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TYPES OF INDUSTRIAL SHEDS

The different types of shed are as follows:

Cold Roll Formed Portal Frame Shed

The cold rollformed portal frame shed is the most common type of pre-engineered shed.
It usually arrives as a kit, and the builder assembles it on your property. The main
structure of this kind of shed is called the portal frame. It contains rolled purlins, batton,
girts, brackets, and top hat. All types of cold rollformed portal frame sheds have
common cladding and flashings.

In a cold rollformed portal frame shed, the rafters and columns contain purlins which
consist of cold rolled C section. The purlins are connected by fabricated brackets which
bolt the assemblies together. Once the portal frames are stood, the wall and roof
members are added.

The main advantages to this type of shed,

• Is that it is extremely efficient,


• can be easily transported, and
• can be put together onsite without a lot of specialized equipment.
Structural Fabricated Steel Shed

• A structural fabricated steel shed is similar to the cold roll formed portal frame
shed.
• The rafters and columns are welded sections such as I beam, H Section, or C
channels, and the ends all have welded cleats and joiners.
• This design is for larger sheds and industrial applications. It is extremely popular
for warehouses over 18 metres in width.
• Structural steel is very heavy, and requires heavy equipment to assemble. The
assembly is fast as the steel is predrilled and bolts together easily, and the sheds
are extremely strong.

Prefabricated Factory Shed


Prefabricated Factory Shed is widely used as a temporary structure for catering various
on-site requirements. Constructed in accordance with industry standards using light
weighted well insulated panels, this factory shed is completely protected from
earthquake, adverse weather conditions and any kind of leakage. With highest
structural ability, these are properly insulated with polyurethane/EPS to restore heat
during winter and resist heat during summer time.

Features of Prefabricated Factory Sheds:

• Highly appreciated for their excellent aesthetics


• Completely protected from natural disasters
• Easy to transport due to their light weight
• Constructed using well insulated panels

Used for:

• Warehouse
• Fully equipped kitchen
• Manufacturing unit

Warehouse Shed

Warehouse Shed is the ultimate solution for urgent needs of stacking and storage. Best
suited for onsite locations in both cold and hot regions, it is designed and developed in
compliance with predefined industry standards. Moreover, it is manufactured with
insulated panels for comfortable temperature inside. Easy to transport and lift, this,
Warehouse Shed does not require any civil foundation and can be placed directly on
targeted site.

Features of Warehouse Sheds:


• Leak- proof and can be easily lifted and shifted
• Excellent structural stability
• Can sustain adverse weather conditions
• Best suited for hot and cold regions
• Ready to move in structures
• No foundation required for construction
• Easy to install safety products like smoke detectors and firefighting equipment
• Quick to assemble and dismantle

Used for:
• Warehouses
• Industrial manufacturing unit
• Temporary accommodation
• Application areas:
• Rural development projects
• Large scale construction projects
• Manufacturing industries
Box Type Sheds

These industrial sheds are constructed using PUF(Polyurethane Foam) /


EPS(Expanded Polystyrene Foam) insulated sandwich panels with PPGI (Pre-Painted
Galvanized Iron )sheet.

Features:

• These are ready to move in structures.


• Constructed using excellent thermal insulation for effective thermal efficiency.
• Completely protected against weather conditions, corrosion and other
environment conditions.
• These structures are light in weight and thus, easy to relocate and lift to any
location.
• Designed with insulated doors and all other requisite facilities.
• Provided with complete electrical and sanitary fittings.
Metal sheds

A corrugated iron shed. Metal sheds are made from thin sheet metal sheathing
(galvanized steel, aluminium , or corrugated iron) attached to a metal frame. Metal
sheds are a good choice when long-term strength and resistance to fire, rot, or termites
is desired. However, metal sheds may rust over time, particularly if they are constructed
from steel that is not galvanized. Since concrete is highly corrosive so care needs to be
taken when assembling your shed to avoid contact with the outside panels.

As well, some types of metal sheds that have thin walls are easily dented, which may
makes some types of thin metal sheds a poor choice for vandal-prone areas or for high-
traffic activities such as small businesses.

In cold climates, metal sheds with thin walls need to have snow and ice cleared from the
roof, because the thin metal may be damaged by a heavy accumulation. Since thin
metal sheds weigh much less than wood or PVC plastic sheds, thin metal sheds are
more at risk of being damaged by heavy winds. To prevent wind damage, thin metal
sheds should be attached to a concrete foundation with screws.

