protea

low cost, high quality housing

- Low cost / High quality housing - Insulated structure - Fast and easy installation

PROTEA | Affordable quality housing

PROTEA is a modular construction system. Standardised components are entirely prefabricated in factories, packed in protective containers and delivered on-site, ready to be assembled in 4 days by 4 local people. The PROTEA building system ensures long term living conditions with respect to safety, insulation, health and comfort. Newcastle, South Africa Colours: Opale 4936 for walls, Bordeau 4802 for roof

South Africa

Mounting walls Newcastle, South Africa - Colours: Sand 4102 for walls, Bordeau 4802 for roof

Internal finishing with plasterboard

2

France
Contrisson, France Colours: Opale 4936 Contrisson, France Colours: Stone 4703 for walls, Abyss 4505 for roof

Dubai
PROTEA 40m - 5 projects These five different projects illustrate the numerous implementation possibilities and options of PROTEA in terms of: - Colours - Floors (concrete slab or steel deck) - Integration of solar panels - Doors and windows - Interior finishing and equipment

Mounting on a dry steel deck

Mounting walls

Photovoltaic panels

Internal finishing with plasterboard

3

Dubai, United Arab Emirates Colours: Opale 4936 for walls, Bordeau 4802 for roof

PROTEA | Four days for one house

Four workers can complete the construction, including doors and windows, in just 4 days. Assembly is kept simple by using screw connections only. An installation guide is provided, making the installation fast and easy. The components, prefabricated in factories, are packed conveniently in protective containers and delivered on site ready to be assembled. Three 40m PROTEA kits can be stored in one 40 container.
Phase 1: Reception of kits on site Phase 2: Preparation of the ground - implementation

Day 1
PROTEA Kit delivered to prepared foundation (concrete slab or dry steel deck) and elements are unpacked for assembly.

Day 1
U-profile elements, which will join the foundation with the wall panels, are fixed on the foundation. First two panels are assembled in the corner.

Phase 3: Walls and partitions assembly

Phase 4: Two last wall panels

Day 2
Mounting of pre-fabricated wall and partition elements is sequenced to build rigid subsets and so ensure stability during construction, especially in case of strong winds.

Day 2
Wall construction is finalised by the connection of the two last panels at the opposite corner.

Phase 5: Wall and roof joined by a U profile

Phase 6: Finishing accessories

Day 3
Kits in container on truck
U-profile elements to join walls and roof panels are fixed to the top of all the wall panels.

Day 4
4
Assembly of the roofing panels including finishing (mono and duo-pitch ridge, edge,...)

PROTEA | Installation guide abstract

Each PROTEA kit comes with complete assembly instructions. Two documents detail all the different steps in the construction process. Layout of the elements Installation plans giving laying order and position for each element:
1 2 3 Bedroom 2 4 6 5 22 Kitchen 23 25 Bathroom / Bedroom3 31 30 29
600

2 - Fastenings plans

1 - Construction manual

24

26 27

This second document contains a complete range of drawings showing the number and precise position of all the different fastenings.
30 30 235 100 280 340 100 235 30 210 210 215 100 235 230 230 230 230 235 100 200 195 195 200 30

In this first document, the following points are covered: Necessary tools: Description of the needed equipment.

7 9 8 10 11

12

32 33

28

215

13

14

Bedroom 1

18

Lounge

36
600

600

15 16 17 20

19 21 34 35 38 39

37

250

250

40 275

165

250

250

40 275

165

250

250

40 275

165

250

250

40 275

165

250

250

275

Panel female side

Panel female side

Panel female side

Panel female side

Panel female side

1-38: Laying order

: male side of panels

40

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

208,5

40

201,5

201,5

201,5

201,5

201,5

201,5

201,5

201,5

201,5

201,5

201,5

201,5

201,5

40

213

213

213

213

213

213

213

213

213

40

Connection details: How specific connections are treated?

