PRE ENGINEERED BUILDINGS

1.0 INTRODUCTION

1.1 PRE ENGINEERED BUILDINGS

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 1960s 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.

Though initially only off the shelf products were available in these configurations aided by
the technological development tailor made solutions are also made using this technology in very
short durations. 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.

Steel is material which has high strength per unit mass. It is used in construction of structures
with large column-free space. The concept of PEB is the frame geometry which matches the shape of
the bending moment diagram thus optimizing material usage and reducing the total weight of the
structure.

PEB can be fitted with different structural accessories including gantry girder, principal rafter,
purlin, profiled sheets etc. Steel is material which has high strength per unit mass. It is used in
construction of structures with large column-free space. The concept of PEB is the frame geometry
which matches the shape of the bending moment diagram thus optimizing material usage and
reducing the total weight of the structure. PEB can be fitted with different structural accessories
including gantry girder, principal rafter, purlin, profiled sheets etc.

Although PEB systems are extensively used in industrial and many other non residential
constructions worldwide, it is relatively a new concept in India. These concepts were introduced to
the Indian markets lately in the late 1990s with the opening up of the economy and a number of
multi nationals setting up their projects. The market potential of PEBs is 1.2 million tons per annum.
The current pre engineered steel building manufacturing capacity is 0.35 million tons per annum. The
industry is growing at the compound rate of 25 to 30 %.

With respect to design of the structure and aesthetic appearance India is way behind. Indian
manufacturers are trying to catch up; comparatively PEBs is a new concept in India. Beside, in
fabrication and other areas of PEB India is very good. As compared to other countries Indian codes
for building design are stringent but safer. IS standards are upgraded continuously. In India,
American codes are also followed.

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
fine-shed 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 meters. Low rise buildings are ideal for offices, houses, showrooms, shop fronts
etc. The application of pre engineered buildings concept to low rise buildings is very economical and
speedy. Buildings can be constructed in less than half the normal time especially when
complemented with the other engineered sub systems.
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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.

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2.0 Pre Engineered Buildings Vs Conventional Steel Buildings

2.1PROPERTY

2.1.1 STRUCTURE WEIGHT

Pre engineered buildings: these are on the average 30% lighter because of the efficient use of
steel. Primary framing members are tapered built up section with the large depths in areas of higher
stress. Secondary members are light weight roll formed Z or C shaped members.
Conventional steel buildings: Primary steel members are selected hot rolled T sections. Which are,
in many segments of the members heavier than what is actually required by design? Members have
constant cross section regardless of the varying magnitude of the local stresses along the member
length. Secondary members are selected from standard hot rolled sections which are much heavier.

2.1.2 DESIGN
Quick and efficient: since PEBs are mainly formed by standard sections and connections
design, time is significantly reduced. CSB Basic design based on international design codes are used
over and over. Each conventional steel structure is designed from scratch with fewer design aids
available to the engineer.
PEB: Specialized computer analysis design programs optimize material required. Drafting is
also computerized using standard detail that minimizes the use of project custom details. Design shop
detail sketches and erection drawings are supplied free of cost by the manufacturer. Approval
drawing is usually prepared within in 2 weeks. PEB designers design and detail PEB buildings
almost every day of the year resulting in improving the quality of designs every time they work
CSB: Substantial engineering and detailing work is required from the very basic is required
by the consultant with fewer design aids. Extensive amount of consultant time is devoted to the
alterations that have to be done. As each project is a new project engineers need more time to develop
the designs and details of the unique structure.

2.1.3 DELIEVERY
PEB: Average 6 to 8 weeks
CSB: Average 20 to 26 weeks

2.1.4 FOUNDATIONS
PEB: Simple design, easy to construct and light weight.
CSB: Extensive, heavy foundation required.

2.1.5 ERECTION SIMPLICITY

PEB: Since the connection of compounds is standard the learning curve of erection for each
subsequent project is faster. Periodic free of charge erection is provided at the site by the
manufacturer.
CSB: The connections are normally complicated and differ from project to project resulting
tin increasing the time for erection of the buildings. There has to be separate allocation of labour for
the purpose of erection.