In countries where the climate is generally mild, such as Australia, very large metal
sheds are used for many types of industry.
Plastic sheds

• Lifetime blow-molded plastic sheds. Plastic shed kits utilizing heavy molded
plastics such as PVC and polyethylene are less expensive than sheet-metal
sheds.
• PVC resins and high-impact, UV light-resistant polyethylene make plastic outdoor
sheds stronger, lighter, more durable, and more resistant to denting and chipping
than wood, and tend to be more stable.
• Plastic shed kits sided with vinyl are typically among the least-expensive types of
shed construction.
• Higher-quality sheds use UV-resistant plastic and powder-coated metal frames.
Many plastic sheds are modular to allow for easy extensions, peg-boards,
shelving, attic-storage, windows, skylights, and other accessories to be added
later.
• Plastic sheds are not susceptible to termite or wood-boring insect damage, and
they require little maintenance. Being rot-proof they do not need to have
preservative applied.
Vinyl-sided sheds

An Amish-style vinyl-sided shed. Vinyl-sided sheds are typically built with standard
wood framing construction and oriented strand board (OSB) on the walls covered with
standard vinyl siding. Vinyl-sided sheds never need to be painted, and are
maintenance-free. They are stronger than plastic or metal sheds, and are usually built to
conform with the local building codes. They offer good value for money because they
hold up in all weather, including winters with heavy snowfall. Metal, plastic and resin
sheds are cheaper, but they cannot handle the weight of snow in winter (roof caves in).
Vinyl sheds also offer the most colour options.
Industrial buildings are generally designed as enclosures that provide functional space
for internal activities, which may involve use of overhead cranes or suspended
equipment as well as provision of office space or mezzanine floors. Various structural
forms have been developed over the last 30 years that optimize the cost of the steel
structure in relation to the space provided. However, in recent years, forms of
expressive structure have been used in architectural applications of industrial buildings,
notably suspended and tubular structures.

A single large hall is the main feature of most industrial buildings. The construction and
appearance of an industrial building provides the design engineer with a wide range of
possible configurations in order to realize the architectural ideas and the functional
requirements. Generally, an industrial building has a rectangular floor space, which is
extendable in its long direction. The design of the building has to be coordinated with
functional requirements and the energy-saving concept, including lighting.

The following forms of industrial buildings represent an overview of the possible


architectural and constructional solutions. Exhibition halls, railway stations, airports and
sports arenas tend to be special structures. However, the following general issues are
restricted to ‘standard’ floor plans.

DIFFERENT COMPONENTS OF AN INDUSTRIAL BUILDING

The structural engineer has to consider the following points during the planning and
design of industrial buildings:

 Selection of Roofing and wall material


 Selection of bay width
 Selection of structural framing system
 Roof trusses
 Purlins, girts and sag rods
 Bracing systems to resist lateral loads
 Gantry girders, columns, base plates, and foundations

Roofing and wall material


In India, corrugated galvanized iron (GI) sheets are usually adopted as coverings for
roofs and sides of industrial buildings. Light gauge cold-formed ribbed steel or aluminum
decking can also be used. Sometimes asbestos cement (AC) sheets are also provided
as roof coverings owing top their superior insulating properties.

Bay width

In most cases, the bay width may be indicated by owner requirements. Gravity loads
generally control the bay size. Based on both strength and stiffness (L/180)
requirements, the maximum economical span is 9m.

Structural Framing

For the purpose of structural analysis and design, industrial buildings are classified as:

• Braced frames
• Unbraced frames

In braced buildings, the trusses rest on columns with hinge type of connections and the
stability is provided by bracings in the three mutually perpendicular planes. These
bracings are identified as follows:

• Bracings in the vertical plane in the end bays in the longitudinal direction
• Bracings in the horizontal plane at bottom chord level of the roof truss
• Bracings in the plane of upper chords of the roof truss
• Bracings in the vertical plane in the end cross sections usually at the gable ends

Purlins, Girts and Eave strut

Secondary structural members such as purlins and girts span the distance between the
primary building structures portal frames or truss-column system). They support the roof
and wall covering and distribute the external load to the main frames or trusses. Purlins
form a part of the roof bracing system and girts are a part of the wall bracing system of
the building. The third type of secondary structural member is the Eave strut. This
member is located at the intersection of the roof and the exterior wall and hence acts as
both the first purlin and the last (highest) girt. The building’s eave height is measured to
the top of this member.

