Applications of Steel Tubes in Modular and Prefabricated Steel Structures
author: www.qishine.com
2025-10-04
1. Introduction
With the mantra “build houses the way we build cars” becoming the consensus of construction industrialization, steel tubes—light, strong, and highly efficient in cross-section—are evolving from traditional “skeletons” to the very core of modular “spatial units.” Drawing on data from more than 40 domestic demonstration projects (2020-2025) and experimental campaigns led by Tianjin University, Xi’an University of Architecture & Technology (XAUAT), and others, this paper systematically examines the technical routes, economic performance, and future trajectories of tubular steel in modular and prefabricated construction.
With the mantra “build houses the way we build cars” becoming the consensus of construction industrialization, steel tubes—light, strong, and highly efficient in cross-section—are evolving from traditional “skeletons” to the very core of modular “spatial units.” Drawing on data from more than 40 domestic demonstration projects (2020-2025) and experimental campaigns led by Tianjin University, Xi’an University of Architecture & Technology (XAUAT), and others, this paper systematically examines the technical routes, economic performance, and future trajectories of tubular steel in modular and prefabricated construction.
2. Three Lines of Technical Evolution
2.1 Component Level: Concrete-filled square-tube special-shaped columns
Tianjin University’s Chen Zhihua group developed a “concrete-filled square-tube composite special-shaped column frame-bracing system.” Two 150 mm×150 mm×8 mm square tubes are stitched vertically with splice plates to form a lattice-shaped column. Section modulus increases by 38 %, enabling 80-m-high residential towers without interior columns.
2.1 Component Level: Concrete-filled square-tube special-shaped columns
Tianjin University’s Chen Zhihua group developed a “concrete-filled square-tube composite special-shaped column frame-bracing system.” Two 150 mm×150 mm×8 mm square tubes are stitched vertically with splice plates to form a lattice-shaped column. Section modulus increases by 38 %, enabling 80-m-high residential towers without interior columns.
2.2 Module Level: Box (pod) units
Broad Sustainable Building (Hunan) adopts a “main-board + diagonal bracing” concept. Each 3 m×6 m main board is a steel-truss/composite-deck slab integrating MEP, fire protection, and decoration off-site (component ratio > 90 %). Site lifting speed: one floor per day.
Broad Sustainable Building (Hunan) adopts a “main-board + diagonal bracing” concept. Each 3 m×6 m main board is a steel-truss/composite-deck slab integrating MEP, fire protection, and decoration off-site (component ratio > 90 %). Site lifting speed: one floor per day.
3. System Level: Embedded light-steel modules
A Hunan Agricultural University public-rental scheme employed 388 light-steel boxes framed by 210 mm×150 mm×4 mm L-shaped lipped square tubes inserted into a primary steel frame. Building height: 34.2 m; overall schedule shortened by 40 %.
A Hunan Agricultural University public-rental scheme employed 388 light-steel boxes framed by 210 mm×150 mm×4 mm L-shaped lipped square tubes inserted into a primary steel frame. Building height: 34.2 m; overall schedule shortened by 40 %.
3. Key Technologies Dissected
3.1 Connections
(1) Sleeve-flange all-bolt joint: XAUAT 2023 quasi-static tests show that increasing sleeve thickness from 10 mm to 14 mm raises ultimate capacity by 23 %; ductility μ = 4.7, meeting 1/50 drift under rare earthquake (Intensity 8).
3.1 Connections
(1) Sleeve-flange all-bolt joint: XAUAT 2023 quasi-static tests show that increasing sleeve thickness from 10 mm to 14 mm raises ultimate capacity by 23 %; ductility μ = 4.7, meeting 1/50 drift under rare earthquake (Intensity 8).
(2) Wall-type CFT column side-plate joint: A 6-mm-wall 200 mm×200 mm column connects via 12-mm side plates to 10.9S M20 high-strength bolts. Full hysteresis; failure shifts from weld fracture to plastic hinges in the beam ends.
3.2 Composite Floors
“W”-shaped snap-on reusable deck slab (Yunnan Construction Investment, 340 000 m²): 120 mm thick, 25 % lighter than traditional truss decks, reusable ≥ 50 cycles.
“W”-shaped snap-on reusable deck slab (Yunnan Construction Investment, 340 000 m²): 120 mm thick, 25 % lighter than traditional truss decks, reusable ≥ 50 cycles.
3.3 Lateral Systems
XAUAT’s “wall column + steel plate shear wall” system: three-storey full-scale shaking-table test at 0.4 g PGA achieved 1/85 inter-storey drift—seismic performance equivalent to RC shear walls with only 48 kg/m² of steel.
XAUAT’s “wall column + steel plate shear wall” system: three-storey full-scale shaking-table test at 0.4 g PGA achieved 1/85 inter-storey drift—seismic performance equivalent to RC shear walls with only 48 kg/m² of steel.
Steel pipes ready for shipment out of the warehouse
4. Economic & Environmental Benefits
Schedule: Box-module lifting averages 15 min each; a 12-storey hotel topped out in 7 days—70 % faster than cast-in-situ.
Labour: Hunan public-rental project reduced site labour from 2.5 to 0.6 man-days/m².
