INDUSTRIAL TRAINING REPORT

Submitted by,

DHINESHKUMAR V
(Reg. No. : 17202005)

Submitted in partial fulfilment of the requirements for the award of the degree in
MASTER OF ENGINEERING
(STRUCTURAL ENGINEERING)

Submitted to the Department of

CIVIL AND STRUCTURAL ENGINEERING

ANNAMALAI UNIVERSITY
ANNAMALAI NAGAR – 608002
JUNE – 2018

ANNAMALAI UNIVERSITY

1
 FACULTY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CIVIL & STRUCTURAL

ENGINEERING
III – SEMESTER, M.E (STRUCTURAL ENGINEERING)

STEI304: INDUSTRIAL TRAINING REPORT

This is to certify that Mr. DHINESHKUMAR V Reg.No.17202005 of

III-semester M.E. Structural Engineering has undergone the Industrial
Training at AALAYA HOUSING at Villupuram during 01.06.2018 to
30.06.2018. This Industrial Training Report is submitted in partial
fulfilment of the requirements for the award of the degree during the year
2018 – 2019.

Signature of the Guide Signature of the HoD

Examiners:
Place: Annamalai Nagar.
Date:

2
 ACKNOWLEDGEMENT
My profound thanks to Dr. P.N. RAGUNATH professor and head of the department of civil &
structural engineering for his support and encouragement to undertake the Internship training
during the course which is very essential to carry out the thesis and to update our knowledge in
the construction field.
I would like to express my gratitude to my thesis guide Dr. R. BASKAR Associate Professor,
Department of civil & structural engineering whose ingenious suggestions, support, effort and
encouragement during the Internship program.
I would like to thank Dr. R.M.SENTHAMARAI professor, Department of civil & structural
engineering for sharing his thoughts and suggestions regarding the internship to carry out our
program in an efficient and prosperous way.
I extend my sincere thanks to Er. T. Hemanathan Civil engineer, Aalaya Housing for providing
the valuable suggestions required to carry out this work.
Finally, I would like to thank my parents and friends for every help they offered for carrying out
the internship training very successfully.

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 TABLE OF CONTENT

`S.N CONTENT PAGE

O NO

I INTRODUCTION
1.1 PROGRAMME DETAILS 6
1.2 SCOPE AND OBJECTIVE OF THIS 8
PROGRAMME 13
1.3 CLASSIFICATION OF BUILDINGS 15
1.4 PRE – ENGINEERED BUILDING
1.5 FEATURES AND ADVANTAGES 31
II METHODOLOGY 32
2.1 COMPONENTS OF PEB 37
2.1.1 PRIMARY COMPONENTS 43
2.1.2 SECONDARY COMPONENTS 47
2.1.3 COMPONENTS ERECTION 50
2.1.4 ACCESSORIES
2.2 CONSTRUCTION OVERVIEW 58
III DESIGN OF PEB 59
3.1 GENERAL 62
3.2 DESIGN CYCLE
3.3 DETAILED PLANS AND SITE IMAGES 67
IV CONCLUSION
4.1 GENERAL

4
ABOUT THE ORGANIZATION – AALAYA HOUSING PVT LTD.

Aalaya Housing Private Limited is a professionally managed company with its corporate
base in Villupuram/Tamilnadu. The company was incepted on humble beginnings; the
very idea was conceived and implemented by a well-experienced Er. T. Hemanathan,
who envisioned a success story waiting to take shape in the Retail Business In this past
five years of standing in Construction Industry, they excelled in so many avenues of
construction and has done remarkable contributions to Society by constructing major
projects. They undertake/develop the construction of diverse Industrial Projects.
Multistoried Buildings, Hotels, Housing Complexes, Commercial Buildings Complexes.
At Aalaya Housing Private Limited, timely execution of projects has been our key stone
to success and we consistently strive to meet tough deadlines in their work. Although
nothing is perfect and there's always room for improvement, they strive to create the most
innovative, engaging and intuitive experiences by seamlessly blending our creativity with
basing usability principles and human psychology.

This Internship program was about the construction methods and practices
involved in Pre Engineered Building. The project site located in between the NH –
47 of Villupuram and Puducherry. The project is about construction of a warehouse
for the client Rajesh Kanna Food Factories Chennai. With this Internship
Programme I’m very much blessed with the opportunity to explore the new method
of construction that booming in the industry for past decade. In this report I have
tried my best to deliver my observations as much as possible in this 1 month of
internship programme. I was into the programme only at the mezzanine Flooring
stage and collected as much information I can on previous happenings in the project.
This project delivers me an outline in construction methods and practices in Pre
Engineered Buildings that I had come across in my theoretical paper last semester.

5
 CHAPTER 1

INTRODUCTION

1.1 GENERAL

Buildings & houses are one of the oldest construction activities of human beings the
construction technology has the beginning from primitive construction technology
to the present concept of modern house building. The present construction
methodology for buildings calls for the best aesthetic look, high quality & fast
construction, cost effective & innovative touch.

1.1 Programme details

This Internship program was about the construction methods and practices involved
in Pre Engineered Building. The project site located in between the NH – 47 of
Villupuram and Puducherry. The project is about construction of a warehouse for
the client Rajesh Kanna Food Factories Chennai. With this Internship Programme
I’m very much blessed with the opportunity to explore the new method of
construction that booming in the industry for past decade. In this report I have tried
my best to deliver my observations as much as possible in this 1 month of internship
programme. I was into the programme only at the mezzanine flooring stage and
collected as much information I can on previous happenings in the project. This
project delivers me an outline in construction methods and practices in Pre
Engineered Buildings that I had come across in my theoretical paper last semester.

PEB IN INDIA

India has the second fastest growing economy in the world and a lot of it, is
attributed to its construction industry which figures just next to agriculture in its
economic contribution to the nation. In its steadfast development, the construction

6
industry has discovered, invented and developed a number of technologies, systems
and products, one of them being the concept of Pre-engineered Buildings (PEB s).
As opposed to being on-site fabricated, PEB s are delivered as a complete finished
product to the site from a single supplier with a basic structural steel framework
with attached factory finished cladding and roofing components. The structure is
erected on the site by bolting the various building components together as per
specifications. PEB s are developed using potential design software. The onset of
technological advancement enabling 3d modelling and detailing of the proposed
structure and coordination has revolutionized Conventional building construction.
PEB has boon to Multi storey Buildings in India. Decking sheets with concrete over
can be used as roofing and raised to any extent above 40 meters. These have a
tracking rate of 80% in western countries. PEB Buildings is the future for India.
Most of the Indian business community is just started to realize the benefits of PEB
.Where you have been building with concrete for as long as anyone can remember,
it is difficult to change.
However India’s most progressive companies are seeing the benefits of PEB

Although PEB systems are extensively used in industrial and many other non–
residential constructions worldwide it is relatively a new concept in India .these
concept were introduced to the Indian markets lately in the late 1990’s with the
opening up of the economy and a number of multi nationals setting up their projects
.the market potential of PEB is 1.2 million tonnes per annum .the current pre –
engineered steel building manufacturing capacity is 0.35 tonnes per annum. The
industry is growing at the compound rate of 25 to 35 % [16].

1.2 SCOPE AND OBJECTIVES

SCOPE

1. Steel buildings in which excess steel is avoided by tapering the sections which in
turn is more economical and aesthetic than conventional steel building
7
 2. Tapering is done as per Bending Moment requirements as to avoid excess of steel.

3. Components are manufactured in factory and assembled on site.

4. Larger plate dimensions are used in areas of higher load effects in case of large
spans and high rise industrial building such as aircraft hangars, warehouse etc.

5. An efficiently designed Pre-Engineered Building can be lighter that the

conventional steel buildings by up to 30% and thus economical

PEB concept has been very successful and well established in North America, Australia
and is presently expanding in U.K and European countries. PEB construction is 30 to
40% faster than masonry construction. PEB buildings provide good insulation effect and
would be highly suitable for a tropical country like India.

The pre-engineered building calls for very fast construction of buildings and with
good aesthetic looks and quality construction. Pre-engineered Buildings can be
used extensively for construction of industrial and residential buildings.

OBJECTIVE

The following are objective of the programme and detailed report on Construction
methods and practices of the pre-engineered building is discussed in the upcoming
chapters.

1. To Study Pre-Engineered Building.

2. To Study the Effect Of P.E.B. For Following Issues:

i. To Reduce Complexity

ii. To Achieve Accuracy.

8
 iii. Speed of Work.

1.3 CLASSIFICATION OF BUILDINGS

A healthy trend in the form of growth in demand for construction works in

residential, Commercial, Institutional, industrial and infrastructure sectors are being
seen over the past decade. Modern Structures are much more complex and
sophisticated as compared to earlier period. One of the major changes which are
being felt by all is that the present structures are taller and thinner. 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 between steel, concrete and other construction materials.

