A Comparative Analysis of Conventional Steel Building and Pre-Engineered Building Systems: a case study Approach

Project Session – 01

1. Introduction

• • Conventional Steel Buildings

Conventional steel building systems typically use truss structures. The structural members that are utilized are hot-rolled and supplied in accordance with the IS code; nevertheless, in many cases, they are heavier than what is actually needed by design. Members maintain a constant cross section regardless of how much the local stresses fluctuate throughout the length of the member. The materials are moved to the location after being manufactured in the plant. Before manufacturing the raw materials are treated on the site to get the required shape and size. Modifications can be done by welding and cutting as the structure is being assembled. Secondary components, which are somewhat heavier, are supplied with standard hot rolled sections.

• Pre-engineered buildings

Through a variety of new goods and services, technological advancement over time has greatly improved people’s quality of life. One such revolution was the Pre-engineered buildings (PEBs). Pre-engineered building concept involves the steel building systems which are predesigned and prefabricated. As the name suggests, this idea entails pre- engineering structural components utilizing a pre-established register of construction materials and manufacturing processes that may be effectively used in compliance with a broad range of structural and aesthetic design requirements. The PEB concept is based on the idea that a section should only be provided at a location if it is necessary there. The bending moment graphic indicates that the sections may change across the length. This results in the use of rigid, non-prismatic frames with thin parts.

For example, tapered I sections made with built-up thin plates are used to achieve this configuration. In pre-engineered building concept, the complete designing and fabrication is done at the factory and the building components are brought to the site in complete knock down condition. These components are then fixed / joined at the site and raised with the help of cranes. The pre-engineered building calls for very fast construction of buildings and with good aesthetic looks and quality construction.Pre-engineered buildings are widely used in the construction of both residential and commercial structures. The PEB concept has shown to be highly effective and well-established in North America, Australia, and is currently spreading throughout the United Kingdom and Europe. PEB construction is 30 to 40% faster than masonry construction. PEB buildings provide a good insulation effect and would be highly suitable for a tropical country like India. PEB is also ideal for construction in remote & hilly areas.

• Basic terminologies of Pre-engineered building
•  

Fig. 1. Main frame cross section

Fig.2 PEB Model

2. Objectives

 The main objective of this paper is as follows-

1. To study pre-engineered
2. To find estimate of PEB and CSB

3. Literature Review Summary:

The construction industry has witnessed a significant evolution in building technologies, particularly in the shift from conventional construction methods to pre-engineered building (PEB) systems. This review aims to compare these two approaches in terms of design, construction, performance, and sustainability, providing insights into their respective advantages and limitations. Conventional buildings are constructed using traditional methods, with components fabricated on-site based on architectural and engineering drawings. In contrast, PEBs are prefabricated off-site and assembled on-site, often using standardized components that are designed and manufactured in a controlled environment (Al-Asadi et al., 2021).Research suggests that both conventional buildings and PEBs can meet structural requirements. However, PEBs are often lauded for their lightweight design and high-strength materials, allowing for larger clear spans and reduced foundation requirements compared to conventional buildings (Kumar et al., 2018).While the initial cost of PEBs may be higher due to specialized materials and manufacturing processes, studies have shown that they can offer long-term cost savings through reduced construction time and labor costs (Kumar et al., 2018).PEBs have the potential to be more environmentally friendly than conventional buildings due to reduced material waste and energy-efficient design. However, the environmental impact can vary depending on factors such as material sourcing, transportation, and end-of-life considerations (Al-Asadi et al., 2021).

In conclusion, the comparison between conventional building and pre-engineered building highlights the importance of considering project-specific requirements, budget constraints, and sustainability goals. While both approaches have their advantages and limitations,

PEBs offer potential cost and time savings, as well as environmental benefits, making them an attractive option for many construction projects.

4. Methodology

We can have a case study to explain the comparison between the conventional building and the pre-engineered building. A building of an industrial structure is considered for design with conventional steel structure and pre-engineered building structure (25m x 52.5m building). The description of the building which is considered for the design purpose is tabulated in table 1

The detailed estimation of the PEB and CSB is done on Excel sheet and actual cost of the project with existing dimensions is found out as a PEB structure. Same dimensions are taken for CSB structure and actual cost is found out. Finally comparison is done between the costs of 2 projects.

Table 1. Description of building for study

Building Drawing – The plan & cross section of the building which is considered for the design purpose as shown in fig. no.3

Fig. 3(a) Column Layout Plan

Fig. 3 (b) Cross Section

5. Result and Discussion

Cost effectiveness of Pre-engineered building over conventional building

Cost effectiveness of Pre-engineered Building over conventional building is studied using estimates and also by comparing and calculating the cost of steel quantity of PEB member and conventional steel building member.

5.1 Estimate of PEB

For the above PEB, the estimate was calculated and displayed in the table below:

Table 2. Estimate sheet for PEB

5.2 Break up Sheet

The break up summary sheet of above estimated sheet.