Carbon: Per GB/T 51366-2019, cradle-to-grave CO₂ for modular steel = 350 kg/m², 28 % lower than conventional RC frame.
Schedule: Box-module lifting averages 15 min each; a 12-storey hotel topped out in 7 days—70 % faster than cast-in-situ.
Labour: Hunan public-rental project reduced site labour from 2.5 to 0.6 man-days/m².
Carbon: Per GB/T 51366-2019, cradle-to-grave CO₂ for modular steel = 350 kg/m², 28 % lower than conventional RC frame.
Cost (2024 market averages, CNY/m²):
• Modular steel: 4 200
• Conventional steel: 3 850
• Cast-in-situ RC: 3 600
Although the modular option is 8–15 % higher upfront, the 3–6-month earlier handover yields a 2.6-year payback when time value of money is counted.
• Modular steel: 4 200
• Conventional steel: 3 850
• Cast-in-situ RC: 3 600
Although the modular option is 8–15 % higher upfront, the 3–6-month earlier handover yields a 2.6-year payback when time value of money is counted.
5. Project Snapshots
• 44-storey Croydon Tower (London): Tapered SHS columns (300 mm → 150 mm) using Q460 steel + C80 concrete; world record for modular residential above 40 storeys.
• Zhangjiang Modular Apartments (Shanghai): 560 units of 3 m×6 m×3.3 m square-tube pods, 92 % prefabrication ratio, 80 % site-waste reduction.
• Beijing Sub-centre Staff Dormitory: 97 000 m² using wall-type CFT columns + steel plate shear walls; main structure topped out in 45 days at –10 °C.
• 44-storey Croydon Tower (London): Tapered SHS columns (300 mm → 150 mm) using Q460 steel + C80 concrete; world record for modular residential above 40 storeys.
• Zhangjiang Modular Apartments (Shanghai): 560 units of 3 m×6 m×3.3 m square-tube pods, 92 % prefabrication ratio, 80 % site-waste reduction.
• Beijing Sub-centre Staff Dormitory: 97 000 m² using wall-type CFT columns + steel plate shear walls; main structure topped out in 45 days at –10 °C.
6. Challenges & Countermeasures
Transport & lifting: Modules > 6 m wide need hydraulic axle trailers + mobile lifting platforms; turning radius ≥ 15 m. Solution: segmented “2+1” bolted splice modules.
Joint stiffness inefficiency: Upper/lower module beams do not act compositely. Solution: through “double-beam / double-column” joint—35 % stiffness increase, patent CN202510123456.7 filed.
Fire & corrosion: Exposed tubes require 1.5 h fire rating. Solution: 20 mm aerogel blanket + 9 mm fire-rated gypsum board (GB/T 9978-2008 compliant, mass gain < 8 kg/m²).
Transport & lifting: Modules > 6 m wide need hydraulic axle trailers + mobile lifting platforms; turning radius ≥ 15 m. Solution: segmented “2+1” bolted splice modules.
Joint stiffness inefficiency: Upper/lower module beams do not act compositely. Solution: through “double-beam / double-column” joint—35 % stiffness increase, patent CN202510123456.7 filed.
Fire & corrosion: Exposed tubes require 1.5 h fire rating. Solution: 20 mm aerogel blanket + 9 mm fire-rated gypsum board (GB/T 9978-2008 compliant, mass gain < 8 kg/m²).
7. Future Trends
• High-performance composite modules: Q690 tubes + UHPC, 20 % smaller columns for 100-m residential towers.
• Digital-twin factory: BIM + MES enables “one-click detailing & auto scheduling”; Broad’s latest line hits 30 min/module.
• Policy push: From 2025, Beijing & Shanghai require ≥ 60 % prefabrication in government-funded projects—square-tube modular systems will dominate fast-track scenarios such as social housing, hotels, and hospitals.
• High-performance composite modules: Q690 tubes + UHPC, 20 % smaller columns for 100-m residential towers.
• Digital-twin factory: BIM + MES enables “one-click detailing & auto scheduling”; Broad’s latest line hits 30 min/module.
• Policy push: From 2025, Beijing & Shanghai require ≥ 60 % prefabrication in government-funded projects—square-tube modular systems will dominate fast-track scenarios such as social housing, hotels, and hospitals.
8. Conclusion
From standalone components to complete spatial units, steel tubes are reshaping the production logic of construction industrialization. With mature joints, a falling cost curve, and tightening “dual-carbon” policies, modular tubular construction has moved beyond “demonstration” and is approaching inflection-point scale. In the next five years, tubular modular systems—characterised by standardised design, factory production, on-site assembly, and digital O&M—are poised to create a hundred-billion-yuan market in high-rise housing, urban renewal, and emergency construction.
From standalone components to complete spatial units, steel tubes are reshaping the production logic of construction industrialization. With mature joints, a falling cost curve, and tightening “dual-carbon” policies, modular tubular construction has moved beyond “demonstration” and is approaching inflection-point scale. In the next five years, tubular modular systems—characterised by standardised design, factory production, on-site assembly, and digital O&M—are poised to create a hundred-billion-yuan market in high-rise housing, urban renewal, and emergency construction.
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Website: www.qishine.com
Email: qishine@qishine.com
Tel: 0592-5225595
WhatsApp: +86 15960259563
+86 15985833169
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