Structural Design, Analysis, Material List And Market Adaptability Of Brisbane Steel Structure Warehouse

Structural Design, Analysis, Material List and Market Adaptability of Brisbane Steel Structure Warehouse

 

This document focuses on the structural design, analysis, detailed material list and market adaptability analysis of a steel structure warehouse located in Brisbane, Australia. The warehouse is designed with specific dimensions and functional requirements, and this document will also discuss the applicability of the project in the markets of the Philippines, Papua New Guinea, Chile and South Africa, as well as the corresponding adjustment measures to meet the local needs.

 

 

The core design parameters of the Brisbane steel structure warehouse are based on the user's requirements, ensuring structural safety, functional applicability and economic rationality. The specific parameters are as follows:

Main structure length: 130.95 meters

Frame spacing: 8.73 meters, total 16 frames

Warehouse width: 63 meters

Wind-resistant columns: 1 column every 7 meters

Middle column: 1 row of middle columns arranged in the middle of the warehouse, dividing the warehouse into north and south parts without partition walls

Overhead cranes: 1 double-beam truss crane in each of the north and south parts, with a lifting capacity of 20 tons and a lifting height of 7.5 meters

Main warehouse height: 12.5 meters

Roller shutter doors: 3 roller shutter doors on each of the north and south walls, 6 meters high and 5 meters wide

Canopies: 1 canopy on each of the north and south walls, 113.5 meters long and 9 meters overhanging width

Roof lighting: Reasonably arranged roof lighting panels to ensure indoor lighting

Office building (west side): 2 floors, 8 meters high, 6.6 meters wide (east-west), 35 meters long (north-south)

Wall and roof materials: 0.6mm color steel single plate for the steel structure warehouse; sandwich panel for the office building (wall and roof); floor slab: 1mm galvanized floor bearing plate provided by CBC Company, with on-site cast-in-place concrete

 

 

2.2.1 Main Frame Structure

The main structure of the warehouse adopts a portal steel frame system, which is composed of 16 steel frames with a spacing of 8.73 meters, forming a stable spatial structure. The portal frame is made of welded H-section steel, which has the advantages of high bearing capacity, good ductility and light weight. The frame columns and beams are connected by rigid joints to ensure the overall stability of the structure. The span of each frame is 63 meters, and the middle column is arranged to divide the span into two 31.5-meter spans, reducing the section size of the frame beams and columns, and optimizing the economic performance of the structure.

2.2.2 Wind-Resistant Column Design

Wind-resistant columns are arranged along the length of the warehouse (130.95 meters) with a spacing of 7 meters. The wind-resistant columns are made of H-section steel, which are connected with the main frame and the wall panels to resist the lateral wind load acting on the warehouse. The bottom of the wind-resistant columns is fixed on the foundation, and the top is hinged with the roof truss to ensure that the wind-resistant columns can effectively transmit the wind load to the foundation.

2.2.3 Overhead Crane Beam Design

Two double-beam truss cranes are arranged in the north and south parts of the warehouse, each with a lifting capacity of 20 tons and a lifting height of 7.5 meters. The crane beams are made of welded H-section steel, and the crane rails are fixed on the top of the crane beams. The crane beams are supported on the frame columns and middle columns, and the connection nodes are designed as rigid connections to ensure that the crane beams have sufficient bearing capacity and stability under the action of crane load (including vertical load, horizontal impact load and lateral load).

2.2.4 Canopy Structure Design

Canopies are arranged on the north and south walls of the warehouse, each 113.5 meters long and 9 meters overhanging width. The canopy structure adopts a cantilever steel truss system, which is connected with the main frame columns of the warehouse. The truss members are made of angle steel and channel steel, and the roof of the canopy is covered with 0.6mm color steel single plate, consistent with the warehouse roof. The cantilever truss is designed to resist the wind load and its own weight, and the connection nodes with the main frame are reinforced to prevent structural deformation.