2.1.6 ERECTION COST AND TIME

PEB: Both costs and time of erection are accurately known based upon extensive experience
with similar buildings. The erection process is faster and much easier with very less requirement for
equipment.

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CSB: Typically, conventional steel buildings are 20% more expensive than PEB in most of
the cases, the erection costs and time are not estimated accurately. Erection process is slow and
extensive field labors required. Heavy equipment is also needed.

2.1.7 SEISMIC RESISTANCE

PEB: The low weight flexible frames offer higher resistance to seismic forces.
CSB: Rigid heavy frames do not perform well in seismic zones.

2.1.8 OVER ALL PRICE

PEB: Price per square meter may be as low as by 30 % than the conventional building.
CSB: Higher price per square meter.

2.1.9 ARCHITECTURE
PEB: Outstanding architectural design can be achieved at low cost using standard
architectural details and interfaces.
CSB: Special architectural design and features must be developed for each project which
often requires research and thus resulting in higher cost.

2.1.10 SOURCING AND COORDINATION

PEB: Building is supplied complete with all accessories including erection for a single ONE
STOP SOURCE.
CSB: Many sources of supply are there so it becomes difficult to co ordinate and handle the
things.

2.1.11 COST OF CHARGE ORDER

PEB: manufactures usually stock a large amount of that can be flexibly used in many types of
PEB projects. Change orders are easily accommodated at all stages of the order fulfillment process.
Little or no material is wasted even if a change order is made after fabrication starts.
CSB: Substitution of hot rolled sections infrequently rolled by mills is expensive and time
consuming. Change orders that are made after the dispatch of hot rolled sections result in increasing
the time and cost involved in the project.

2.1.12 BUILDING ACCESSORIES

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

2.1.13 FUTURE EXPANSIONS

PEB: All project records are safely and orderly kept in electronic format which make sit easy
for the owner to obtain a copy of his building record at any time. Future expansion is very easy and
simple.
CSB: It would be difficult to obtain project records after a long period of time. It is required
to contact more than one number of parties. Future expansion is most tedious and more costly.

2.1.14 SAFETY AND RESPONSIBILTY

PSB: Single source of responsibility is there because all the job is being done by one supplier.
CSB: Multiple responsibilities can result in question of who is responsible when the
components do not fit in properly, insufficient material is supplied or parts fail to perform
particularly at the supplier/contractor interface.

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2.1.15 PERFORMANCE
PSB: All components have been specified and designed specially to act together as a system
for maximum efficiency, precise fir and peak performance in the field. Experience with similar
buildings, in actual field conditions worldwide, has resulted in design improvements over time,
which allow dependable prediction of performance.
CSB: Components are custom designed for a specific application on a specific job. Design
and detailing errors are possible when assembling the diverse components into unique buildings.
Each building design is unique, so predication, of how components will perform together is
uncertain. Materials which have performed well in some climates may not do well in other
conditions.

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3.0 Design of Pre Engineered Buildings (PEB)

The main framing of PEB systems is analyzed 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.

3.1 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.
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.

3.2 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.

3.3 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.
Imposed live load on the frame with tributary reductions as well.
Collateral load such as false ceiling, light fixtures, AC ducting loads, sprinkler systems and
many other suspended loads of similar nature

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4.0 Applications of Pre Engineered Buildings (PEB)

Warehouses
Factories
Workshops
Offices
Gas stations
Vehicle parking sheds
Showrooms
Aircraft hangars
Metro stations
Schools
Recreational
Indoor stadium roofs
Outdoor stadium canopies
Bridges
Railway platform shelters

Fig1: Pre Engineered Building

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5.0 Advantages of Pre Engineered Buildings

Reduced Construction Time: Due to the systems approach, the use of high strength steel,
use of tapered built-up sections which are optimized by the computerized design program and
the use of continuous light gage secondary steel section, there is an overall reduction in steel
weight, cost and time relative to conventional steel construction.
Pre-engineered buildings are a predetermined inventory of raw materials that has proven over
time to satisfy a wide range of structural and aesthetic requirements. The components are engineered
beforehand and standardized. Use of these standard components reduces the engineering, production
and erection time. Use of customized software for design & drafting increases the speed of the
project.
The production line is highly sophisticated, having Auto welders, multi-cutting torches, shear
cutting machines etc., which greatly reduce the time of fabrication of built-up components. Roll
forming machines for producing Z & C members and sheeting, having standard dimension, increases
the production capacity of secondary members. Use of standard accessories greatly increases the
speed of production & erection.
Buildings are typically delivered in just a few weeks after approval of drawings. Foundation and
Anchor Bolts are cast in parallel with manufacture of the building. Site assembly is fast, as all
building components are delivered finished, ready for site bolting.
It can reduce total construction time on a project by at least 50%. This will allow faster occupancy
and earlier realization of revenue.

