8-Pre-Engineered Steel Buildings

Pre Engineered Steel Buildings
Presentation by : Er. P SURYA PRAKASH, Managing Director

SatyaVani Projects and Consultants Pvt. Ltd.
A 203, Kushal Towers, Khairatabad, Hyderabad – 500 004.
Tel: +91 40 39804646, Fax: +91 40 23308184, e-Mail: suryapp@yahoo.com
OVERVIEW
 Introduction  Other Projects on PEB by SVPCPL
 Component Parts  PEB images of China & UK
 Erection of PEB  PEB in India
 Challenges of Vertical Construction  Conclusion
 Preparedness of PEB In India
 Profile Deck
 Planning of PEB
 Projects on PEB by SVPCPL

INTRODUCTION
PRE ENGINEERED BUILDINGS
 Pre Engineered Buildings are extremely quick and efficient.

 They have a simple design and are light weight.
 It is easy to construct and delivery takes an average of 6 to 8 weeks. Apart from these, it is 15 to 20% cheaper than a
conventional method. Thus, both costs and time of erection are minimized.
 Although PEB systems are extensively used in industrial and many other non residential constructions worldwide, it is
relatively a new concept in India.
 These concepts were introduced to the Indian markets gradually at late 1990’s. With the opening of economy and a
number of multi nationals are setting up their projects.
 The market potential of Pre Engineered Buildings is nearly 1.2 million tons per annum.
 The current pre engineered steel manufacturing capacity is 0.35 million tons per annum. This industry is growing at the
compound rate of 25 to 30 %.
INTRODUCTION
PRE ENGINEERED BUILDINGS
 Pre engineered steel buildings can be fitted with different structural accessories including mezzanine floors, canopies,
fascias, interior partitions etc.
 These PEBs are generally low rise buildings however the maximum eave height can be limited from 25 to 30 meters.
 Pre Engineered buildings were ideal for offices, houses, showrooms, shop fronts etc.
INTRODUCTION
ADVANTAGES PRE-ENGINEERED BUILDING STRUCTURE
Construction Time or faster installation
Lower Cost
Flexibility in Expansion
Large Clear Spans
Quality Control
Low Maintenance
Energy Efficient Roofing
Erection
INTRODUCTION
PRE ENGINEERED STEEL BUILDINGS Vs. CONVENTIONAL STEEL BUILDINGS
Pre-Engineered Conventional
Steel Buildings Steel Buildings
Seismic Resistance - Low Seismic Resistance - Rigid.
Weight flexible frames offers higher

resistance to seismic Forces. Heavy weight structures don’t perform
well in seismic zones.
Architecture -achieved at low cost.
Architecture-achieved at higher cost
Overall price 30% lower.
Overall price - More heavy.

30% lighter
Primary member is tapered section Primary member is hot rolled section.

INTRODUCTION
PRE ENGINEERED STEEL BUILDINGS Vs. CONVENTIONAL STEEL BUILDINGS
Pre-Engineered Conventional
Steel Buildings Steel Buildings
Secondary members are light
Secondary members are ‘I’ or ‘C’
weight rolled framed ‘Z’ & ‘C’
sections which are heavy in weight.
sections.
Erection cost & time-accurately Erection cost & time-20% more than
known. PEB.
Erection process is easy, fast step by Erection process is slow and

step. extensive field labor required.
Delivery-average 6 to 8 weeks. Delivery-average 20 to 26 weeks.