Reinforced Cement Concrete Buildings

Reinforced concrete is concrete in which reinforcing bars have been integrated to

improve one or more properties of the concrete. For many years, it has been utilized
as an economical construction material in one form or another. A large part of its
worldwide appeal is that the basic constituent materials cement, sand, aggregate,
water, and reinforcing bars are widely available and that it is possible to construct a
structure using local sources of labour and materials.

Timber Buildings

Timber Buildings are more feasible in areas where wood materials are easily
accessible, wood construction is often considered to be the cheapest and best
approach for small housing structures. Wooden or timber buildings are constructed
in western countries where temperatures are too low. In wooden buildings the
members such as beams, columns and roofs are made of wood. The wooden
buildings may be in thatched, gypsum and ply wood sheeting etc.
Steel Buildings

Steel is the material of choice for design because it is inherently ductile and flexible.
It flexes under extreme loads rather than crushing and crumbling. Structural steel s
9
low cost, strength, durability, design flexibility, adaptability and recyclability
continue to make it the material of choice in building construction. Today s
structural steel framing is bringing grace, art and function together in almost
limitless ways and is offering new solutions and opportunities to create challenging
structures, which were once thought impossible. Steel structures have reserve
strength. Simple stick design in the steel framings allows construction to proceed
rapidly from the start of erection.

Conventional Steel Buildings

Conventional Steel buildings are consultant and conservative. The Structural

members are hot rolled and are used in conventional buildings. The materials are
produced or manufactured in the plant and are shifted to the site. The raw materials
are processed in the site for the desired form and erected. The modifications can be
done during erection by cut and weld process. Truss systems are used in
conventional system.

Pre-engineered Steel Buildings

Pre-engineered Steel Buildings are manufactured or Produced in the plant itself.

The manufacturing of structural members is done on customer requirements. The
detailed structural members are designed for their respective location and are
numbered, which cannot be altered; because members are manufactured with
respect to design features. These components are made in modular or completely
knocked condition for transportation. These materials are transported to the
customer site and are erected. Welding and cutting process are not performed at the
customer site. No manufacturing process takes place at the customer site. [6]
In the Design Process the frame data is assembled based on number of frame
members, number of joints, number of degrees of freedom, the conditions of
restraint and the elastic properties of the members. Based on this, the data is stored
and member section properties are computed.
• Allowable stress design method is used as per the AISC specifications.
10
 • Unless otherwise specified, the deflections will go to MBMA, AISC criteria and
standard industry practices.

• In Primary Framing Moment resisting frames with pinned or fixed bases.

• Using IS 875 Part 3 design wind loads are calculated and Using IS 1893- 2002
seismic loadings are calculated.

Pre-engineered Buildings vs. conventional buildings [16]

Property Pre-engineered-Steel Conventional Steel buildings

buildings

Structural • Pre-engineered buildings • Primary steel members are

weight are on the average 30% selected hot rolled t sections.

lighter because of the Which are, in many segments
efficient use of steel. of the members heavier than
Primary framing members what is actually required by
are tapered built up section. design? Members have
With the large depths in constant cross section
areas of higher stress. regardless of the varying
magnitude of the local

11
 • Secondary members are stresses along the member
light weight roll formed z or length.
c shaped members • Secondary members are
selected from standard hot
rolled sections which are
much heavier

Property Pre-engineered-Steel Conventional Steel buildings

buildings
Design Quick and efficient: since PEB’s Each conventional steel structure is
are mainly formed by standard designed from scratch with fewer
sections and connections design, design aids available to the engineer.
time is significantly reduced. Basic Substantial engineering and detailing
design based on international work is required from the very basic
design codes are used over and is required by the consultant with
over. fewer design aids.
Specialized computer analysis
design programs optimize material
required. Drafting is also
computerized using standard
details to minimize the use of
project custom details.

Delivery Average 6 to 8 weeks Average 20 to 26 weeks

Foundation Simple design, easy to construct and Extensive, heavy foundation

light weight. required.

12
 Since the connection of compounds The connections are normally
Erection
is standard the learning curve of complicated and differ from project
erection for each subsequent to project resulting tin increasing the
project is faster. time for erection of the buildings.

Cost of PEB manufactures usually Substitution of hot rolled sections

stock a large amount of that can infrequently rolled by mills is
Charge order be flexibly used in many types expensive and time consuming.
of PEB projects.

Building Designed to fit the system with Every project requires different and
standardized and inter special design accessories and
Accessories changeable parts. Including pre special sourcing for each item.
designed flashing and trims. Flashing and trims must be uniquely
Building accessories are mass designed and fabricated.
produced for economy and are
available with the building.

Future Future expansion is very easy Future expansion is most tedious and
and simple. more costly.
Expansion

13
 Single source of responsibility Multiple responsibilities can result
is there because the entire job in question of who is responsible
Safety is being done by one supplier. when the components do not fit in
properly, insufficient material is
All components have been
supplied or parts fail to perform
specified and designed
particularly at the
supplier/contractor interface.
Components are custom designed
for a specific application on a
specific
Property Pre-engineered-Steel Conventional Steel buildings
buildings
Performance specially to act together as a job. Design and detailing errors are
system for maximum possible when assembling the
efficiency, precise fir and peak diverse components into unique
performance in the field. buildings.

1.4 PRE-ENGINEERED BUILDINGS or (PEB)

General

India being a developed country massive house building construction is taking

place in various parts of the country. [10] Since 30% of Indian population lives in
towns and cities; hence construction is more in the urban places. The requirement
of housing is tremendous but there will always be a shortage of house availability
14
as the present masonry construction technology cannot meet the rising demand
every year. Hence one has to think for alternative construction system for steel or
timber buildings, but timber is anyway not suitable to tropical countries like India.

In structural engineering, a pre-engineered building (PEB ) is designed by a

manufacturer to be fabricated using a pre-determined inventory of raw materials
and manufacturing methods that can efficiently satisfy a wide range of structural
and aesthetic design requirements. Within some geographic industry sectors these
buildings are also called Pre-Engineered Metal Buildings. Historically, the primary
framing structure of a pre-engineered building is an assembly of I shaped members,
often referred as I beam. In PEB, I section beams used are usually formed by
welding together steel plates to form of I section. I section beams are then field-
assembled (e.g. bolted connections) to form the entire frame of the pre-engineered
building. Cold formed Z and C-shaped members may be used as secondary
structural elements to fasten and support the external cladding. Roll-formed
profiled steel sheet, wood, tensioned fabric, precast concrete, masonry block, glass
curtain wall or other materials may be used for the external cladding of the building.

In order to accurately design a pre-engineered building, engineers consider the clear

span between bearing points, bay spacing, roof slope, live loads, dead loads,
collateral loads, wind uplift, deflection criteria, internal crane system and
maximum practical size and weight of fabricated members. Historically, pre-
engineered building manufacturers have developed pre-calculated tables for
different structural elements in order to allow designers to select the most efficient
I beams size for their projects.

In pre-engineered building concept the complete designing is done at the factory

and the building components are brought to the site in CKD (Completely knock
down condition). These components are then fixed / jointed 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-
15
engineered Buildings can be used extensively for construction of industrial and
residential buildings. The buildings can be multi storied (4-6 floors). These
buildings are suitable to various environmental hazards. Pre-engineered buildings
can be adapted to suit a wide variety of structural applications; the greatest
economy will be realized when utilizing standard details. An efficiently designed
pre-engineered building can be lighter than the conventional steel buildings by up
to 30%. Lighter weight equates to less steel and a potential price savings in
structural framework.

1.5 Features and Advantages

Features: 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. [6]

Pre-engineered steel buildings can be fitted with different structural accessories

including mezzanine floors, canopies, fascias, interior partitions etc. and the
building is made water proof by use of special mastic beads, filler strips and trims.
This is very versatile buildings systems and can be finished internally to serve any
functions and accessorized externally to achieve attractive and unique designing
styles. It is very advantageous over the conventional buildings and is really helpful
in the low rise building design.
Pre-engineered buildings are generally low rise buildings however the maximum
eave height can go up to 25 to 30 metres. Low rise buildings are ideal for offices,
houses, showrooms, shop fronts etc. The application of pre-engineered buildings
concept to low raise buildings is very economical and speedy. Buildings can be
16
constructed in less than half the normal time especially when complemented with
the other engineered sub systems.

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

Advantages:

Reduction in Construction Time: Buildings are typically delivered in just a few weeks
after approval of drawings. Foundation and anchor bolts are cast parallel with finished,
ready for the site bolting. In India the use of PEB will reduce total construction time of
the project by at least 50%. This also allows faster occupancy and earlier realization of
revenue.

Lower Cost: Due to the systems approach, there is a significant saving in design,
manufacturing and on site erection cost. The secondary members and cladding nest
together reducing transportation cost.

Flexibility of Expansion: Buildings can be easily expanded in length by adding

additional bays.

Also expansion in width and height is possible by pre designing for future
expansion.

Larger Spans: Buildings can be supplied to around 80M clear spans.

Quality Control: As buildings are manufactured completely in the factory under

controlled conditions the quality is assured.