Table 3. Break-up summary sheet for PEB

5.3 Cost calculations:

5.4  Estimate sheet for convention building system

The same above plan was considered for the estimation but as per conventional steel building system. It is tabulated in the table below:

Table 4. Estimate sheet for conventional building system

5.5 Break up sheet

The break up summary sheet of above estimated sheet which help for comparison of mainframe system & cold form as shown in Table No 3.4

Table 5. Break up summary sheet for conventional steel building

5.6 Cost calculations

• Cost savings in Material Cost

The distribution of Material cost in PEB and conventional steel building is displayed along with the cost savings by PEB as shown in the figure below figure below:

Fig 4. Distribution of material cost obtained from break-up summary

5.8 Comparison of Material Cost in PEB and Conventional Steel Building

The Material cost in PEB and conventional steel building is calculated from the estimate above and it is compared in the figure below:

Fig. 5. Cost comparison in Material cost of PEB and conventional steel building

5.9 Comparison of Transportation Cost in PEB and Conventional Steel Building

The Transportation cost in PEB and conventional steel building is calculated from the estimate above and it is compared in the figure below:

Fig. 6. Cost comparison in transportation cost of PEB and conventional steel building

5.10 Comparison of Laboure cost in PEB and conventional steel building

The Transportation cost in PEB and conventional steel building is calculated from the estimate above and it is compared in the figure below:

Fig. 7. Cost comparison in labour cost of PEB and conventional steel building

5.11 Cost-effectiveness of the PEB over conventional steel building

Overall project cost in CSB               = 3417558 INR Overall project cost in PEB                                                                = 20,27,527.5 INR

Cost savings in PEB project              = 3417558.50 – 20,27,527.5

= 13,90,031 INR

Cost-effectiveness in %                   = (1390031/3417558)*100

           = 40.67 %

6. Conclusion

1. PEBs need a huge initial investment in comparison to normal conventional
2. Indian education has most of the focus on RCC buildings in course curriculum and hence advancement in steel construction is ignored.
3. The pre-engineered building was found more cost effective than conventional steel buildings by comparing the estimates of the building for the same floor area. The most varying parameters were considered like material cost, transportation cost and labour cost. It was found to have approximately 40% of the cost savings in PEB by considering the above parameters.

7. References

1. Al-Asadi, , Al-Fakih, A., Al-Safi, M., & Jawad, M. (2021). A Comparative Study of the Structural Performance between Pre-Engineered Buildings and Conventional Buildings. IOP Conference Series: Materials Science and Engineering, 1112(1), 012027.
2. Kumar, R., Singh, A., & Kumar, S. (2018). Comparative Study of Pre-Engineered Buildings and Conventional Steel Buildings. International Journal of Engineering Technology Science and Research, 5(3), 270-273.
3. Implementing combinative distance base assessment (CODAS) for selection of natural fibre for long lasting composites S Wankhede, P Pesode, S Gaikwad, S Pawar, A Chipade Materials Science Forum 1081, 41-48 2023
4. Metal oxide coating on biodegradable magnesium alloys, P Pesode, S Barve, SV Wankhede, A Chipade 3c Empresa: investigación y pensamientocrítico 12 (1), 392- 421 5 2023
5. Statistical analysis of rainfall data using non-parametric methods of Solapur District, Maharashtra, India CS Chavan, A Chipade, G Ghadvir, M Deshpande E3S Web of Conferences 405, 04046 1 2023
6. Contractor Performance Evaluation In Construction Industry , A Chipade, International Journal for Science and Advance Research In Technology 7 (6), 5, 2021
7. Overview on Manufacturing of Tiles from Plastic Waste ,A Chipade International

Journal for Research in Applied Science and Engineering …2021

8. Integrated GIS and Remote Sensing for Mapping Groundwater Potential Zones : Case Study , A Chipade International Journal of Scientific Research in Engineering and Management …2021
9. Application of value Engineering System to a Residential Building –A Case Study, A Chipade International Journal of Scientific research in engineering and management 5

(5) 2021

10. Economic Evaluation of Plastic Filled Concrete block Pavement, A Chipade International Journal for Science and Advance Research in Technology (IJSART

…2021

11. Smart method for Predicting Flooding in Cities Current advances and Challenges, A Chipade International Research journal of engineering and Technology 8 (5)2021
12. Smart method for Predicting Flooding in Cities ,A Chipade Journal of Emerging Technologies and Innovative Research 8 (5) 2021
13. Earned Value Analysis of residential Building., A Chipade, Mallinath Pujari., Journal of Emerging Technologies & Innovative Research 8 (Issue 7)2021
14. Review Paper on Retrofitting of RCC Beam Column Joint Using Hybrid Reinforced Fiber Reinforced Concrete
15. AM Chipade IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) 16 (Issue 6 Ser 2019
16. Retrofitting of RCC Beam Column Joint Using (HFRC) Hybrid Fiber Reinforced Concrete, Amar Chipade, Sushma Sawadatkar, RESEARCH REVIEW International Journal of Multidisciplinary 4 (11), 2 2019
17. Smart method for predicting flooding in cities ,A Chipade International Journal of Emerging Technologies and Innovative Research 8 (5), 3 2019

Project Session – 02

1.INTRODUCTION

Conventional Steel Buildings (CSB) and Pre-Engineered Buildings (PEB) are the two common approaches to construct steel-framed buildings. This study undertakes a comparison of both PEB and CSB, by focusing on the critical aspect of steel takeoff. Both methods present unique features, challenges and advantages influencing the overall efficiency, sustainability and cost of construction projects. In Conventional steel building construction, components are fabricated on-site whereas, pre- engineered buildings are units of construction in which the components of structure are designed and fabricated off-site with accurate proportions required on-site. After fabricating, the components are transferred to site and fitted using bolted connections [1].