Design: Since PEBs are mainly formed of standard sections and connections, the design time
is significantly reduced. Specialized computer analysis and design programs optimize
material require. Drafting also computerized using standard details that minimizes project
custom details. The low-weight flexible frames offer higher resistance to seismic forces.

Lower Cost: Due to the systems approach, there is a significant saving in design,
manufacturing and site erection cost. The structural elements are shaped to follow the stress
diagram of the member, thus reducing weight, cost and load to foundations. The secondary
members
and cladding nest together reducing transportation cost. The overall price per square meter
may be reduced as much as 30% lower than conventional steel.

Foundations:Pre-engineered Buildings are about 30% lighter than the conventional steel
structures. Hence, the foundations are of simple design, easy to construct and lighter weights.

Erection: Since all the connections of the different components are standard, the erection
time is faster.

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.

Large Clear Spans: Buildings can be supplied to around 90M clear spans.

Quality Control: As buildings are manufactured completely in the factory under controlled
conditions, the quality is assured.

Low Maintenance: Buildings are supplied with high quality paint systems for cladding and
steel to suit ambient conditions at site, which results in long durability and low maintenance
costs.

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Energy Efficient Roof and Wall Systems: Buildings can be supplied with polyurethane
insulated panels or fiberglass blanket insulation to achieve required U values.

Single Source Responsibility: 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.

Disadvantages :

Transportation: carrying a huge 30 m span pre fabricated structures from one place to another
place is little difficult.
In-situ work of PEB requires a higher degree of accuracy then normal on site buildings.
A mistake in mass production of PEB ahead of the measurable site work is a serious risk.
Additional cost of temporary bracings for transportation or lifting is required.

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6.0 Case study

6.1 Industrial Warehouse structure located at Ernakulum

Fig2: PEB Industrial Warehouse structure located at Ernakulum.

The present study is included in the design of an Industrial Warehouse structure located at
Ernakulum. The structure is a container warehouse of Vallarpadam Container Terminal. The actual
structure is proposed as a Pre-Engineered Building with four spans each of 30 meters width, 16 bays
each of 12 meters length and an eave height of 12 meters. In this study, a typical PEB frame of 30
meter span is taken into account and the design is carried out by considering wind load as the critical
load for the structure. CSB frame is also designed for the same span considering an economical roof
truss configuration. Both the designs are then compared to find out the economical output. The
designs are carried out in accordance with the Indian Standards and by the help of the structural
analysis and design software Staad.Pro.

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Fig3: CSB Industrial Warehouse structure located at Ernakulum.

6.1.1 WAREHOUSE PARTICULARS

Type of building: Container Warehouse
Type of structure: Single Storey Industrial Structure
Location: Ernakulum
Area of site: 43348 m2 (466597.872 sq.ft.)
Type of building: Industrial Warehouse
Area of building: 22979 m2 (247343.900 sq.ft.)
Eave height: 12.00 m
Number of spans: 4 Nos
Single span width: 30.00 m
Total span width: 120.00 m
Number of bays: 16 Nos
Single bay length: 12.00 m
Total bay length: 192.00 m
Support condition: Pinned
PEB roof slope: 5 degree
CSB roof slope: 15 degree

6.2 DISCUSSION ON CASE STUDY

The structural analysis and design of the structural frame considered was done using the
Staad.Pro software which is very user friendly and effective. First a typical frame is selected from the
structure. First the frame was analyzed and designed according to the PEB concept and then by the
CSB concepts. On comparing the results of both the analysis, the following results were obtained as
in Table 3.