17
Low Maintenance: Buildings are supplied with high quality paint systems for
cladding and steel to suit ambient conditions at the site, which results in long
durability and low maintenance costs. Energy Efficient Roofing and Wall Systems:
Buildings can be supplied with polyurethane insulated panels or fiberglass blankets
insulation to achieve required U values [16]].

Architectural Versatility: Building can be supplied with various types of fascias,

canopies, and curved eaves and are designed to receive pre-cast concrete wall
panels, curtain walls, block walls and other wall systems.

Single Source Availability: As the complete building package is supplied by a

single vendor, compatibility of all the building components and accessories is
assured. This is one of the major benefits of the pre-engineered building systems.

Benefits of PEB:

Pre-engineered building systems provide real value to clients without sacrificing

durability, seismic and wind resistance, or aesthetic appearance. Cost savings begin
right at the drawing preparation stage. Systems engineering and fabrication
methods help reduce interim financing costs through faster construction and
minimized field erection expense. An added benefit is earlier occupancy of the
facility and a head start on day-to-day operations by the client.
Apart from costs, there is an assurance of factory-built quality and uniformity in
design and fabrication. These systems are also energy efficient; incorporate
watertight roofing systems; enable easy disassembly or future expansion and have
the lowest life cycle maintenance costs.
Adding to these; there is no mess of sand and cement; power savings; walkable
ceilings; progressive and non-progressive panel systems for walls. A poor man can
be provided with a home created under strict quality control and having a longer
life span, with greater safety against natural disasters like earthquakes and
cyclones.

18
Moreover, it is possible to create the building in required form and shape. And the
'system approach' renders a holistic way of thinking at one platform for consultants,
designers, architects, and builders. Thus it tends to achieve a perfect harmony
among various stringent specifications and aesthetic requirements in a most
economical way.

In nutshell, the benefits may be summarized as under

• Easy future expansion/modification.

• Weather proof and fire hazards.

• Optimized design of steel reducing weight.

• International Quality Standards

• Seismic & Wind pressure resistant.

• Quality design, manufacturing and erection, saving around 30-40% of

project time

• Quick delivery and Quick turn-key construction.

• Pre-painted and has low maintenance requirement.

• Erection of the building is fast.

• The building can be dismantled and relocated easily.

• Future extensions can be easily accommodated without much hassle.

• Increased Life cycle performance and cost competitiveness

• Environment friendly structures

• Better rainwater harvesting through gutters and down-take arrangements

• Lighter weight; savings in foundation cost of 10-20 percent

19
 • The building can be dismantled and relocated easily

• Easy integration of all construction materials

• Energy efficient roof and wall system using insulations.

• Suitability for Hilly regions and other geographically difficult areas

• Unlimited architectural possibilities

Applications of PEB

Almost every conceivable building use has been achieved with PEB the most common
applications are industrial, institutional and commercial.
In India, Pre-engineered building systems find application primarily in the
construction of Warehouses, & Industrial sheds & Buildings. The recent focus has
also shifted to cover rural as well as urban, individual and mass housing projects,
farmhouses, slum re-organization projects and rehabilitation projects, amenity
structures like health centre, kiosks, primary schools, panchayats etc. The
pharmaceutical industries and exhibition centre, and functional requirements like
offices, seminar halls, call centre, supermarkets, showrooms etc. [6] have also
attracted PEB. Earthquake-resistant buildings are the recent applications of PEB
with wide and immediate acceptance.
PEB concept has acted as a catalyst in the infrastructure development of the country.
Single storied 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.
Applications of Pre-engineered steel buildings include

• Houses & Living Shelters

• Factories

• Warehouses

20
 • Sport Halls ( Indoor and Outdoor)

• Aircraft Hangers

• Supermarkets

• Workshops

• Office Buildings

• Labour Camps

• Petrol Pumps/Service Buildings

• Schools

• Community centres

• Railway Stations

• Equipment housing/shelters.

There is a great possibility of improving the aesthetic quality with a choice of

roofing elements, exterior finishes, weather-sheds, colour system and variations in
planning as well as massing.

PROFILE OF PEB

All over the world, pre-engineered building system or PEB system is becoming an
eminent segment in pre-engineered construction industry. It has become possible
because pre-engineered building system encompasses all the characteristics that are
compatible to modern demands viz. speed, quality and value for money.
Preengineered buildings find many pre-engineered construction applications,
which could be intrinsic and high-end.

21
PEB prospect in the world:

Technological improvement over the year has contributed immensely to the

enhancement of quality of life through various new products and services. One such
revolution was the pre-engineered buildings. Through its origin can be traced back
to 1960 s its potential has been felt only during the recent years. This was mainly
due to the development in technology, which helped in computerizing the design.

PEB concept has been very successful and well established in North America,
Australia and is presently expanding in U.K and European countries. PEB
construction is 30 to 40% faster than masonry construction. PEB buildings provide
good insulation effect and would be highly suitable for a tropical country like India.
PEB is ideal for construction in remote & hilly areas. [16]. A recent survey by the
Metal Building Associations (MBMA) shows that about 60% of the non- residential
low rises building in USA are pre-engineered buildings.

MARKET POTENTIAL

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 lately in the late 1990 s with the opening up
of the economy and a number of multi nationals setting up their projects. The
market potential of PEB is 12 lakh Metric tonnes per annum. The current pre-
engineered steel building manufacturing capacity is 0.35 million tonnes per annum.
The industry is growing at the compound rate of 25 to 30 %. [16]
FUTURE OF PEB

The steel structures (SS) market in India is in excess of 4.5 Mn.MT, growing at a
rapid pace of more than 10% p.a. over the past few years. This market has
22
experienced a higher growth compared to both Indian steel industry as well as
Indian construction GDP. Overall construction sector accounts for majority
(greater than 80%) of the steel structures market (volume terms) in India.
The current pre-engineered steel building manufacturing capacity is 0.35 million tonnes
per annum. The industry is growing at the compound rate of 25 to 30%.

2.4.1 PRODUCTION

Pre-engineered Steel Buildings are tailor made buildings which are those fully
manufactured in the factory after designing. This fabrication is done in a controlled
environment with latest technology. The production is done under standard
conditions. The Raw material required is imported from major companies like Tata
BlueScope to all the companies in India.
Historically, the primary framing structure of a pre-engineered building is an
assembly of I shaped members, often referred as I beam. In pre-engineered
buildings, I beams used are usually formed by welding web and flange plates
together to form I section. I beams are then field assembled (e.g. bolted
connections) to form the entire frame of the pre-engineered building. Some
manufacturers taper the framing members (varying in web depth) according to the
local loading effects. Larger plate dimensions are used in areas of higher load
effects.

Cold formed Z and C-shaped members may be used as secondary structural

elements to fasten and support the external cladding. Roll-formed profiled steel
sheet, wood, tensioned fabric, precast concrete, masonry block, glass curtain wall
or other materials may be used for the external cladding of the building.
MANUFACTURING OR PROCESSING

Manufacturing is done through the raw material which is imported from steel
production companies. The imported steel is in the form of rolled sheets. For the

23
hot rolled and cold formed sheets cutting is done to desired dimensions and welded
with submerged arc welding.

The PEB production process primarily consists of FOUR major parallel processing lines,
as under:

1. Built-up members for Primary frame

2. Cold forming for Secondary framing

3. Profiling for Roof and Wall sheeting

4. Accessories & Bracings like Gutters,

down take pipes, ridge Vents, Skylights,

clips etc.
The design and final processing inspection is done for production, ready for shipment
in completely knocked Down Condition (CKD) conditions.

1. Plate cutting using Shear/Plasma/Multi-torch through nesting software for

optimized use of plate area.

2. H-beam welding on automatic welding machines using SAW or MIG

welding process

3. Fabrication for fitments like end plates, stiffeners and connections cleats.

4. Cleaning the surface for painting

5. Slitting HR coils for cold forming operations to make Z and C sections with

punching
6. Cutting and threading sag rods and bracing rods

7. Fabrication of Diagonal bracing angles or pipes

8. Profiling the Galvalume / Zincvalume sheets for roofing and wall cladding

9. Manufacturing Gutters, down take pipes in press bend

24
 10. Procuring and assigning required matching fasteners for connections

11. Organizing some bought out accessories

12. Quality control tests & inspection; and matching with project wise Bill of

Quantities as given by the engineering department.