COMPONENT PARTS
 Primary Members (Main Frame)
o Columns
o Rafters
 Secondary Members
o Purlins
o Girts
 Sheeting
o Roof
o Wall
o Fascias Etc
 Accessories
o Ventilators
o Sky Lights
COMPONENT PARTS
PRIMARY MEMBERS (MAIN FRAME)
 Main framing basically includes the rigid steel frames of the building.
 The PEB rigid frame comprises tapered/straight columns and tapered rafters (steel plate fabricated 'I' or 'H' sections are
referred to as built-up members).
 The frame is erected by bolting the end plates of connecting sections together.
COMPONENT PARTS
SECONDARY MEMBERS
 Purlins, girts and eave struts are also known as secondary cold-formed members.
 There is no welding involved in their preparation.
 They are prepared by press bending the HR steel coil giving it the desired shape(Z- or C-shape).
COMPONENT PARTS
Roof & Wall Panels SHEETING
• Metallic plain or color coated profiled steel sheets are used as roof and wall sheeting.
• The steel sheets are generally made from Zincalume or Galvalume coils in thickness range of 0.47mm to
0.55mm.
• The color coating is also available in various options in polyester paint coating like regular modified polyester,
silicon modified polyester and super polyester coatings.
• Metal roofing and siding profiles can be manufactured to any length – limited only by transportation
constraints (usually to 12 meters).
• Lap joints with 150mm to 200mm overlap virtually eliminate water ingress.
• At the initial project planning stage, roof slope is a key consideration for architects incorporating roof systems
into their designs.
COMPONENT PARTS
Roof & Wall Panels SHEETING
• Slopes as shallow as 1:20 are possible ensuring sufficient drainage of water and good long term performance
of roof panels.
• These profile steel sheets are usually categorized into two types depending upon the type of fixing
arrangement followed.
• These two types are known as Through Fastened and second one is Standing Seam.
• Installation of this type of roofing & cladding system can provide 30 years or more of trouble-free service in
most environments.
COMPONENT PARTS
ROOF SHEETING
COMPONENT PARTS
SHEETING - INSULATIONS
 These buildings can be properly insulated by providing fibrous insulation slabs/rolls of non-combustible Rockwool,
Aluminum foil laminated, placed over a metal mesh bed created between the purlins, and then the roofing steel sheet fixed
over it.
 The siding walls can also be insulated by providing a double skin profile steel sheet wall cladding having Rockwool
Insulation slab sandwiched in between and held in position with the help of 'Z' spacers in between the two profile steel
sheets.
 In similar pattern a double skin insulated roofing system can also be erected.
COMPONENT PARTS
SHEETING - SANDWICH PANELS
 Another alternative is to provide pre-fabricated insulated panels, which comprises two single skin panels (plain steel
sheets zincalume color coated) with polyurethane foam insulation in between.
 These panels are intended for use as thermally efficient roof and wall claddings for buildings e.g., in high altitude areas
and cold storages.
 In addition to the above sandwich panels also find extensive use in residential as well as non-residential buildings.
 The panels provide sufficient insulation and noise reduction properties.
 Now a days large cold storage units (Potato, Onion, vegetables, processed foods etc.) are also made with this Pre-
Engineered Building technique.

ROOF COMPONENTS
INSULATED ROOFS
COMPONENT PARTS
ACCESSORIES
 As per the functional and architectural requirements, accessories are supplied in ready to fit condition.
 Ventilation and lighting systems should be properly designed in consultation with an expert.
VENTILATION
LIGHTING SYSTEMS
TILE FLOOR IN PEB
CRANES IN PEB
ERECTION OF PEB
 Steel framing members are delivered at site in pre-cut sizes, which eliminates cutting and welding at site.
 Being lighter in weight, the small members can be very easily assembled, bolted and raised with the help of cranes.
 This system allows very fast construction and reduces wastage and labour requirement.
 These buildings can then be provided with roof decking and wall cladding with metal profile sheets and proper insulation.
 The framing are so designed that electrical and plumbing services are part of it and can be very easily concealed
 However, the erection process is highly technical and needs skilled and trained manpower to handle heavy construction
equipments.
 Proper training of erection engineers for understanding of drawings and execution of work is necessary.
 A qualified and experienced work agency should be employed for erection work.
STRUCTURE
ERECTION OF PRE-FABRICATED MEMBERS
FLOW CHART ON MANUFACTURING OF PEB
VERTICAL CONSTRUCTIONS
 Engineers are constantly developing the way we use materials in the construction of tall buildings.
 Whether they are traditional materials like steel and concrete or newer ones like carbon fiber, we try to incorporate them
in a way that makes the tall building both stronger and more efficient.
 Crucially lighter, stronger materials allow us to reduce the weight of the structure, minimize loads on foundations and
ultimately make the building more economically viable.

