Original Research Article: (2022), «EUREKA: Physics and Engineering»

full paper
Number 4

DEVELOPMENT OF THE PROJECT OF MODULAR

PREFABRICATED BUILDINGS
Galym Issabayev
Department of Architecture 1

Aimash Slyambayeva
Department of Construction 1

Alpysbay Kelemeshev
Department of Construction1

Dina Amandykova*
Department of Design 1
[email protected]

1International
Education Corporation
28 Ryskulbekov str., Almaty, Republic of Kazakhstan, 050042

*Corresponding author

Abstract
The issues of working design with the construction of modular prefabricated buildings, with the minimization of cold
bridges are revealed. Cold bridges are typical for prefabricated buildings with inadequate attention to the design of both load-bear-
ing metal and enclosing structures, as well as their connections. Connections should not pass through its cross section both zero
and negative temperatures. As a result, an original project of two modular buildings was developed from easily prefabricated
metal structures and wall structures with light mineral wool filling. This project is also intended for sharply continental regional
natural and climatic conditions (regardless of the geographical location on the territory of Republic of Kazakhstan – south-
eastern Republic of Kazakhstan, central, eastern or western Republic of Kazakhstan. In winter, natural and climatic conditions
are similar in these areas). As a result of this study, it was found that the developed project meets the requirements of thermal in-
sulation – at the interface of the supporting and enclosing structures. The thermal insulation requirements of the above structures
are important to eliminate the dew point and consequently the formation of moisture and mold in all structures. In turn, mold and
other microorganisms, as studies show, adversely affect the health and normal stay of people in the premises, both during the night
and during the day. Many developers do not consider these factors in prefabri­cated buildings. These buildings are inten­ded for
various industries. For example, in healthcare, these are mobile hospitals. In military camps – buildings of temporary residence
as barracks, etc.
Keywords: modular prefabricated buildings, load-bearing structures, metal profile, enclosing structures, microclimate.

DOI: 10.21303/2461-4262.2022.002499

1. Introduction
Modular prefabricated buildings do not lose their relevance in modern architecture and con-
struction, in view of such main advantages as: high speed and all-weather installation, lower cost
compared to traditional construction methods. As a rule, unified elements of modular buildings are
manufactured at the factory, with further assembly at the construction site.
In general, the modular design method in the production of architecture and construction
products can be regarded as one of the highest forms of activity in the field of standardization. The
research methods in this article were based on the unification of the structural elements of struc-
tural products, as well as on the methods of measuring drawings of building spots, on the basis
of tacheometric equipment, etc. Thanks to these methods, it was possible to obtain geometrically
accurate structural products at the metal structures manufacturer.
The purpose of this article is to study the development of a project for a modular prefabrica­
ted building, taking into account the speed and ease of construction, the cost-effectiveness of pro-

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Original Research Article: (2022), «EUREKA: Physics and Engineering»
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duction and installation of structures, as well as the creation of post-and-beam units of structures
connecting enclosing sandwich panels, while minimizing heat loss in the form of cold bridges.
To achieve this goal, the following tasks are defined:
– to develop unified load-bearing structures of a prefabricated modular building with simple
and quick installation;
– unified load-bearing structures must have a profile that would allow tightly connecting
ceiling and wall sandwich panels;
– unified post-beam profile should be able to exclude the formation of cold bridges as much
as possible.
At the present stage in construction practice, such issues of modular prefabricated con­
struction as:
– optimization strategies in overcoming key limitations in the construction of modular pre-
fabricated structures [1];
– efficiency of prefabricated building systems [2];
– modular construction technology [3];
– manufacturing technology of prefabricated structures [4];
– impact of prefabrication on the profitability of modular construction, in comparison with
traditional methods [5];
– comparative study of prefabricated and traditional construction [6];
– obstacles to the development of prefabricated construction [7];
– high-rise construction of modular buildings [8];
– review of the performance of prefabricated building systems [2];
– optimization of structures of prefabricated buildings [9] and many others.
The above scientific sources substantiate the issues of production, technological, economic
and other aspects of prefabricated modular buildings. While, in this article, emphasis is placed
on such aspects as: the creation of conjugation structures for enclosing mineral wool sandwich
panels, with the elimination of the penetration of the cold of the external environment into the
premises of prefabricated buildings, with an emphasis on energy saving. These aspects are quite
relevant for the construction of prefabricated modular buildings in the winter climatic conditions
of the region.
In the Republic of Kazakhstan, the construction of modular prefabricated buildings is at the
initial stage of its development. Of the well-known modular buildings built in the country, low-rise
buildings of frame structures made of light thin-walled metal structures of the Energy company
can be noted [10].

