of existing and underlying constraints, the adoption of modular buildings is still relatively low. To reveal factors hindering the development of high-rise modular buildings, a comprehensive literature review, coupled with a focus group study, were conducted. A questionnaire survey inquiring about all stakeholders was implemented to quantify constraints. The results were further examined according to a real-life case study. This paper manifested that “Lack of coordination and communication among stakeholders”, “Higher cost”, “Lack of government support”, “Lack of experience and expertise”, “Lack of building codes and standards”, “Poor supply chain integration”, and “Complexity of connection” are the top barriers curbing the uptake of modular buildings. The findings should provide a valuable reference for stakeholders adopting modular buildings, whilst mitigating risks amid modular construction. Future research is expected to exploit building information modelling and design for manufacture and assembly to alleviate these existing constraints and promote the performance of modular construction as well.
Recently, a growing number of the containers have been used in the building structures, therefore, the full size container stiffness have been studied under the longitudinal load, including the 20 ft container, 40 ft container and the 20 ft combined container. Firstly, the full size container experiment has been studied, and then, the load–displacement curve and load-stress curve have been got. Secondly, based on the nonlinear finite element software of Abaqus, the container model has been established and analyzed. By comparing with the load–displacement curves and load-stress values of experiment, the finite element model has been verified. Finally, based on the verified finite element model, the parametric analysis of the corrugated sheeting size, corrugated sheeting cross section, elasticity modulus of top side beam, and every sheeting action for container stiffness has been given, and the design advice of single and combined container has been given. The research results have made feasible in design and construction of container buildings and provided some references to corresponding specification preparation.
Since container buildings are widely used nowadays, this paper attempts to make a study on the longitudinal stiffness of container with holes under external load. Firstly, by applying diaphragm theory, a mechanical analysis and stiffness calculation method of container with holes were given, followed by examples to illustrate the calculation process. Then, through nonlinear finite element software of ABAQUS, a finite element model of container was established. Based on the area and aspect ratio of the hole, a parametric analysis was given to obtain the influence law of parameters on the stiffness of container with holes and some suggestions about the design were followed. Finally, five experimental studies of container with holes were conducted, and both the theoretical and finite element simulation results were compared with experimental data, which were in good agreement. The research result can offer some references not only in the design and construction of container buildings, but also in the description of relevant norms.
This is an introduction to modular steel equipment shelters designed for areas with potential explosion hazards. It serves to review the chronological development of the concept of modular blast resistance, discuss processing industry events driving market demands, and catalog some typical industry responses to date. The paper also reviews levels of industry risk in the context of life safety and protection for essential/critical systems. For the purpose of this discussion, the first tier of risk (personnel protection and life safety) is briefly discussed to provide adequate background. The paper examines the second tier of risk (essential/critical equipment and electrical systems) that facility managers are becoming increasingly concerned with. The paper compares the following: 1) industry guidelines; 2) the known criterion; and 3) the available governing standards for the design and construction of modular blast-resistant structures. It presents a contemporary approach to the second tier of risk and examines the supporting data and analysis. The paper illustrates the process by discussing the following: 1) the design; 2) construction; and 3) testing of one company's blast-resistant modular systems. This includes design verification employing both Single-Degree-of-Freedom (SDOF) models and Finite Element Analysis (FEA). Further validation of the computer modeling techniques was provided by shock tube testing of the structural assemblies, under a range of peak pressures from 5.5 to 60.0 kPa (0.8-8.7 psi). Readers are able to gain knowledge and confidence in the extension of the definition of blast-resistant shelters to include electrical equipment enclosures, further reducing risk and minimizing downtime in the event of an explosive event.
Analysis of blast resistant modular structures
- B F Harrison
B.F. Harrison, Analysis of blast resistant modular structures, in: Proceedings of the 29th DoD Explosive Safety Seminar, Department of Defense Explosives Safety Board, Session 7A, 2000.
ExxonMobil Baton Rouge chemical complex’s approach to facility siting of temporary buildings
- W Scott
- Ostrowski
Scott W. Ostrowski, ExxonMobil Baton Rouge chemical complex's approach to facility siting of temporary buildings, in: Proceedings of the Environmental Health Safety Seminar, Texas Chemical Council, Session II, PSM/RMP, 2001.