PEB-Conventional Structure Comparison

8/11/2019 PEB-Conventional Structure Comparison

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INDIAN RAILWAY INSTITUTE OF

CIVIL ENGINEERING, PUNE

Sr. Professional Course (Bridges and General) Session No. 822

(From 21-04-08 to 16-05-08)

PROJECT REPORT

Use of Pre-Engineering Building Structure in Railway

By

PRADEEP KUMAR

Deputy Chief Engineer/Con./Jogighopa

N.F.Railway


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Definition

The required building is designed to meet the Specific requirement, all

members are fabricated ,cut, punched in factory in ready to installation

Position

All members, purlins, grits, Cladding , connected plates, Bolts, Screws &other accessories are delivered to site as a Package Solution.

PEB INDUSTRY EVOLUTION

Concept of metal buildings originated in U.S. And gained momentum after

the world war in early 1960s.Mass production of defence buildings in steel

using pre-fabricated concept became popular in 1940s.Metal building

systems was recognized as a favourable method of construction overconventional methods

Computerised designs allowed buildings to be tailored to individual

customer requirements in1960s.Roll forming lines allowed continuous spancold rolled z-purlins. Color coated panels and factory insulated panels

improved architecturalappearance

The term pre-engineered buildings came into existence

PRE ENGINEERED METAL BUILDINGS dominated the low rise building

market in the developed world in 1990s.MBMA statistics show, about 60%of industrial and commercial bldgs in the developed world, use PEB.

Developing countries started using PRE ENGINEERED METAL

BUILDINGS.

PEB concept widely accepted in the developing countries like India in2001.Over 3000 pre-engineered buildings supplied by kirby in india in a

short span of 6 years.

STANDARDS for PEB

MBMA (Metal Building Manufacturers Association) formed in 1956 inUSA.Develops engineering standards, with the latest-updates, for the

manufacturers of pre-engineered metal building systems.

MBMA Lowrise Building Systems Manualis followed by the peb industryworldwide for design and construction of metal building systems.


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MBMA/ AISC/ AISI works closely in updat ing/sponsoring the latest

development and research findings in steel buildings systems.

MAIN FEATURES OF PEB

Buildings are pre-engineeredas they rely on standard designs with standard

configurations, with each components of the building system uniquely profiled andpre-engineered to suit design requirements.

By using sophisticated manufacturing facilities and engg software, the pebs arecustom desi gned to meet the specifi c customer needs.

PEBS are always manufactured in factories and shipped to job sites for assembly.

PEB uses systems approach by combining elements such as roof panels, wall panels,purl ins, girts, main frames, wind bracings etc to act integrally.

Comparison of PEB Vs. COncevtional

PRE ENGINEERED BUILDINGS CONVENTIONAL

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All sections are optimally designed withavailable inventory . Non availability of

sections does not arise and hence ensures noprice escalation.

Non-availability of designed sections oftenforces the designers to go for higher

sections resulting in higher weight andescalation in the project cost.

Designed as per International Standardssuch as AISC, AWS, MBMA, which are

proven worldwide. American codes are

regularly updated based on latest researches

IS-Codes are not regularly updated. Willincrease the weight and cost of building.

More competitive on life-cycle cost due to

signif icant time savin g (nearly 50%) inproject completion, which in turn t ranslates

to earlier realization of revenue.

Project cost escalation due to delays in site

fabrication and co-ordination with severalagencies which costs time and money.

Offers maintenance-free roof system, with

att ractive color coated sheets

Requires periodical maintenance at frequent

intervals.

MAIN COMPONENTS OF PEB

PEB IS a bui lding shell utilizing three distinct product categories

PRIMARY FRAMING: I shaped built-up( 3 p lated) members, MinimumYield Stren gth 345Mpa.

S ECONDARY MEMBERS : cold formed Zed AND Cee sections, HighTensile Steel With Yield Stress of 450 MPa

ROOF AND WALL CLADDING: roll formed profiled sheeting, HighTensile Steel With Yield Stress of 550 MPa,

Zn-AL Alloy Coated For better corrosionResistance, Available in various colours.

PEBS use pre-determined inventory of raw materials, proven over a long time, to

satisfy wide range of structural and architectural requirements.