13. Dispatching to project sites as per sequence of erection.

SCOPE FOR FUTURE STUDY

TRACKING GROWTH OF PEB

Emerging from their hiding places in concrete columns pre-engineered steel

structures (PEB s) are innovative solutions for construction projects across several
sectors now as discovers.
As Infrastructure construction across the country is combining speed, economy,
safety, strength and aesthetics at awe inspiring levels, steel structures, until now a
primary foundation element, have risen as complete solutions in construction
projects for various structural requirements. India is growing fast as an economy
for pre-engineered buildings (PEB s) as it is witnessing a boom in the
infrastructure sector. Structural steel buildings or PEB s are addressing parameters
including finishes, environment control and life cycle with a panache derived from
product innovation and technology advancement.
Emerging as a strong alternative to conventional concrete construction methods,
PEB in India is validated by the 33% market share of PEB s in the construction
industry. While this figure is lower than some European countries, it marks India's
growing global market share at 9.5 percent -- a step ahead of China's 8.5 percent.
"The market demand is pegged at 425,000 TPA with a 15% growth per
annum,"(Kirby). "Current market size is around Rs.3.500 Crores and it is expected
to grow at 10% to 15% per year,"

25
Strength Building:

With the country's five year plan catering for infrastructure addition in the form of
airports, metros and bridges sector differentiation is expected to separate industrial
buildings and building systems. These include Design & Engineering,
Manufacture and Construction & Erection. This pattern of restructuring indicates
an industry that sees PEB s coming into its own with experiencing exponential
growth with diversification into various sectors and segments.
Add to that the reduced time to completion with the benefit of quality, and there is recipe
for success.
"PEB is getting its due credit as a favourable alternative construction
methodology in India today. More sectors are realizing the benefits of metal over
brick and mortar. The scope of metal/steel buildings is very vast for the Indian
market. PEB proves to be relevant and beneficial to several construction verticals
including warehousing, infrastructure, oil & gas refineries as well as group
housing,"(Kirby). "The advantages of having a steel structure or building over
traditional concrete are far too many. Primarily, speed and quality of construction
are the top two benefits. Steel buildings are fire, quake and cyclone resistant hence
from a safety and longevity perspective, these buildings are timeless".

SCOPE FOR FUTURE STUDY

Multi Storey Buildings:

PEB has boon to Multi storey Buildings in India. Decking sheets with concrete
over can be used as roofing and raised to any extent above 40 meters. These have
a tracking rate of 80% in western countries.

26
Fibre Glass Wool Insulation for PEB:

A critical and necessary ingredient in the PEB System is thermal and acoustic
insulation. This is necessary to minimize heat gain (or energy loss, for an air
conditioned building) as well as to provide acoustic insulation from heavy rain and
other outside noises. In a typical PEB structure, the roof accounts for approx. 40
to
50% of total heat gain, while walls account for approx. 15 to 20% of heat gain. [6]
Almost 100% of PEB s world-wide are insulated for the following reasons.

• Minimize heat gain

• Maximize thermal comfort

• Minimize energy loss, cooling load and operating cost for air conditioned
buildings

• Provide acoustic insulation

• Prevent unwanted moisture condensation

Cellular Columns or Rafters:

Cellular beams can achieve the same strength as solid I beams of the same depth
with significantly less steel use resulting in Lighter weight. These beams offer
designers a number of opportunities for sizes and sections including varying the
depth of the beam and creating tapered sections.

Standard Seam Roofina:

Standard Seam roofina which is particularly used for sheeting. Sheets are not
punched and rolled to one above the other in order to protect leakage of water
during rains.

27
 CHAPTER 2
METHODOLOGY
GENERAL:
Pre-engineered Buildings are custom designed to meet client s requirements. PEB
are defined for definite measurements. The produced members fit to the designed
dimensions. Measurements are taken accurately for the requirements. The basic
parameters that can define a PEB are as follows.

WIDTH OR SPAN OF BUILDING:

The centre to centre length from one end wall column to the other end wall column
of a frame is considered breadth or span of the building. The width between two
columns can be measured as span. The span length for different buildings varies.
The design is done on span length given by customer. [16] The basic span length
starts from 10 to 150 meters or above with intermediate columns. Aircraft hangars,
manufacturing industries, Stadiums possess major span width. No modifications or
extending span be done.

LENGTH OF BUILDING:

The length of PEB is the total length extending from one front end to the rear end of the
building. The length of PEB can be extendable in future.

BUILDING HEIGHT:

Building height is the eave height which usually is the distance from the bottom of
the main frame column base plate to the top outer point of the eave strut. When
columns are recessed or elevated from finished floor, eave height is the distance
from finished floor level to top of eave strut.
ROOF SLOPE:

28
This is the angle of the roof with respect to the horizontal. The most common roof
slopes are 1/10 and 1/20 for tropical countries like India. The roof slope in snow
fall locations can go up to 1/30 to 1/60. Any practical roof slope is possible as per
customer s requirement.

DESIGN LOADS:

Unless otherwise specified per-engineered buildings are designed for the following
minimum loads. The designed loads play a crucial role in case of PEB. The failure
of the structures occurs if not properly designed for loads.

The determination of the loads acting on a structure is a complex problem. The

nature of the loads varies essentially with the architectural design, the materials,
and the location of the structure. Loading conditions on the same structure may
change from time to time, or may change rapidly with time.
Loads are usually classified into two broad groups as dead loads and live loads.
Dead loads (DL) are essentially constant during the life of the structure and
normally consist of the weight of the structural elements. On the other hand, live
loads (LL) usually vary greatly. The weight of occupants, snow and vehicles, and
the forces induced by wind or earthquakes are examples of live loads. The
magnitudes of these loads are not known with great accuracy and the design values
must depend on the intended use of the structure. [6]

Dead Load:

The structure first of all carries the dead load, which includes its own weight, the
weight of any permanent non-structural partitions, built-in cupboards, floor
surfacing materials and other finishes. It can be worked out precisely from the
known weights of the materials and the dimensions on the working drawings.

Live Load:

29
All the movable objects in a building such as people, desks, cupboards and filing
cabinets produce an imposed load on the structure. This loading may come and go
with the result that its intensity will vary considerably. At one moment a room may
be empty, yet at another packed with people. Imagine the `extra' live load at a lively
party.

Wind loads:

Wind has become a very important load in recent years due to the extensive use of
lighter materials and more efficient building techniques. A building built with
heavy masonry, timber tiled roof may not be affected by the wind load, but on the
other hand the structural design of a modern light gauge steel framed building is
dominated by the wind load, which will affect its strength, stability and
serviceability. The wind acts both on the main structure and on the individual
cladding units. The structure has to be braced to resist the horizontal load and
anchored to the ground to prevent the whole building from being blown away, if
the dead weight of the building is not sufficient to hold it down. The cladding has
to be securely fixed to prevent the wind from ripping it away from the structure.

Roof load:

Live loads produced by maintenance activities, rain, erection activities, and other
movable or moving loads by not including wind, snow, seismic, crane, or dead loads.

Roof snow load:

Gravity load induced by the forces of wind blowing from any horizontal direction.

Collateral loads:

The weight of any non-moving equipment or material such ceilings, electrical or

mechanical equipment, sprinkler system, or plumbing.

30
Auxiliary loads:

Dynamic loads induced by cranes, conveyers, or other material handling systems.

Seismic loads:

Horizontal loads acting in any direction structural systems due to action of an earthquake.

Floor Live loads:

Loads induced on a floor system by occupants of a building and their furniture,

equipment, etc.

BAY SPACING:

The distance between the two adjacent frames of a building is called as a Bay
spacing. The spacing between two frames is a bay. End Bay length is the distance
from outside of the outer flange of end wall columns of centre line of the first
interior frame columns. Interior bay length is the distance between the centre lines
of two adjacent interior main frames Columns. The most economical bay spacing
is 7.5m to 8.0m. However bay length up to 10m is possible.

TYPES OF FRAME:

A frame is a combination of Columns and inclined beams (rafters). There are

various type of frames. [6]

Clear Span (CS):

The span length between two columns without any obstruction. It has split Beams
with ridge line at the peak or centre of the building. The maximum practical width
or span is up to 90 meters, but it can also be extended up to 150 meters in case of
Aircraft Hangars. Arched Clear Span: The column is an RF column while the
Rafter is curved. It has no ridge line and peak. The curved roof rafter is used in for

31
aesthetic look. The maximum practical is up to 90 meters, but can be extended to
120 meters.

Multi Span (MS):

The Multi spans (MS) are those which have more than 1 span. The intermediate
column is used for the clear span in which width of each span is called width
module.

Arched Multi Span (AMS):

Arched multi span has RF column and a curved Rafter with one intermediate
column.

It has width module for the entire span.

Multi Span (MS):

The Multi Span (MS) has more than one intermediate span. It has three width modules
with one ridge line.

Single Slope:

It has two columns with different heights having Roof sloping on both the columns.

Multi Gable:

Multi gable has two or more spans where no intermediate columns are used. The columns
are added to the extended width and columns are not placed at the ridge lines.

Roof Systems:

It has straight columns with Roof having supports are not by TPCA.

Lean To:

Lean to slopes is used extremely for an extending to a building on either side with
short span. The rafters rest on column designed for lean to on one side and rests on
the main column of the building.
32
Canopy:

Canopies are used in case of open ends where there is an easy access. There are
columns in straight path having roof extended to a large length.