250

250

40 275 Panel female side

165

250

250

40 275 Panel female side

165

500

275 Panel female side

250

40 275 Panel female side

165

250

250

40 275 Panel female side

165

500

275 Panel female side

165

250

250

40 275 Panel female side

165

250

250

275 Panel female side

Nomenclature: Extensive nomenclature of the kit contents. Site preparation: How to prepare the construction site prior to beginning?
8500

Wall panel Screw

Floor rail Screw Tightness joint

600

600

600

250

250

40 275

165 Panel female side

250

250

40 275

165 Panel female side

250

250

40 275 Panel female side

170

250

40 275

165 Panel female side

250

250

120 275 Panel female side

165

250

250

40 275

165 Panel female side

250

250

275 Panel female side

Ridge
20 130 325

Floor

325

325

325

Openings: How to install and fasten doors and windows?

325

325

325

Reservations Pattern L
5600

325 283 150

Eaves

diameter Welded wire reinforcement. L=150mm, and =8mm

Safety recommendations

Recommendations, preliminary operations: For example about checking panels verticality. 5

Take extra care of safety on the working site. All workers must wear all necessary safety equipment, which is gloves, safety shoes, helmet, safety glasses.

PROTEA | Designs
12 m shelter
4058

Main room ~12m

1m

Outside perspective

Top view

3169

Floor plan

20m cottage
5168

Room2 ~10m

Room1 ~10m

1m

Outside perspective

Top view 6

Floor plan

4060

PROTEA | Designs
30m family house
Bedroom 2 ~7.5m
6057

Kitchen / Lounge ~15m

Bedroom 1 ~7.5m

1m

Outside perspective

Top view

Floor plan

40m family house

Bedroom 2 ~7.5m

8052

Bath ~5m Kitchen / Lounge ~20m

5168 5164

Bedroom 1 ~7.5m

Outside perspective

Top view 7

1m

Floor plan

PROTEA | Designs
55m residence
998

9053 8055

Bedroom1 ~13m

3654

Entrance Hall ~2m Corridor ~2m Kitchen / Lounge ~21m

Bedroom2 ~13m
7242

Bathroom ~5m

3588

Canopy ~9m

1m

Outside perspective

Top view

Floor plan

71m residence
Bedroom 2 ~12m

9059

Bedroom 1 ~11m

Bathroom ~5m

WC ~2m
8178

Bedroom 3 ~12m Kitchen / Lounge ~29m

1m

Canopy ~12m

Outside perspective

Top view 8

Floor plan

PROTEA | Designs
100m residence
Bedroom 3 ~8.5m Bedroom 1 ~12m Access ~1m
12128

Bathroom ~5.5m

WC ~2m Kitchen ~10m

Bedroom 2 ~12m

Lounge ~34m

Bedroom 4 ~12m

13074 1m

Canopy ~12m

Outside perspective

Top view

Floor plan

Internal finishing
Inside the house, PROTEA panels can be covered with a plasterboard to perform: - Aesthetic finishing - Fire resistance Plasterboard are not included in the PROTEA kit, and must be purchased locally. Plasterboard can be screwed directly onto the steel sheet panels and folded parts. The type and thickness of the plasterboard must be determined according to local regulations. Plasterboard Plasterboard

Wall aspect: with and without plasterboard

8178

PROTEA | Kit offer & components characteristics

Wall panels:
Insulated, structural panels PUR foam thickness: 60mm (standard) Steel sheet thickness: -interior: 0,50mm (standard) -exterior: 0,63mm (standard)
Overall width: 1016mm 60mm Useful width: 1000mm 8mm 0.25mm Exterior microribbed face Useful width: 1000mm

Roof panels:
Insulated, structural panels PUR foam thickness: 40mm (standard) Steel sheet thickness -interior: 0,50mm (standard) -exterior: 0,63mm (standard)
Overall width: 1078mm

Included in the kit

- Walls, partitions and roof in sandwich panels with all accessories - Technical guide for all elements and installation guide - Technical drawings and Performance Guarantee - Screws & rivets compatible in shape and colors with wall and roof panels
40mm

Options

- Dry steel deck - Doors and windows - Solar panel system - Plumbing and electricity - Supervision training and technical assistance during construction, to be discussed case by case.

Not included

Wall panels interlocking

Roof panels interlocking

- Concrete slab - Plasterboard - Floor finishing - External finishing These elements should be subcontracted to local companies.

