Detailed Project Report on PRE ENGINEERED BUILDINGS AND COLD FORMED STRUCTURE

Pre Engineered Buildings (PEB) is the buildings which are engineered at a factory and assembled at site. Usually PEBs are steel structures. Built-up sections are fabricated at the factory to exact size, transported to site and assembled at site with bolted connections. This type of Structural Concept is generally used to build Industrial Buildings, Metro Stations, and Warehouses etc.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



PRE ENGINEERED BUILDINGS AND COLD FORMED
STRUCTURE
[EIRI/EDPR/4743] J.C.: 2963XL


Pre Engineered Buildings (PEB) is the buildings which are engineered at a factory
and assembled at site. Usually PEBs are steel structures. Built-up sections are
fabricated at the factory to exact size, transported to site and assembled at site
with bolted connections. This type of Structural Concept is generally used to build
Industrial Buildings, Metro Stations, and Warehouses etc.

The adoptability of PEB in the place of Conventional Steel Building design concept
resulted in many advantages, including economy & easier fabrication. These type
of building structure can be finished internally to serve any functions that is
actually help in low rise building design. Examples of Pre- Engineered Buildings
are warehouses, Canopies, Factories, Bridges etc.

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.

These Pre-Engineered Steel Buildings can be fitted with different structural
accessories including mezzanine floors, canopies, fascias, interior partitions, crane
systems etc. The building is made water-tight by use of special mastic beads,
filler strips and trims. This is a very versatile building system and can be finished
internally to serve any required function and accessorized externally to achieve
attractive and distinctive architectural styles. It is most suitable for any low-rise
building and offers numerous benefits over conventional buildings.

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Pre-engineered buildings are generally low rise buildings; however the maximum
eave heights can go upto 25 to 30 metres. Low rise buildings are ideal for offices,
houses, showrooms, shop fronts etc. The application of pre- engineered concept to
low rise buildings is very economical and speedy. Buildings can be constructed in
less than half the normal time especially when complimented with other
engineered sub-systems.

The most common and economical type of low-rise building is a building with
ground floor and two intermediate floors plus roof. The roof of a low rise building
may be flat or sloped. Intermediate floors of low rise buildings are made of
mezzanine systems. Single storeyed 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.

Purlin is a horizontal structural member spanning between beams or trusses to
support a roof deck. In slope glazing, purlins are the horizontal framing members.
Purlins have been used in roofing system for decades. Roof purlins account for a
substantial proportion of cold formed steel usage in buildings. Purlins are ideally
suited for production as cold rolled sections and over 60000 tonnes of cold formed
steel purlins are produced annually in United Kingdom.

There are various types of purlins available in the market; the most commonly are
Cee and Zed purlins which take the form of C and Z letter. The Zed shape purlin
was introduced from USA around 1960. Another type of purlins shape is the
Sigma shape which was introduced a few years later after the Zed shape. In recent
years the fierce competition between purlin manufacturers has led to substantial
research and development effort in the field of purlin design to produce purlin
with even greater efficiency. This has lead to further developments of the Zed
shape in particular such as Zeta shape and the UltraZED shape. All the typical
shapes of purlins are shown in Figure 1.1. Most purlins are produced from steel
and most recently galvanized steel which has a greater advantage over steel in
terms of strength. Most purlins are cold formed which means that they are formed
in the cold state from a strip of uniform thickness.

