PreEngineeredBuildings

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IntroductiontoPreEngineeredBuildings
Technologicalimprovementovertheyearhascontributedimmenselytotheenhancementofqualityoflifethroughvariousnewproductsandservices.
Onesuchrevolutionwasthepreengineeredbuildings.Throughitsorigincanbetracedbackto1960sitspotentialhasbeenfeltonlyduringtherecent
years.Thiswasmainlyduetothedevelopmentintechnology,whichhelpedincomputerizingthedesignanddesign.
Thoughinitiallyonlyofftheshelfproductswereavailableintheseconfigurationsaidedbythetechnologicaldevelopmenttailormadesolutionsarealso
made using this technology in very short durations. A recent survey by the Metal Building Associations (MBMA) shows that about 60% of the non
residentiallowrisesbuildinginUSAarepreengineeredbuildings.
AlthoughPEBsystemsareextensivelyusedinindustrialandmanyothernonresidentialconstructionsworldwide,itisrelativelyanewconceptinIndia.
Theseconceptswere introduced to the Indian markets lately in the late 1990swiththeopeningupoftheeconomyandanumberofmultinationals
settinguptheirprojects.ThemarketpotentialofPEBsis1.2milliontonesperannum.Thecurrentpreengineeredsteelbuildingmanufacturingcapacity
is0.35milliontonesperannum.Theindustryisgrowingatthecompoundrateof25to30%.
WithrespecttodesignofthestructureandaestheticappearanceIndiaiswaybehind.IndianmanufacturersaretryingtocatchupcomparativelyPEBsis
anewconceptinIndia.Beside,infabricationandotherareasofPEBIndiaisverygood.AscomparedtoothercountriesIndiancodesforbuildingdesign
arestringentbutsafer.ISstandardsareupgradedcontinuously.InIndia,Americancodesarealsofollowed.
Preengineeredsteelbuildingscanbefittedwithdifferentstructuralaccessoriesincludingmezzanine
floors, canopies, fascias, interior partitions etc. and the building is made water proof by use of
special mastic beads, filler strips and trims. This is very versatile buildings systems and can be
finished internally to serve any functions and accessorized externally to achieve attractive and
uniquedesigningstyles.Itisveryadvantageousovertheconventionalbuildingsandisreallyhelpful
inthelowrisebuildingdesign.
Preengineeredbuildingsaregenerallylowrisebuildingshoweverthemaximumeaveheightcango
upto25to30metres.Lowrisebuildingsareidealforoffices,houses,showrooms,shopfrontsetc.
Theapplicationofpreengineeredbuildingsconcepttolowrisebuildingsisveryeconomicaland
speedy.Buildingscanbeconstructedinlessthanhalfthenormaltimeespeciallywhen
complementedwiththeotherengineeredsubsystems.
The most common and economical type of low rise buildings is a building with ground floor and
twointermediatefloorplusroof.Theroofoflowrisebuildingsmaybeflatorsloped.Intermediate
floors of low rise buildings are made of mezzanine systems. Single storied houses for living take
minimumtimeforconstructionandcanbebuiltinanytypeofgeographicallocationlikeextreme
coldhillyareas,highrainproneareas,plainlandobviouslyandextremehotclimaticzonesaswell.
ApplicationsofPreEngineeredBuildings(PEB)
1.WAREHOUSES
2.FACTORIES
3.WORKSHOPS
4.OFFICES
5.GASSTATIONS
6.VEHICLEPARKINGSHEDS
7.SHOWROOMS
8.AIRCRAFTHANGARS
9.METROSTATIONS