Equivalence of insulation power between polyurethane (PUR) and some other common materials:
PUR foam Polystyrene Mineral wool Wood Bricks Stone Concrete 60mm 100mm 110mm 460mm 1870mm 4080mm 5830mm

Steel characteristics

-Steel grade: S350GD -Hot dip galvanised Z275 -25m prepainted steel coating (standard) -A dedicated coating will be selected in regions with agressive climatic conditions (sea shore...)

Adaptability

Any specific design can be investigated on a case by case basis by the ArcelorMittal Construction Design & Engineering team.

10

Colours
Type of coating: thermosetting polyester resin. - Good corrosion resistance - Good colour and appearance stability - Good external sustainability - Good metal forming suitability

Doors and windows (option)

Steel deck (option)

Walls

Roof

Sand 4102
Ral 1002

Bordeau 4802
Ral 8012

Stone 4703
Ral 7032

Abyss 4505
Ral 5008

A kit comprising doors and windows can be provided. Exterior doors are insulated, and windows feature double glazing. All doors and windows are made of PVC, except for the exterior doors frames, which are made of aluminium. For protection, all windows can be equipped with anti intrusion bars. A steel deck can be provided for each type of house (12, 20, 30, 40, 55, 71 and 100m). It is delivered ready to be assembled, with all fastenings and connection parts, including connections between the structure and the concrete pads. Depending on the house type, the number of concrete pads will vary. This solution allows a good evenness of the floor, even on a uneven soil, and is a must in terms of protection in case of torrential rains.

Opale 4936
Ral 9010

Other colours can be investigated case by case by ArcelorMittal

Top coat: 20 microns Primer: 5 microns
Zinc (hot dip galvanizing S275GD) Steel (guaranteed minimum yield stress) Zinc (hot dip galvanizing S275GD) Back coat reinforced

11

Extension kit (option)

Rainwater system (option)

A gutter system allowing the harvesting of rainwater can be provided. The system includes gutters, gutter stops, down pipe connections and down pipes, elbows, junctions and brackets

Photovoltaic panels (option)

A system of rails able to support various types of photovoltaic modules can be provided.

Down pipe

Gutter

A 15m extension kit is available, for the following house types: 20m, 30m and 40m.
8052 3028

Detail of the mechanical testing of the rail

Water tank (not provided)

Roof example with 7 rails and 6 solar modules:

Bedroom 2 ~7.5m Kitchen / Lounge ~20m

Bath ~5m

Bedroom 4 ~7.5m

5164

Bedroom 1 ~7.5m
1m

Bedroom 3 ~7.5m

Rails

Solar modules

40m.

15m.

55m.
Extension example with the 40m house

Concerning the photovoltaic panels, a study can be done to match your specific needs. 12

PROTEA | Excellent performances

Technical agreement:
ArcelorMittal complies with local construction regulations in countries where PROTEA is erected. Wind forces: The calculation shows that the PROTEA house is able to resist to winds up to 36m/s (130km/h) with peaks up to 50m/s (180km/h).

Thermal performance calculation:

The PROTEA thermal performance has been assessed by thermal calculation.

Comparison of indoor temperatures between PROTEA and standard south-african house, during the hottest week in climate zone 1 (Bloemfontein)
42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 time (from 1/25 to 1/31)

Fire performance:

*Council for Scientific and Industrial Research Simulation of wind action (confirmed the calculation model)

Fire test in South Africa

Seismic forces: Moreover, steel is known to behave well in an earthquake. Global failures and huge numbers of casualties are mostly associated with structures made from other materials. This is mainly due to three major qualities of steel: - Light weight: Steel structures are generally lighter than those using other materials. Some steel structures are sufficiently light so that seismic design is not critical. - Flexibility: Steel structures are generally more flexible than other types of structure. Constraints in the structure and its foundations are therefore lower. - Ductility: Unlike other materials, steels failure mode is ductile; this means that when submitted to strong forces, steel doesnt break but dissipates energy by plastic deformation. 13

temperature (C)

The CSIR* in South Africa performed a fire resistance test on the 60mm wall panel, with a 15mm Firestop plasterboard on the exposed side. The complex achieved a Fire Resistance Rating (FRR) of 30 minutes.

Comfort temperature PROTEA

External Temperature

Comfort temperature standard SA house

As a result, this calculation shows that the PROTEA house provides better summer comfort compared to a traditional brick and mortar house (up to 5C cooler).