  PEB with columns, rafters and purlins is shown in Figure1.

Design and fabrication of the structural units are done under the direction of a quality control officer. The adoptability of PEB by replacing CSB arises in numerous advantages including its economy and quick fabrication. Due to its ductile property steel is earth-quake resistant compared to concrete which is the key reason for increase in steel structures. Under the influence of earthquake forces, the performance of PEB is much better than CSB. It is due to the good structural behaviour and lighter weight of the PEB [1]. Almost in every single feature, PEB gives finer result compared with traditional steel building. The steel buildings are custom-made to have a lighter weight and higher strength. So, the usage of PEB should be adopted more in India as it is eco-friendly.

Figure 1. A typical PEB with Columns, Rafters and Purlins.

Comparison between both structures is based on different parameters of existing Pre-Engineered and Conventional Steel Buildings. Those parameters involve resistance to seismic forces, further expansions, architectural design, accessories of building, software need, usage of codal provisions, and the weight of the overall structure either directly or indirectly. The factors mentioned above play a crucial part in the sustainable construction of structures. Pre-engineered Building shows better solutions in all the factors over Conventional Steel Building [1]. The major problem in structural engineering is safety. In PEB all the precautionary measures are followed by reducing construction rate and time. In future, PEB is going to play a vital role in India [2]. Usage of steel structures is rapidly increased from past few decades. PEB theory was evolved in US, and almost 70% of one- storied buildings at present utilizes pre-engineered structures for non-domestic construction. Up to 1990, PEB was utilized in the Middle east and North America but at present it is utilized in every segment of Asia and Africa [2][3]. PEB design is mostly preferred by contractors and designers for speedy construction and cost-effectiveness.

Cost savings for PEB is nearly 35% compared to CSB[3][4]. In today’s circumstances reducing time and money is increasing their significance in all sectors which include the construction industry. The world is rushing for sustainability. PEB is positioned at the top when differentiated from other technologies in every aspect. The used material for PEB is reusable and biodegradable too. In pre- engineered buildings, steel is the key material among all materials. Steel is a biodegradable material that reflects sustainability. By effectively using high-grade steel and also advanced composite materials the economy of construction in civil can be attained. Traditional steel buildings use steel that is twice as heavy as PEB. The quantity of steel required for the PEB structure is smaller than for the CSB structure [4].

Mainly, the performance relies on the load combination and structural design framework by following Indian and international codes. Pre-engineered building analysis and design will be carried out both manually and with the use of Staad Pro software. The outcome displays how the two codes, using tonnage and deflection criteria, differ from one another. The PEB structure’s design procedure is easy with country standards and its construction is faster, eco-friendly, and sustainable [5]. Reason for increasing in weight using IS 800-2007 is due to additional load combination of wind load than AISC. This is based on detailing and designing [5]. Compared to the Indian Code, AISC code gives economical solution. So, that’s the major priority for adopting AISC codes [5][6].

For distinct spacing of bay and length of span, the AISC code shows 3% to 10% lighter sections than the IS code. This is based on a lower factor of safety of the American code [6]. Deflection limits are lesser for MBMA than IS codes. Because of limiting ratios, IS 800-2007 shows greater weight than AISC/MBMA [7]. The suitable retrofitting technique for the available seismic deficient structures that are not only affordable but also acceptable to stakeholders, owners, and investors is identified. For non-engineered structures, losses can be reduced by 2-11 times and by 3-50 times respectively with the use of proper retrofitting techniques. The huge loss is minimized for steel bracing then after for shear wall and then jacketing [8]. Newly manufactured pre-engineered connection and traditional welded junction are compared in terms of bearing capacity [9].

PEC (Partially Encased Composite Column) is a combination of steel section that is partially outfitted to support a concrete composite column. Tensile strength and ductility are high in steel whereas, fire resistance and compressive strength are high in concrete. So, high strength and stiffness is achieved [10]. Framed beams and columns helps the structure to withstand during earthquake. Repairing the framed structure which is damaged during an earthquake is challenging, and its performance is also poor [11]. Compared to pre-engineered buildings, traditional steel buildings are heavier in weight [12]. Pre-engineered buildings are less expensive when it comes to steel takeoff [12].

2. OBJECTIVES AND NUMERICAL STUDY

The objectives of the present research work are presented below.

• To model a Conventional Steel Building (CSB) and Pre-Engineered Building (PEB).
• To estimate the different loads acting on the
• To analyze the CSB and PEB subjected to different loads and load
• To design the various elements of PEB and CSB as per IS
• To compare the PEB with CSB.

2.1.  Geometry

A Pre-Engineered Building has been modelled in Staad Pro software. Load calculations have been computed for a 19 m width x 41.1 m length. The geometrical model of the PEB along with the bay spacings in X, Z directions are shown in Figure 2. The columns, rafters and bracings of the PEB are shown in Figures 3 to 5 respectively.

