INDIAN RAILWAY INSTITUTE OF

CIVIL ENGINEERING, PUNE

Sr. Professional Course (Bridges and General) Session No. 822
(From 21-04-08 to 16-05-08)




PROJECT REPORT
Use of Pre-Engineering Building Structure in Railway
By
PRADEEP KUMAR
Deputy Chief Engineer/Con./Jogighopa
N.F.Railway

Definition

The required building is designed to meet the Specific requirement, all
members are fabricated ,cut, punched in factory in ready to installat ion
Position
All members, purlins, grits, Cladding , connected plates, Bolts, Screws &
other accessories are delivered to site as a Package Solution.


PEB INDUSTRY EVOLUTION

Concept of metal buildings originated in U.S. And gained momentum after
the world war in early 1960s.Mass production of defence buildings in steel
using pre-fabricated concept became popular in 1940s.Metal building
systems was recognized as a favourable method of construction over
conventional methods


Computerised designs allowed buildings to be tailored to individual
customer requirements in1960s.Roll forming lines allowed continuous span
cold rolled z-purlins. Color coated panels and factory insulated panels
improved architectural appearance
The term pre-engineered buildings came into existence

PRE ENGINEERED METAL BUI LDINGS dominated the low rise building
market in the developed world in 1990s.MBMA statistics show, about 60%
of industrial and commercial bldgs in the developed world, use PEB.
Developing countries started using PRE ENGINEERED METAL
BUI LDINGS.

PEB concept wi dely accepted in the developing countries like India in
2001.Over 3000 pre-engineered buildings supplied by kirby in india in a
short span of 6 years.

STANDARDS for PEB

MBMA (Metal Building Manufacturers Association) formed in 1956 in
USA.Develops engineer ing standards, with the latest-updates, for the
manufacturers of pre-engineered metal building systems.
MBMA Lowrise Building Systems Manual is followed by the peb industry
worldwide for design and construction of metal building systems.

MBMA/ AISC/ AISI works closely in updat ing/sponsoring the latest
development and research findings in steel buildings systems.


MAIN FEATURES OF PEB


Buildings are pre-engineered as they rely on standard designs with standard
configurations, with each components of the building system uniquely profiled and
pre-engineered to suit design requirements.

By using sophisticated manufacturing facilities and engg software, the pebs are
custom designed to meet the specific customer needs.

PEBS are always manufactured in factories and shipped to job sites for assembly.

PEB uses systems approach by combining elements such as roof panels, wall panels,
purlins, girts, main frames, wind bracings etc to act integrally.

Comparison of PEB Vs. COncevtional

PRE ENGINEERED BUILDINGS CONVENTIONAL
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All sections are optimally designed with
available inventory. Non availability of
sections does not arise and hence ensures no
price escalation.
Non-availability of designed sections often
forces the designers to go for higher
sections resulting in higher weight and
escalation in the project cost.
Designed as per International Standards
such as AISC, AWS, MBMA, which are
proven worldwide. American codes are
regularly updated based on latest researches
IS-Codes are not regularly updated. Will
increase the weight and cost of building.
More competitive on life-cycle cost due to
significant time saving (nearly 50%) in
project completion, which in turn translates
to earlier realization of revenue.
Project cost escalation due to delays in site
fabrication and co-ordination with several
agencies which costs time and money.
Offers maintenance-free roof system, with
attractive color coated sheets
Requires periodical maintenance at frequent
intervals.

MAIN COMPONENTS OF PEB

PEB IS a building shell utilizing three distinct product categories


PRIMARY FRAMING: I shaped built-up( 3 plated) members, Minimum
Yield Strength 345Mpa.
SECONDARY MEMBERS: cold formed Zed AND Cee sections, High
Tensile Steel With Yield Stress of 450 MPa

ROOF AND WALL CLADDING: roll formed profiled sheeting, High
Tensile Steel With Yield Stress of 550 MPa,
Zn-AL Alloy Coated For better corrosion
Resistance, Available in various colours.


PEBS use pre-determined inventory of raw materials, proven over a long time, to
satisfy wide range of structural and architectural requirements.