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CONTENTS

INTRODUCTION

ROOF PURLIN SYSTEM IN COMMON USE

WHY CHOOSE PRE-ENGINEERED STEEL BUILDINGS

1. COST SAVINGS

2. QUALITY CONTROL

3. QUICK ERECTION

4. FLEXIBILITY

5. ENERGY EFFICIENCY

TOP MANUFACTURERS COMPANY I N INDIA

RIDDHIMA BUILDING SYSTEM PRIVATE LIMITED

KIRBY BUILDING SOLUTIONS INDIA LIMITED

MULTI DÉCOR INDIA PRIVATE LIMITED

TATA BLUESCOPE STEEL LIMITED

EVEREST INDUSTRIES LIMITED

TIGER STEEL ENGINEERING INDIA PRIVATE LIMITED

LLOYD INSULATIONS INDIA L IMITED

EPACK PREFAB

JINDAL BUILDSYS LIMITED

HINDUSTAN ALCOX LIMITED

VARIOUS SYSTEMS IN PEB

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PRIMARY SYSTEM

SECONDARY SYSTEM

WIND BRACING SYSTEM

ROOFING & CLADDING SYSTEM

ACCESSORIES

FINISHING

COMPONENTS OF PEB

THERE ARE BASICALLY NINE MAJOR COMPONENTS IN A PRE-ENGINEERED
BUILDING SUCH AS:

MAIN FRAMING

END WALL FRAMING

PURLINS, GIRTS AND EAVE STRUTS

THE PURLINS ARE SUBJECTED TO THE FOLLOWING LOADS:-

THE GIRTS ARE SUBJECTED TO THE FOLLOWING LOADS:-

THE EAVE STRUTS ARE SUBJECTED TO THE FOLLOWI NG LOADS:-

PANELS AND INSULATION

CRANE SYSTEM

MEZZANINE SYSTEM

BRACING SYSTEM

PAINTS AND FINISHES

DOORS AND WINDOWS

FALSE CEILING

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PARTITION WALLS

FLOORING

ADVANTAGES OF PEB:

BENEFITS

DISADVANTAGES OF PEB

INNOVATION IN CONSTRUCTION: ADVANCING BUILDING TECHNIQUES WITH
PEB

USES AND APPLICATION

COLD FORMED STEEL PURLIN

TYPES OF COLD FORMED ROOF PURLIN

FIGURE: COMMON C AND Z SHAPED-PURLINS

ADVANTAGES OF COLD STEEL OVER OTHER MATERIALS

COLD FORMED STEEL IN ENGINEERING STRUCTURE

PROCESS FLOW CHART FOR PEB

FABRICATION PROCESS OF PEB

THE PEB PRODUCTION PROCESS PRIMARILY CONSISTS OF FOUR MAJOR
PARALLEL PROCESSING LINES, AS UNDER:

THE PRODUCTION & SHIPMENT OF THESE COMPONENTS FOR A PEB
STRUCTURE USES FOLLOWING PROCESSES:

CUTTING

CNC PLASMA & OXY GAS

CNC (6100 X 20) MM SHEARING MACHINE

CNC (6100 X 12) MM SHEARING MACHINE

EQUIPMENT AND MACHINES:

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HOLE PUNCHING

ASSEMBLING

VERTICAL ASSEMBLING

HOT ROLLED ASSEMBLING

AUTOMATIC ASSEMBLING MACHINE

EQUIPMENT AND MACHINES

WELDING AND CONNECTION DETAILS WELDING

MANUAL WELDING AND DETAILING

EQUIPMENT AND MACHINES

SURFACE CLEANING

SHOT BLASTING MACHINE, ROOM (8000 X 20000 X 6000 MM)

EQUIPMENT AND MACHINES:

PAINTING

PAINTING MACHINE

EQUIPMENT AND MACHINES

LOADING

QUALITY CONTROL

FOR FABRICATION PROCESS

FABRICATION TOLERANCES:

STRAIGHTNESS:

TWISTS:

CAMBER:

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LENGTH:

SQUARE-NESS AT END OF MEMBERS

BUTT JOINTS

DEPTH OF MEMBER

WEB PLATES:

FLANGE PLATES:

COLUMN FABRICATION TOLERANCES:

CRANE RUNWAY GIRDER FABRICATION TOLERANCES:

GIRDER ENDS:

CRANE GIRDER ALIGNMENT:

FOR HOLING PROCESS

FOR WELDING PROCESS

INSPECTION OF WELDS:

TESTS ON WELDS:

(1) MAGNETIC PARTICLE TEST:

(2) DYE PENETRATION TEST:

(3) RADIOGRAPHIC INSPECTION:

TESTING OF FABRICATION COMPONTS

(6) ROOF SHEETING:

(7) WALL PANELS:

(8) HEATING FASTENERS:

(9) SEALER:

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(10) CLOSURES:

(11) FLASHING AND TRIM:

(12) ROOF & WALL BRACINGS:

(14) PAINTING FOR STRUCTURAL STEEL WORK:

MANUFACTURE AND CONSTRUCTION OF STEEL FORMED STRUCTUE

MANUFACTURING METHODS:

CONSTRUCTION METHODS:

PANELIZATION METHOD OF FRAMING VERSUS CONVENTIONAL FIELD
ASSEMBLY METHOD:

FRAMING OPTIONS:

COLD FORMED STEEL STRUCTURAL MEMBERS

INDIVIDUAL STRUCTURAL FRAMING MEMBERS (BAR MEMBERS):

(I) SINGLE OPEN SECTIONS:

(II) THE HOLLOW FLANGE BEAM (LITESTEEL BEAM):

(III) OPEN BUILT-UP SECTIONS:

(IV) CLOSED BUILT-UP SECTIONS:

PANELS AND DECKS:

APPLICATION OF COLD FORMED STEEL STRUCTURAL MEMBERS

CFS PRIMARY LOAD BEARING MEMBERS:

THE PRIMARY AREAS OF LOAD-BEARING CFS APPLICATIONS ARE: FRAMING:

COMPOSITE SECTIONS:

LATERAL LOADS RESISTING SYSTEM (LFRS):

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BENEFITS OF COLD FORMED STEEL SECTION

1. NO INSECT AND FUNGAL INFECTION:

2. CONSISTENCY AND ACCURACY OF PROFILE:

3. VERSATILITY OF PROFILE SHAPE:

4. IT COULD BE PRE-GALVANIZED OR PRE-COATED:

5. VARIETY OF CONNECTION AND JOINTING METHODS:

6. SPEEDY IN CONSTRUCTION, AND SUIT FOR SITE ERECTION:

7. INCREASE IN YIELD STRENGTH DUE TO COLD FORMING:

8. MINIMIZATION OF MATERIAL USAGE:

9. HIGH PROFITABILITY:

PRE ENGINEERED BUILDING MARKET OVERVIERW

PRE-ENGINEERED BUILDINGS MARKET SEGMENT ANALYSIS:

PRE-ENGINEERED BUILDINGS MARKET REGIONAL INSIGHTS:

PREENGINEERED BUILDING MARKET ANALYSIS

OVERVIEW OF ECONOMY GLOBAL ECONOMY

PEB OVERVIEW

MARKET SIZE AND EXPECTED GROWTH

EXHIBIT 5: US PEB MARKET GROWTH

KEY REGULATIONS AND POLICIES

INDUSTRY SPECIFIC REGULATIONS

BUREAU OF INDIAN STANDARDS ACT, 2016(“BIS ACT”)

THE LEGAL METROLOGY ACT, 2009 AND LEGAL METROLOGY (PACKAGED
COMMODITIES) RULES, 2011 (“LM RULES”)

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STEEL AND STEEL PRODUCTS (QUALITY CONTROL) ORDER, 2020 (“QC
ORDER”)

ENVIRONMENT LAWS AND REGULATIONS

THE ENVIRONMENT (PROTECTION) ACT, 1986 AND THE ENVIRONMENT
(PROTECTION) RULES, 1986

THE ENVIRONMENTAL IMPACT ASSESSMENT NOTIFICATION, 2006 (“EIA
NOTIFICATION”)

THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (“WATER
ACT”)

THE AIR (PREVENTION AND CONTROL OF POLLUTION) ACT, 1981 (“AIR ACT”)

THE HAZARDOUS AND OTHER WASTES (MANAGEMENT AND TRANSBOUNDARY
MOVEMENT) RULES, 2016 (“HAZARDOUS WASTE RULES”)