                    Figure 4. Rafters of PEB                                                        Figure 5. Bracings of PEB

2.2.  Properties

The properties of PEB columns are shown in Table 1. The properties of end and middle rafters (Rafter-1, 2) are shown in Table 2. The properties of cross-bracings of PEB are shown in Table 3.

Table 1. Description of PEB columns

Table 2. Description of PEB rafters

Table 3. Description of bracings and cross-bracings of PEB

The properties columns, rafters, eave strut and cross-bracings used in CSB are shown in Table 4.

Table 4. Description of CSB elements

2.3.  Computation of Wind load

Wind load acting on PEB at angles θ=0⁰, 90⁰, 180⁰ and 270⁰ are calculated as per IS 875 (Part III) and tabulated in Tables 5 & 6.

Table 5. Wind load on members with internal pressure coefficient Cpi= + 0.2

Table 6. Wind load on members with internal pressure coefficient Cpi= – 0.2

2.4.  Seismic parameters

Site location                                                     : Hyderabad

Zone factor                                                       : 0.1

Importance factor (I)                                       : General building

Damping ratio (DM)                                        : 0.05

Type of structure (ST)                                     : Steel frame building

Response reduction Factor (RF)                   : Special RC moment resisting frame Rock and soil site factor (SS)                                                         : Medium soil

Live loads acting on middle and end rafters are shown in Figures 6, 7 and Wind loads with internal pressure coefficients +0.2 acting on Pre-Engineered building are shown in Figures 8 to 11 respectively.

Figure 6. LL acting on middle rafters

Figure 7. LL acting on end rafters

Figure 8. WL-Left at angle θ = 0⁰ & +0.2 Cpi

Figure 9.WL-Right at angle θ = 180⁰ & + 0.2 Cpi

Figure 10. WL-Top at angle θ = 900 & +0.2 Cpi

Figure 11. WL-Bottom at angle θ = 270⁰ &+ 0.2 Cpi

Maximum bending moment and shear forces of PEB are shown in Figures 12 to 13. The maximum

bending moment and shear forces of CSB are shown in Figures14 to 15

3. RESULTS AND DISCUSSION

The PEB and CSB are analysed for 74 different load combinations as per the IS codes. The results obtained from the analysis are tabulated in Tables 7 and 8.

Table 7. Steel take-off for PEB

Table 8. Steel take-off for CSB

Table 9. Analysis results of PEB and CSB

The results of PEB are compared with that of CSB and the quantity of steel required for Pre- engineered building is reduced by 24.90 % compared to CSB. Thus, the cost of PEB is reduced considerably. For eave struts and cross bracings, same pipe sections are used. When compared both seismic and wind load analysis, wind load combinations are found to be critical.

PEB and CSB were analyzed for various load combinations and results obtained from the analysis were presented in Table 9. The maximum BM, maximum SF, maximum AF and maximum support reactions are presented in Table 9.

4. CONCLUSIONS

Two typical steel buildings, one with PEB sections and the other with CSB sections available from steel tables have been designed for various load combinations.

• The quantity of steel required for Pre-Engineered Building (PEB) is lesser by 24.90 % compared to Conventional Steel Building (CSB), which is considered to be significant.
• When compared to both seismic and wind loads, wind load combination is found to be more critical compared with seismic load combination.
• It is observed that the maximum bending moment, shear force, axial force and support reactions in PEB and CSB varies from 6.3 to 9.5 %
• As the PEB offers various advantages like cost reduction, speedy construction, future expansion, good architectural view over CSB, structural engineers can prefer PEB’s over CSB’s.
• It is concluded that a PEB is considerably cost effective compared to a

REFERENCES

• Sharma L, Taak N, Mishra PK. 2020. A comparative study between the pre-engineered structures and conventional structures using Materials Today: Proceedings. 45:3469-75. https://doi.org/10.1016/j.matpr.2020.12.942.
• Zoad MD. 2012. Evaluation of pre-engineering structure design by IS-800 as against pre- engineering structure design by AISC. International Journal of Engineering Research & Technology (IJERT).1(5):8.
• Sai VV, Poluraju P, Rao BV. 2021. Structural Performance of Pre Engineered Building: A Comparative Study.IOP Conference Series: Materials Science and Engineering.

1197:012086.https://doi.org/10.1088/1757-899X/1197/1/012086

• Shaik K, BSS RR, Jagarapu 2020. An analytical study on pre engineered buildings using staad pro. Materials Today: Proceedings. 33:296-302. https://doi.org/10.1016/j.matpr.2020.04.076
• Dipali K. Chhajed, Dr Sachin B. Mula. 2020. Design and Analysis of Pre Engineered Steel Building with Indian Standard Code and International Code. International Research Journal of Engineering and Technology (IRJET).7(9):2395-0056.
• Nihar S, G.Vanza,& Prasham V. 2021. Comparative study of PEB by Indian and American Code. International Research Journal of Engineering and Technology

(IRJET). 8(5):2395-0056.

Kiran GS, Rao AK, Kumar RP. 2014. Comparison of design procedures for pre-engineering buildings (PEB): a case study. International Journal of Civil, Architectural &Construction Engineering(IJCASCE).8(4):477-81.

