protea - PGA Consultants

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
South Africa
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
Mounting walls
Newcastle, South Africa - Colours: Sand 4102 for walls, Bordeau 4802 for roof
2
Internal finishing with plasterboard

France
Dubai
Contrisson, France
Colours: Opale 4936
Contrisson, France
Colours: Stone 4703 for walls,
Abyss 4505 for roof
PROTEA 40m² - 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 40m² PROTEA kits can be stored in one
40’ container.
Phase 1: Reception of kits on site
Day 1
PROTEA Kit delivered to prepared foundation (concrete slab or dry steel
deck) and elements are unpacked for assembly.
Phase 3: Walls and partitions assembly
Phase 2: Preparation of the ground - implementation
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 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.
Phase 5: Wall and roof joined by a U profile
Day 2
Wall construction is finalised by the connection of the two last panels at
the opposite corner.
Phase 6: Finishing accessories
Kits in container on truck
Day 3
U-profile elements to join walls and roof panels are fixed to
the top of all the wall panels.
4
Day 4
Assembly of the roofing panels including finishing (mono and duo-pitch
ridge, edge,...)

250
250
250
250
40
275
Panel
female
side
250
250
40 40
275 165 250 250 275 165
Panel
Panel
female
female
side
side
40 40
40 40
275 165 250 250 275 165 250 250 275 165 250 250 275 165 250 250 275
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 40
165
250
250
40
275
Panel
female
side
165
250
500
250
275
Panel
female
side
40
275
Panel
female
side
170
250
250
40
275
Panel
female
side
165
40
275 165
Panel
female
side
250
250
250
250
40
275
Panel
female
side
120
275
Panel
female
side
165
500
275
Panel
female
side
165
165
250
250
40
275
Panel
female
side
165
250
250
275
Panel
female
side
40
250 250 275 165 250 250 275
Panel
Panel
female
female
side
side
PROTEA | Installation guide abstract
Each PROTEA kit comes with complete assembly
instructions. Two documents detail all the different
steps in the construction process.
1 - Construction manual
In this first document, the following points are
covered:
Necessary tools:
Description of the needed equipment.
Layout of the elements
Installation plans giving laying order and position for
each element:
2
7
1 3 4 5 22 23 24 26
6
25
Bedroom 2 Kitchen Bathroom
/
Bedroom3
12
32
9 10 11 31 30
33
8
13
14
Bedroom 1
18
Lounge
27
28
29
36
2 - Fastenings plans
This second document contains a complete range of
drawings showing the number and precise position of
all the different fastenings.
600 600 600
30
215
210
210
215 100 235
230
230
235 100 280
30
30 30
340 100 235 230 230 235 100 200 195 195 200
15
16
19
17 20 21 34 35 38 39
37
Panel
Panel
Panel
Panel
Panel
female
female
female
female
female
side
side
side
side
side
1-38: Laying order : male side of panels
Nomenclature:
Extensive nomenclature of the kit contents.
Connection details:
How specific connections are treated
Screw
Wall panel
Floor rail
Screw
600 600 600
Site preparation:
How to prepare the construction site prior to
beginning
8500
Pattern L
Reservations
5600
Floor
Tightness joint
Openings:
How to install and fasten doors and windows
130
325
325
325
325
325
325
325
325
150
20
283
Ridge
Eaves
diameter Ø
Welded wire reinforcement. L=150mm, and Ø=8mm
Recommendations, preliminary operations:
For example about checking panels verticality.
Safety recommendations
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.
5

PROTEA | Designs
12 m² shelter
4058
Main room
~12m²
3169
1m
Outside perspective
Top view
Floor plan
20m² cottage
5168
Room2
~10m²
Room1
~10m²
4060
1m
Outside perspective
Top view
6
Floor plan

PROTEA | Designs
30m² family house
6057
Bedroom 2
~7.5m²
Kitchen / Lounge
~15m²
5168
Bedroom 1
~7.5m²
1m
Outside perspective
Top view
Floor plan
40m² family house
8052
Bedroom 2
~7.5m²
Bath
~5m²
Kitchen / Lounge
~20m²
5164
Bedroom 1
~7.5m²
Outside perspective
Top view
1m
Floor plan
7