10.SCHOOLS
11.RECREATIONAL
12.INDOORSTADIUMROOFS
13.OUTDOORSTADIUMCANOPIES
14.BRIDGES
15.RAILWAYPLATFORMSHELTERS
AdvantagesofPreEngineeredBuildings
REDUCEDCONSTRUCTIONTIME:Buildingsaretypicallydeliveredinjustafewweeksafterapprovalofdrawings.Foundationandanchorbolts
arecastparallelwithfinished,readyforthesitebolting.OurstudyshowsthatinIndiatheuseofPEBwillreducetotalconstructiontimeoftheproject
byatleast50%.Thisalsoallowsfasteroccupancyandearlierrealizationofrevenue.
LOWERCOST:Duetothesystemsapproach,thereisasignificantsavingindesign,manufacturingandonsiteerectioncost.Thesecondarymembers
andcladdingnesttogetherreducingtransportationcost.
FLEXIBILTYOFEXPANSION:Buildingscanbeeasilyexpandedinlengthbyaddingadditionalbays.Alsoexpansioninwidthandheightispossible
bypredesigningforfutureexpansion.
LARGECLEARSPANS:Buildingscanbesuppliedtoaround80Mclearspans.
QUALITYCONTROL:Asbuildingsaremanufacturedcompletelyinthefactoryundercontrolledconditionsthequalityisassured.
LOWMAINTENANCE:Buildingsaresuppliedwithhighqualitypaintsystemsforcladdingandsteeltosuitambientconditionsatthesite,which
resultsinlongdurabilityandlowmaintenancecoats.
ENERGYEFFICIENTROOFINGANDWALLSYSTEMS:Buildingscanbesuppliedwithpolyurethaneinsulatedpanelsorfiberglassblankets
insulationtoachieverequiredUvalues.
ARCHITECTURALVERSTALITY:Buildingcanbesuppliedwithvarioustypesoffascias,canopies,andcurvedeavesandaredesignedtoreceivepre
castconcretewallpanels,curtainwalls,blockwallsandotherwallsystems.
SINGLESOURCERESPONSIBILTY:Asthecompletebuildingpackageissuppliedbyasinglevendor,compatibilityofallthebuildingcomponents
andaccessoriesisassured.Thisisoneofthemajorbenefitsofthepreengineeredbuildingsystems.
PreEngineeredBuildingsVsConventionalSteelBuildings
PROPERTY

PEBBUILDINGS

CONVENTIONALSTEEL
BUILDINGS

STRUCTUREWEIGHT

Preengineeredbuildingsareon
theaverage30%lighterbecause
oftheefficientuseofsteel.
Primaryframingmembersare
taperedbuiltupsection.Withthe
largedepthsinareasofhigher
stress.

Primarysteelmembersare
selectedhotrolledTsections.
Whichare,inmanysegmentsof
themembersheavierthanwhatis
actuallyrequiredbydesign?
Membershaveconstantcross
sectionregardlessofthevarying
magnitudeofthelocalstresses
alongthememberlength.

Secondarymembersarelight
weightrollformedZorC
shapedmembers.

DESIGN

Secondarymembersareselected
fromstandardhotrolledsections
whicharemuchheavier.

Quickandefficient:sincePEBs
aremainlyformedbystandard
sectionsandconnectionsdesign,
timeissignificantlyreduced.
Basicdesignbasedon
internationaldesigncodesare
usedoverandover.

Eachconventionalsteelstructure
isdesignedformscratchwith
fewerdesignaidsavailabletothe
engineer.

Specializedcomputeranalysis
designprogramsoptimize
materialrequired.Draftingis
alsocomputerizedusingstandard
detailthatminimizetheuseof
projectcustomdetails.

Substantialengineeringand
detailingworkisrequiredfrom
theverybasicisrequiredbythe
consultantwithfewerdesign
aids.

Designshopdetailsketchesand
erectiondrawingsaresupplied
freeofcostbythemanufacturer.
Approvaldrawingisusually
preparedwithinin2weeks.

Extensiveamountofconsultant
timeisdevotedtothealterations
thathavetobedone.

PEBdesignersdesignanddetail
PEBbuildingsalmosteveryday
oftheyearresultinginimproving
thequalityofdesignseverytime
theywork

Aseachprojectisanewproject
engineersneedmoretimeto
developthedesignsanddetailsof
theuniquestructure.

DELIEVERY

Average6to8weeks

Average20to26weeks

FOUNDATIONS

Simpledesign,easytoconstruct
andlightweight.

Extensive,heavyfoundation
required.

ERECTIONSIMPLICITY

Sincetheconnectionof
compoundsisstandardthe
learningcurveoferectionfor
eachsubsequentprojectisfaster.

Theconnectionsarenormally
complicatedanddifferfrom
projecttoprojectresultingtin
increasingthetimeforerection
ofthebuildings.

Periodicfreeofchargeerection
isprovidedatthesitebythe
manufacturer.