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Component of a Pre-Engineering Building


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MMAAIINNFFRRAAMMEESS

RIGID FRAME BEAM COLUMN -1 BEAM COLUMN - 2 BEAM COLUMN - 3SPACE SAVER

MONO SLOPE L - CANOPY T - CANOPY MULTI SPAN LEAN TO

Product Range


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SSEECCOONNDDARRIIEESSProduct Range


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CCLLAADDDDIINNGGSSYYSSTTEEMMSS

KIRBY RIB (KR)

KIRBY WALL (KW)

KIRBY DECK PANEL

KIRBY WALLINSULATED PANES

KWIP

KIRBY FLATINSULATED PANES - KFIP

Product Range

AACCCCEESSSSOORRIIEESS

SLIDING DOORS

LOUVERS NUTS AND BOLTS INSULATIONS SEALENTS

SKYLIGHTS AND WALL LIGHTS WALK DOORS

POWER VENTILATORS

WINDOWS

ROOF CURBS RIDGEVENTS ROOF JACKS

Product Range


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Use of Pre-Engineering Building in Railway A

Comparative study

Recently 3 Nos Pre-engineering Building Structureshas been provided in New Bongaigan C& W

Workshop, N.F. Railway in Connection with Modernization of NBQ Workshop. Name of Workalongwith relevant portion of Tender S chedule is furnished below;TEND ER SCHEDULE

A ty pical tender schedule used in recently ex ecuted work in N.F. Railw ay is given below:

TENDER NO.CE/CON/NBQ/W.Shed/2006/01

Name of work :-Construction of A.C.POH Shed 54m x 15.24m x 11.74m, ex tension of ex isting WTS by42.7m x15.25m x 10m,ex tension of corrosion repair shop by 30m x20m x 12.22m, ex tension of CLS/BG by

61m X15.50m x11.5m, s hifting of ex isting abandoned shed 61m x 20m x11.74m to store depot a t New

Bongaigaon in connection with modernization of New Bongaigaon Workshop.

SCHEDULE OF ITEMS OF WORKS AND APPROXIMATE QUANTITIES

Sl.No Description of works Un it Qty, Rate in figures & words

ALTERNATE PROPOSALAlternate proposal submitted by the contractor for design ,manufacturing/ fabrication, supply and erection of Pre-

Engineering metal building designed as per relev ant IS-Code as stated in the attached specification w ith original offer

dated 08.12.2007 acc epted by Railw ay.

PART-1: ex tension of ex isting WTS Shed, heavy corrosion

repair shed ,CLS/BG & construction of AC POH Shed

1 Cons truc tion of AC POH Shed Sqm 822.96 Rs 11650/-

2 Ex tension of existing WTS Sqm 651,17 Rs .12,180/-

3 Ex tension of exis ting Corrosion repair Shed Sqm 600 Rs .12,500/-

4 Ex tension of exis ting CLS/BG Sqm 945.5 Rs .12,200/-

PART-2 Shifting of ex isting abandoned shed of size of size61m X 20m X 11.74m to the store depot at NBQ Workshop.

Items as per conventional system (Both NS & SRitems)


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N.B.:- Payment for part-1 is on Sqm basis on c/c distances between columns includingfoundation work as per approved drawings. No further extra payment will be payable for

projection of roofing etc.

Brief Particulars of these sheds is given below :

1. Carriage Lifting Shop ( CLS /BG) S upplied by Kirby Building System .Size-61m x 15.5m x 11.74mArea = 61x15.50 = 945.50 S qm.

No. of Column = 9x2 = 18 Nos.Overhead Crane =20T CapacityFoundation Concrete =117.90 Cum = 117.90/945.50 = 0.123 Cum/Sqm

Structural Steel (HTS) = 90.50 MT= 90.50/945.50 = 0.096 MT/ Sqm

Cost of complete structure = Rs.12, 200 /Sqm(Excluding industrial flooring)

2. Corrosion Repair S hop (CRS) - S upplied by Kirby Building System.Size -30m x 20m x 12.22m

Area = 30x20 = 600Sqm.No. of Column = 5x2 = 10 Nos.

Overhead Crane = 20 T CapacityFoundation Concrete =75 Cum = 75/600 = 0.125 Cum/SqmStructural Steel (HTS) = 60.40 MT= 60.40/600 = 0.107 MT/ S qm

Cost of complete structure = Rs.12, 500 /Sqm(Excluding industrial flooring)

3. AC POH S hed - S upplied by Tata Blue Scope Steel.Size -54m x 15.24m x 11.74mArea = 54x15. 24 = 822.96 Sqm.No. of Column = 8x2 = 16 Nos.