2.2.5 Roof and Wall Structure Design

The roof and walls of the steel structure warehouse are covered with 0.6mm color steel single plate, which is fixed on the purlins and wall girts by self-tapping screws. The purlins and wall girts are made of C-section steel, with a spacing of 1.5 meters, ensuring the flatness and stability of the wall and roof. Roof lighting panels are reasonably arranged between the purlins, with a spacing of 8.73 meters (consistent with the frame spacing), and the lighting panels adopt FRP transparent panels, which can effectively improve the indoor natural lighting and reduce the energy consumption of artificial lighting.

2.2.6 Office Building Structure Design

The office building is located on the west side of the warehouse, 2 floors high, 8 meters high, 6.6 meters wide (east-west) and 35 meters long (north-south). The structure of the office building adopts a steel frame system, and the columns and beams are made of H-section steel. The wall and roof are covered with sandwich panels, which have the advantages of heat insulation, sound insulation and fire resistance. The floor slab adopts 1mm galvanized floor bearing plate provided by CBC Company, with on-site cast-in-place concrete, ensuring the flatness and bearing capacity of the floor.

2.2.7 Foundation Design

Combined with the geological conditions in Brisbane, the foundation of the warehouse and office building adopts independent reinforced concrete foundation. The foundation size is determined according to the bearing capacity of the soil and the load transmitted by the upper structure. The foundation of the frame columns, middle columns and wind-resistant columns is designed as expanded foundation to ensure that the foundation has sufficient bearing capacity and settlement control. The bottom of the foundation is provided with a cushion layer to prevent the foundation from being eroded by the soil.

 

 

The structural analysis is based on the relevant Australian steel structure design codes (AS/NZS 4600:2018), and various loads acting on the structure are calculated accurately, including permanent load, live load, wind load, snow load and crane load.

3.1.1 Permanent Load

Permanent load mainly includes the self-weight of the structure (steel frame, purlins, wall girts, wall panels, roof panels, sandwich panels, floor slabs, etc.) and the weight of fixed equipment (crane rails, lighting fixtures, etc.). The self-weight of the structure is calculated according to the material density and section size, and the weight of fixed equipment is determined according to the actual layout.

3.1.2 Live Load

Live load includes the floor live load of the office building and the roof live load of the warehouse. The floor live load of the office building is taken as 2.5 kN/m² (in line with the office use requirements), and the roof live load of the warehouse is taken as 0.5 kN/m² (considering the maintenance load).

3.1.3 Wind Load

Brisbane is located in a coastal area, and wind load is an important control load. According to the wind speed in Brisbane (basic wind speed of 40 m/s), the wind pressure is calculated as 0.8 kN/m². The wind load acts on the wall panels, roof panels, canopies and frame columns, and the lateral wind load is transmitted to the foundation through the wind-resistant columns and frame system. The wind-induced vibration of the structure is also considered to ensure that the structure has sufficient stability under strong wind conditions.

3.1.4 Snow Load

The climate in Brisbane is warm and humid, with little snowfall, so the snow load is taken as 0.1 kN/m² (minimum snow load specified in the code), which has little impact on the structural design.

3.1.5 Crane Load

Each double-beam truss crane has a lifting capacity of 20 tons, and the crane load includes vertical lifting load, horizontal impact load and lateral load. The vertical lifting load is 200 kN (20 tons), the horizontal impact load is 10% of the vertical lifting load (20 kN), and the lateral load is 5% of the vertical lifting load (10 kN). The crane load is applied to the crane beams, and the influence of the crane's movement on the structure is considered in the analysis.

 

 

Using professional structural analysis software (SAP2000), the spatial structural model of the warehouse and office building is established, and the internal force (axial force, shear force, bending moment) of each structural member (frame columns, beams, wind-resistant columns, crane beams, truss members, etc.) is calculated under the combined action of various loads. The analysis results show that the internal force of all structural members is within the allowable range, and the section size of the members is reasonable.

 

 

The stability analysis of the structure includes overall stability and local stability. The overall stability of the portal steel frame is ensured by the rigid connection of columns and beams, the arrangement of cross braces and the constraint of the foundation. The local stability of the H-section steel columns and beams is ensured by controlling the width-thickness ratio of the flange and web, which meets the requirements of the design code. In addition, the stability of the cantilever canopy truss is checked, and the reinforcement measures are taken at the connection nodes to prevent local buckling.

