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: [email protected]
 OVERVIEW
➢ Introduction

➢ Component Parts

➢ Erection of PEB

➢ Challenges of Vertical Construction

➢ Preparedness of PEB In India

➢ Profile Deck
 OVERVIEW
➢Planning of PEB

➢ Projects on PEB by SVPCPL

➢Other Projects on PEB by SVPCPL

➢ PEB images of China & UK

➢ PEB in India

➢ Conclusion
 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.
▪It is 15 to 20% cheaper than a conventional method.
▪Both costs and time of erection are minimized.
 INTRODUCTION
PRE ENGINEERED BUILDINGS

▪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 since late 1990’s.
▪With the opening of economy, number of multi nationals
have set up the Plants.
 INTRODUCTION
PRE ENGINEERED BUILDINGS

▪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.
▪ The industry is growing at the compound rate of 25 - 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 are 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
Overall price 30% at higher cost
lower. Overall price - More
30% lighter heavy.
Primary member is tapered Primary member is hot
section rolled section.
 INTRODUCTION
PRE ENGINEERED STEEL BUILDINGS Vs. CONVENTIONAL STEEL BUILDINGS

Pre-Engineered Conventional
Steel Buildings Steel Buildings
Secondary members are Secondary members are ‘I’ or
light weight rolled framed ‘C’ sections which are heavy in
‘Z’ & ‘C’ sections. weight.

Erection cost & time- Erection cost & time-

accurately known. 20% more than PEB.
Erection process is
Erection process is
slow and extensive
easy, fast step by step.
field labor required.
Delivery-average 6 to 8 Delivery-average 20 to
weeks. 26 weeks.
 COMPONENT PARTS

▪ Primary Members
(Main Frame)
o Columns
o Rafters
▪ Secondary Members
o Purlins
o Girts
 COMPONENT PARTS

▪ 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
PRIMARY MEMBERS (MAIN FRAME)

Battery Line
STEEL
 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 manufactured by press bending the HR steel coil
giving it the desired shape(Z- or C-shape).
COMPONENT PARTS
SECONDARY MEMBERS
 COMPONENT PARTS
SHEETING

• Metallic plain or color coated profiled metal sheets are used as

roof and wall sheeting.
Roof & Wall Panels

• The metal 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) Or Site Rolled.
 COMPONENT PARTS
SHEETING

• Lap joints with 150mm to 200mm overlap virtually

Roof & Wall Panels

eliminate water ingress depending on slope.

• At the initial project planning stage, roof slope is a
key consideration for architects incorporating roof
systems into their designs.
 COMPONENT PARTS
SHEETING

• Slopes as shallow as 1:20 are possible ensuring

sufficient drainage of water and good long term
Roof & Wall Panels

performance of roof panels.

• These profile steel sheets are usually categorized into
two types depending upon the type of fixing
arrangement followed.
 COMPONENT PARTS
SHEETING

• These two types are known as Through Fastened and

Roof & Wall Panels

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
Low Rise structures
 TechM Auditorium
Completed in 60 days
from Bhoomi Puja to
Inauguration in 2004
Completely Pre-
Engineered including
stepped Flooring with
AAC Panels
 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 metal

sheet fixed over it.

 COMPONENT PARTS
SHEETING - INSULATIONS

▪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.
 COMPONENT PARTS
SHEETING - SANDWICH PANELS

▪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

 INSULATED ROOFS

Roof Sheet

Insulation

Liner Panel
 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.

ROOF COMPONENTS
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
 ERECTION OF PEB
▪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. Approved erection methodology followed.

▪ A qualified and experienced work agency should be employed for erection

STRUCTURE
STRUCTURE
ERECTION OF PRE-FABRICATED MEMBERS
FLOW CHART ON MANUFACTURING OF PEB
 VERTICAL CONSTRUCTIONS

▪ Engineers are constantly developing the materials in the construction of tall buildings.

▪ Special Fabrication facility is required in the plant for Vertical Construction

▪Every PEB company doesn’t have Vertical Construction Capability

▪ 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.