Spacing of Purlin

The spacing of the purlins largely depends on the maximum safe span of the roof
covering and glazing sheets. Hence they should be less than or equal to their safe
spans when they are directly placed on purlins.

Plane Trusses

A structure that is composed of a number of line members pin-connected at the ends to


form a triangulated framework is called a truss. In a truss, the members are so arranged
that all the loads and reactions occur only at the joints (intersection point of the
members). For common trusses with vertically acting loads, compressive forces are
usually developed in the top chord members and tensile forces in the bottom chord
members. However, it is often necessary to design the various members of a truss both
for tension and compression and select the member size based on the critical force.
Spacing of trusses

The spacing of trusses is mostly determined by the spacing of supporting columns


which in turn is determined by the functional requirements. When there are no functional
requirements, the spacing should be such that the cost of the roof is minimized. It can
be shown that an economic system is obtained when the cost of trusses is equal to the
cost of roof covering plus twice the cost of purlins. i.e.

Ct = Cr + 2Cp

Where,

Ct = Cost of the trusses/unit area

Cr = Cost of the roof coverings/unit area

Cp = Cost of the purlins/unit area

Load Combinations for Design

For shed type buildings, the following combinations of loads are considered when there
is no crane load:

• Dead loads + imposed loads (live loads)


• Dead loads + snow loads
• Dead loads + wind loads (wind direction being normal to ridge or parallel to ridge
whichever is severe)
• Dead loads + imposed loads + wind loads (which may not be critical in most of
the cases)

The 3rd combination is considered with internal positive air pressure and internal
suction air pressure separately to determine the worst combination of wind load.

FORMS OF INDUSTRIAL BUILDINGS

The most elementary system used for an industrial building consists of two columns and
a beam. This configuration can be modified in numerous ways using various types of
connections between the beams and columns and for the column base. The types of
structures most commonly used in industrial buildings are portal frames with hinged
column bases.

Portal frames provide sufficient in-plane stability, and thus only require bracings for out-
of-plane stability.

The figure shows a variety of rigid frames with fixed (a) or hinged (b) column bases.

Fixed column bases may be considered when heavy cranes are used, as they deflect
less under horizontal forces. Hinged column bases have smaller foundations and simple
base connections. In examples (c) and (d), the structure is located partly outside the
building, and so details concerning the piercing of the building envelope have to be
designed carefully. The complex details in these types of structure also serve
architectural purposes.

In the second figure, different structures consisting of beam and columns are presented.
The figure (a) shows an example of a structure without purlins that is stiffened by
diaphragm action in the roof and bracings in the walls. In Figure (b), purlins are used,
leading to a simple design of the roof cladding, which has reduced spans and only
serves to support vertical loads. The roof is stiffened by plan bracing. The structure
without purlins may offer a more pleasant appearance when viewed from the inside.
Figures (c) and (d) show lattice trusses and cable suspended beams, which may be
beneficial to achieve larger spans, as well as desirable for visual reasons. Arch
structures offer advantageous load carrying behavior as well as having a pleasant visual
appearance.

In next figure (a), a building with a three-hinged arch is shown.


Alternatively, the structure can be elevated on columns or integrated in a truss structure,
as in Figure (d). The forms of buildings with primary and secondary structural elements
described above are all directional structures, for which the loads are carried primarily
on individual directional load paths. Spatial structures and space trusses are non-
directional structures; they can be expanded, but would become heavy for long spans.
The next figure shows some examples of spatial structures.

PORTAL FRAMES

Steel portal frames are widely used in most of the European countries because they
combine structural efficiency with functional application. Various configurations of portal
frames can be designed using the same structural concept as shown in figure.
Multi-bay frames can also be designed, as in Figure (e) and (f), either using single or
pairs of internal columns. In addition to the primary steel structure, a wide range of
secondary components has also been developed, such as cold formed steel purlins,
which also provide for the stability of the framework. These simple types of structural
systems can also be designed to be architecturally more appealing by using curved
members, cellular or perforated beams etc. Innovative structural systems have also
been developed in which portal frames are created by moment resisting connections
using articulations and ties.