 

 

The deflection of the frame beams, crane beams and canopy trusses is checked to ensure that the deflection does not exceed the allowable value specified in the code. The allowable deflection of the frame beams is L/250 (L is the span of the beam), the allowable deflection of the crane beams is L/500, and the allowable deflection of the canopy trusses is L/200. The check results show that the deflection of all members meets the design requirements, and the structure has good stiffness.

 

 

Based on the load calculation, internal force analysis, stability analysis and deflection check, the structural safety of the warehouse and office building is evaluated. The results show that the structure meets the requirements of Australian steel structure design codes, has sufficient bearing capacity, stability and stiffness, and can safely bear various loads under normal use conditions, ensuring the safe operation of the warehouse and office building.

 

The material list is divided into two parts: the steel structure warehouse and the office building, including the material name, specification, model, quantity and dosage, ensuring accuracy and detail for construction reference.

 

Material Name			Specification/Model	Quantity	Dosage (kg)	Remarks
Welded H-section steel (frame beam)			H1000×400×16×20	16 pieces	80000	Span 63m, each 63m long, thickened section
Welded H-section steel (frame column)			H900×350×14×18	32 pieces	70000	Height 12.5m, each 12.5m long, thickened section
Welded H-section steel (middle column)			H800×300×12×16	16 pieces	40000	Height 12.5m, each 12.5m long, thickened section
Welded H-section steel (wind-resistant column)			H700×300×12×14	19 pieces	30000	Height 12.5m, spacing 7m, 130.95m length, thickened section
Welded H-section steel (crane beam)			H800×300×12×16	4 pieces	29000	2 pieces in north and south, each 130.95m long, thickened section
Crane rail			QU100	4 pieces	10476	2 pieces in north and south, each 130.95m long
C-section steel (purlin)			C250×75×20×2.5	45 pieces	45000	Spacing 8.73m, length 63m, increased quantity
C-section steel (wall girt)			C200×70×20×2.0	180 pieces	40000	Spacing 1.5m, height 12.5m, increased quantity
Color steel single plate (roof/wall)			0.6mm, color: gray	1 batch	28620	Roof area: 130.95×63=8249.85㎡; wall area: (130.95×12.5×2)+(63×12.5×2)=4848.75㎡; total area: 13098.6㎡
FRP lighting panel			1.0mm, transparent	1 batch	3330	Spacing 8.73m, each 63m long, width 1.2m; total area: 16×63×1.2=1209.6㎡
Roller shutter door			6m×5m, manual	6 pieces	1800	3 pieces on north and south walls respectively
Angle steel (canopy truss)			L100×100×10	1 batch	9900	2 canopies, each 113.5m long, 9m overhanging
Channel steel (canopy purlin)			C160×60×20×2.0	32 pieces	2560	Spacing 4m, length 9m
High-strength bolt			M20×80, 10.9 grade	2000 pieces	1800	For connection of steel members
Self-tapping screw			ST5.5×50	50000 pieces	750	For fixing color steel plate and lighting plate
Concrete			C30	1 batch	120000	Independent foundation, total volume 40m³ (3000kg/m³)
Reinforcement			HRB400E, Φ16/Φ12/Φ8	1 batch	15000	For independent foundation
Windows			1.2m×1.5m, aluminum alloy	20 pieces	1200	Evenly arranged on north and south walls
Total Dosage of Warehouse Materials					519656	Approximately 519.66 tons

 