2. Materials and methods

Since 2016, the architectural bureau of the Kazakh Leading Academy of Architecture and
Civil Engineering has completed several completed projects of modular canteen buildings for mi­
litary units.
In the proposed modular system of prefabricated elements, in contrast to the common con-
tainer type (Fig. 1), such advantages of the first option are indicated as:
– simple installation of metal structures;
– simplified transportation of disassembled structures, in contrast to the cumbersome and
more costly transportation of containers.
The bearing post-and-beam profile indicated later in the article, in the studied projects
of prefabricated modular buildings, was made of carbon steel grade S 235 JR. Also, this profile
was taken in accordance with the standards and requirements of the Republic of Kazakhstan on
the physical and mechanical properties of steel and their calculated values, with an elastic mo­
dulus equal to: E = 210 kN/mm 2 [11]. After the development of the project of this prefabricated
modular building and the interface nodes of the post-beam profile, it became possible to sub-
mit these nodes for patenting. Currently, documentation is being developed for submitting these
units of load-bearing structures, with interfacing enclosing sandwich panels, for an application
for patenting.

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Fig. 1. Main advantages and disadvantages of two modular systems

3. Results and discussion

From July to December 2020, two modular buildings were designed and built. These modular
buildings were intended for the military unit. They were located in the suburban area of the metro­
polis of Almaty. On the west side. According to the terms of reference, the buildings being designed
and under construction (barracks and headquarters) had to meet such basic requirements as:
– simplicity and all-weather assembly of one-story buildings in the field;
– enclosing structures made of wall and ceiling sandwich panels (with mineral wool thermal
insulation 120 and 150 mm thick);
– post-beam system of the supporting frame with the maximum elimination of cold bridges,
since many contractors erected and handed over buildings that during operation had condensate
inside at the interfaces of wall, floor and ceiling structures.
The natural and climatic conditions near the Shemolgan settlement (Almaty region), in con-
trast to the metropolis, are characterized by more severe conditions. In winter, the area is characte­
rized by strong cold winds. The natural and climatic features of this area are explained, in contrast
to calm Almaty, by the active movements of air masses in the indicated open steppe spaces, bet­
ween the gorges of the Zailiysky Alatau ridge and the Kapshagai reservoir located in the northeast.
Taking into account the conditions – the terms of reference and the natural and climatic data
of the construction site, the designers were faced with the task of developing two modular buildings
with the following features:
– load-bearing post-and-beam structures connecting enclosing sandwich panels should have
been designed to minimize the passage of cold in winter and demi-season;
– manufacturability and ease of assembly of structures without wet processes during the
cold period;
– mobility and lightness of structures during transportation;
– the strength of structures and their joints that can withstand both the passage of cold and
sufficiently strong wind currents and seismic loads.
To solve design problems related to the simplicity and manufacturability of the installation
of load-bearing and enclosing structures, with the minimization of heat leakage of the technical

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specifications and the manufacturability of the process of installation of load-bearing and enclos-
ing structures, the designers developed a unified profile used for both racks and crossbars (Fig. 2).
This profile, into which the wall enclosing sandwich panels are «threaded», has a dual function.
It effectively works in compression (in racks-columns), in bending and torsion (in girder beams).
And also, due to the small thickness (2–2.5 mm), (2.5 mm); it does not allow the penetration of cold
at the junction of the profile with wall and ceiling structures of sandwich panels. The thickness
of the wall and ceiling sandwich panels (made of significantly thermally insulated rigid mineral
wool boards) is 120 and 150 mm, respectively.
Thus, the profile, receiving thermal exposure from sandwich panels of considerable
thickness, does not allow the penetration of cold through the enclosing structures of walls and
ceilings. Thickness of enclosing wall panels – 120 mm, ceiling enclosing panels – 150 mm. There-
fore, they exceed the physical dimensions of the supporting post-and-beam profile (2.5 mm)
by 48 and 60 times, respectively. Due to this, a significant thermal mass of sandwich panels in
comparison with the supporting profile prevents the penetration of cold into the designed buildings.
When the dew point is cut off, even in severe frosts. On the first half of the enclosing structures,
from the outer edge of the outer walls and ceilings.