LATTICE TRUSSES

Long span industrial buildings can be designed with lattice trusses, using C, H or O
sections. Lattice trusses tend to be beam and column structures and are rarely used in
portal frames. Various configurations of lattice trusses are illustrated in Figure.
The two generic forms are W or N bracing arrangements. In this case, stability is
generally provided by bracing rather than rigid frame action. However, columns can also
be constructed in a similar way, in order to provide in-plane stability. Using lattice
structures, a comparatively high stiffness and load bearing resistance can be achieved
while minimising material use. Besides the ability to create long spans, lattice structures
are attractive and enable simple service integration. A pinned structure is an idealisation
used in design. Moment-resisting connections can be designed using bolted or welded
connections. The resulting additional internal forces are accounted for in the design of
the lattice members, when the lattice truss acts to stabilise the building against lateral
loads.

SUSPENDED STRUCTURES

By using suspended structures, longspan buildings with high visual and architectural
quality can be realised. The division into members that are predominantly subject to
either tension or compression permits the design of lightweight structures. However,
structures that save on materials use do not necessarily lead to economic solutions.
Particularly in space structures, the joints may be very complex and more time
consuming to construct and install. Therefore, possible applications of this type of
structure are industrial buildings that also serve architectural purposes rather than
merely functional buildings. Suspended structures can be designed by extending
columns outside the building envelope. Suspended structures accomplish longer spans,
although the suspension cables or rods also penetrate the building envelope, and can
be obstructive to the use of the external space.

Lattice and suspended structures is complex and are not covered in detail in this Best
Practice Guide.

FIRE SAFETY

Even though the general context of fire safety regulations is the same throughout
Europe, national differences do exist. For example a single-storey industrial building in
the Netherlands with a compartment size of 50 x 100 m has no requirements
concerning fire resistance, whereas in France, a fire resistance of 30 minutes is
required in many cases, and in Italy the requirement is possibly as high as 90 minutes.
At the design stage, the following fire safety issues should be addressed:

 Means of escape (number of emergency exits, characteristics of exit signs,


number of staircases, width of doors).
 Fire spread (including fire resistance and reaction to fire).
 Smoke and heat exhaust ventilation system.
 Active fire fighting measures (hand extinguishers, smoke detectors, sprinklers,
plant fire brigade).
 Access for the fire brigade.

Fire resistance requirements should be based on the parameters influencing fire growth
and development, which include:

 Risk of fire (probability of fire occurrence, fire spread, fire duration, fire load,
severity of fire, etc.).
 Ventilation conditions (air input, smoke exhaust).
 Fire compartment (type, size, geometry).
 Type of structural system.
 Evacuation conditions.
 Safety of rescue team.
 Risk for neighboring buildings.
 Active fire fighting measures.

BUILDING PHYSICS

Thermal insulation

The main purpose of thermal insulation in industrial buildings is to ensure an adequate


indoor climate depending on the use of the building. During the heating season, one of
the main functions of the building envelope is to reduce the heat loss by means of
effective insulation. This is particularly true for buildings with normal indoor
temperatures, such as retail stores, exhibition halls and leisure centers; it is true to a
lesser extent for buildings with low indoor temperatures, such as workshops and
warehouses.

For large panels, thermal bridges and air tightness of joints have a major influence on
the energy-balance of the building. The thermal insulation has to be placed without gaps
and the building envelope must be sealed and made airtight at longitudinal and
transverse joints.

In the summer, the role of the building envelope is to reduce the effects of solar gain on
the interior space. The summer heat reduction depends on the total area and orientation
of openings, as well as the effectiveness of solar protection measures.

Condensation risk

Thermal and moisture protection are linked closely, because damage arising from high
local humidity is often the result of missing or improperly installed thermal insulation. On
the other hand, lack of moisture protection can lead to condensation in the construction,
which in turn affects the effectiveness of the thermal insulation.
In multi-skin roof or wall constructions, condensation risk has to be controlled by
installing a vapour barrier on the inner skin of the structure. Wall constructions that are
vapour proof on both sides, like sandwich panels, prevent diffusion. However, the
humidity in the internal space also has to be regulated by air conditioning.

Acoustic insulation

The minimum requirements exist on the sound insulation of buildings. In addition, for
industrial buildings, it may be necessary to limit values of acoustic emissions from
particular machinery. In steel framed buildings, acoustic insulation is mainly achieved by
the construction of the building envelope. All measures of acoustic insulation are based
on the following physical principles:

 Interruption of transmission, e.g. by using multi-skin constructions.


