Detailed Project Report on pre engineered buildings
Detailed Project Report on pre engineered buildings
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PRE ENGINEERED BUILDINGS
[CODE NO 4019]
Brief Introduction to Pre-Engineered Buildings
Pre-Engineered Buildings (PEB) refer to steel structure buildings that are usually engineered at a factory and assembled at the site. These buildings are the latest trend in India. The built-up sections are normally fabricated at the factory to exact size, transported, and then assembled with bolted connections at the site.
In structural engineering, these buildings are designed by PEB supplier or PEB manufacturer using various methods and materials to satisfy aesthetic design requirements. PEBs are becoming increasingly common due to custom-aided designs. The preferred choice of material for design is steel as it is inherently flexible and ductile. Steel is known to flex under extreme loads rather than crumbling or crushing. Structural steel is used which is known to have adaptability, low cost, recyclability, durability and design flexibility. Thus, it is the material of choice for building construction. Steel is extensively used for such projects for medium and heavy buildings where it is not feasible to have concrete construction.
PEBs are designed by a manufacturer to be fabricated using specific raw materials as inventory and various manufacturing methods that suffice the aesthetic design requirements. These buildings can be fitted with different structural accessories including interior partitions, canopies, mezzanine floors and much more. These are water proof buildings with the use of trims, filler strips and special mastic beads.
The various components of PEBs are depicted in Fig-2 above. Complete designing of the building is done at the factory and these components are then brought to the site in knock down condition. A pre-engineered building that is efficiently designed is mostly lighter than the conventional steel buildings.
Advantages of PEBs
- PEBs are known to drastically reduce construction time.
- PEBs relate to low maintenance too.
- These buildings are known for optimal utilization of resources and are known for maximum leverage of technology.
- These buildings have gained a global reputation for durability, water resistance and earthquake resistance.
- These buildings are extremely versatile and are easy to set-up, modify and transport to different locations.
- PEBs are known to be environmentally friendly and have unique aesthetic features.
- PEBs can be delivered in just about 5-8 weeks to the site.
- Various unique techniques are deployed during fabrication which in turn leads to making these buildings lighter than regular steel structures.
- These buildings do not involve any kind of welding or fabrication at the site – thus are known for their increased efficiency.
- PEBs depict architectural versatility as these can be supplied with various types of fascia’s, canopies, curved eaves, concrete wall panels, blocked walls, curtain walls and other wall systems.
- PEBs assure compatibility of all building components and accessories as the complete building package is taken by a single vendor.
APPLICATIONS OF PEBs
PEBs have diverse applications as factories, warehouses, aircraft hangers, workshops, labour camps, schools, community centers, railway stations, equipment housing, office buildings, supermarkets, petrol pumps, service buildings, and others.
Various systems in PEB
Primary System
Primary system consists of tapered or parallel columns and tapered beams which are called as rafters. The base of the columns can be either pinned or fixed based on the load requirements. Lengths of these members are generally restricted to 12m for ease of transports. Joints are connected with high tensile bolts.
Secondary System
Secondary structural system consists of Purlins (roof), Girts (side cladding) and Eave struts (at eaves) stiffened with sag rods. This also includes the flange stiffeners which connects the untied flanges of the PEB primary structure to secondary system. Some of the commonly used secondary system are Lipped C or Lipped Z purlins, MS rods and Lipped Angles. These are generally cold formed sections conforming to IS: 801.
Wind Bracing System
There are two types of wind bracing systems.The first one is Rod bracing system and the second one is portal system. Each type of system is chosen based on the design and functional requirement of the structure.
Roofing & Cladding System
Roofing and cladding system can be with single skin zinc and aluminum coated steel sheets, GI sheets, both of which could be bare or color coated; It could with double skin sheets with or without insulation material in between; It could be sandwich panels with steel sheets outside and PUF/PIR/Mineral Wool/Glass wool core inside. Roofing and cladding could have skylights with Poly Carbonate/ PVC or FRP sheets.
Accessories
Accessories include, Turbo Ventilators, Ridge vents, Flashings, trims, Gutters, Down pipes, ladders, Louvers etc.
Finishing
Primary structural members are generally finished with shot peening, Sand blasting, and two coats of anti corrosive primers, followed by two coats of paints to specifications. Secondary members or either painted after sand blasting or Galvanized to 275 gsmor above based on the requirement.
COST ESTIMATION
Plant Capacity 41 MT/Day
Land & Building (8000 sq.mt.) Rs. 6.28 Cr
Plant & Machinery Rs. 2.56 Cr
Working Capital for 2 Months Rs. 11.30 Cr
Total Capital Investment Rs. 20.52 Cr
Rate of Return 34%
Break Even Point 47%
INTRODUCTION
VARIOUS SYSTEMS IN PEB
PRIMARY SYSTEM
SECONDARY SYSTEM
WIND BRACING SYSTEM
ROOFING & CLADDING SYSTEM
ACCESSORIES
FINISHING
COMPONENTS OF PEB
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 FOLLOWING LOADS:-
PANELS AND INSULATION
MEZZANINE SYSTEM
BRACING SYSTEM
PAINTS AND FINISHES
DOORS AND WINDOWS
FALSE CEILING
PARTITION WALLS
FLOORING
ADVANTAGES OF PEB:
BENEFITS
DISADVANTAGES OF PEB
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR PEB
FABRICATION PROCESS OF PEB
CUTTING
CNC PLASMA & OXY GAS
CNC (6100 X 20) MM SHEARING MACHINE
CNC (6100 X 12) MM SHEARING MACHINE
EQUIPMENT AND MACHINES:
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:
LENGTH:
TYPE OF MEMBER TOLERANCE
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) HEETING FASTENERS:
(9) SEALER:
(10) CLOSURES:
(11) FLASHING AND TRIM:
(12) ROOF & WALL BRACINGS:
(14) PAINTING FOR STRUCTURAL STEEL WORK:
QUALITY CONTROL
MARKET POSITION
DRIVERS
BRIEF MARKET RESEARCH ANALYSIS
BY MATERIAL
BY APPLICATION
KEY PLAYERS
INDIA PEB MARKET
SOME MORE INSIGHTS
KEY VENDORS
OTHER PROMINENT VENDORS
GOVERNMENTS INITIATIVE IN GROWTH OF PEB
THE CHALLENGES
PEB ADVANTAGE
PLANT LAYOUT
SUPPLIERS OF PEB STRUCTURE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF STRUCTURAL STEEL PLATE
SUPPLIERS OF STRUCTURAL STEEL SHEET PLATE
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 MACHINE
SUPPLIERS 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
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
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
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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