Technical specification of Pre- Engineered Building

SPECIFICATIONS :

• PROJECT SITE INFORMATION & INTENT OF SPECIFICATION

• These Technical Specifications cover the technical requirements for the design, engineering, fabrication, manufacture, transport, Supply, Construction, and Erection / Installation of Complete Structural and Architectural Works.
• The Technical Specification is intended for the general description of the works, quality and workmanship. These Technical Specification are however, not intended to cover the minute details of Works and Workmanship. The execution of Works and the Workmanship shall be according to the description given in the schedule of items, tender drawings, ‘Released for Construction’ drawings and relevant Indian standard Codes. In absence of relevant Indian standards Codes, the execution of Works and Workmanship shall be according to the best prevailing engineering practices and / or to the recommendations of relevant British and / or American standards and / or to the Instructions of Engineer-in-charge.

• SCOPE

• It covers design ,engineering, manufacturer, transport, supply, erection of various pre-engineered components like structural steel including all other fittings / fixtures like purlins, flashing, bracing & Anchor Bolts, etc., for Canopies and Sheds.
• The broad scope shall cover but not be limited to the following Structural steel Works for PEB:
• Complete Engineering Design and preparation of drawings for construction of Pre-engineered buildings including furnishing of design, working drawings, calculations, data sheets, records and getting the same approved from the Owner / Consultant, testing and quality assurance, inspection and quality checks, setting and layout and levels, safety measures and inspection etc.
• Manufacturing, Testing at Shop, Painting at shop, Supply, Transportation, Receipt, Unloading  and  Storage  at  Site,  Handling,  Erection  and

Commissioning at Site of Pre-engineered Steel Structure, furnishing of design, working drawings, calculations, data sheets, records and getting the same approved from the Owner / Consultant, testing and quality assurance, inspection and quality checks complete. The Scope of Pre-engineered Steel Structure includes various components of structural steel sections, internal including all fittings / fixtures like purlins, flashing, bracing & Anchor Bolts, Nuts, Washer, permanent bolts with templates etc. complete.

• Providing all labor, supervision, materials, consumables, fuel, construction equipment, tools and plants, supplies, transportation, all sampling, testing and quality assurance, providing necessary facilities and equipment to Project Manager/engineer in charge for carrying out the inspection and quality checks, setting out layout and levels, safety measures, carrying out erection in a mechanized manner, storage, repair / rectification / maintenance until handing over, furnishing of design, working drawings, calculations, data sheets, records, etc. complying with statutory provisions and applicable laws etc.
• Covering all incidental items not specifically mentioned but reasonably implied and necessary for successful completion of the work.
• Preparation and submission of all construction drawings (Layout, Architectural, color scheme and Structural) required for the complete execution of the works, material selection and material take off. SUFFICIENT DETAILING SHALL BE DONE IN ALL DRAWINGS SO THAT NO DIFFICULTY IS FACED BY SITE ENGINEERS DURING EXECUTION.

Architectural drawings including preparation Animated Computer model in 3D Max.

• After award of work Contractor should submit, design Basis Report for approval of Owner/consultant. On the approval of the same the detailed design & drawing of the buildings to be submitted. All the copies are to be submitted in 3 sets of hard copies & a soft copy.
• Contractor may depute their supervisor at site during placing of Anchor Bolts before casting of concrete.
• Change in Frame type, bay spacing, position & style of roof and wall bracing system as shown in tender drawing is permitted to optimize the structure.

However the fabrication of the structure is to be started only after approval of the “Good for Construction” drawings.

• CODES AND STANDARD

IS Code Practice for General Construction in Steel          : (IS:800-2007) IS Code Practice for Hot rolled sections and plates    : (IS:2062)

IS Code of Practice for Cold Form      : (IS:801-1975)

IS Code of Practice for Design Loads Part-3     : (IS:875-1987) IS Code of Practice for Earth Quake Loads Part-1           : (IS:1893-2002) American Welding Society Specification              : (AWS D1.1.98)

American Institute of steel construction             : (AISC)

Metal building manufactures association           : (MBMA) Manual of steel construction, 9th edition

The 1996 edition of low rise building system manual.

• MATERIAL OF CONSTRUCTION

1. Built up Section from high tensile steel grade as per ASTM A572 Grade-50, 345MPa.
2. Hot rolled secondary members for channels, angles, pipes confirming ASTM A572, Grade36, 250MP / IS: 2062, Gr. A, 250Mpa.

• Cold formed secondary member conforming to ASTM A570M grade 50, 340Mpa / IS513, IS801.

2062. Anchor bolts for foundation-ASTM A 36M / IS 2062.
2063. Bracing and sag rods to conform to IS 2062, Gr. A, 250Mpa / ASTM A36, 250Mpa. Minimum dia. for sag rods shall be 16 mm.
2064. Primary connection            bolts-      High       strength  bolts,      ASTM    A325-ANSI 18.2.3.7/18.2.3.6 M.

• Secondary connection bolts – Machine bolts ASTM, A307 / IS: 1367 CLASS

4.6 (part 1 to 3).