▪Efficient Seismic load resistence

Vertical Construction
Multi Storey Car Park and Residential Building
TECH MAHINDRA INFO CITY
 FACTORS
HighRise Vertical ConstructionT
▪ Material Handling can be a limiting factor when we build highrise.

▪Fabrication of Higher thick base plates

▪Heated Welding for continuous Welding

▪Heavy plated Girders

▪Fire Rating with intumescent paint/ Vermiculate/ Concrete fill/

Encasement
 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 accessories are ready-made but the building components are either

ready-made/manufactured against specific orders.

 PREPAREDNESS OF PEB IN INDIA
▪These buildings are 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

 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.

 PROFILE DECK

▪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)

 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.
 PROFILE DECK

▪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.

 PROFILE DECK

▪ The composite slabs - common form of floor decks in major

buildings.

▪ the profile sheet - permanent formwork-tensile reinfmnt.

▪Challenge is span capability of deck sheet for dead load and

construction load
 PROFILE DECK
▪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.

▪Avoids double staging for greater floor heights & reduced

manpower on site.
MEASUREMENTS OF PROFILE DECK
CONCRETE PROFILE DECK
REINFORCEMENT WITH CONCRETE
PROFILE DECK (STUD CONNECTORS)
DECK SLAB CONNECTIONS
Latticed Decking
Latticed Decking
 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

 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.

 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.

Control on Condensation PLANNING OF PEB
▪ 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 :

o Schneider Electrical, Kirby, MUSCO, Musaddilal Projects Limited, Pune, Vapi

oAmazonPreBid,Decathlon 3, Arunachal Pradesh ALG, Gemini Fats&Foods, ITC Narsaraopet

oGSG Mall
VAPI Warehouse Unilever

700,000 sft Floor Area

 PROJECTS ON PEB BY SVPCPL

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 value: 520 MINR

Project Status: On progress

Project Size: 22 acres

Highlight: PEB structure with more clear height for stack loading
PROJECTS ON PEB BY SVPCPL
MUSADDILAL MODERN WAREHOUSE

Rigid Frame Elevation

PROJECTS ON PEB BY SVPCPL
MUSADDILAL MODERN WAREHOUSE

Wall Panel Detail

PROJECTS ON PEB BY SVPCPL
MUSADDILAL MODERN WAREHOUSE

Roof Framing Plan

PROJECTS ON PEB BY SVPCPL
MUSADDILAL MODERN WAREHOUSE

Eave Purlin Connection

Gemini Fats & Foods Kakinada
BIM Model of Amazon centre @ GMR
 PROJECTS ON PEB BY SVPCPL

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
PROJECTS ON PEB BY SVPCPL
SCHNEIDER
SCHNEIDER
PROJECTS ON PEB BY SVPCPL
SCHNEIDER
PROJECTS ON PEB BY SVPCPL
SCHNEIDER
SCHNEIDER
 PROJECTS ON PEB BY SVPCPL

Client Name: Kirby Buildings

Project Name: Kirby Building System

Our Contribution: Consultancy Services

Project Location: Hyderabad

Project Configuration: 36,000 SqM

Project value: 800 MINR

Project Status: Completed

Project Size: 30 acres

Highlight: First PEB Structure in India with Large Spans 360m * 67m
PROJECTS ON PEB BY SVPCPL
KIRBY BUILDINGS SYSTEMS, HYDERABAD
PROJECTS ON PEB BY SVPCPL
KIRBY BUILDINGS SYSTEMS, HYDERABAD
PROJECTS ON PEB BY SVPCPL
KIRBY BUILDINGS SYSTEMS, HYDERABAD
KIRBY BUILDING SYSTEMS
(BUILDING UNIT – G.A.)
KIRBY BUILDING SYSTEMS
(PLANT ROOF TRUSS)
KIRBY BUILDING SYSTEMS
(LAYOUT)
 PROJECTS ON PEB BY SVPCPL

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

Project value: 100 MINR

Project Status: Completed

Project Size: 8 acres

Highlight: International workshop with vibration analysis to resist resonance

MAHINDRA UGINE STEEL CO. LTD.
MUSCO
PROJECTS ON PEB BY SVPCPL
MAHINDRA UGINE STEEL CO. LTD.