Material Name			Specification/Model	Quantity	Dosage (kg)	Remarks
Welded H-section steel (column)			H400×200×8×10	16 pieces	3840	Height 8m, each 8m long
Welded H-section steel (beam)			H300×150×6×8	24 pieces	2880	Span 6.6m, each 6.6m long
Sandwich panel (wall)			100mm, EPS core, color steel surface	1 batch	7040	Wall area: (35×8×2)+(6.6×8×2)-15 (windows/doors)=616.6㎡; weight: 11.42kg/㎡
Sandwich panel (roof)			100mm, EPS core, color steel surface	1 batch	2420	Roof area: 35×6.6=231㎡; weight: 10.47kg/㎡
Galvanized floor bearing plate			1mm, provided by CBC Company	1 batch	2541	Floor area: 35×6.6×2 (2 floors)=462㎡; weight: 5.5kg/㎡
Concrete (floor)			C30	1 batch	27720	Floor thickness: 100mm; volume: 462×0.1=46.2m³; weight: 3000kg/m³
Reinforcement (floor)			HRB400E, Φ12/Φ8	1 batch	4158	Reinforcement ratio: 0.9%
C-section steel (purlin/wall girt)			C140×50×20×1.8	40 pieces	1440	Spacing 1.5m
High-strength bolt			M16×60, 10.9 grade	800 pieces	576	For connection of steel members
Self-tapping screw			ST5.5×40	15000 pieces	225	For fixing sandwich panels
Doors and windows			Doors: 1.8m×2.1m; Windows: 1.2m×1.5m	Doors: 4; Windows: 12	1800	Aluminum alloy, heat-insulating glass
Concrete (foundation)			C30	1 batch	9000	Independent foundation, volume 3m³
Reinforcement (foundation)			HRB400E, Φ14/Φ8	1 batch	1125	For independent foundation
Total Dosage of Office Building Materials					65605	Approximately 65.61 tons

 

 

Total dosage of steel structure warehouse materials: 519656 kg (519.66 tons)

Total dosage of office building materials: 65605 kg (65.61 tons)

Total dosage of the whole project: 585261 kg (585.26 tons)

 

The original design of the project is based on the climate, geological conditions and design codes in Brisbane, Australia. In order to adapt to the markets of the Philippines, Papua New Guinea, Chile and South Africa, it is necessary to analyze the local natural conditions, building codes and user needs, and put forward corresponding adjustment measures to ensure the applicability, safety and economy of the project in the target markets.

 

 

5.1.1 Adaptability Analysis

The Philippines is located in the tropical monsoon climate zone, with high temperature, heavy rainfall, frequent typhoons (basic wind speed up to 50 m/s) and complex geological conditions (many areas are prone to earthquakes, seismic intensity up to 7-8 degrees). The original design has the following adaptability problems:

Wind load: The original design is based on the basic wind speed of 40 m/s in Brisbane, which is lower than the typhoon wind speed in the Philippines, so the wind resistance of the structure is insufficient.

Seismic performance: The original design does not fully consider the seismic requirements, and the connection nodes of steel members and the foundation design cannot meet the local seismic intensity requirements.

Rainfall: The heavy rainfall in the Philippines requires better roof drainage design, otherwise water leakage may occur.

Material corrosion: The marine climate in the Philippines is humid and salty, which is easy to cause corrosion of steel structures, and the anti-corrosion performance of the original design needs to be improved.

 

5.1.2 Adjustment Measures

Wind resistance adjustment: Increase the section size of frame columns, beams and wind-resistant columns, and increase the number of wind-resistant columns (spacing adjusted to 5 meters) to improve the lateral stiffness of the structure. Strengthen the connection nodes of the canopy truss and the main frame to prevent the canopy from being damaged by typhoons. Optimize the roof slope (adjust from 5% to 8%) to improve the wind resistance of the roof.

Seismic adjustment: Adopt flexible connection nodes for part of the steel members to improve the ductility of the structure. Increase the reinforcement ratio of the foundation and set anti-seismic isolation pads at the bottom of the columns to reduce the impact of earthquakes on the structure. Strengthen the connection between the crane beam and the frame column to ensure the stability of the crane under seismic conditions.

Roof drainage adjustment: Increase the number of roof drainage pipes (arrange 1 pipe every 10 meters) and expand the diameter of the drainage pipes (from Φ100 to Φ150) to ensure smooth drainage. Use waterproof sealant with better performance for the connection of roof panels and lighting panels to prevent water leakage.

Anti-corrosion adjustment: Adopt hot-dip galvanizing anti-corrosion treatment for all steel members (galvanizing thickness ≥80μm), and apply anti-corrosion paint (two coats of primer and two coats of finish) on the surface. Replace the 0.6mm color steel single plate with 0.6mm galvanized color steel single plate to improve the anti-corrosion performance. Regular anti-corrosion maintenance measures are formulated.