• Self drilling self tapping screws – AS3566.1-2202 corrosion resistance class 3 or equivalent.

1. Wind ties, if required, shall be minimum flat of size 40 mm x 6 mm.

1. Structural steel where ever not mentioned shall conform to Grade ‘A’ of IS: 2062

• DESIGN CRITERIA

1. Loads

 Live Load

Live Load on roof and frame shall be 0.75kN/m^2 as per IS-875 Part-2

Dead load

Dead load on roof shall be min. 0.15kN/m^2

Earthquake load

As per IS 1893 (Part-1) – 2002.

Importance Factor & Response reduction as per IS 1893 Part IV.

Wind load as per IS 875 Part 3, 1987

Other Loads

Design of all structures shall also consider any other relevant stresses imparted to the structure due to variation in daily and seasonal temperature, water label, erection and maintenance loads, creep shrinkage etc.

Wind and seismic forces shall not be considered to act simultaneously.

Individual members of the frame shall be designed for the worst combination of forces such as bending moment, axial force, shear force, torsion etc. resulted from the most critical combinations of loads as specified below.

1. LOAD COMBINATON:

1. Strength load combination for buildings with or without equipment shall be:

1.5* Dead Load + 1.5* Live / Imposed Load

1.5* Dead Load + 1.5* Live / Imposed Load + 1. 5* Piping/Fire fighting Load

1.5* Dead Load + 1.5* (Wind / Seismic Load) 0.9* Dead Load + I.5*(Wind / Seismic Load)

1.2* Dead Load + 1.2* Live/Imposed Load + 1.2* Piping/Fire fighting + 1.2* (Wind / Seismic load)

Service load combinations for general buildings shall be: 1.0* Dead Load + 1.0* Live/Imposed Load

1.0* Dead Load + 1.0* Live/Imposed Load 1.0* Piping/Fire fighting Load

1.0* Dead Load + 1.0* (Wind/ Seismic Load)

1.0* Dead Load + 1.0* Piping/Fire fighting Load + 0.8*(Wind/ Seismic Load)

1 .0 * Dead Load + 0.8* Live/Imposed Load + 0.8* Piping/Fire fighting Load + 0.8*(Wind/ Seismic Load)

Permissible stresses for different load combinations shall be taken as per relevant IS Codes.

1. GENERAL

Angle/Rod bracing for roof and wall is considered.

Main frame column base considered as pinned support.

Built up & Hot rolled sections to be designed as per Manual of Steel Construction, 9^th edition, American Institute of Steel Construction (AISC) & IS: 800.

Cold formed members to be designed as per 1996 Edition of Cold-Formed Steel Design Manual, American Iron and Steel, Institute (AISI), IS: 801&

IS: 513.

Welding shall be applied in accordance with: American Welding Society (AWS D1.1.98) Structural Welding Code – Steel. IS: 800, IS: 813 & IS: 816.

1. PERMISSIBLE DEFLECTIONS

The permissible vertical deflection for structural steel members shall be as specified below:

1. For Primary Span / 180
2. For Secondary Span / 150

Steel Structure simple span Beam shall be Span / 240.

Steel Structure for cantilever span Beam shall be Span / 120.

Permissible horizontal displacement at crane level / eaves level shall be Height / 150.

Permissible Deflection for Purlin shall be Span / 150. Permissible Deflection for Side Runner Shall be Span / 150

Permissible Deflection for Chequered Plate/Grating shall be Span / 200 or 6 mm, whichever is lower.

• QUALITY ASSURANCE PLAN ( QAP)

The Contractor shall adopt suitable quality assurance plan to ensure that materials and services under the scope of contract, whether manufactured or performed within the contractor’s works or at the owner’s site or at any other place of work are in accordance with the specifications. Such Plan shall be outlined by the contractor and shall be finally accepted by the owner/ consultant. QAP shall be submitted to owner/consultant for review and comment. Hard copies of final quality plans shall be submitted for stamping and approval.

Manufacturing Quality Plan (MQP) will detail out for all the components, various test/ inspection, to be carried out as per requirement of this specification and standard mentioned therein and quality practices and procedures followed by contractor’s Quality Control Organization, the relevant reference documents and standards, acceptance norms etc. during all stages of manufacturing including raw material procurement, in-process manufacturing, assembly, and final testing.

Field Quality Plans (FQP) will detail out for all the equipment, the quality practices and procedures etc. To be followed by the contractor’s “Site Quality Control Origination “, during various stage of site activities.

• REVIEW OF DESIGN AND APRPOVED GOOD FOR CONSTRUTION

DRAWINGS

• Complete structural design and construction drawings shall get reviewed by Owner / Consultant in detail before taking up any fabrication / manufacturing activity.
• For all structures, requisite number of prints of design calculation and working drawing shall be sent to Owner / Consultant for approval and site for construction.

• SURFACE PREPARATION OF STRUCTURAL STEEL

Surface Preparation: The surfaces to be painted shall be shot blasted as per SAE 2.5.

The following specification shall be used for painting of structural steel work.

• PAINTING ON STRUCTURAL STEEL

Painting for structural members shall be one or more coat of Red Oxide primer and 2 or more coats of Synthetic Enamel Paint of approved brand having thickness of 90-100 micron DFT at site.