TECH MAHINDRA INFO CITY
FACTORS
VERTICAL TRANSPORT
 Lift technology can be a limiting factor when we try to build taller.
 It is a problem because the steel cables used to suspend lifts are subjected to huge strain, mostly due to their own weight.
 Lifts can even be put out of service on particularly windy days, as they are easily affected by buildings swaying.
CONCRETE PUMPING SYSTEM
 The majority of tall buildings under construction in Canada are concrete.
 The significant increase in the use of concrete in tall building construction is attributed to improvements in concrete
technology including strength, admixtures, pumping, construction techniques and structural systems (Rizk 2010).
 To accommodate tight construction schedules, hydraulic concrete pumping has developed as a fast and economical
method of transporting concrete due to its reduction in labour requirements and the ability to deliver continuous concrete
pours (Mechtcherine et al. 2014).
 The traditional crane and bucket method of delivering concrete is limited by the availability of cranes, the effects of heavy
winds, and its inability to deliver a continuous flow of concrete.

FACTORS AFFECTING DURING PUMPING
VISIBILITY PROBLEMS
 Increased height often comes with visibility problems due to congested construction sites, the location of the crane cab,
and intensified weather conditions.
 Limited visibility forces the operator to rely on radio communications when they are unable to see the load or the crew
providing hand signals.
 In these cases, communication, responses, and productivity become slower.
 Typical visibility problems include blind lifts, sight distance, and poor weather
PREPAREDNESS OF PEB IN INDIA
 Pre-engineered steel buildings" are those which are fully fabricated in the factory after designing, shipped to site in
CKD(completely knocked down) condition; and all components are assembled and erected at site with nut-bolts, thereby
reducing the time of completion.
 The designs were ready-made but the building components were either ready-made/manufactured against specific orders.
 These buildings were pre-designed or 'pre-engineered' into standard sizes, spans, bays and heights, and use standard
details for fixing cladding, roofing, gutters, flashing, windows, doors etc taking advantage of industrial practices of mass
production of components economically.
 Modern day requirement of structures is that these should be lighter yet not compromising on functionality.
 Civil engineering construction has seen a continual economic competition between steel, concrete and other construction
material
PROFILE DECK
 The composite slabs have now become a common form of construction of floor decks in major buildings.
 In composite slabs, the profile sheet is used as permanent formwork and as tensile reinforcement.
 In this composite slab, there is 30% saving in concrete material, resulting in reduced structural weight.
 It favours fast and easy construction and also it proves to be economical.

CONCRETE PROFILE DECK
REINFORCEMENT WITH CONCRETE
PROFILE DECK (STUD CONNECTORS)
PROFILE DECK
 Thin-walled cold-formed profiled steel decks
 Quality steel sheets conforming to ASTM A653 (2008) and IS 1079 (1994)
 A galvanized surface coating with an average thickness of 0.0254 mm is finished on each face of the steel deck
 Yield strength of sheet = 250 N/sq.mm
As per EN 1993-1-1, 3.2.6.
 Shape= Trapezoidal type sheeting
 Embossments= Oval and concave
 Size of sheeting = 1.8mx0.830m
 Thickness = 1.1mm
(a min. of 0.7 mm i.e. recommended)

DECK SLAB CONNECTIONS
MEASUREMENTS OF PROFILE DECK
PROFILE DECK
 Where the slab acts compositely with a beam, or is used as a diaphragm: The overall depth of the slab h ≥ 90 mm; and
the thickness of concrete above the top of the ribs of the sheeting hc ≥ 50 mm.
 Where the slab does not act compositely with a beam, or has no other stabilizing function: The overall depth of the slab
h ≥ 80 mm; and the thickness of concrete above the top of the ribs of the sheeting hc ≥ 40 mm.
 Here the depth of deck alone is 52mm and so 40mm to 50mm is the minimum thickness of concrete above deck sheet.
 Hence over all slab thickness will be 110mm.
 This is much less than conventional RCC Slab.