Fig. 2. Wall and ceiling sandwich panels (thickness 120 and 150 mm, respectively) are «sewn»
into the supporting metal profile (2–2.5 mm thick), (2.5 mm) during installation

The bearing post-beam profile was conceived with a complex configuration (Fig. 3). In
order to give it the necessary strength in compression, bending and torsion. These strength charac-
teristics of the profile (made according to our drawings) were calculated by the manufacturer using
a special computer software product Autodesk LIRA. The central compressive force on the profile
turned out: N = 2180 kN; maximum design bending moment Mmax = 539.5 kN·m. Also, this profile
is optimal for rigid fastening of enclosing sandwich panels.
In plan, the designed headquarters buildings and barracks have a rectangular configuration
with overall dimensions along the axes – 14×17.045 m and 14.46×56.005, respectively (Fig. 4, 5).
At the same time, for ease of installation, without the use of lifting mechanisms (light weight of op-
timally sized racks and beams), the pitch of the columns in the longitudinal direction was 2.435 m,
and in the transverse direction – from 2.48 to 3.025 m and 4.8 m.

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Fig. 3. Post-beam unified profile of complex configuration for rigid fastening of enclosing
sandwich panels; as well as giving, with its insignificant thickness, compressive strength (racks),
bending and torsion (beams)

Fig. 4. Plan of the headquarters building

Floor structures for eliminating cold bridges consisted of a «pie» (Fig. 6), which included:
– a metal profile in the form of the letter omega (profiled in this form for rigidity and bend-
ing strength), resting on the channels of the floor base;

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– fastened wooden bars 50×100 mm (cold-proof), mounted on the «omega» profile;

– boards 20×100 mm, with a step of 400 mm, mounted on the previous structures of the beams;
– plates made of CSP (cement chipboard, resistant to moisture), representing the basis of the
finished floor in the interior space of the building. Mineral wool mats with a thickness of 100 mm were
laid between the beams and the structure of the insulated floor on a base made of galvanized sheets.

Fig. 5. Photo of the interior of the barracks building

Fig. 6. Thermally insulated floor structures in the designed buildings

Wall and ceiling enclosing structures made of sandwich panels, designed by modular pre-
fabricated buildings, were sequentially mounted in the bearing profiles of racks and beams (Fig. 7).

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And thus, they made up a solid heat-insulated, rectangular parallelepiped in plan, with a rigid frame
seismic-resistant system of metal columns and crossbars integrated into it.

a b
Fig. 7. Structures from sandwich panels: a – 3D-scheme of enclosing sandwich panels
in the bearing profiles of racks and beams; b – the device of a gable roof on the top of the beams
and rafters (from galvanized profiled sheet)

These modular headquarters buildings (Fig. 8, 9) and barracks were assembled according to
the projects under consideration by the contractor (with heating networks) in early December 2020
and were tested, with operation until mid-April 2021 (end of the heating period). During operation,
a comfortable average temperature of +24 degrees Celsius was maintained inside the building.
At all joints of load-bearing racks and beams; and enclosing wall and ceiling structures, no traces
of condensate were found. This designed and built modular prefabricated type can have not only an
administrative and economic purpose, but also residential functions for non-permanent residence,
such types of structures as hostels, barracks and shift houses.
To evaluate these modular buildings in terms of thermal characteristics, below is a thermal
calculation of enclosing structures. The thermotechnical calculation of load-bearing structures,
taking into account cold bridges, is planned to be carried out in further studies when financing
development work (including the use of a thermal imager). Several subsoil users are interested
in these experimental design technologies, which intend to build seasonal prefabricated housing
and shift camps.

Fig. 8. Photo of the designed and built headquarters building

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a b
Fig. 9. Examples of mounted interiors: a – photo of the mounted headquarters corridor;
b – photo of one of the mounted headquarters rooms

Thermotechnical calculation of enclosing structures. Initial data:

– thermal conductivity of structural layers: λ1–50; λ3–50 (metal profile, steel), construction
thickness: δ1–0.002; δ3–0.002 m;
– thermal conductivity of the insulation: λ2 – 0.043, thickness of the insulation δ2ut–0.12 m.
The climate parameters of the Almaty region are taken from regional standards for clima-
tology [12]:
– coefficient of heat absorption of the inner surface αv = 8.7W/(m2·°С);
– heat transfer coefficient of the outer surface αn = 23W/(m2·°С);
– temperature of the heating period theat – 2.2 °С;
– duration of the heating period Zheat = 168 days;
– type of thermal insulation: mineral wool;
– thermal conductivity coefficient of insulation λin = 0.043 W/(m2·°С);
– internal and external air temperature τin = 21 °С; τout = –23 °С;
– DHHP – degree hours of the heating period:

DHHP = (tin –theat)⋅zheat = 3898.