SUBSYSTEMS

Major companies use standard components and designs to manufacture a wide

range of structural subsystems according to customers' requirements. These
structural subsystems fulfil the requirements of two type’s viz. Aesthetic and
Functional. They produce a large number of structural subsystems according to
exact specifications as the strength of the pre-engineered building system depends
largely on various incorporated structural subsystems. Subsystems are available for
following structures End wall Roof Extension: End wall roof extensions consist
of end wall panel, Roof panel, Gable trim, soffit panel, and end wall rafter. The end
wall is extended to an extent under end wall panel support.
Sidewall Roof Extension: The sidewall roof extension has the same assembly but the
soffit panels are above the Roof Extension Rafter.
Centre Curved Fascia: The centre curved fascia consist Backup panel, soffit panel.
It is an assembly of Cap flashing, Fascia panel with valley gutter or eave gutter on
the rafter with rigid frame support.

Bottom Curved Fascia: The entire assembly of Centre curved fascia contains for the
Bottom curved Fascia a slight change in Connection of wall panel to Frame.

Top and Bottom Curved Fascia: In this the assembly is a combination of Top Curved
Fascia which has curvature at top and bottom curved Fascia having bottom Fascia. [6]

Roof Platform: The roof platform has Grating on above and roof panels on the
sides.

33
2.1 COMPONENTS OF PEB

A typical assembly of a simple metal building system is shown below to

illustrate the Synergy between the various building components as described
below and the every component is discussed in detail as follows

The following are the several components of Pre - engineered building

1. Primary components

2. Secondary components

3. Sheeting (or) cladding

4. Accessories

34
STRUCTURAL FRAMING

All framing members shall be shop fabricated for field bolted assembly. The
surfaces of the Bolted connections shall be smooth and free from burrs or
distortions. All shop connections shall be in accordance with the manufacturer's
standard design practices.

2.1.1 PRIMARY COMPONENTS

All rigid frames shall be welded built-up "I" sections or hot-rolled sections. The
columns and the rafters may be either uniform depth or tapered. Flanges shall be
connected to webs by means of a continuous fillet weld on one side. All end wall
roof beams and end wall columns are in cold formed "C" sections, mill-rolled
sections, or built-up "I" sections depending on design requirements. All base plates,
splice and flanges shall be shop fabricated to include bolt connection holes. Webs
are shop fabricated to include bracing holes. [16].

35
 3.1 Pictorial representation of Primary component

Main framing:

Main framing basically includes the rigid steel frames of the building. The PEB rigid
frame comprises of tapered columns and tapered rafters (the fabricated tapered
sections are referred to as built-up members). The tapered sections are fabricated
using the state of art technology wherein the flanges are welded to the web. Splice
plates are welded to the ends of the tapered sections. The frame is erected by bolting
the splice plates of connecting sections together. All rigid frames shall be welded
built – up "I" sections or
or hot-rolled sections. The columns and the rafters may be either uniform depth or
tapered. Flanges shall be connected to webs by means of a continuous fillet weld
on one side. All end wall roof beams and end wall columns shall be cold formed
"C" sections, mill-rolled sections, or built-up "I" sections depending on design
requirements. Plates, Stiffeners, etc. All base plates splice plates, cap plates, and
stiffeners shall be factory welded into place on the structural members. Built- up I
section to build primary structural framing members (Columns and Rafters)

36
Columns:

The main purpose of the columns is to transfer the vertical loads to the foundations.
However a part of the horizontal actions (wind action) is also transferred through
the columns.
Basically in pre-engineered buildings columns are made up of I sections which are
most economical than others. The width and breadth will go on increasing from
bottom to top of the column. I section consists of flanges and web which are made
from plates by welding.

Rafter

Fig. 3.2 Schematic representation of a Column

Rafter:
A rafter is one of a series of sloped structural members (beams) that extend from
the ridge or hip to the wall-plate, down slope perimeter or eave, and that are
designed to support the roof deck and its associated loads.

37
 Fig. 3.3 Schematic representation of a Rafter

2.1.2 SECONDARY COMPONENTS

Purlins, Grits and Eave struts are secondary structural members used as support
to walls and roof panels. Purloins are used on the roof; Grits are used on the walls
and Eave struts are used at the intersection of the sidewall and the roof. They are
supplied with minimum yield strength of 34.5 KN/m. Secondary members act as
struts that help in resisting part of the longitudinal loads that are applied on the
building such as wind and earthquake loads and provide lateral bracing to the
compression flanges of the main frame members for increasing frame capacity.
Purloins, Grits and Eave struts are available in high grade steel conforming to
ASTM 607 Grade 50 or equivalent, available in 1.5 mm, 1.75 mm. 2.0 mm, 2.25
mm, 2.5 mm and 3.0 mm thickness. They come with a pre-galvanized finish, or
factory painted with a minimum of 35 microns (DFT) of corrosion protection
primer. Purlins and girts shall be cold formed "Z" section With stiffened flanges.
Flange stiffeners shall be sized to comply with the requirements of the latest edition
of AISI.

Purlins and Girts:

Purlins and girts shall be roll formed Z sections, 200 mm deep with 64 mm flanges
shall have a 16 mm stiffening lip formed at 45 to the flange. Purlins and girts shall
38
be cold-formed "Z" sections with stiffened flanges. Flange stiffeners shall be sized
to comply with the requirements of the latest edition of AISC .Purlin and girt
flanges shall be unequal in width to allow for easier nesting during erection. They
shall be pre punched at the factory to provide for field bolting to the rigid frames.
[6] They shall be simple or continuous span as required by design. Connection
bolts will install through the webs, not flanges

Fig. 3.4 Schematic representation of a Purlin

Eave Struts

Eave Struts shall be unequal flange cold-formed "C" sections. Eave struts are 200
mm deep with a 104 mm wide top flange, a 118 mm wide bottom flange, both are
formed parallel to the roof slope. Each flange has a 24 mm stiffener lip.

39
 Fig. 3.5 Schematic representation of a Eave Strut

Bracings:

The Cable bracing is a primary member that ensures the stability of the building against
forces in the longitudinal direction such as wind, cranes, and earthquakes.
Diagonal bracing in the roof and sidewalls shall be used to remove longitudinal
loads (wind, crane, etc.) from the structure. This bracing will be furnished to length
and equipped with bevel washers and nuts at each end. It may consist of rods
threaded each end or galvanized cable with suitable threaded end anchors [6]

3.2.3 SHEETING OR CLADDING:

The sheets used in the construction of pre- engineered buildings are composed of the
following:

Base metal of either Galvalume coated steel .Galvalume coating is 55%

Aluminium and about 45% Zinc by weight. An exterior surface coating on painted
sheets of 25 microns of epoxy primer with a highly durable polyester finish.

An interior surface coating on painted sheets of 12 microns of epoxy primer and

modified polyester or foam. The sheeting material is cold-rolled steel, high tensile
550 MPA yield stress, with hot dip metallic coating of Galvalume sheet.

40
Fig. 3.7 Schematic representation of a GI Sheets

3.8 Pictorial representation of Secondary component.

41
Bracing
Diagonal bracing in the roof and sidewalls shall be used to remove longitudinal
loads (wind, crane, etc.) from the structure. This bracing will be furnished to length
and equipped with bevel washers and nuts at each end. It may consist of rods
threaded each end or galvanized cable with suitable threaded end anchors. If load
requirements so dictate, bracing may be of structural angle and/or pipe, bolted in
place. [16]

3.9 Pictorial representation of Bracings component.

42
Welding
Welding is a fabrication or sculptural process that joins materials, usually metals.
In Pre-engineered Steel Buildings the hot rolled steel sections are subjected to
submerged arc welding. Shielding gas is used in order to protect the welding region.
Welding is
Done by passing the Steel plates into the welding machine, which welds along the
joints. In PEB the Tapered sections are welded, but at some locations manual
welding is done. Double side welding is preferred according to Indian Code but
Single side Welding is much beneficent because it increases the Quality of steel
sections. Single side welding is more economical, all manufactures follow the
American code which states Single side welding.
Base plates are welded to base of columns for the structural strength. These base
plates are provided with bolt holes. Anchor bolt dimensions are taken into account
for Base plate preparation. [16]
Anchor Bolts:
Anchor bolts are manufactured with circular steel rods having threading portion at
the top for bolting and bent up at the bottom for Foundation. These are bent at 90
degrees for embedding into the soil. The dimensions for Anchor bolts are taken from
support reactions of the columns.

3.10 Pictorial representation of anchoring component.

43
Surface Preparation:
The surface of columns and rafters are prepared in order to protect it from rusting.
Abrasive paper is used to scrub the top layers of columns and rafters in order to
remove accumulated rust on the top of the sections. This is old method, it is done
manually. Advancement technologies avoided manual procedure and brought Sand
blasting and short blasting into existence.
Sand blasting: Sand Blasting is a method in which sand is blown with high
velocities to the members. This is blown with sand particularly with 2 to 4 mm thick
sand and surface is cleared.
Short Blasting: Short blasting is a latest process in which members are sent into
the machine and hit with iron balls of 3mm thick under a huge velocity. Periodical
removal of rust is done in case of short blasting. Short blasting is observed as more
efficient surface cleaning process

Varnishing or Painting: Normally the primary and secondary steel are coated
with one coat (35 microns) of red oxide paint without any special treatment to steel.
However, if some special paint has to be applied to steel in order to give better
anticorrosion properties etc. then the steel members have to be shot-blasted and
then coated with the special paints.