• The following points must be observed for painting work:

1. Primer and paint shall be compatible to each other and should be from the same manufacturer.
2. The recommendation of the paint manufacturer regarding mixing, matching and application must be followed meticulously.
3. Technical representative of paint manufacturer should be available at site as and when required by Owner / Consultant for their expert advice as well as to ensure that the painting work is executed as per the instruction of paint manufactures. Paints and primers shall be supplied at site in original container with factory seal otherwise such paints and primers shall not be allowed to be used. Mode of application i.e. by spray, brush or roller shall be strictly as per recommendation of paint manufacturer. Painting materials must be used before the expiry date indicated on the containers. Number of coats and DFT per coat must be strictly followed as indicated above. If the desired DFT is not achieved for primer and finish paints in two coats (each), contractor shall be required to apply extra coat (s) to achieve the desired DFT without any extra cost to Owner / Consultant. Color shade for each coat of primer and finish paint must be different to identify the coats without any ambiguity. Shade for the final finish coat shall be decided by Owner / Consultant at site. All painting materials must be accompanied by manufacturers test certificates. However, Owner / Consultant has any doubt regarding quality of materials, he shall have the right to direct contractor to get the doubtful material tested or and provided (by contractor) testing agencies for which no extra payment shall be made to the contractor and the charges shall deem to be covered in the unit rates quoted for fabrication and erection of structural work.

• ERECTION AND SETTING OF STEEL STRUCTURE

• The erection of steel work shall be in accordance with Bureau of Indian Standard Specifications Nos. IS-800 and IS – 816.
• The contractor shall be responsible for the suitability, safety and capabilities of all plant and equipment used for erection.
• Prior to starting erection of fabricated structure, defects if any shall be rectified. The contractor shall give to the Owner / Consultant not less than 24 hours notice of his intention to set out or give levels for any part of works, in order that arrangements may be made for checking. The contractor shall

provide all necessary arrangements and assistance, which the Owner / Consultant may require for checking the setting out.

• The contractor shall erect the structural steel members in position, to dimension, and levels, as in relevant drawings and shall take care to see that component parts are not interchanged. Girders, stanchions etc., must rest fairly on their beds and will not be taken as erected until completely plumbed, aligned leveled, bolted or welded and strengthened, in every respect. The camber, if any, is to be maintained as shown in relevant drawings.
• Particular care should be taken to ensure free expansion and contraction wherever provided in the relevant design / drawings or so directed on site.
• While erecting, the holes in different component parts of structure should be made concentric with the use of drifts before any service bolts are fitted. No drifting shall be allowed except for bringing together several parts forming a member but the drifts must not be driven with such force as to disturb or damage the metal above the holes. Hammering of bolts to make holes concentric shall in no case be allowed. No nuts should be allowed to become loose and no unfilled bolt-holes are to be left in any part of the structure unless otherwise specified in the relevant drawings. Welding should be adopted wherever specified in the drawings. Wooden rams or mallets shall be used in forcing members to position, in order to protect metal from injury or shocks, chipped edges shall be finished off smooth and all concave surface rounded off.
• All erection tools and plants viz. derricks, cranes etc. will have to be provided by the contractor as required in the erection work. All erection devices must be removed after the work is over, in such a way that no damage is done to the erected structures. Any damages, in this respect must be rectified by the contractor at his own cost.
• The maximum tolerance for line and level of the steel work shall be + 3.0 mm on any part of the structure. The structure shall not be out of plumb more than

3.5 mm on each 10 M. Section of height and not more than 7.0 mm per 30 meter section. These tolerances shall apply to all parts of the structure unless mentioned in the drawings issued for erection purposes.

The Ultimate Guide to Pre-Engineered Buildings (PEB) & Steel Structures: Design, Components, and Advantages

Introduction: Why Pre-Engineered Buildings (PEB) Are Shaping Modern Construction In the evolving world of construction, businesses across industries demand faster, cost-effective, and sustainable building solutions. Traditional methods involving brick, mortar, and RCC are often slow, labor-intensive, and difficult to modify later.

This is where Pre-Engineered Buildings (PEB), also known as steel buildings, modular or prefabricated buildings, come into play. Leveraging advanced construction technologies, structural steel, and modular design, PEB systems are revolutionizing how we build industrial buildings, warehouses, manufacturing facilities, retail outlets, schools, hospitals, and even community centers.

What Are Pre-Engineered Buildings (PEB)?
A Pre-Engineered Building is a steel structure system that’s designed, fabricated, and quality-checked in a factory-controlled environment, then shipped to the site in
ready-to-assemble kits. This approach ensures:
1. Precision-engineered design
2. Superior structural integrity & durability
3. Rapid on-site installation (erection)
4. Reduced labor and minimal material wastage.

Where Are PEB Systems Used?
PEBs have become the go-to solution across multiple sectors due to their flexibility and robustness. Typical applications include:

Industrial: Warehouses, Factories & workshops, Manufacturing plants, Cold storage facilities, Petrochemical & power plants, Food processing facilities.
Commercial: Retail showrooms & shopping complexes, Office buildings, Exhibition halls.
Institutional & Public: Schools & colleges, Hospitals, Community centers, Sports arenas
Agricultural: Storage barns, Dairy facilities, Poultry farms.
Special structures: Aircraft hangars, Car parks, Logistics hubs.