Therehastobeseparate
allocationoflabourforthe
purposeoferection.

Bothcostsandtimeoferection
areaccuratelyknownbasedupon
extensiveexperiencewithsimilar
buildings.

Typically,conventionalsteel
buildingsare20%more
expensivethanPEBinmostof
thecases,theerectioncostsand
timearenotestimatedaccurately.

Theerectionprocessisfasterand
mucheasierwithveryless
requirementforequipment.

Erectionprocessisslowand
extensivefieldlabourisrequired.
Heavyequipmentisalsoneeded.

Thelowweightflexibleframes
offerhigherresistancetoseismic

Rigidheavyframesdonot
performwellinseismiczones.

ERECTIONCOSTANDTIME

SEISMICRESISTANCE

forces.
OVERALLPRICE

Pricepersquaremetermaybeas
lowasby30%thanthe
conventionalbuilding.

Higherpricepersquaremeter.

ARCHITECTURE

Outstandingarchitecturaldesign
canbeachievedatlowcostusing
standardarchitecturaldetailsand
interfaces.

Specialarchitecturaldesignand
featuresmustbedevelopedfor
eachprojectwhichoftenrequire
researchandthusresultingin
highercost.

SOURCINGAND
COORDINATION

Buildingissuppliedcomplete
withallaccessoriesincluding
erectionforasingleONESTOP
SOURCE.

Manysourcesofsupplyarethere
soitbecomesdifficulttoco
ordinateandhandlethethings.

COSTOFCHARGEORDER

PEBmanufacturesusuallystock
alargeamountofthatcanbe
flexiblyusedinmanytypesof
PEBprojects.

Substitutionofhotrolledsections
infrequentlyrolledbymillsis
expensiveandtimeconsuming.

Changeordersareeasily
accommodatedatallstagesof
theorderfulfillmentprocess.
Littleornomaterialiswasted
evenifachangeorderismade
afterfabricationstarts.

Changeordersthataremadeafter
thedispatchofhotrolledsections
resultinincreasingthetimeand
costinvolvedintheproject.

BUILDINGACCESSORIES

Designedtofitthesystemwith
standardizedandinter
changeableparts.Includingpre
designedflashingandtrims.
Buildingaccessoriesaremass
producedforeconomyandare
availablewiththebuilding.

Everyprojectrequiresdifferent
andspecialdesignfroaccessories
andspecialsourcingforeach
item.Flashingandtrimsmustbe
uniquelydesignedandfabricated.

FUTUREEXPANSIONS

Allprojectrecordsaresafelyand
orderlykeptinelectronicformat
whichmakesiteasyforthe
ownertoobtainacopyofhis
buildingrecordatanytime.

Itwouldbedifficulttoobtain
projectrecordsafteralong
periodoftime.Itisrequiredto
contactmorethanonenumberof
parties.

Futureexpansionisveryeasy
andsimple.

Futureexpansionismosttedious
andmorecostly.

SAFETYANDRESPONSIBILTY

Singlesourceofresponsibilityis
therebecauseallthejobisbeing
donebyonesupplier.

Multipleresponsibilitiescan
resultinquestionofwhois
responsiblewhenthecomponents
donotfitinproperly,insufficient
materialissuppliedorpartsfail
toperformparticularlyatthe
supplier/contractorinterface.

PERFORMANCE

Allcomponentshavebeen
specifiedanddesignedspecially
toacttogetherasasystemfor
maximumefficiency,precisefir
andpeakperformanceinthe
field.

Componentsarecustomdesigned
foraspecificapplicationona
specificjob.Designanddetailing
errorsarepossiblewhen
assemblingthediverse
componentsintounique
buildings.

Experiencewithsimilar
buildings,inactualfield

Eachbuildingdesignisunique,
sopredication,ofhow

conditionsworldwide,has
resultedindesignimprovements
overtime,whichallow
dependablepredictionof
performance.

componentswillperform
togetherisuncertain.Materials
whichhaveperformedwellin
someclimatesmaynotdowellin
otherconditions.