Component of a Pre-Engineering Building
















M
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RIGID FRAME BEAM COLUMN -1 BEAM COLUMN - 2 BEAM COLUMN - 3 SPACE SAVER
MONO SLOPE L - CANOPY T - CANOPY MULTI SPAN LEAN TO
Product Range



















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Product Range







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KIRBY RIB (KR)
KIRBY WALL (KW)
KIRBY DECK PANEL
KIRBY WALL
INSULATED PANES
KWIP
KIRBY FLAT
INSULATED PANES - KFIP
Product Range
A
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SLIDING DOORS
LOUVERS NUTS AND BOLTS INSULATIONS SEALENTS
SKYLIGHTS AND WALL LIGHTS WALK DOORS
POWER VENTILATORS
WINDOWS
ROOF CURBS RIDGEVENTS
ROOF JACKS
Product Range

Use of Pre-Engineering Building in Railway A
Comparative study

Recently 3 Nos Pre-engineering Building Structures has been provided in New Bongaigan C& W
Workshop, N.F. Railway in Connection with Modernization of NBQ Workshop. Name of Work
alongwith relevant portion of Tender Schedule is furnished below;
TENDER SCHEDULE
A ty pical tender schedule used in recently ex ecuted work in N.F. Railway is given below:

TENDER NO.CE/CON/NBQ/W.Shed/2006/01
Name of work :-Construction of A.C.POH Shed 54m x 15.24m x 11.74m, ex tension of ex isting WTS by
42.7m x15.25m x 10m,ex tension of corrosion repair shop by 30m x20m x 12.22m, ex tension of CLS/BG by
61m X15.50m x 11.5m, shifting of ex isting abandoned shed 61m x 20m x 11.74m to store depot at New
Bongaigaon in connection with modernization of New Bongaigaon Workshop.

SCHEDULE OF ITEMS OF WORKS AND APPROXIMATE QUANTITIES
Sl.No Description of works Unit Qty, Rate in figures & words
ALTERNATE PROPOSAL
Alternate proposal submitted by the contractor for design ,
manufacturing/ fabrication, supply and erection of Pre-
Engineering metal building designed as per relev ant IS-
Code as stated in the attached specification with original offer
dated 08.12.2007 accepted by Railway.

PART-1: ex tension of ex isting WTS Shed, heavy corrosion
repair shed ,CLS/BG & construction of AC POH Shed

1 Construction of AC POH Shed Sqm 822.96 Rs 11650/-
2 Ex tension of existing WTS Sqm 651,17 Rs.12,180/-
3 Ex tension of existing Corrosion repair Shed Sqm 600 Rs.12,500/-
4 Ex tension of existing CLS/BG Sqm 945.5 Rs.12,200/-
PART-2 Shifting of ex isting abandoned shed of size of size
61m X 20m X 11.74m to the store depot at NBQ Workshop.
Items as per conventional system (Both NS & SR
items)

N.B.:- Payment for part-1 is on Sqm basis on c/c distances between columns including
foundation work as per approved drawings. No further extra payment will be payable for
projection of roofing etc.

Brief Particulars of these sheds is given below :

1. Carriage Lifting Shop ( CLS /BG) Supplied by Kirby Building System .
Size-61m x 15.5m x 11.74m
Area = 61x15.50 = 945.50 Sqm.
No. of Column = 9x2 = 18 Nos.
Overhead Crane =20T Capacity
Foundation Concrete =117.90 Cum = 117.90/945.50 = 0.123 Cum/Sqm
Structural Steel (HTS) = 90.50 MT= 90.50/945.50 = 0.096 MT/ Sqm
Cost of complete structure = Rs.12, 200 /Sqm
(Excluding industrial flooring)

2. Corrosion Repair Shop (CRS) - Supplied by Kirby Building System.
Size-30m x 20m x 12.22m
Area = 30x20 = 600Sqm.
No. of Column = 5x2 = 10 Nos.
Overhead Crane = 20 T Capacity
Foundation Concrete =75 Cum = 75/600 = 0.125 Cum/Sqm
Structural Steel (HTS) = 60.40 MT= 60.40/600 = 0.107 MT/ Sqm
Cost of complete structure = Rs.12, 500 /Sqm
(Excluding industrial flooring)