INDUSTRIAL, EMPLOYMENT AND LABOUR LAWS

THE PUBLIC LIABILITY INSURANCE ACT, 1991 & THE PUBLIC LIABILITY
INSURANCE RULES, 1991

THE FACTORIES ACT, 1948

THE CODE ON WAGES, 2019

THE OCCUPATIONAL SAFETY, HEALTH AND WORKING CONDITIONS CODE,
2020

THE CODE ON SOCIAL SECURITY, 2020

THE INDUSTRIAL RELATIONS CODE, 2020

THE CHILD AND ADOLESCENT LABOUR (PROHIBITION AND REGULATION) ACT,
1986

THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION,
PROHIBITION AND REDRESSAL) ACT, 2013

INTELLECTUAL PROPERTY LAWS

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THE PATENTS ACT, 1970 (“PATENTS ACT”)

THE TRADE MARKS ACT, 1999 (“TRADE MARKS ACT”)

THE COPYRIGHT ACT, 1957 (“COPYRIGHT ACT”)

THE DESIGNS ACT, 2000 (“DESIGNS ACT”)

FOREIGN TRADE REGULATIONS

FOREIGN EXCHANGE MANAGEMENT ACT, 1999 (“FEMA”)

THE FOREIGN TRADE (DEVELOPMENT AND REGULATION) ACT, 1992 AND
FOREIGN TRADE (REGULATION) RULES, 1993

LAWS IN RELATION TO TAXATION

INCOME TAX ACT, 1961

GOODS AND SERVICES TAX ACT, 2017

GENERAL LAWS

THE CONSUMER PROTECTION ACT, 2019

THE COMPETITION ACT, 2002

THE COMPANIES ACT, 2013 (“COMPANIES ACT”)

THE INDIAN CONTRACT ACT, 1872

INDIAN STAMP ACT, 1899

THE REGISTRATION ACT, 1908

THE NEGOTIABLE INSTRUMENTS ACT, 1881

SUPPLIERS OF PEB STRUCTURE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF STRUCTURAL STEEL PLATE

SUPPLIERS OF STRUCTURAL S TEEL SHEET PLATE

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SUPPLIERS OF MIG WELDING WIRE ELECTRODE

SUPPLIERS OF ZINC INGOT

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF HYDROCHLORIC ACID

SUPPLIERS OF DEGREASING CHEMICAL

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF UNCOILING MACHINE

SUPPLIERS OF SHEET LAVELING MACHINE

SUPPLIERS OF PUNCHING PRESS

SUPPLIERS OF POWER PRESS

SUPPLIERS OF SHEARING MACHINE

SUPPLIERS OF ROLLING MACHINE

SUPPLIERS OF BENDING MACHINE

SUPPLIERS OF CNC PLASMA CUTTING MACHINE

SUPPLIERS OF COLD ROLL FORMING MACHINE

SUPPLIERS OF WELDING MACHINESUPPLIERS OF MIG WELDING MACHINE

SUPPLIERS OF AUTOMATIC H-BEAM WELDING MACHINE

SUPPLIERS OF PAINTING EQUIPMENTS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

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SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

SUPPLIERS OF SUBMERSIBLE WATER PUMP

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

7. WASTE DISPOSAL:

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8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

UTILITIES

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

INDIAN MANUFACTURING INDUSTRY

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INTRODUCTION

MARKET SIZE

INVESTMENT

GOVERNMENT INITIATIVES

ROAD AHEAD

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

WEIGHING BREIDGE MANUFACTURER

WEIGHING MACHINES

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

ELECRICAL GOOD & SWITCH MANUFACTURE

SS PIPE & TUBE MANUFACTURER

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENT S:

LICENCE OF PLASTIC WASTE IMPORT

DOCUMENTS REQUIRED ARE:-

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

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THREATS

ORGANIZATION CHART

PLANT LAYOUT

IMPLEMENTATION SCHEDULE


APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

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17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)



COST ESTIMATION

Plant Capacity 40 MT/Day

Land & Building Rs. 5.05 Cr

Plant & Machinery Rs. 7.65 Cr

Working Capital for 2 Months Rs. 16.57 Cr

Total Capital Investment Rs. 29.49 Cr

Rate of Return 23%

Break Even Point 53%