Material adjustment: Use corrosion-resistant materials for doors, windows and other accessories, such as stainless steel hardware, to extend the service life.

 

 

5.2.1 Adaptability Analysis

Papua New Guinea is located in the tropical rainforest climate zone, with high temperature, high humidity, heavy rainfall, frequent earthquakes (seismic intensity up to 7 degrees) and complex geological conditions (many mountainous areas, poor foundation bearing capacity). The original design has the following adaptability problems:

Geological conditions: The foundation bearing capacity in many areas is low, and the original independent foundation cannot meet the requirements.

Rainfall and humidity: High rainfall and high humidity lead to poor indoor ventilation and easy corrosion of steel structures and materials.

Seismic performance: The original design does not meet the local seismic intensity requirements, and the structure is prone to damage in earthquakes.

Transportation and construction: The traffic in Papua New Guinea is underdeveloped, and the transportation of large steel members is difficult; the local construction level is low, and the construction difficulty of complex structures is high.

5.2.2 Adjustment Measures

Foundation adjustment: For areas with low foundation bearing capacity, replace the independent foundation with a strip foundation or pile foundation to improve the bearing capacity of the foundation. The pile foundation adopts reinforced concrete precast piles with a length of 10-15 meters, which are suitable for complex geological conditions.

Ventilation and anti-corrosion adjustment: Increase the number of windows and set ventilation fans in the warehouse to improve indoor ventilation and reduce humidity. All steel members adopt hot-dip galvanizing + anti-corrosion paint treatment, and the sandwich panels of the office building adopt moisture-proof EPS core material. The roof and walls are equipped with moisture-proof layers to prevent moisture penetration.

Seismic adjustment: Refer to the local seismic design codes, optimize the structural system, and adopt rigid-flexible combination nodes to improve the seismic ductility of the structure. Reduce the span of the frame (adjust the frame spacing from 8.73 meters to 7 meters) to improve the overall stability of the structure. Strengthen the connection between the middle column and the frame beam to enhance the seismic performance of the structure.

Construction and transportation adjustment: Simplify the structural design, split large steel members into small sections for transportation, and assemble them on site to facilitate transportation in mountainous areas. Choose simple and easy-to-construct connection methods (such as bolt connection instead of welding) to adapt to the local construction level. Provide detailed construction drawings and on-site technical guidance to ensure the construction quality.

Roof drainage adjustment: Increase the roof slope to 10% and add more drainage pipes to ensure smooth drainage in heavy rain.

 

5.3.1 Adaptability Analysis

Chile is located in the west coast of South America, with a long and narrow territory, complex climate (from tropical to temperate), frequent earthquakes (one of the countries with the highest seismic activity in the world, seismic intensity up to 9 degrees), and strong wind in coastal areas. The original design has the following adaptability problems:

Seismic performance: The original design cannot meet the high seismic intensity requirements in Chile, and the structure is prone to severe damage in strong earthquakes.

Wind load: The coastal areas of Chile have strong winds, and the wind resistance of the original structure needs to be improved.

Temperature difference: There is a large temperature difference between day and night in some areas of Chile, which may cause thermal expansion and contraction of steel structures, leading to structural deformation.

Design codes: Chile has strict building codes, and the original design based on Australian codes cannot meet the local code requirements.

5.3.2 Adjustment Measures

Seismic adjustment: Adopt a seismic isolation design for the whole structure, set seismic isolation bearings at the bottom of the frame columns to reduce the seismic response of the structure. Use high-ductility steel for key steel members (such as frame columns and beams) to improve the seismic performance of the members. Optimize the section size of the members, increase the thickness of the flange and web, and enhance the bearing capacity and stability of the members. Strengthen the connection nodes of all steel members to ensure that the nodes have sufficient strength and ductility.