DesignofPreEngineeredBuildings(PEB)
ThemainframingofPEBsystemsisanalyzedbythestiffnessmatrixmethod.Thedesignisbasedonallowablestressdesign(ASD)aspertheAmerican
instituteofSteelConstructionspecificationortheIS800.thedesignprogramprovidesaneconomicandefficientdesignofthemainframesandallows
theusertoutilizetheprogramindifferentmodestoproducetheframedesigngeometryandloadingandthedesiredloadcombinationsasspecifiedby
the building code opted by the user. The program operates through the maximum number of cycles specified to arrive at an acceptable design. The
programusesthestiffnessmatrixmethodtoarriveatanacceptabledesign.Theprogramusesthestiffnessmatrixmethodtoarriveatthesolutionof
displacements and forces. The strain energy method is adopted to calculate the fixed end moments, stiffness and carry over factors. Numerical
integrationisused.
DesignCycle
Thedesigncycleconsistsofthefollowingsteps:
1.Setupsectionsizesandbracelocationsbasedonthegeometryandloadingspecifiedfortheframedesign.
2.Calculatemoment,shear,andaxialforceateachanalysispointforeachloadcombination.
3.Computeallowableshear,allowableaxialandallowablebendingstressincompressionandtensionateachanalysispoint.
4.Computethecorrespondingstressratiosforshear,axialandbendingbasedontheactualandallowablestressesandcalculatethecombinedstress
ratios.

5.Designtheoptimumsplicelocationandchecktoseewhetherthepredictedsizesconfirmtomanufacturingconstraints.
6.Usingtheweboptimizationmode,arriveattheoptimumwebdepthsforthenextcycleandupdatethememberdatafile.
7.Attheendofalldesigncycles,ananalysisisruntoachieveflangebraceoptimization.
FrameGeometry
Theprogramhasthecapabilitytohandledifferenttypesofframegeometryasfollows
Framesofdifferenttypesviz.rigidframes,frameswithmultipleinternalcolumns,singleslopeframes,leantoframesetc.
Frameswithvaryingspans,varyingheightsandvaryingslopesetc.
Frameswithdifferenttypesofsupportsviz.pinnedsupports,fixedsupports,sinkingsupports,supportswithsomedegreesoffreedomreleased.
Unsymmetricalframeswithoffcentric,unequalmodules,varyingslopesetc.
Userspecifiedpurlinandgirtspacingandflangebracelocation.
FrameLoading
Framedesigncanhandledifferenttypesofloadingsasdescribedbelow:
Allthebuildingdeadloadsduetosheeting,purlins,etc.andtheselfweightoftheframe.
Imposedliveloadontheframewithtributaryreductionsaswell.
Collateralloadsuchasfalseceiling,lightfixtures,ACductingloads,sprinklersystemsandmanyothersuspendedloadsofsimilarnature.

Windloadsinputsuchasbasicwindspeedorbasicwindpressurethatwillbeconvertedtodeignwindpressureasperthebuildingcodespecifiedbythe
user and shall be applied to the different members of the building according to the coefficients mentioned in the codes prescribed by the user. The
standardbuildingcodeslikeMBMA,UBC,ANSI,IS:875part3etcareusedfrothispurpose.
Craneandnoncraneloadingcanbespecifiedbytheuserandtheprogramhasthecapabilitytohandlethesespecialloadsandcombinethemwiththe
otherloadsasrequired.
Seismicloadscorrespondingtothedifferentzonecategoriesofvariousinternationalcodescanalsobedefinedandcombinedwithotherloadcasesas
required.Temperature loads can also be specified in the form of different differential temperature value on centigrade and specifying the appropriate
coefficientforthethermalexpansion.Loadcombinationswithappropriateloadfactorscanbespecifiedbytheuserasdesired.
DesignCodes
Followingarethemaindesigncodesgenerallyused:
AISC:Americaninstituteofsteelconstructionmanual
AISI:Americanironandsteelinstitutespecifications
MBMA:Metalbuildingmanufacturerscode
ANSI:Americannationalstandardsinstitutespecifications
ASCE:Americansocietyofcivilengineers
UBC:Uniformbuildingcode
IS:Indianstandards
DesignCriteria
DESIGNMETHOD:AllowablestressdesignmethodisusedaspertheAISCspecifications.
DEFLECTIONS:Unlessotherwisespecified,thedeflectionswillgotoMBMA,AISCcriteriaandstandardindustrypractices.
PRIMARYFRAMING:Momentresistingframeswithpinnedorfixedbases.
SECONDARYFRAMING:ColdformedZsectionsorCsectionsforpurlinsorgirtsdesignedascontinuousbeamsspanningoverraftersandcolumns
withlaps.
LONGITUDANALSTABILITY:Windloadonbuildingendwallsistransferredthroughroofpurlinstobracedbaysandcarriedtothefoundations
throughdiagonalbracing.
DESIGNSOFTWARE
ThelatestsoftwarethatisusedfordesignisSTAAD2007.
DESIGNPROCESS
Theframedataisassembledbasedonnumberofframemembers,numberofjoints,numberofdegreesoffreedom,theconditionsofrestraintandthe
elasticpropertiesofthemembers.Basedonthis,thedataisstoredandmembersectionpropertiesarecomputed.Theoveralljointstiffnessmatrixis
obtainedbasedontheaboveframedatabysummationofindividualstiffnessmatricesconsideringallpossibledisplacements.Theloadvectoristhen
generatedbasedontheloadingdataandtheunknowndisplacementsareobtainedbyinvertingtheoveralljointstiffnessmatrixandmultiplyingwiththe
loadvector.
Knowingthefreejointdisplacements