Cross Section Detail For Rigid Frame

PROJECTS ON PEB BY SVPCPL
MAHINDRA UGINE STEEL CO. LTD.

Side Wall Framing Elevation

PROJECTS ON PEB BY SVPCPL
MAHINDRA UGINE STEEL CO. LTD.

Side Wall Sheeting Layout

PROJECTS ON PEB BY SVPCPL
MAHINDRA UGINE STEEL CO. LTD.

End Wall Framing Elevation

INDUSTRIAL WARE HOUSE – GATI
(Jan 2006 - May 2007)
 GATI STEEL BUILDING

WIND BRACING CONNECTION DETAILS WINDOW OPENING DETAILS

INDUSTRIAL WARE HOUSE – GATI
SUJANA METAL INDUSTRIES
IJM STEEL FACTORY BUILDING
(Oct 2007)
IJM STEEL FACTORY BUILDING
IJM STEEL FACTORY BUILDING
APEX ENCON INDUSTRIAL SHED
(Jun 2010)
APEX ENCON INDUSTRIAL SHED
APEX ENCON INDUSTRIAL SHED
APEX ENCON INDUSTRIAL SHED
APEX ENCON INDUSTRIAL SHED
DECATHLON, UPPAL
(Mar 2014)
DECATHLON, UPPAL
ITC - ILTD DIVISION, CHIRALA
ITC - ILTD DIVISION, CHIRALA
ITC - ILTD DIVISION
ITC - ILTD DIVISION, CHIRALA
ITC - ILTD DIVISION, CHIRALA
ITC - ILTD DIVISION
ITC - ILTD DIVISION, CHIRALA
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)
ITC - ILTD DIVISION, CHIRALA

Detail at Door Opening

ITC - ILTD DIVISION, CHIRALA
ITC - ILTD DIVISION, CHIRALA
PALMTECH INDIA LIMITED
SNOW WORLD, HYDERABAD
KADEVI ROLLING MILL
KADEVI ROLLING MILL
 PORTABLE CABINS
➢ A Portable Cabins is a building designed
and built to be movable rather than
permanently located.

Portable cabins are available in

different sizes and can be
customized according to
requirements.

Defence,
Communications
PEB IMAGES OF CHINA & UK
PEB IMAGES OF CHINA & UK
PEB IMAGES OF CHINA & UK
Shard Tower, Tallest PEB –
About 300m by Severfield UK
Group Experience Commercial Offices

Bishopsgate Regents Place Canary Wharf

153
 Heron Tower , London

154
Heron Tower, London

155
Medium Rise Structures
Medium Rise Structures
Medium Rise Structures
Medium Rise Structures
Medium Rise Structures
Moment Resisting Frame
Moment Resisting Frames
Moment Resisting Frames
 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
 G+3 – Residential Building

Perspective View Framing View of the model

ERECTION –DIFFERENT STAGES
Braced Wall Panel- Load Transfer Details
Concrete Slab Casting:

LIGHTER | FASTER | EASIER 171

Work Under Progress

LIGHTER | FASTER | EASIER

 PROJECTS ON PEB
G+13 JAMMU RESIDENTIAL PROJECT
 PROJECTS ON PEB
G+13 JAMMU RESIDENTIAL PROJECT
 PROJECTS ON PEB
G+13 JAMMU RESIDENTIAL PROJECT
Restaurant Using Speed Floor System

LIGHTER | FASTER | EASIER

Multi Storey Car Park

LIGHTER | FASTER | EASIER

COMBINATION OF HRS ,LGS AND SPEED FLOOR ,FOR DORMITORY
BUILDING .
Moment Resisting Frames
Moment Resisting Frames
Braced
Braced
Steel Frame
 CONCLUSION
▪ Pre-engineered steel structures building offers low cost, strength,

durability, design flexibility, adaptability and recyclability.

▪ Steel is the basic material that is used for Pre-engineered steel building.

▪ It negates from regional sources.

▪ Infinitely recyclable, steel is the material that reflects the imperatives of

sustainable development.
 CONCLUSION
▪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 design automation, the 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 [email protected]
(or)
Call me +91 93933 48484
Thank You