The Key Components of a PEB Structure
A well-designed PEB integrates multiple systems:

Primary Members
Columns & Rafters (Portal Frames): Often with tapered design to use material efficiently.

Gable Frames & End Frames: Provide rigidity and shape.

Secondary Members
Purlins & Girts: Support roof & wall panels. Often made from cold-formed steel.

Eave Struts, Bracings, Sag Rods: Ensure structural stability.

Base Plates & Anchor Bolts: Connect the structure to the foundation.

Roof & Wall Systems
Roof Panels & Wall Panels: Typically metal sheets or sandwich panels with insulation.

Ridge Caps, Gutters, Downspouts: Manage rainwater.

Flashing: Seals edges & joints to prevent leaks.

Interior & Accessories
Doors, Windows, Louvers, Skylights: For light, air, and access.

Mezzanine Floors: Adds interior levels.

Crane Systems: Integrated for industrial operations.

Materials & Structural Steel in PEB
Types of Steel Used
Steel Grade Yield Strength Use Cases
E250A / E250BR ~350 MPa General framing, light to medium industrial
E350 ~550 MPa Heavy-duty industrial, crane systems.

PEB structures typically use:
Hot-rolled steel: For primary built-up members (columns, rafters)
Cold-formed steel: For secondary members like purlins, girts
Galvanized / Pre-galvanized: For corrosion protection
Special coatings (e.g. Burger paints) for longer life

Key Properties
Formability & weldability: Essential for fabrication & complex profiles.
Corrosion resistance: Extended life in harsh environments.
Fire & seismic resistance: Designed as per local codes.

Engineering Standards & Design Codes
PEB manufacturers adhere to strict international and local codes for safety and performance:
IS:800: Indian Standard for general steel design
AISI: Design of cold-formed steel structures
AWS D1.1: Welding standards for structural steel
Also considers:
Wind load, snow load, live load, dead load, seismic load
Material specifications & steel grade certifications

Fabrication, Quality & Construction Process

1. Design Engineering
Using 3D Modeling & BIM (Building Information Modeling) to ensure clash-free, optimized designs.

2. Factory Fabrication
Cutting, forming, welding, assembly: Controlled for precision.

Built-up members (columns, rafters) use hot-rolled plates welded into I-sections.
Secondary members like purlins, girts use cold-formed C/Z sections.

3. Quality Control & Testing
Dimension checks, welding tests, material certification, paint thickness checks.

4. On-Site Installation (Erection)
Delivered as a kit. Bolted together on pre-prepared foundations using anchor bolts, guided by design drawings.

Advantages of PEB Over Traditional Construction
Benefit Traditional RCC PEB Steel Structures
Speed Slow (12-18 months) Fast (4-6 months)
Cost Control Often overruns Predictable, fixed pricing
Quality Inconsistent Factory-controlled precision
Flexibility Difficult to expand Easy to extend or relocate
Sustainability Waste intensive Recyclable steel, minimal waste
Maintenance Cracks, damp Minimal, easy repaint & inspect.

Special Types of Steel Buildings
Clear Span Buildings: Large unobstructed interiors for aircraft hangars, sports stadiums.

Multi-Span Buildings: Large factories requiring multiple frames.

Single Slope & Portal Frames: For efficient water drainage & simplicity.

Low-Rise Buildings: Typical for most PEB.

Hybrid solutions for limited high-rise: Combining PEB with RCC for up to 10+ floors.

Case Study: PEB in Action
Project: Cold Storage & Processing Facility
Size: 30,000 sq ft
Structure: Clear span with mezzanine, integrated crane system
Steel: E350 grade primary, cold-formed secondary
Completion: 5 months (vs 12 with RCC)
Results: Early operation, saved 30% on project costs, reduced energy needs via insulated panels.

Conclusion: Why PEB is the Smart Choice
Whether you’re planning a warehouse, factory, hospital, or retail outlet, a PEB system delivers unmatched speed, cost efficiency, quality, and sustainability. By working with reputable PEB manufacturers & suppliers, you ensure compliance with international codes, superior fabrication quality, and long-term performance.

Short FAQs
What is a Pre-Engineered Building (PEB)?
A building fully engineered at a factory, fabricated with steel members, and assembled on-site for faster, higher quality construction.

What are PEB structures typically used for?
Warehouses, factories, cold storage, showrooms, hospitals, schools, aircraft hangars, and agricultural facilities.

How long does a PEB building take to complete?
Usually 30-50% faster than traditional RCC construction. Many projects complete in 4-6 months.

Is it possible to expand or modify PEB structures later?
Yes. PEBs are modular—easy to extend, relocate, or retrofit.

What standards are followed in PEB design?
IS:800, AISI for cold-formed, AWS D1.1 for welding, plus local wind, seismic, and fire codes.

How is steel protected from rust?
Via galvanizing, specialized paint systems, and quality controlled fabrication.

What’s the difference between hot-rolled and cold-formed steel?
Hot-rolled is used for heavy primary frames; cold-formed for lighter secondary members like purlins and girts.