3. AC POH Shed - Supplied by Tata Blue Scope Steel.
Size-54m x 15.24m x 11.74m
Area = 54x15. 24 = 822.96 Sqm.
No. of Column = 8x2 = 16 Nos.
Overhead Crane = 5 T Capacity
Foundation Concrete =138.08 Cum = 138.08/822.96 = 0.168 Cum/Sqm
Structural Steel (HTS) = 60 MT= 60/822.96 = 0.073 MT/ Sqm
Cost of complete structure = Rs.11, 650 /Sqm
(Excluding industrial flooring)









Further, Shifting of one abandoned shed having conventional structure has
also been done under above work and another conventional structure for
Sickline Shed at NBQ yard was completed 2 years ago. Brief Particulars of
these is given below :

1. Sickline Shed at NBQ
Size-76m x 18m x 11.74m
Area = 76x18 = 1368 Sqm.
No. of Column = 20x2 = 18 Nos.
Overhead Crane =20T Capacity
Foundation Concrete =704.24 Cum = 704.24/1368 = 0.515Cum/Sqm
Structural Steel (HTS) = 295.31 MT= 295.31/1368 = 0.215 MT/ Sqm
Cost of complete structure = Rs.2,17,26,580/1368 =Rs.15, 882 / Sqm
(Excluding industrial flooring)


2. Shifting of Abandoned Shed in NBQ Workshop
Size-61m x 20m x 11.74m
Area = 61x20 = 1220 Sqm.
No. of Column = 11x2 = 22 Nos.
Overhead Crane =20T Capacity
Foundation Concrete =416.57 Cum = 416.57/1220 = 0.341 Cum/Sqm
Structural Steel (HTS) = 245 MT= 245/1220 = 0.201 MT/ Sqm
Cost of complete structure = -
(Excluding industrial flooring)

Comparison of Consumption of Concrete, Steel and Cost
of Structure

(A) Conventional Steel Building
(B)
S.No Name of
Building
Foundation
Concrete,
Cum/Sqm
Steel

MT/Sqm
Cost

Rs./Sqm
Remarks
1 Sick line Shed
(76x18x11.74)
0.515 0.215 15,882 Work completed 2
years ago
2 Abandoned
Shed
(61x20x11.74)
0.341 0.201 - Recently completed,
Existing steel utilized
Average 0.428 0.208 15,882*
*Considering escalation @ 5% for 2 years, the cost of connectional Steel
Building works out as 15882(1+2x0.5) = Rs.17, 470








(C) Pre- Engineering Steel Building

S.No Name of
Building
Foundati
on
Concrete,
Cum/Sqm
Steel

MT/Sqm
Cost

Rs./Sqm
Remarks
1 CLS/BG
(61x15.50x11.5)
0.123 0.096 12,200 Recently completed
2 Corrosion repair
Shed
(30x20x12.22)
0.125 0.107 12,500 Recently completed
Average 0.124 0.102 12,350


Observations

From above tables, it is seen that consumption of Steel is about 50% less
in case of Pre-Engineering steel buildings resulting in very lighter
Foundation i.e. about 70 % less as compared to traditional Steel
Buildings.
Over all cost of structure is reduced by about 30%.
Besides,above PEB construction has been very fast, totally hassle free for
field officials and with complete ease of measurement involving only
item ( per Sqm of shed area) for each shed which is otherwise very
cumbersome in conventional system. Further, question of Variation
normally does not arise in this type of construction.

Conclusion/Reccomendations

(i) PEBs should be used for workshops structures as well as Diesel
shed,Sick Line and goods godowns as it provides very economic,
aesthetically better looking structure in a very short Period.
(ii) Some Guidelines /provision should be made in relevant codes &
manual to facilitate use of PEBs,

Reference:
(i) Tata blue Scope Steel Limit ed.(www.tatabluescopesteel.com)
(ii) Kirby Building System(www.kirbybuildingsystem.com)
(iii) www.zamilsteel.com









Shifting of abandoned Shed to new location Conventional Structure

New Bongaigaon Workshop in Progress



Figure 1









Shifting of abandoned Shed completed

Figure 3






Figure 4 Newly constructed Pre-EngineeringBuilding-CLS/BG







Figure 2 Newly constructed Pre-EngineeringBuilding-CLS/BG



Figure 5 ;Pre-Engineering Building-Corrosion Repair shop in progress






Figure 6: Another view of Corrosion repair Shop


Figure 7 : Inside View of newly erected Pre-Engineering Building of AC POH Shed
























Figure 8: View of completed Sick Line Shed at NBQ Yard- Conventional Structure