 Sound absorption, e.g. by using perforated sheeting or cassettes.
 Reducing response by increasing the mass of a component.

For single sound sources, a local enclosure or isolation is recommended. In order to


reach a high level of acoustic insulation, special sound-absorbing roof and wall cladding
are effective. For multiskin panels the level of sound insulation can be controlled by
varying the acoustic operating mass. Due to the complexity of this issue, it is
recommended to consult the specialist manufacturers.

FLOORS

In most cases, the floors for industrial buildings are used for vehicles or heavy
machinery. They are designed to support heavy loads and have to be ’flat’.
Concentrated loads due to vehicles, machines, racking and containers have to be
considered, depending on the application. Most industrial buildings have a concrete
floor with a minimum thickness of 150 mm on top of a layer of sand or gravel, which is
also at least 150 mm thick. For large floor areas, a sliding layer between the base layer
and the concrete is required, typically using two layers of synthetic material.
LIGHTING

Requirements for the lighting of industrial buildings depend on the type of use. The
concept and arrangement of openings to provide natural lighting permit diversity in
architectural design. Rooflights and gable glazed roofs are common, along with
lightbands in the façade (Figure). Openings for natural lighting can serve as smoke and
heat outlets in case of fire.

Well-designed natural day lighting can have a significant impact on a building’s carbon
emissions. However, too much natural day lighting can result in excessive solar gain in
the summer, leading to overheating, and increased heat loss through the envelope in
the winter. The decision to utilize natural daylight within a building and the type of day
lighting selected has important implications for the overall building design.

VENTILATION

Natural ventilation reduces the reliance on air conditioning systems, which in turn
means a reduction in the building’s CO2 emissions. The effectiveness of natural
ventilation depends on the size and orientation of the building. Roof vents are a
common option for natural ventilation in buildings without suitably large openings,
however these need to be carefully positioned so as to maximize their performance.
Hybrid ventilation systems are now popular in industrial buildings. They use
predominantly natural ventilation, but with mechanically driven fans to improve
predictability of performance over a wider range of weather conditions.

Mechanical Heat and Ventilation Recovery (MHVR) systems use the heat from the
exiting warm stale air to heat up the fresh cool air as it enters the building. The warm air
is vented out of the building alongside the incoming fresh air, allowing heat transfer from
the exiting to the incoming air. Although this heat transfer will never be 100% efficient,
the use of MHVR systems can significantly reduce the amount of energy required to
warm the fresh air to a comfortable level.
SHAHI EXPORTS PVT LTD
Total area of the industry - 105507.2 sq. mt.

Total workforce - 1200

Total number of floors – 5

 Basement
o Boiler Room – 935 sq. mt
o LT room – 672 sq. mt.
o Security – 935 sq. mt.
o Reception - 935 sq. mt.
o Dispensary – 672 sq. mt.
o Laboratory - 984 sq. mt.
o Fabric Storage – 5671 sq. mt.
o Fabric Audit – 4687 sq. mt.
o Bitting – 1537 sq. mt
o Embroidery – 7102 sq. mt.
 Ground floor
o Washing Department – 1224 sq. mt.
o Cutting and Spreading Department – 7382.9 sq. mt
o CTPAT – 3691.5 sq. mt.
o Super-Market – 1246 sq. mt.
 First floor
o Maintenance
o Accessory Store – 969 sq. mt.
o Sewing Lines - 7382.9 sq. mt
 Needle Counter
 Sub-Store
o Finishing Lines – 6678 sq. mt
o IED – 935 sq. mt.
 Second floor
o Sewing Lines - 7382.9 sq. mt
 Needle Counter
 Sub-Store
o Finishing Lines – 6678 sq. mt.
o IE Lab - 935 sq. mt.
o HRD - 935 sq. mt.
o Conference Room – 1876 sq.mt.
o GM Cabin - 935 sq. mt.
o Planning - 935 sq. mt.
o TQA - 935 sq. mt.
 Third floor
o Canteen – 3691.5 sq.mt.
o Training – 3691.5 sq. mt.
o Sampling Department

TYPE OF SHED USED – Structural fabricated shed

FORM OF BULIDING – Frame with hinged column bases

LATTICE TRUSS – Articulated bow string


LAYOUT

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