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Table 1: Software Description PEB CSB

Analysis Results
Summary Sl. No.
1 Steel Take Off (kN) 53.221 84.595
2 Support Reaction 355.475 375.582
(kN)
3 Maximum deflection 1.862 8.611
(mm)
4 Maximum Shear 340.940 453.981
Force (kN)
5 Maximum Moment 888.97 908.577
(kNm)

Pre-Engineered Buildings have vast advantages over the Conventional Steel Buildings.
The results of the software analysis and literature studies conducted for both the concepts suggest
the same. The various inferences made from the studies are described below.

6.2.1 Material Take off

PEB structures are lighter than CSB structures. From the software analysis it was found
that the PEB roof structure is almost 30% lighter than the CSB structure. Regarding the
secondary members, light weight Z purlins are used for PEB structure whereas heavier hot-rolled
sections are used for CSB structure.

6.2.2 Design
PEB design is rapid and efficient compared CSB design. Basic design steps are followed
and optimization of materials while software analysis is possible for PEB, increasing the quality
of design. CSB design is done with fewer design aids and each project needs to develop the
designs which require more time, as in . Connection design is also lesser for PEB when measured
up to CSB.

6.2.3 Foundation
Support reaction for PEB is much lesser than CSB as per the analysis. Hence, light
weight foundation can be adopted for PEB which leads to simplicity in design and reduction is
cost of construction of foundation, as in . Heavy foundation will be required for CSB structure.

6.2.4 Delivery of materials

For PEB, For PEB, delivery is done in around 6 to 8 weeks and for CSB it is 20 to 26
weeks.

6.2.5 Erection
Erection procedure is standard for all the projects and it is done free of cost by the
manufacturer which results in faster and cost effective erection for PEB. Erection of CSB differs
from project to project and separate labour has to be allocated, leading to 20 percent more
expense than PEB.
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6.2.6 Earthquake resistance

Low weight flexible frames of PEB offer higher resistance to earthquake loads than rigid heavy
frames of CSB, as in.

6.2.7 Cost
PEB costs 30% lesser than cost for CSB, in passing. Outstanding architecture can be
achieved at low cost for PEB. Single sourcing and co-ordination of PEB is highly cost effective
than multiple sourcing system of CSB. Building accessories are mass produced for PEB which
also leads to economy.

6.2.8 Change of order

Due to standardized design, PEB manufacturers are able to stock large amount of
elements and accessories which can be flexibly used in many types of PEB construction. Hence
change of order can be fulfilled easily at any stage of construction. Cost for change of order is
also lesser in this case. In case of CSB, change of order is expensive and time consuming as
substitute sections are infrequently rolled by mills, in passing.

6.2.9 Future expansion

Single sourcing of PEB is advantageous for future expansion whereas multiple sourcing
of CSB poses difficulty. Future expansion is easy and simple for PEB whereas it is most tedious
and costly for CSB.

6.2.10 Performance
All components of the PEB system are specially designed to act together as a system for
highest efficiency. PEB designs are revised regularly with respect to the actual field conditions
and in accordance with various country codes, which resulted in improved standardized designs
leading to high performance of the structure. CSB system components are conventionally
designed for a specific project and the performance depends on how the individual project is
designed.
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7.0 Inference

Steel is such a versatile material that every object we see in our daily life has used steel
directly or indirectly.
There is no viable substitute to steel in construction activities. Steel remains and will
continue to remain logical and wide choice for construction purpose, environmentally
also, as much of the steel used is recycled.
Steel building offers more design and architectural flexibility for unique or conventional
styling. Its strength and large clear spans mean the design is not constrained by the need
for intermediate support walls.
Steel building offers more design and architectural flexibility for unique or conventional
styling. Its strength and large clear spans mean the design is not constrained by the need
for intermediate support walls.
As requirements change over the years, one can reuse, relocate, & modify the structure.
Pre-engineered Metal building concept forms an unique position in the construction
industry in view of their being ideally suited to the needs of modern Engineering
Industry.
Structures can be easily designed by simple design procedures in accordance with
country standards. It can be concluded that PEB structures are more advantageous than
CSB structures in terms of cost effectiveness, quality control speed in construction and
simplicity in erection.