PRE ENGINEERED BUILDINGS

[EIRI/EDPR/3944] J.C.: 2068

INTRODUCTION

Pre Engineered Buildings (PEB) is the buildings which are engineered at a factory
and assembled at site. Usually PEBs are steel structures. Built-up sections are
fabricated at the factory to exact size, transported to site and assembled at site
with bolted connections. This type of Structural Concept is generally used to build
Industrial Buildings, Metro Stations, Warehouses etc.

The adoptability of PEB in the place of Conventional Steel Building design concept
resulted in many advantages, including economy & easier fabrication. These type
of building structure can be finished internally to serve any functions that is
actually help in low rise building design. Examples of Pre-Engineered Buildings
are warehouses, Canopies, Factories, Bridges etc.

Pre-Engineered Steel Buildings use a combination of built-up sections, hot rolled

sections and cold formed elements which provide the basic steel frame work with a
choice of single skin sheeting with added insulation or insulated sandwich panels
for roofing and wall cladding. The concept is designed to provide a complete
building envelope system which is air tight, energy efficient, optimum in weight
and cost and, above all, designed to fit user requirement like a well fitted glove.

These Pre-Engineered Steel Buildings can be fitted with different structural

accessories including mezzanine floors, canopies, fascias, interior partitions, crane
systems etc. The building is made water-tight by use of special mastic beads,
filler strips and trims. This is a very versatile building system and can be finished
internally to serve any required function and accessorized externally to achieve
attractive and distinctive architectural styles. It is most suitable for any low-rise
building and offers numerous benefits over conventional buildings.

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Pre-engineered buildings are generally low rise buildings, however the maximum
eave heights can go upto 25 to 30 metres. Low rise buildings are ideal for offices,
houses, showrooms, shop fronts etc. The application of pre-engineered concept to
low rise buildings is very economical and speedy. Buildings can be constructed in
less than half the normal time especially when complimented with other
engineered sub-systems.

The most common and economical type of low-rise building is a building with
ground floor and two intermediate floors plus roof. The roof of a low rise building
may be flat or sloped. Intermediate floors of low rise buildings are made of
mezzanine systems. Single storeyed houses for living take minimum time for
construction and can be built in any type of geographic location like extreme cold
hilly areas, high rain prone areas, plain land, extreme hot climatic zones etc.

Various systems in PEB

Primary System

Primary system consists of tapered or parallel columns and tapered beams which
are called as rafters. The base of the columns can be either pinned or fixed based
on the load requirements. Lengths of these members are generally restricted to
12m for ease of transports. Joints are connected with high tensile bolts.

Secondary System

Secondary structural system consists of Purlins (roof), Girts (side cladding) and
Eave struts (at eaves) stiffened with sag rods. This also includes the flange
stiffeners which connects the untied flanges of the PEB primary structure to
secondary system. Some of the commonly used secondary system are Lipped C or
Lipped Z purlins, MS rods and Lipped Angles. These are generally cold formed
sections conforming to IS: 801.

Wind Bracing System

There are two types of wind bracing systems.The first one is Rod bracing system
and the second one is portal system. Each type of system is chosen based on the
design and functional requirement of the structure.

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Roofing & Cladding System

Roofing and cladding system can be with single skin zinc and aluminum coated
steel sheets, GI sheets, both of which could be bare or color coated; It could with
double skin sheets with or without insulation material in between; It could be
sandwich panels with steel sheets outside and PUF/PIR/Mineral Wool/Glass wool
core inside. Roofing and cladding could have skylights with Poly Carbonate/ PVC
or FRP sheets.

Accessories

Accessories include, Turbo Ventilators, Ridge vents, Flashings, trims, Gutters,

Down pipes, ladders, Louvers etc.

Finishing

Primary structural members are generally finished with shot peening, Sand
blasting, and two coats of anti corrosive primers, followed by two coats of paints to
specifications. Secondary members or either painted after sand blasting or
Galvanized to 275 gsmor above based on the requirement.