PLANNING OF PEB
HEAT
FLOOR HEIGHT DUCTS
RESISTANT
QUALITY &
PRODUCTION LOGISTIC
PAINT
PLANNING PLANNING
QUALITY
COST
PLANNING OF PEB
FLOOR HEIGHT
 These PEBs are generally low rise buildings however the maximum eave height can be limited from 25 to 30 meters.
PLANNING OF PEB
HEAT RESISTANT
Almost 100% of PEBs world-wide are insulated for the following reasons, which are addressed in further detail below:
 Minimize heat gain
 Maximize thermal comfort
 Minimize energy loss, cooling load and operating cost for air conditioned buildings
 Provide acoustic insulation
 Prevent unwanted moisture condensation

PLANNING OF PEB
Minimize heat gain and maximize thermal comfort

 By using fiberglass wool as under deck insulation, heat transmittance through the roof and walls is reduced substantially.
 Sufficient temperature drop occurs across the roof and wall system, resulting in lower temperature and a comfortable
workplace environment
PLANNING OF PEB
Minimize Energy Loss

 If the PEB is centrally air conditioned, a project owner can reduce the capital as well as operating cost of chiller, motor and
AHU by providing adequate thermal insulation.
 Thermal insulation having sufficiently high thermal resistance(R value) should be installed on roof and walls.
 Air conditioning load can be reduced substantially and hence one can save scarce fuel energy/electric energy.
PLANNING OF PEB
Acoustic Benefit
 A noisy workplace reduces working efficiency, concentration, and negatively impacts overall performance.
 Consider the noise inside a PEB shed without insulation which is bombarded with heavy drops of rain or hail which occurs
during monsoons every year.

PLANNING OF PEB
Control on Condensation
 Condensation should be strictly controlled in PEBs as structural metal in contact with condensed water droplets can
corrode.
 To prevent moisture, proper insulation thickness and thermal resistance of the insulation is of utmost importance so that
the surface temperature of the same does not go below the dew point temperature.
 Please note, using aluminum foil on its own as a vapor-retarder does NOT control condensation.
PROJECTS ON PEB BY SVPCPL
 A pre-Engineered building requires a proper detailed drawing for clear understanding and execution.
 Projects planned and designed for pre-engineered construction by SVPCPL were mentioned below:
o Schneider Electrical (July 2006 - December 2008)
o Kirby
o MUSCO (June 2013 - May 2015)
o Musaddilal Projects Limited (April 2014 - Till)

Client Name: Ameco Infrastructure Pvt. Ltd. (July 2006 - December 2008)
Project Name: Schneider Electricals
Our Contribution: Project Management Consultancy Services
Project Location: Gagillapur, Hyderabad
Project Configuration: 12000 SqM
Project value: 120 MINR
Project Status: Completed
Project Size: 10 acres
Highlight: International Quality Standard with Standing Seem 22m Long Profile
SCHNEIDER
SCHNEIDER
SCHNEIDER
SCHNEIDER
SCHNEIDER
Client Name: Kirby Buildings
Project Name: Kirby Building System
Our Contribution: Consultancy Services
Project Location: Hyderabad
Project Configuration: 36,000 SqM
Highlight: First PEB Structure in India with Large Spans 360m * 67m
KIRBY BUILDINGS SYSTEMS, HYDERABAD
KIRBY BUILDING SYSTEMS
(BUILDING UNIT – G.A.)
(PLANT ROOF TRUSS)
(LAYOUT)
Client Name: Mahindra Ugine Steel Co. Ltd. (June 2013 – May 2015)
Project Name: Mahindra Project
Our Contribution: Consultancy Services
Project Location: Zaheerabad, Telangana
Project Configuration: 8969 SqM
Highlight: International workshop with vibration analysis to resist resonance