2.1.3 COMPONENTS ERECTION

The major components comprise of rigid frame, columns and rafter, eave struts,
purlins, girts, flange braces, end-wall columns and bracing systems which may be
cables, rods angles or portals. All materials for the first bay erection are prepared.
The rafter sections required are identified by part number, and then assembled as
near as possible to their lifting positions. Then the first four columns are erected at
the braced bay, meanwhile the part number, Orientation and position over anchor

44
bolts were verified. Next step is to position the crane for lifting the assembled rafter
sections.

Raising Rigid Frames:

The intermediate or interior frames nearest the bearing end wall are usually erected
first. This bay usually contains the diagonal bracing. The proper completion and
plumbing of this first bay is extremely important to the successful completion of
the building. Although several methods are used to erect rigid frames, it has been
found most satisfactory to erect the columns first, tie them together with the girt
and tighten the anchor bolts. On small spans and short eave heights, columns can
often be set in place by hand without the use of hoisting equipment. Temporary
bracing should always be installed as soon as sections are lifted in place.

Completing and Plumbing the First Bay:

After the first intermediate or interior frames have been set, all purlins, girts, and
eave struts be installed in the braced bay and the entire bay plumbed, aligned and
braced before proceeding further. If the building is designed without cable bracing,
the erector is responsible for providing temporary erection bracing. When this bay
is properly and accurately plumbed and braced, the remaining members, to a large
degree, will automatically plumb and align when installed.

After the columns have been erected, the ground-assembled rafter is hoisted into
place and connected to the columns. The size of the rafter that can be safely handled
depends on the equipment available and the experience of the erection foreman.
Generally as many connections as possible are made on the ground.

The flange brace should be bolted to the rafter prior to raising in order to save time.
The hoisting equipment should never be released from the rafter until the frame is
adequately braced, so it cannot buckle or tip in the longitudinal direction of the
building. The same general procedures of erection apply to either clear span or
multiple span frames.

45
Two words of caution concerning the erection of rigid frames are in order. The first
is that rigid frames, especially free ends or cantilevered sections should never be
left for the day in an unsupported, unbraced condition. Such practice has resulted
in the total loss of considerable amounts of erected steel because of wind. The
second word of caution pertains to the additional care required in the erection of
multiple span frames compared to clear span frames. Frames with interior columns,
because of closer supports, have much lighter sections. They are much more apt to
buckle during erection than clear span frames, and consequently require greater
care in rigging and handling.
Erecting column Beam end walls:

Column and beam end walls of 50 feet or less in span may be raised into position
and set on the anchor bolts as a unit. All rafters, column, girts (except outside end
wall girts which connect to the sidewall girts), door headers, door jambs, clips,
diagonal brace rods, etc. should be assembled on the ground with the bolts left
finger tight. A spreader bar should be used to raise the end wall frame. Because of
the flexibility of the column and beam frames, care must be taken in locating the
points of attachment of the cables, and in raising the frame, to avoid bending about
the minor axis.

For spans of 60 feet and greater, the columns are usually erected first and then
capped with the end wall rafter. Girts, headers, jambs and diagonal brace rods are
then added between the end columns. During this erection process, the frame must
be properly braced or guyed before the lifting lines are disengaged. Final bolt
tightening should be done once the frame is plumb and square.

Erecting the remaining frames:

The remaining frames are erected in like manner, initially with only a few purlins
being installed in each bay, as shown below, working from one end of the building
to the other. To lend overall rigidity to the structure, install flange braces to the
purlins at specified locations. All purlin, girt and eave strut connection bolts are left

46
loose so that the entire skeleton framework can be plumbed without undue
difficulty. The remaining purlins can be positioned on the rafter in each bay to
facilitate the completion of the roof framing.

Steel construction is considered as a process that involves many related activities.

Preengineered buildings (PEB) steel parts are required to be installed in a specific
order due to structural safety requirements and to the logical sequence of erection.
However, shipping, transportation, unloading and on-site storage does not take into
account the erection order of the assembly. As a result, considerable time is
consumed locating, sorting, and identifying steel Components.

Pre-engineered buildings (PEB) steel parts are required to be installed in a specific order
due to structural safety requirements and to the logical sequence of erection.

3.11 Pictorial representation of Erection process.

47
Erection Drawings:

Erection drawings provide the field erection crew (raising gang) with the roadmap
of how to erect (put together) the steel assemblies after they are delivered to the
field. Essentially, they are a set of instructions on how to put the puzzle pieces
together. Every assembly shipped to the field is given a shipping piece number to
identify it. This number is noted on the drawing and is also stenciled onto the actual
assembly of steel. Erection drawings illustrate how the connections will be
fabricated in the field.

2.1.4 ACCESSORIES

Anchor bolts:

Bolts used to anchor the structural members to the concrete floor, foundation or other
support. This usually refers to the bolts at the bottom of all columns. Anchor bolts are

Anchor bolts are manufactured with circular steel rods having threading portion at the
top for bolting and bent up at the bottom for Foundation.

Fig. 3.12 Schematic representation of an Anchor Bolts

48
Turbo ventilators

A Turbo Ventilator is a free spinning roof ventilator that works on free wind energy.
When there is a difference in thermal or wind pressure between the inside and
outside of the building, the air is forced to move through the opening of the Turbo
Ventilator in order to maintain an equilibrium condition. The benefits of using
turbo ventilators are that it improves air circulation and cuts off the suffocation.
Eco friendly turbo ventilator involves no operating cost, are free from maintenance
and are has trouble free operations.

Fig. 3.13 Schematic representation of an Air Vents

Sky lights (or) wall lights:

Sky lights may consists of poly carbonate sheets which is translucent sheet that
allows maximum light and minimum heat. High strength translucent panels are
glass fiber reinforced polyester, high strength and may be either and it provides

49
with an estimated light transmitting capacity of 60%. High strength translucent
panels match standard panel profiles, are 1/16 thick, weigh 8 ounces per square
foot, and are white with a granitized top surface.
Insulated translucent panels are available in type 1, "R" panel and standing seam profiles
only.

Damper, Standard size is 3000 mm long with a throat opening of 300 mm.

Fig. 3.14 Schematic representation of a Day Light Sheets

Louvers:

Standard Louvers shall have a 26 gauge galvanized steel frame, painted, with 26
gauge blades. Heavy Duty Louver frames shall be 18 gauge galvanized steel frame,
painted, with 20 gauge blades They shall be equipped with adjustable or fixed
blades as specified. Nominal sizes shall be 2 -0" x 2 0" x 2'0", 3'-0" x 3'-0" 4'-0" x
3'-0", and 3'0" x 4'-0

50
 Fig. 3.15. Schematic representation of a Louvers

Walking doors:

Walk doors are generally 915 mm or 1830 mm wide x 2134 mm high made of 20
gauge electro galvanised steel with a core of polyurethane insulation. Door fixture is
provided. [6]

Aluminium windows:

Designed for installation with wall panel, double slide, self -flashing with pre-glazed clear
glass and removable half insect screen. Standard size is 1 m x 1 m. multiple
Windows can be formed by joining the jamb fins together

Fasteners:

Standard fasteners shall be self -drilling screws with metal and neoprene washers. All
screws shall have hex heads and are zinc plated.

2.2 CONSTRUCTION OVERVIEW:

Before the PEB Components arrives, the site and foundation should be prepared. This
includes levelling the terrain and constructing the foundation.

A. Remove trees, debris, and other items from the building

location.

B. Smooth and level the ground where the foundation is to be

made.

51
C. Construct the foundation using the materials recommended as
per design parameters. Transiting on all corners the foundation
locations are determined and trenches are made for foundation. In
foundation trenches the Anchor bolts are set along with the concrete.

Anchor Bolt Setting:

It is extremely important that anchor bolts be placed accurately in accordance with

the anchor bolt setting plan. All anchor bolts should be held in place with a template
or similar means, so that they will remain plumb and in the correct location during
placing of the concrete. Check the concrete forms and anchor bolt locations prior
to the pouring of the concrete. A final check should be made after the completion
of the concrete work and prior to the steel erection. This will allow any necessary
corrections to be made before the costly erection labour and equipment arrives.