Wind resistance adjustment: Increase the section size of wind-resistant columns and frame beams, and reduce the spacing of wind-resistant columns to 6 meters. Strengthen the canopy structure, adopt a more stable truss system, and increase the number of supporting points between the canopy and the main frame. The roof panels and wall panels are fixed with more self-tapping screws to prevent them from being blown off by strong winds.

Temperature difference adjustment: Set expansion joints in the structure (every 50 meters along the length of the warehouse) to release the stress caused by thermal expansion and contraction, and prevent structural deformation. Choose steel materials with good thermal stability, and apply thermal insulation paint on the surface of steel members to reduce the impact of temperature difference. The roof and walls of the office building adopt sandwich panels with better thermal insulation performance to improve the indoor thermal comfort.

Code adaptation: Refer to the Chilean steel structure design code (E050) and seismic design code (NCh433), adjust the design parameters (such as load combination, safety factor, etc.) to meet the local code requirements. The fire resistance design of the structure is optimized to meet the local fire safety requirements.

Anti-corrosion adjustment: For coastal areas, adopt hot-dip galvanizing + anti-corrosion paint treatment for steel members, and use corrosion-resistant materials for accessories to adapt to the marine climate.

 

 

5.4.1 Adaptability Analysis

South Africa is located in the southern hemisphere, with a subtropical climate, large temperature difference between day and night, less rainfall in most areas, strong solar radiation, and occasional strong winds and earthquakes (seismic intensity up to 6-7 degrees). The original design has the following adaptability problems:

Temperature difference and solar radiation: Large temperature difference between day and night may cause structural deformation; strong solar radiation will accelerate the aging of color steel plates and anti-corrosion paint.

Anti-corrosion performance: Some areas of South Africa have high humidity, and the steel structure is prone to corrosion, which affects the service life.

Wind and seismic performance: Occasional strong winds and earthquakes require the structure to have certain wind resistance and seismic performance.

Energy conservation: Strong solar radiation leads to high indoor temperature, and the original design has poor thermal insulation performance, which increases energy consumption.

5.4.2 Adjustment Measures

Temperature difference and solar radiation adjustment: Set expansion joints in the structure to release thermal stress. Replace the 0.6mm color steel single plate with color steel plate with anti-ultraviolet coating to slow down aging caused by solar radiation. The roof lighting panels adopt anti-ultraviolet FRP panels to improve the service life. Apply thermal insulation paint on the surface of steel members to reduce the impact of temperature difference.

Anti-corrosion adjustment: All steel members adopt hot-dip galvanizing + anti-corrosion paint treatment, and the anti-corrosion paint selects products with good weather resistance and anti-aging performance. Regular anti-corrosion maintenance is carried out to extend the service life of the structure. The connection parts of steel members are sealed with waterproof and anti-corrosion sealant to prevent moisture penetration.

Wind and seismic adjustment: According to the local wind speed and seismic intensity, appropriately increase the section size of frame columns and wind-resistant columns, and optimize the connection nodes to improve the wind resistance and seismic performance of the structure. Strengthen the canopy structure to prevent damage caused by strong winds.

Energy conservation adjustment: The roof and walls of the warehouse are covered with a layer of thermal insulation cotton (50mm thick) between the color steel plate and the purlins/wall girts to improve thermal insulation performance. The office building adopts sandwich panels with better thermal insulation performance (150mm thick EPS core) to reduce indoor temperature and energy consumption. Install sunshades outside the windows of the office building to block strong solar radiation.

Foundation adjustment: According to the local geological conditions, optimize the foundation design, and adopt independent foundation or strip foundation to ensure the bearing capacity of the foundation. For areas with poor geological conditions, appropriately expand the foundation size.

 

The steel structure warehouse project in Brisbane, Australia, is designed with reasonable structure, complete functions and meets the local design codes and use requirements. The detailed material list and dosage provided in this document can provide accurate reference for construction. For the markets of the Philippines, Papua New Guinea, Chile and South Africa, due to the differences in local natural conditions, building codes and user needs, corresponding adjustment measures are needed to solve the problems of wind resistance, seismic performance, anti-corrosion, foundation adaptability and energy conservation. After adjustment, the project can meet the local applicable requirements, and has good economic and social benefits in the target markets.