MAHINDRA UGINE STEEL CO. LTD.
Cross Section Detail For Rigid Frame

Side Wall Framing Elevation

Side Wall Sheeting Layout

End Wall Framing Elevation

Client Name: Musaddilal Properties Pvt. Ltd. (April 2014 - Till)
Project Name: Modern Warehouse
Our Contribution: Project Management Consultancy Services
Project Location: Pune
Project Configuration: 19653.027 SqM
Project Status: On progress
Highlight: PEB structure with more clear height for stack loading
MUSADDILAL MODERN WAREHOUSE
Rigid Frame Elevation

Wall Panel Detail

Roof Framing Plan

Eave Purlin Connection

INDUSTRIAL WARE HOUSE – GATI
(Jan 2000 - May 2007)
INDUSTRIAL WARE HOUSE – GATI
ITC ILTD FACTORY BUILDING, CHIRALA
(Apr 2004)
ITC ILTD FACTORY BUILDING
HPCL, VIZAG
(Oct 2004)
106 FA CCPP PROJECT - DHUVARAN, GUJARAT
(Sep 2004)
106 FA CCPP PROJECT - DHUVARAN, GUJARAT
106 FA CCPP PROJECT
106 FA CCPP PROJECT
106 FA CCPP PROJECT
106 FA CCPP PROJECT
STERLITE (STEEL STRUCTURE FOR FFE MINERALS)
(Jan 2007)
STERLITE
STERLITE
STERLITE
STERLITE
IJM STEEL FACTORY BUILDING
(Oct 2007)
APEX ENCON INDUSTRIAL SHED
(Jun 2010)
DECATHLON, UPPAL
(Mar 2014)
DECATHLON, UPPAL
HYDERABAD INDUSTRIES LIMITED, KONDAPALLI
ITC - ILTD DIVISION, CHIRALA
ITC - ILTD DIVISION
ITC - ILTD DIVISION
ITC - ILTD DIVISION
ITC - ILTD DIVISION
ITC - ILTD DIVISION
ITC - ILTD DIVISION
ITC - ILTD DIVISION
ITC - ILTD DIVISION
(DETAILS)
ITC - ILTD DIVISION
(DETAILS)
ITC - ILTD DIVISION
(DETAILS)
Detail at Door Opening

NAGARJUNA AGRO TECH LIMITED (ARANI)
NAGARJUNA AGRO TECH LTD. (ARANI)
NAGARJUNA AGRO TECH LTD. (ARANI)
PALMTECH INDIA LIMITED
ROOF TRUSS
ROOF TRUSS TYPICAL DETAILS
PALMTECH INDIA LTD.
(LAYOUT)
PALMTECH INDIA LTD.
(LAYOUT)
PALMTECH INDIA LTD.
(G.A)
PALMTECH INDIA LTD.
(G.A)
PALMTECH INDIA LTD.
(STEEL)
PALMTECH INDIA LTD.
(STEEL)
PALMTECH INDIA LTD.
(STEEL)
PALMTECH INDIA LTD.
(STEEL)
PALMTECH INDIA LTD.
(STEEL)
GAMES VILLAGE, HYDERABAD
SNOW WORLD, HYDERABAD
SNOW WORLD
ROOF TRUSS
SNOW WORLD
ROOF TRUSS - GA
SARDAR SAROVAR NARMADA NIGAM LTD.
KADEVI ROLLING MILL
KADEVI ROLLING MILL
KADEVI ROLLING MILL
KADEVI ROLLING MILL
KADEVI ROLLING MILL
KADEVI ROLLING MILL
(COLUMN WITH GUTTER)
KADEVI ROLLING MILL
KADEVI ROLLING MILL
(COLUMN WITH PORTAL CONNECTION)
KADEVI ROLLING MILL
(PORTAL CONNECTION DETAILS)
NALSAR UNIVERSITY
(SPORTS PAVILION)
NALSAR UNIVERSITY
(SPORTS PAVILION)
PEB IMAGES OF CHINA & UK
PEB IN INDIA
 In India, PEB industry is still in the growth phase. It is a highly fragmented industry as many players are competing for the
same share of pie in different parts of the country.
 The barriers to entry for pre-fabrication which is major aspect of pre-engineered buildings are minimal.
 Profits margins have eroded as a result. However, companies can create switching costs and competitive advantages for
themselves by focusing on engineering and supply chain aspects