Required heat transfer resistance:

R 0r = 2.76 (m2·°С)/W [13].

The solution. Heat transfer resistance:

R = (1/αin+δ1/λ1+δ2in/λin+δ3/λ3+1/α out) =
= (1/8.7+0.002/50+0.12/0.043+0.002/50+1/23) = 2.95 (m2·°C)/W.

The resulting heat transfer resistance is higher than the required heat transfer resis-
tance R>R 0r, therefore: the constructions of the walls of the given modular assemblies have high
heat-insulating properties, in comparison with the normative values of the thermal resistance.
Recently, there are a number of scientific works in the Kazakh scientific community,
where it is possible to note separately the work investigating energy consumption, when energy

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conservation becomes relevant in the region, combined with mathematical modeling of climatic
parameters [14]. This also applies to prefab modular structures. Often in prefab modular buildings,
due to their rapid construction, insufficient attention is paid to energy saving and calculation of
energy efficiency parameters.
In addition to significant heat-insulating qualities, the considered insulating sandwich
panels and metal structures have certificates of compliance with hygienic parameters. The main
enclosing building material for the walls and ceilings in this project of a prefabricated modular
building are sandwich panels with mineral wool filling, with a shell made of thin (2 mm) profiled
metal sheets. These materials, having hygienic certificates, correspond to the Technical Regulation
of the Republic of Kazakhstan: «Requirements for the safety of built and constructed, construction
materials and products» [15].
The advantage of the architectural and structural solutions proposed in this study consists,
first of all, in the development of a special metal profile in the rack-and-beam system of prefabrica­
ted buildings. This metal profile, with a complex configuration, allows to connect wall and ceiling
sandwich panels, as well as floor structures. Moreover, the specified connections have the ability
to prevent heat leakage from the internal spaces of the buildings under consideration.
Boundaries and special conditions of the proposed solutions are related to the load-bearing
constructions of the assembled structures. When the main requirement for load-bearing structures
from the proposed complex metal profile is their compressive and bending strength. Also, in earth-
quake-prone areas, it is necessary to limit the storeys of prefabricated buildings to two.
The development of this research consists in the further creation of experimental and design
developments related to the supporting and enclosing structures of the buildings. Experimental and
design developments should be directed, in particular, to the study of energy-saving characteris-
tics of load-bearing racks and beams, including the use of the latest equipment, including thermal
imagers. The theoretical aspects of prospective studies on this topic are also the development of
conceptual models of modular prefabricated buildings for various natural and climatic regions of
the Kazakhstan region. And also for various landscapes of the territory of the country – with flat
steppe or hilly, foothills and mountainous terrain.

4. Conclusions
Thus, the presented projects have specially developed nodes. These nodes show the coupling
of load-bearing and enclosing structures. These nodes also give the possibility of erecting one-sto-
ry modular buildings without the formation of cold bridges. Moreover, the construction process
takes place in field all-weather conditions, without the use of lifting mechanisms.
The experience of building the first building of this type showed the real terms of its con-
struction. They made one, one and a half months. The cost of construction and assembly works
was 40 % of the cost of traditional buildings (with a reinforced concrete frame and walls made
of brick and aerated concrete). At the same time, the cost of construction of this first building, in
comparison with similar low-rise prefabricated modular structures [10], turned out to be less by
approximately 10–12 %. Mainly due to the ease of installation and the absence of the need to use
lifting mechanisms.
The potential application of the prefab structures presented above will be interesting for
regional developers who are constructing fast-erecting buildings in harshly continental natural and
climatic conditions. These developers may include both subsoil users and builders of shift settle-
ments, as well as representatives of the armed forces, medical institutions, etc.

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Received date 07.04.2022 © The Author(s) 2022

Accepted date 04.07.2022 This is an open access article
Published date 30.07.2022 under the Creative Commons CC BY license

How to cite: Issabayev, G., Slyambayeva, A., Kelemeshev, A., Amandykova, D. (2022). Development of the project of modular
prefabricated buildings. EUREKA: Physics and Engineering, 4, 36–45. https://doi.org/10.21303/2461-4262.2022.002499

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