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 CONTENTS

INTRODUCTION
VARIOUS SYSTEMS IN PEB
PRIMARY SYSTEM
SECONDARY SYSTEM
WIND BRACING SYSTEM
ROOFING & CLADDING SYSTEM
ACCESSORIES
FINISHING
COMPONENTS OF PEB
MAIN FRAMING
END WALL FRAMING
PURLINS, GIRTS AND EAVE STRUTS
THE PURLINS ARE SUBJECTED TO THE FOLLOWING LOADS:-
THE GIRTS ARE SUBJECTED TO THE FOLLOWING LOADS:-
THE EAVE STRUTS ARE SUBJECTED TO THE FOLLOWING LOADS:-
PANELS AND INSULATION
MEZZANINE SYSTEM
BRACING SYSTEM
PAINTS AND FINISHES
DOORS AND WINDOWS
FALSE CEILING
PARTITION WALLS
FLOORING
ADVANTAGES OF PEB:
BENEFITS
DISADVANTAGES OF PEB
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR PEB
FABRICATION PROCESS OF PEB
CUTTING
CNC PLASMA & OXY GAS
CNC (6100 X 20) MM SHEARING MACHINE
CNC (6100 X 12) MM SHEARING MACHINE
EQUIPMENT AND MACHINES:
HOLE PUNCHING
ASSEMBLING
VERTICAL ASSEMBLING
HOT ROLLED ASSEMBLING

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AUTOMATIC ASSEMBLING MACHINE
EQUIPMENT AND MACHINES
WELDING AND CONNECTION DETAILS WELDING
MANUAL WELDING AND DETAILING
EQUIPMENT AND MACHINES
SURFACE CLEANING
SHOT BLASTING MACHINE, ROOM (8000 X 20000 X 6000 MM)
EQUIPMENT AND MACHINES:
PAINTING
PAINTING MACHINE
EQUIPMENT AND MACHINES
LOADING
QUALITY CONTROL
FOR FABRICATION PROCESS
FABRICATION TOLERANCES:
STRAIGHTNESS:
TWISTS:
CAMBER:
LENGTH:
TYPE OF MEMBER TOLERANCE
SQUARE-NESS AT END OF MEMBERS
BUTT JOINTS
DEPTH OF MEMBER
WEB PLATES:
FLANGE PLATES:
COLUMN FABRICATION TOLERANCES:
CRANE RUNWAY GIRDER FABRICATION TOLERANCES:
GIRDER ENDS:
CRANE GIRDER ALIGNMENT:
FOR HOLING PROCESS
FOR WELDING PROCESS
INSPECTION OF WELDS:
TESTS ON WELDS:
(1) MAGNETIC PARTICLE TEST:
(2) DYE PENETRATION TEST:
(3) RADIOGRAPHIC INSPECTION:
TESTING OF FABRICATION COMPONTS
(6) ROOF SHEETING:
(7) WALL PANELS:
(8) HEETING FASTENERS:
(9) SEALER:
(10) CLOSURES:
(11) FLASHING AND TRIM:
(12) ROOF & WALL BRACINGS:

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(14) PAINTING FOR STRUCTURAL STEEL WORK:
QUALITY CONTROL
MARKET POSITION
DRIVERS
BRIEF MARKET RESEARCH ANALYSIS
BY MATERIAL
BY APPLICATION
KEY PLAYERS
INDIA PEB MARKET
SOME MORE INSIGHTS
KEY VENDORS
OTHER PROMINENT VENDORS
GOVERNMENTS INITIATIVE IN GROWTH OF PEB
THE CHALLENGES
PEB ADVANTAGE
PLANT LAYOUT
SUPPLIERS OF PEB STRUCTURE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF STRUCTURAL STEEL PLATE
SUPPLIERS OF STRUCTURAL STEEL SHEET PLATE
SUPPLIERS OF MIG WELDING WIRE ELECTRODE
SUPPLIERS OF ZINC INGOT
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF HYDROCHLORIC ACID
SUPPLIERS OF DEGREASING CHEMICAL
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF UNCOILING MACHINE
SUPPLIERS OF SHEET LAVELING MACHINE
SUPPLIERS OF PUNCHING PRESS
SUPPLIERS OF POWER PRESS
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF ROLLING MACHINE
SUPPLIERS OF BENDING MACHINE
SUPPLIERS OF CNC PLASMA CUTTING MACHINE
SUPPLIERS OF COLD ROLL FORMING MACHINE
SUPPLIERS OF WELDING MACHINE
SUPPLIERS OF MIG WELDING MACHINE
SUPPLIERS OF AUTOMATIC H-BEAM WELDING MACHINE
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)

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SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION

Plant Capacity 41 MT/Day

Land & Building (8000 sq.mt.) Rs. 5.28 Cr
Plant & Machinery Rs. 3.20 Cr
Working Capital for 2 Months Rs. 7.57 Cr
Total Capital Investment Rs. 16.70 Cr
Rate of Return 73%
Break Even Point 33%

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