CONCLUSION
 Pre-engineered steel structures building offers low cost, strength, durability, design flexibility, adaptability and
recyclability.
 Steel is the basic material that is used in the materials that are used for Pre-engineered steel building.
 It negates from regional sources.
 Infinitely recyclable, steel is the material that reflects the imperatives of sustainable development.
 As it is seen in the present work, the weight of steel can be reduced to 27% for the hostel building, providing lesser dead
load which in turn offers higher resistance to seismic forces.
 With the advent of computerization, the design possibilities became almost limitless.
 Saving of material on low stress area of the primary framing members makes Pre-engineered.
CONCLUSION
 Buildings more economical than Conventional steel buildings especially for low rise buildings.
 To Conclude “Pre-Engineered Building Construction gives the end users a much more economical and better solution for
long span structures where large column free areas are needed”.
ANY QUESTIONS ?
Please Mail to suryapp@yahoo.com
(or)
Call me +91 93933 48484
Thank You

8-Pre-Engineered Steel Buildings

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Pre Engineered Steel Buildings

Presentation by : Er. P SURYA PRAKASH, Managing Director

 Introduction  Other Projects on PEB by SVPCPL

 Component Parts  PEB images of China & UK

 Erection of PEB  PEB in India

 Challenges of Vertical Construction  Conclusion

 Preparedness of PEB In India

 Projects on PEB by SVPCPL

 Pre Engineered Buildings are extremely quick and efficient.

Construction Time or faster installation

Large Clear Spans

Energy Efficient Roofing

Weight flexible frames offers higher

Overall price - More heavy.

Primary member is tapered section Primary member is hot rolled section.

Erection process is easy, fast step by Erection process is slow and

Delivery-average 6 to 8 weeks. Delivery-average 20 to 26 weeks.

sheets zincalume color coated) with polyurethane foam insulation in between.

and cold storages.

 The panels provide sufficient insulation and noise reduction properties.

Engineered Building technique.

ultimately make the building more economically viable.

 Lift technology can be a limiting factor when we try to build taller.

 The majority of tall buildings under construction in Canada are concrete.

pours (Mechtcherine et al. 2014).

winds, and its inability to deliver a continuous flow of concrete.

and intensified weather conditions.

providing hand signals.

 In these cases, communication, responses, and productivity become slower.

reducing the time of completion.

production of components economically.

 It favours fast and easy construction and also it proves to be economical.

 Yield strength of sheet = 250 N/sq.mm

As per EN 1993-1-1, 3.2.6.

 Shape= Trapezoidal type sheeting

 Embossments= Oval and concave

 Size of sheeting = 1.8mx0.830m

(a min. of 0.7 mm i.e. recommended)

 Hence over all slab thickness will be 110mm.

 This is much less than conventional RCC Slab.

 Minimize heat gain

 Maximize thermal comfort

 Provide acoustic insulation

 Prevent unwanted moisture condensation

Minimize heat gain and maximize thermal comfort

Minimize Energy Loss

AHU by providing adequate thermal insulation.

during monsoons every year.

o Schneider Electrical (July 2006 - December 2008)

o MUSCO (June 2013 - May 2015)

o Musaddilal Projects Limited (April 2014 - Till)

Project Name: Schneider Electricals

Our Contribution: Project Management Consultancy Services

Project Location: Gagillapur, Hyderabad

Project Configuration: 12000 SqM

Project value: 120 MINR

Project Status: Completed

Project Size: 10 acres

Client Name: Kirby Buildings

Project Name: Kirby Building System

Our Contribution: Consultancy Services

Project Location: Hyderabad

Project Configuration: 36,000 SqM