PROTEA | Designs
55m² residence
998
9053
8055
Bedroom1
~13m²
Entrance Hall
~2m²
Kitchen / Lounge
~21m²
Corridor
~2m²
Bedroom2
~13m²
Bathroom
~5m²
3654 3588
7242
Canopy
~9m²
1m
Outside perspective
Top view
Floor plan
71m² residence
9059
Bedroom 1
~11m²
Bathroom
~5m²
Bedroom 2
~12m²
WC
~2m²
8178
Bedroom 3
~12m²
Kitchen / Lounge
~29m²
1m
Canopy
~12m²
Outside perspective
Top view
Floor plan
8

PROTEA | Designs
100m² residence
12128
Bedroom 3
~8.5m²
Bathroom
~5.5m²
Bedroom 1
~12m²
Access
~1m²
WC
~2m²
Kitchen
~10m²
8178
Bedroom 2
~12m²
Lounge
~34m²
Bedroom 4
~12m²
13074
1m
Canopy
~12m²
Outside perspective
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.
Top view
Floor plan
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
9
Plasterboard
Wall aspect:
with and without plasterboard

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)
8mm
0.25mm
Overall width: 1016mm
Useful width: 1000mm
Exterior microribbed face
60mm
Roof panels:
• Insulated, structural panels
• PUR foam thickness: 40mm (standard)
• Steel sheet thickness
-interior: 0,50mm (standard)
-exterior: 0,63mm (standard)
Overall width: 1078mm
Useful width: 1000mm
40mm
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
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.
Wall panels interlocking
Roof panels interlocking
Not included
- 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 60mm
Polystyrene 100mm
Mineral wool 110mm
Wood
460mm
Bricks
1870mm
Stone
4080mm
Concrete
5830mm
Steel characteristics
-Steel grade: S350GD
-Hot dip galvanised Z275
-25μm 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
Stone 4703
Ral 7032
Bordeau 4802
Ral 8012
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.
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
For protection, all windows can be equipped with anti
intrusion bars.
11
A steel deck can be provided for each type of house
(12, 20, 30, 40, 55, 71 and 100m²).
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.

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 15m² extension kit is available, for the following
house types: 20m², 30m² and 40m².
Detail of the mechanical
testing of the rail
8052 3028
Water tank (not provided)
Roof example with 7 rails and 6 solar modules:
Bedroom 2
~7.5m²
Bath
~5m²
Bedroom 4
~7.5m²
Kitchen / Lounge
~20m²
5164
Bedroom 1
~7.5m²
Bedroom 3
~7.5m²
Rails
Solar modules
1m
40m².
15m².
55m².
Extension example with the 40m² 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.
Fire performance:
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.
*Council for Scientific and Industrial Research
Fire test in South Africa
Structural performance:
The PROTEA structural performance has been assessed.
The house structure is essentially ensured by
self bearing panels.
Example: the 55m² house and its maximal
calculated horizontal deflection
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).
Simulation of wind action (confirmed the calculation model)
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, steel’s failure mode is ductile;
this means that when submitted to strong forces,
steel doesn’t break but dissipates energy by plastic
deformation.
13
Thermal performance calculation:
The PROTEA thermal performance has been assessed
by thermal calculation.
temperature (°C)
42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
As a result, this calculation shows that the PROTEA
house provides better summer comfort compared to a
traditional brick and mortar house (up to 5°C cooler).
Thermal performance measurement:
A thermography measurement was performed on a
prototype, showing good thermal insulation and air
tightness.
Infrared images
Indoor
Comparison of indoor temperatures between PROTEA and standard
south-african house, during the hottest week in climate zone 1
(Bloemfontein)
time (from 1/25 to 1/31)
Comfort temperature PROTEA External Temperature Comfort temperature standard SA house
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 Earth’s 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 manufacturing’s energy consumption
and CO 2
emissions by half compared with 1960 levels.
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 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 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» Haïti 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
U wall
=0.29-0.47W/m².K (100-60 mm)
U roof
= 0.28-0.58W/m².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/s²
Reaction to fire
SBI test with 10mm plasterboard: B s1 d0
(EU norms)
15

PROTEA | Fast and easy installation
• Low cost, high quality housing
• Dry and clean construction site
• Watertight structure completed in just 4 days
Day 1
- Products reception and
site preparation
- Chalk line tracing
- Preparing and installing
the floor rails on the slab
Day 2
- Installing the walls and partitions
Day 3&4
- Installing the top rails
- Installing the roof
- Installing wall to roof junctions and
finishing
Version 3 | 03-2012
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
E-mail:sales@pga-consultants.net
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