Unloading and Preparing Parts assembly:

The vehicle transporting your building parts must gain access to the building site
from the adjacent highway or road. Such access should be studied and prepared in
advance of arrival. When the truck arrives with the building, unload the truck
promptly, stack the steel parts evenly on blocks and protect them from the weather.
Unloading and placing the steel parts of the building in the most convenient places
for assembly will make the process easier and faster.
Blocking under the columns and rafters protects the splice plates and the slab from
damage during the unloading process. Extra care should always be exercised in the
unloading operation to prevent injuries from handling the steel and to prevent
damage to materials.
If water is allowed to remain for extended periods in bundles of primed parts such
as girts, purlins, etc., the pigment will fade and the paint will gradually soften
reducing its bond to the steel. Therefore, upon receipt of a job, all bundles of primed
parts should be stored at an angle to allow any trapped water to drain away and

52
permit air circulation for drying. Puddles of water should not be allowed to collect
and remain on columns or rafters for the same reason.

Location of Building Parts:

All the parts are placed around the foundation so that they will be in the most
convenient locations for installation. Bolts and nuts are placed where they will be
accessible to the parts. Purlins and girts, depending on the number of bundles, are
usually stored near the sidewalls clear of other packages or parts. Sheet packages
are usually located along one or both sidewalls off the ground and sloping to one
end to encourage drainage in case of rain. Accessories are usually unloaded on a
corner of the slab or off the slab near one end of the building to keep them as much
out of the way as possible from the active area during steel erection.

Installation of Bracing:

Diagonal bracing in metal buildings is critical. They provide support for wind loads
or other longitudinal loads, such as those created by an overhead crane in the
completed structure. Many times additional temporary bracing is needed to
stabilize the structure during erection. On some smaller buildings, diagonal bracing
is not needed for the building design, so the erector must furnish any erection
bracing needed.
Assemble the next brace cable the same way and connect to the next column to
form an X with the other cable. To square the building, measure the length of the
diagonal cables and tighten or loosen the turnbuckle/eye-bolt until the cable lengths
are the same. Brace each sidewall frame the same way so that you have an x-brace
on each side. Tighten the column anchor nuts after insuring that the building is
square.

The diagonal bracing is cable. It should always be installed as shown on the erection
drawing and should be tensioned so that the building will not sway or rock when
53
the wind blows. Care should be taken, however, not to over tighten and bend the
structural members. The workman should watch the structural members carefully
as he tightens the bracing. Occasionally the bracing in the wall of a building cannot
be installed in the specified bay because of doors or other complications. Usually
these can be moved to other bays without affecting the structural integrity of the
building.

Bolting Procedure in steel structures:

This procedure applies to the permanent fixing of steel structures including the
erection of steel. Construction drawings shall indicate the grade and diameter of all
bolts, nuts and washers required for the construction. Drawings shall indicate
whether a Friction Type or Bearing Type connection is required. The nominal size
of the bolt holes (other than holes in a base plate) shall be 2mm larger than the
nominal bolt diameter for a bolt not greater than 24mm in diameter and not more
than 3mm larger for bolts of diameter more than 24 mm.

Alignment and assembly

The parts to be joined shall line up in such a way that a drift of equal diameter to
the bolt can pass through the bolt holes. Drifting to align the bolt holes shall be
done is such a 3 way as not to bend or damage the parts nor enlarge the holes.
Packing shall be provided as required to ensure parts have full contact over the
mating surfaces. Prior to inserting the bolts the nut should be run up the threads to
ensure there are no thread defects that would impede the tightening process.
Bolts shall be inserted through the holes after alignment from such a direction that the
nut has easiest access for tightening.

Bolt Tightening (Snug Tightening)

Bolt Tightening is required for all Bearing-Type Connections and as a pre-requisite

to Friction Type connections. The sequence of tightening the bolts shall proceed
from the stiffest part of the connection towards the free edges. High strength bolts

54
that are to be tensioned may be tightened during erection to facilitate assembly but
they shall not be finally tensioned until all bolts have been snug tightened in the
correct sequence. Bolt tightening is also known as snug-tightening. Bolt or snug
tightening is achieved either by subjecting the nut to a few impacts of an impact
wrench after standard effort tightening with a spanner or by the full effort of a
person using a standard spanner. The sequence of tightening is to firstly tighten all
nuts with a standard effort and then to snug tighten using a full effort or an impact
wrench.

Wall Insulation

Fiberglass blanket insulation is the most common type used, and these instructions
pertain to this type only. One side of the blanket insulation should have a vapour
barrier that must face the inside of the building regardless of whether the insulation
is for heating or cooling.

Cut the insulation to length allowing an additional 6 or more to facilitate handling.

The wall panel can be used as a guide. The first run of wall insulation should be
installed so that its forward edge is just ahead of the leading edge of the wall panel.
This keeps the forward edge of the insulation ahead of the wall panel for joining
the next blanket.

Roof Insulation:

Pre-cut roof insulation to reach from eave to eave allowing approximately 2 feet of
additional length to facilitate handling. Hold insulation at one sidewall and roll out
insulation across the purlins, vapour barrier to the inside of the building. Stretch
the insulation to provide a tight and smooth inside surface. Double sided tape or
contact adhesives can be used to hold insulation in place while the roof sheets are
being installed. Trim excess insulation to the edge of the eave trim and cut
fiberglass approximately 4 inches from end leaving only facing. Fold facing over
end of blanket insulation to seal the end.

55
Aligning the Girts:

Installation of the building walls is generally done before the roof. Before starting
the wall installation, check to be sure that the eave strut and girts are straight and
plumb. One method of aligning the Girts is to cut temporary wood blocking to the
proper length and install between the lines of girts. This blocking can be moved
from bay to bay, which will reduce the number of pieces required. Normally, one
line of blocking per bay will be sufficient. Banding can also be used to hold the girt
straight and plumb.

Screw alignment:

Good alignment of the screws, especially on the wall panels, will give a
professional appearance to the wall panel installation. One way this can be
accomplished is by predrilling holes in the panels at identical locations. Up to 15
panels can be stacked together and drilled using a template panel. 1/8 or 5/32
diameter drill bit is used for panel to structural fasteners and a 1/4 diameter bit for
the side lap clearance holes.

Installation of wall Panels:

Adjoining panels are installed with the overlapping rib toward the last erected
panel. Position panel to structural making sure that it is kept plumb and install
fasteners at lapped rib. Check for proper coverage and correct as necessary. Install
remaining fasteners.

Fastener Installation:

Correct fastener installation is one of the most critical steps when installing roof
panels. Drive the fastener in until it is tight and the washer is firmly seated. Do not
overdrive fasteners: A slight extrusion of neoprene around the washer is a good
visual tightness check.
Always use the proper tool to install fasteners. A fastener driver (screw gun) with and
rpm of 1700-2500 is used for self-drilling screws.
56
Preparing the Eave:

After installing the first run of insulation, prepare the eave for the first roof panel
by applying tape sealant along the eave outside of the insulation and leaving release
paper in place. Sealant must be applied in a straight line and without voids. Splice
a full closure to the starting closure and apply along the top of the eave sealant. If
roof is subject to ice and snow build-up, the splice in the closure strip must be
caulked to insure weather tightness.

Installation of the first roof panel:

Once the eave is prepared, the first roof panel may be installed. The roof panel is
set in place over the inside closure (after removing the paper from the mastic)
ensuring the major ribs of the panel nest properly with the inside closure.
Align the centre of the major rib of the panel edge with the edge of the end wall
roofline. With the panel properly placed, secure the panel to the structure with
appropriate fasteners.
Roof Sheeting Sequence:

It is recommended that both sides of the ridge of a building be sheeted

simultaneously. This will keep the insulation covered for the maximum amount of
time and the panel ribs can be kept in proper alignment for the ridge panel.
Final Installation:

While back lapping the last roof panel (to match panel coverage with the building
length) is routinely done, this installation method can compromise the integrity of
the roof by trapping moisture between the panels. This moisture could, in time,
create an environment conducive to rust and metal failure. Manufacturer
recommends field cutting the final panel lengthwise to create the desired panel
width necessary to finish off the building. The cut edge of the panel should always
be installed on the outside edge, not the lap edge. The narrow panel should be
57
handled with care, and foot traffic avoided until the final panel is completely
installed.
Skylight Installation:

Skylight panels are installed using the same procedures as a steel panel. Care should
be taken when installing fasteners in the skylights to avoid cracking the material.
Install roof panels, leaving the light-transmitting panel run open, except for lower
light transmitting panel run panel. Install tape sealer to panel side laps and across
panel width as normal. Lay light transmitting panel in place overlapping lower metal
panel [6]. Apply double run of tape sealer across light transmitting panel width at
lower and middle purlins.