Structural performance:

The PROTEA structural performance has been assessed. The house structure is essentially ensured by self bearing panels.

Thermal performance measurement:

A thermography measurement was performed on a prototype, showing good thermal insulation and air tightness.

Infrared images

Example: the 55m house and its maximal calculated horizontal deflection

Indoor

Outdoor

PROTEA | Made of safe, sustainable steel

The advantages of steel are numerous and make it an ideal building material.
Steel, a material coming from nature: Iron ore, its raw material, is one of earths most abundant elements. Steel is sustainable, durable and solid: Today, steel can be effectively protected against corrosion, particularly through the galvanisation process. Sandwich panels recycling process: Different studies show that technical solutions to recover steel in buildings and to transform it in high quality scrap exist.
Sandwich panels Rotary shear

Magnetic drum

Steel is clean; its manufacturing process as well: Steelworks have cut steel manufacturings energy consumption and CO2 emissions by half compared with 1960 levels. Steel reduces building site noise pollution and makes for clean and safe construction: Prefabricated materials are delivered, minimising waste and onsite storage and making building sites safe, dry and dust-free.

Steel is recyclable and recycled Steel is indefinitely and 100% recyclable. More than 40% of the world steel production comes from recycled steel.

Scrap metal

PUR foam flakes

Steel is earthquake-resistant: Steel increases building longevity in earthquake-prone areas and preserves human life through its resistance. The goal is to separate steel from polyurethane foam in such a way that each component will be pure enough to be easily recycled in its own process. Two different tools exist: a shredder commonly used to process end of life vehicles or household appliances, and a rotary shear commonly used to shred steel packaging. However, reusing the sandwich panels at the end of the house life could be a much simpler and cheaper solution of recycling.
Cooperation between Habitat for Humanity Hati and ArcelorMittal Construction Dominicana (steel roof sheets)

For more information: http://www.arcelormittal.com

14

PROTEA | Benefits
Low cost
Cheaper than traditional materials with higher performances

Thermal insulation

Uwall=0.29-0.47W/m.K (100-60 mm) Uroof= 0.28-0.58W/m.K (100-40mm)

Fast installation
- 4 days - 4 workers

Industrial power

Industrialised system available in very large quantities

Sound insulation

Walls (60mm): Rw (C; Ctr): 25(-1;-3) dB Roof (40mm): Rw (C; Ctr): 25(-1;-3) dB

Easy installation kit

Easy to assemble, construction guide provided

Training for local contractors

Supervision training and technical assistance during construction

Corrosion resistance

Validated by salt spray test and humidity resistance

Dry and clean construction site

No water nor concrete needed

Environmentally friendly

- Steel is indefinitely and 100% recyclable - Steel is sustainable, durable and solid

UV resistance

- E 3 - Gloss retention 60%

National certificates

ArcelorMittal Construction respects the national construction regulations

Wind load

Up to 50 m/s (180km/h)

Seismic resistance
Up to 10m/s

SBI test with 10mm plasterboard: B s1 d0 (EU norms)

Reaction to fire

15

PROTEA | Fast and easy installation

Low cost, high quality housing Dry and clean construction site Watertight structure completed in just 4 days

- Products reception and site preparation - Chalk line tracing - Preparing and installing the floor rails on the slab

Day 1

- Installing the walls and partitions

Day 2

- Installing the top rails - Installing the roof - Installing wall to roof junctions and finishing

Day 3&4

Excellent technical performance of: - Thermal insulation - Resistance to fire (with plasterboard)

Resistance to: - Earthquakes - Strong winds - UV rays

Steel characteristics: - High Strength Steel: S350GD - Hot Dip Galvanised - Pre-painted Organic Coating

www.arcelormittal.com/protea

E-mail: contact.housing@arcelormittal.com
This publication is not a contractual document. Due to a policy of continual product development, ArcelorMittal Construction reserves the right to alter any of the specifications given in this publication without prior notice. No responsibility for accuracy is accepted by ArcelorMittal Construction. All information contained within this document is the sole property of our company and any unauthorized use is strictly forbidden.

Document printed on paper made 100% from recycled fibres

Version 3 | 03-2012 - ArcelorMittal