Overhead Crane = 5 T CapacityFoundation Concrete =138.08 Cum = 138.08/822.96 = 0.168 Cum/Sqm

Structural Steel (HTS) = 60 MT= 60/822.96 = 0.073 MT/ SqmCost of complete structure = Rs.11, 650 /Sqm

(Excluding industrial flooring)

Further, Shifting of one abandone d shed having conventional structure hasalso been done under above work and another conventional structure for

Sickline Shed at NBQ yard was completed 2 years ago. Brief Particulars ofthese is given bel ow :


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1. Sickline Shed at NBQ

Size-76m x 18m x 11.74mArea = 76x18 = 1368 Sqm.No. of Column = 20x2 = 18 Nos.

Overhead Crane =20T CapacityFoundation Concrete =704.24 Cum = 704.24/1368 = 0.515Cum/Sqm

Structural Steel (HTS) = 295.31 MT= 295.31/1368 = 0.215 MT/ SqmCost of complete structure = Rs.2,17,26,580/1368 =Rs.15, 882 / S qm(Excluding industrial flooring)

2. Shifting of Abandoned Shed in NBQ WorkshopSize-61m x 20m x 11.74mArea = 61x20 = 1220 Sqm.

No. of Column = 11x2 = 22 Nos.

Overhead Crane =20T CapacityFoundation Concrete =416.57 Cum = 416.57/1220 = 0.341 Cum/S qm

Structural Steel (HTS) = 245 MT= 245/1220 = 0.201 MT/ S qmCost of complete structure = -

(Excluding industrial flooring)

Comparison of Consumption of Concrete, Steel and Costof Structure

(A) Conventional Steel Building(B)

S .No Name of

Building

Foundation

Concrete,

Cum/S qm

Steel

MT/S qm

Cost

Rs./Sqm

Remarks

1 Sick line Shed(76x18x11.74)

0.515 0.215 15,882 Work completed 2years ago

2 Abandoned

Shed(61x20x11.74)

0.341 0.201 - Recently completed,

Existing steel utilized

Average 0.428 0.208 15,882**Considering escalation @ 5% for 2 years, the cost of connectional SteelBuilding works out as 15882(1+2x0.5) = Rs.17, 470


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(C) Pre- Engineering Steel Building

S .No Name ofBuilding

Foundation

Concrete,Cum/Sqm

Steel

MT/S qm

Cost

Rs./Sqm

Remarks

1 CLS/BG(61x15.50x11.5)

0.123 0.096 12,200 Recently completed

2 Corrosion repair

Shed(30x20x12.22)

0.125 0.107 12,500 Recently completed

Average 0.124 0.102 12,350

Observations

From above tables, it is seen that consumption of Steel is about 50% less

in case of Pre-Engineering steel buildings resulting in very lighterFoundation i.e. about 70 % less as compared to traditional Steel

Buildings.Over all cost of structure is reduced by about 30%.

Besides,above PEB construction has been very fast, totally hassle free for

field officials and with complete ease of measurement involving only

item ( per Sqm of shed area) for each shed which is otherwise verycumbersome in conventional system. Further, questionof Variationnormally does not arise in this type of construction.

Conclusion/Reccomendations

(i) PEBs should be used for workshops structures as well as Dieselshed,Sick Line and goods godowns as it provides very economic,aesthetically better looking structure in a very short Period.

(ii) Some Guidelines /provision should be made in relevant codes &manual to facilitate use of PEBs,

Reference:

(i) Tata blue Scope Steel Limited.(www.tatabluescopesteel.com)(ii) Kirby Building System(www.kirbybuildingsystem.com)(iii) www.zamilsteel.com


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Shifting of abandoned Shed to new location Conventional Structure

New Bongaigaon Workshop in Progress

Figure 1


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Shifting of abandoned Shed completed

Figure 3

Figure 4 Newly constructed Pre-EngineeringBuilding-CLS/BG

Figure 2 Newly constructed Pre-EngineeringBuilding-CLS/BG


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Figure 5 ;Pre-Engineering Building-Corrosion Repair shop in progress

Figure 6: Another view of Corrosion repair Shop


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Figu re 7 : Inside View of newly erected Pre-Engin eering Building of AC POH Sh ed

Figure 8: View of completed Sick Line Shed at NBQ Yard- Conventional Structure


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Documents

PEB-Conventional Structure Comparison