REPORTONPLANTVISIT
DEPARTMENTSINTHEPLANT
PRODUCTION,PLANNING&CONTROL(PPC)
SHEARING
BUILTUP
FINISHING
COLDFORM
SHIPPING
QUALITYCONTROL
MAINTENANCE(ELECTRICAL)
MAINTENANCE(MECHANICAL)
PRODUCTION,PLANNING&CONTROL
ThePPCdepartmentinourplantisheadedoverbyMr.C.M.PANDE.ThePPCdepartmentcanbecalledtobethecontrollerofalltheotherdepartments
ofourplantbecauseitkeepsacheckonatwhatpointoftimewhatkindofworkandhowmuchworkaccordingtothemanpoweravailableistobegiven
toaparticulardepartment.Theyalsoplanthereleasesastohowmuchtonnageistobereleasedonanygivendata.Theyalsokeepaproperrecordon
daily,weekly,monthlybasisthathowmuchworkisbeingdonebywhichdepartmentandisitfulfillingthecriteriaornotsoastoensurepropermeeting
upofthetargetsassigned.Wealsogottoknowaboutthemanufacturingprocessesthathowtheytakeplaceinasequentmannerinourplant.Theyalso
madeusawareofthesystemthathowaBOQanddrawingstravelsfromtheheadofficetotheplantandthentheworkisactuallydistributedamongthe
departmentsintheplant.ThePPCdepartmentisusingnestingsoftwaretoprepareproperpartmarksforeg.WegetHRplatesinastandardwidthof
1500mmsonestingsoftwaretellsusthatwhatsizedplatesshouldbecutfromthatsoastominimizethescrap,thisjobisalsodonebythePPCandis
knownaspartmarking.Theentirejobintheplantisdoneaccordingtothesepartmarksonly.Alsothejobofmaintainingtheinventoryofrawmaterials
isdonebythePPCdepartmenti.e.ithastokeepacheckonthequantityofrawmaterialsavailableandhastoensurethatsufficientquantityofmaterial
isalwaysavailable.Alsoithastotakecareofthetransportavailabilityfordispatchingthematerials.PPCdepartmentworksincoordinationwiththe
everydepartmentlikewithaccountsdepartment.
ThisinformationalposthasbeensubmittedtousbyErGursharanSinghandthenmodifiedbyErKanwarjotSingh.Toseethepresentationofthesame
clickhere.
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Comments
HiteshDecember5,2014at12:07am
Kavita
Veryinformativedataonpeb
canutellme,howtocalculatecostforthepebbuilding&mezzanine????/
ReplyLinkQuote
maheshwaldeOctober25,2015at4:22pm
whywenotcomparingingradeofsteel(i.eweusedgenerallyfy250incsbandfy345inpeb)thenwhywecomparedthisthing.thisismypoint
ofview
ReplyLinkQuote
P.NithinReddyOctober29,2015at1:20am
CanCivilengineerspreferPEBSerection?
ReplyLinkQuote
RaphaelIlorahMarch25,2016at5:20pm