Modular Construction Protected by Cradle and Crown™ Method

See an example of the strength and durability of the Protected Cradle & Crown™ Construction

Haz-Safe's Protected Cradle and Crown Construction is a method of utilizing tubular steel bands around the perimeter of the cradle (base) and the crown (roof) with structural steel members filling in the support for the floor, walls and roof and then clad with heavy steel plate. The result is a very strong, continuously welded utilized structure that can out-perform other types of conventional construction and is the foundation of any modular Haz-safe Buildings manufacturing for pharmaceutical, chemical and petroleum manufacturing facilities. Haz-Safe's robust steel buildings and modules when complete (even with concrete floors) can accommodate architectural finishes, utilities, process piping and equipment, all factory installed before units are transported to the final work site. Equipment installed within modules are placed in their final operation location and will not require reassembly or extensive re-testing. Entire systems can be assembled and pre-qualified under controlled workshop conditions. Once on site, individual buildings or multi-modules can be safety crane lifted and bolted in place. Protected Cradle and Crown construction is emphasized every time a Haz-Safe building or modules are lifted into place. See details below...

Crane Lifting Dispensing Module Dispensing Module Being Placed
Left: Typical crane lifting situation where a Haz-Safe paint dispensing module is being placed on the top level of a naval shipyard facility. Floor of building is strong enough to be lifted or non-supported underneath even when it is loaded with user's products. Right: Same module hanging seven stories up and is about to be maneuvered onto its resting place.

Tubular Steel

A true hazmat building should be constructed of very stiff and strong members. Haz-Safe Buildings' exclusive use of hollow structural sections (HSS) or "box" tube steel for fabrication is stronger (higher-strength-to-weight-ratio). Its strength is uniformly consistent along its entire length because tube steel is formed four-sided, not like two-sided angles or three-sided common wall studs. Tube steel's surface is smoother than channel or angle steel, therefore cleaner and easier to paint and its radius edges are architecturally friendly and aesthetically appealing.

Outside view of exterior
Interior view of a non-combustible steel Haz-Safe building
Crain hoist in a building
Outside view of exterior painted 10 gauge steel wall plate (with red stripe) and attached to the wall a 10' high x 4'6" deep x 8' long blast shaft which, constructed same as building, also has a 215 lb. per square foot blast rating. Per FM 6049 Standard. Interior view of a non-combustible steel Haz-Safe building with 1/4" thick 2" x 2" tubular frame on 24" centers within the outside surface of the frame clad with 10 gauge steel plate. Building has 120 lbs. per square foot blast rating with 8' high ceiling. Graphic shows a crane hoist in building. The crane's two runway "I" beams are secured to the roof and walls without adding exposed steel within the room, but are attached with only bolts going through fire rated gypsum to the basic tubular frame of the building. Crane is capable of lifting an individual 4' x 4' x 6' high 550 gallon tote tannk (proof of building's strength).

Skeleton

Tubular steel members, (ASTM-A500 Grade B), are continuously welded together, fabricating the strongest superstructure, therefore the safest building. For example, horizontal and vertical tube steel structural members, like the horizontal 4" x 4" roof tubes, coming together at right angle and connecting on top of the 2" x 4" corner wall tube have 20" of continuous weld! Remember, 1/4" thick steel has, by weight, 186% more steel than 10 gauge, which has 281% more steel than 18 gauge. Imagine how much weaker buildings with 20 gauge common steel studs in walls are as compared to 1/4" thick tubular steel vertical members. With walls from 3/16" up to 5/8" thick.

Here's the difference: A steel worker picks up off the shop floor a single eight foot long section of common 4" steel wall stud. The stud is grabbed at one end and the worker can literally shake it so that it wiggles along its length. But Haz-Safe's smallest member, a 2" x 2" (3/16" thick wall) tube, has to be picked up differently. The tube is handled in the middle of its length because it is too heavy to be picked up from one end and is solid with no wiggle. So, when hundreds of tubes are continuously welded into a skeleton, the resulting building doesn't wiggle or bend either (see photos below).

Steel Skin

10 gauge cold-rolled plate (ASTM - A569) is continuously welded to sump floor, outside walls and roof, creating a unitized steel structure. No mechanical fasteners. Glossy white marine grade macroproxy finish with 6" high red stripe standard. NOTE: 10 gauge plate is approximately 1/8" thick and, after being continuously welded to the frame, it will not show any "oil canning." The term "oil canning" refers to the old time oil cans that were used to oil squeaky door hinges, etc. Pressing in the convex bottom of the oil can with one's thumb would expel a squirt of oil through the tapered nozzle. Sometimes, however, the bottom of the oil can would stay pressed in (concave), frustrating attempts to apply more oil. Continuously welded 14 and 12 gauge steel sheet, since it is thinner, tends to be wavy and have a wrinkled weak appearance.

Structure Performance

Exceeds Factory Mutual (FM) 6049 Standard wall load requirements for (A) " Non-Damage Limiting Construction(N-DLC)" construction for 90 MPH wind and (B) "Damage Limiting Construction(DLC)" adding 215 Ibs. psf. against blast plus installing relief panels per FM's 1-44 calculations. Standard loads are 40 Ibs. psf. snow, 250 Ibs. floor, and Zone 4 earthquake. Actual structural performance is greater for Haz-Safe Buildings. For example, the 10 gauge plate external skin spanning 23" between every vertical wall tube can withstand 215 lbs. ft.2 blast pressure with FM approval up to 215 ft. high (Click here for more information on Blast Resistance Rating - FM approval).

Roof Crane Lifting Lugs

3/4" thick, are welded into the crown, each roof lifting lug capable of lifting over 16,000 Ibs. No spreader bars over the roof or slings under building are required by riggers when building is lifted.

Two cranes lift building
Notice how straight the base and roof edges of the building are as it hangs above the pad. There isn't any bending for this 60' long x 14' wide x 10' high, 65,700 lbs. building. Two cranes lift building using only four rooftop lifting lugs without employing over the roof spreader bars or slings under the floor (proof of strength).
module being lifted into place
The third, or upper level module, is being lifted into place on top of the middle or second module. Each module was 42,000 lbs., yet the lower module wasn't strengthened beyond normal Haz-Safe construction to take on the weight of the upper modules (proof of strength)

Front View: Assembled on a hazmat waste facility site are two patented modular units, making up an 18'8" deep x 28'8" long (535 ft. sq.) x 9'6" high Haz-Safe building, tucked part way into user's "pole barn". Within are three 9'8" wide x 18' deep rooms, each with its own gray painted 3' wide x 6'8" long steel ramp.
Back View: Patented modular roof-top cap seals the joint between modules. Dual fans on the roof (#1 fan runs continuously while #2 fan is in reserve) are ducted down to a posi-vent tube running within the elevated floor grate of each room. Third fan on roof is for an individual fume extractor area for "point of work" protection. Each room has an 8'wide x 4' high explosion relief panel on its back wall.