58
3.3 FLOWCHART OF METHODOLOGY CARRIED OUT

Assuming Dimensions, Structural Conditions

and Cross Sections

Selection Of cross Sections to satisfy Structural

requirements, performance

Design of Rafter

`
Design of Column

Structural Analysis Design of Purlin

Design of Connection

Foundation

On Violating Initial On satisfying

Assumptions Initial assumptions

Final design

59
 CHAPTER 3

DESIGN OF PRE-ENGINEERED STEEL BUILDING

3.1 GENERAL

Pre-engineering of metal buildings can be optimized to meet specific design

criteria. Largely Indian and American practice of design is followed by most of the
consultants and PEB vendors in India these days. A brief of design codes used in
each of these is attached herewith:
The main framing of PEB systems is analysed by the stiffness matrix method. The
design is based on allowable stress design (ASD) as per the American institute of
Steel Construction specification or the IS 800. the design program provides an
economic and efficient design of the main frames and allows the user to utilize the
program in different modes to produce the frame design geometry and loading and
the desired load combinations as specified by the building code opted by the user.
The program operates through the maximum number of cycles specified to arrive
at an acceptable design. The program uses the stiffness matrix method to arrive at
an acceptable design. The program uses the stiffness matrix method to arrive at the
solution of displacements and forces. The strain energy method is adopted to
calculate the fixed end moments, stiffness and carry over factors. Numerical
integration is used.

3.2 DESIGN CYCLE

The design cycle consists of the following steps:

1. Set up section sizes and brace locations based on the geometry and loading specified

for the frame design.

2. Calculate moment, shear, and axial force at each analysis point for each load

combination.

60
3. Compute allowable shear, allowable axial and allowable bending stress in compression

and tension at each analysis point.

4. Compute the corresponding stress ratios for shear, axial and bending based on the actual

and allowable stresses and calculate the combined stress ratios.

5. Design the optimum splice location and check to see whether the predicted sizes

confirm to manufacturing constraints.

6. Using the web optimization mode, arrive at the optimum web depths for the next cycle

and update the member data file.

7. At the end of all design cycles, an analysis is run to achieve flange brace optimization.

[16]

Frame Geometry:

The program has the capability to handle different types of frame geometry as
follows Frames of different types viz. rigid frames, frames with multiple internal
columns, single slope frames, lean to frames etc; Frames with varying spans,
varying heights and varying slopes etc. Frames with different types of supports viz.
pinned supports, fixed supports, sinking supports, supports with some degrees of
freedom released. Unsymmetrical frames with off centric, unequal modules,
varying slopes etc. User specified purlin and girt spacing and flange brace location.

Frame Loading:

Frame design can handle different types of loadings as described below:

All the building dead loads due to sheeting, purlins, etc. and the self- weight of the frame
and Imposed live load on the frame with tributary reductions as well.

Wind loads input such as basic wind speed or basic wind pressure that will be
converted to deign wind pressure as per the building code specified by the user and
shall be applied to the different members of the building according to the
coefficients mentioned in the codes prescribed by the user. The standard building
codes like MBMA, UBC, ANSI, IS: 875 parts 3 etc. are used for this purpose. Crane
61
and noncrane loading can be specified by the user and the program has the
capability to handle these special loads and combine them with the other loads as
required.

Seismic loads corresponding to the different zone categories of various

international codes can also be defined and combined with other load cases as
required. Temperature loads can also be specified in the form of different
differential temperature value on centigrade and specifying the appropriate
coefficient for the thermal expansion. Load combinations with appropriate load
factors can be specified by the user as desired.

Design of a warehouse

The majority of warehouse buildings are made out of steel for obvious reasons of
high strength/weight ratio. A study, on the Efficient Design of Large span
hangars/structures, is presented. A clear span of gable frame of 15 m is adopted and
the designs of Components are discussed below as follows

Structure with Span larger than 40 m can be regarded as long span structures and
need to be carefully designed keeping a balance of all the aspects like its weight,
deflections (sway) and foundation forces. There are many combinations of
designing large spans, like conventional truss & RCC column combination, truss
& steel columns, Preengineered building (PEB) etc.

These days with the concept of PEB, the major advantage we get is the use of high
strength steel plates (usually Fe 350), lighter but high strength cold form purlins,
and 550 Map Galvalume profiled sheets. The use of PEB not only reduces the
weight of the structure because high tensile steel grades are used but also ensures
quality control of the structure. In the following study, we have designed a
warehouse using this modern concept of PEB. [16]

62
DESIGN PROCESS AND PRINCIPLES

Loads on Structure

The determination of the loads acting on a structure is a complex problem. The

nature of the loads varies essentially with the architectural design, the materials,
and the location of the structure. Loading conditions on the same structure may
change from time to time, or may change rapidly with time.

Dead load:

Dead loads shall cover unit weight/mass of materials, and parts or components in a
building that apply to the determination of the dead loads in the design of buildings
and shall be considered as per IS: 875 (Part 1) - 1987 according to the densities of
the possible components. This includes main frames, purlins, girt, cladding, bracing
and connections etc.

Live Load:

Imposed loads shall be considered as per IS: 875 (Part 2) 1987. Live load shall be
considered as 2.675 KN/m for the analysis and design.

Wind Load:

The basic wind speed and design velocity which shall be modified shall be taken

As per IS: 875 (Part 3) 1987.

As though this warehouse building is located within the area surrounded by high
rise apartments and buildings action of wind load is neglected as even the eave
height is limited only to 6m wind load is not considered.

63
4.2.2 DESIGN CODES

Following are the main design codes generally used:

AISC: American institute of steel construction manual

AISI: American iron and steel institute specifications

MBMA: Metal building manufacturer s code

ANSI: American national standards institute specifications

ASCE: American society of civil engineers

UBC: Uniform building code

IS: Indian standards (IS1893-2002 PART 1 FOR EQ) and (IS 875 PARTIII FOR WIND)

64
3.3 DETAILED PLANS AND SITE IMAGES OF THIS PROJECT

65
 PLAN OF THE BUILDING

ELEVATION OF THE BUILDING

SIDE WALL ELEVATION OF THE BUILDING

66
67
68
 CHAPTER 4

CONCLUSION
4.1 GENERAL:

It was a great learning experience at the Aalaya Housing project site. The
time spent was highly educative and informative as I gained an insight into a lot of
construction aspects and their planning. I gained great exposure to almost all the
departments in the site namely safety, quality control, planning, construction
management, stores, work sampling etc. The friendly welcome from all the
employees was very appreciable. All the employees and staff members were very
helpful and shared a lot of knowledge and wisdom. I’m pretty sure that this
experience will help me in my upcoming years to build a great career.

Using of PEB instead of CSB may be reducing the steel quantity and thus reducing
the construction cost and Reduction in the steel quantity definitely reducing the
dead load. Reduction in the dead load reducing the size of Foundation. And
reduction is all but not the performance and life span is the unique property of pre-
Engineered and using PEB increase the Aesthetic view of structure

69
1. REFERENCE:

[1]. Aijaz Ahmad Zende, Prof. A. V. Kulkarni, Aslam Hutagi (Feb 2013).

Comparative Study of Analysis and Design of Pre-Engineered- Buildings and

Conventional Frames. IOSR Journal of Mechanical and Civil Engineering,

Volume 5, Issue.

[2]. C. M. Meera (June 2013). Pre-engineered building design of an industrial

warehouse. International journal of engineering sciences & emerging
technologies.
Volume 5 Issue 2, pp: 75-82 Dr. Ramachandra & Virendra Gehlot “Design of Steel
Structures”

[3]. Design Concept of Pre-engineered Building by Syed Firoz1, Sarath Chandra

Kumar B1, and Design concept of pre-engineered building. International journal
of engineering research & applications, volume 2, issue 2, pp: 267-272

[4]. Design of Long span structures and Hangars by Amit Bharana ERA
buildings ltd.

[5] G. Sai Kiran, A. Kailasa Rao, R. Pradeep Kumar (Aug 2014). Comparison
of Design Procedures for Pre Engineering Buildings (PEB): A Case Study.
International Journal of Civil, Architectural, Structural & Contruction Engineering,
Volume 8, No. 4

[6]. http://www.engineeringcivil.com/pre-engineered-buildings.html

[7]. http://nbmcw.com/articles/PEB -roofing/PEB -prefab-steel-structures/18161-

preengineered-building-systems-a-promising-future.html

70
[8]. http://nbmcw.com/articles/PEB -roofing/PEB -prefab-steel-
structures/18161preengineered-building-systems-a-promising-future.html

[9]. Introduction to Pre-engineered Steel Buildings

http://www.engineeringcivil.com/preengineered-buildings.html

[10]. IS: 800-2007: General Construction in Steel - Code of practice

[11]. IS: 875 (Part 1): - 1987 Code of Practice for Design Loads

[12]. IS: 875 (Part 2): - 1987 Code of Practice for Design Loads

[13]. IS: 875 (Part 3): - 1987 Code of Practice for Design Loads

[14]. Jatin D. Thakar, 2 Prof. P.G. Patel. Comparative study of pre-

engineered steel structure by varying width of structure. International
journal of advanced engineering technology, volume 4, issue3

[15]. N. Subramanian (2010) “Design of Steel Structures”

[16]. P. Dayaratnam “Design of Steel Structures”

[17]. Pre-engineered Metal Buildings < The Latest Trend in Building

Construction. By.K. Mitra Llyods Insulations Limited.12.

[18]. PEB VS Conventional the Zamil Steel Limited

[19]. S.S. Bhavikatti “Design of Steel Structures”

71