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PRELIMINARY COPY-REV-1
BASIC CONCEPTS OF
PRE-ENGINEERED STEEL BUILDINGS
By:
S. Khalid Hashmi
Deputy General Manager –Technical Services
Kirby Building Systems India Ltd
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Table of Contents
1. INTRODUCTION................................................................................................. 3
2. NOMENCLATURE.............................................................................................. 4
11. WARRANTY....................................................................................................... 54
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Chapter – 1
INTRODUCTION
Technological improvement over the years has contributed immensely to enhancement of
quality of life through various new products & services. Another major impact of this
phenomenon was the availability of these products & services in ready-to-use forms. One
such revolution was the Pre-Engineered Steel Buildings (PEB). Though 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 computerize the design &
drawing.
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 a very short duration. A recent survey by the Metal Building Manufacturers
Association (MBMA) shows that about 60% of the non-residential low rise building in
USA are Pre-Engineered steel buildings.
The pre-engineered steel building industry is in its infancy in the Indian sub-continent.
However, with the setting up of the state-of-the-art Kirby Building Systems
Manufacturing plant near Hyderabad and the significant advantages of this form of
construction over conventional structural steel and RCC construction, it is inevitable that
PEB system of construction would soon dominate the Indian construction market.
Unfortunately, design schools and the textbooks tend to ignore this type of construction,
apparently assuming that it belongs to manufacturer’s domain. The principal objective of
this is to present architects, engineers, contractors, construction specifiers, facility
managers and building officials with enough information to enable them to make
intelligent decisions in their design and evaluation activities. Pre-engineered Buildings
offer complete freedom of design to accommodate the customer needs.
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Chapter – 2
NOMENCLATURE
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“C” SECTION: A member formed from steel coils into the shape of a
block “C”.
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DOUBLE SLIDE DOOR: The sliding door with two door leaves.
DRIFT PIN: A tapered pin used during erection to align holes I steel
members to be connected by bolting (also called spud wrench).
EAVE STRUT CLIP: The clip used to support the eave strut.
EDGE DISTANCE: The distance between the plate corner and the
center of the bolt.
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FIN NECK BOLT: The bolts whose heads are flattened (reduced
head size) and used at the exposed surface of the framed openings.
FINISHED FLOOR: Top of the concrete slab or the finished concrete
surface.
FIXED BASE: A column base that is designed to resist rotation as
well as horizontal or vertical movement.
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GIRT CLIP: Angle clips used to connect the girts to the columns.
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LOADS:
a) Dead Load e) Wind Load
b) Impact Load f) Crane Load
c) Roof Live Load g) Collateral Load
d) Seismic Load h) Auxiliary Load
LONGITUDINAL EXPANSION JOINT: A joint down the length of
a building to allow small, relative movements, such as those caused
by temperature change, in the building width.
LOUVER: An opening provided with slanted blades, fixed or
movable, to allow flow of air.
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Mpa: Mega-Pascal.
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PASCAL: Metric unit of stress or pressure, force per unit area (N/M2)
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POP RIVET: Used for joining flashing and light gauge metal trims.
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RAKE: The intersection of the plane of the roof and the plane of the
gable.
RAKE ANGLE: Angle fastened to purlins at rake for attachment of
endwall sheets.
RAKE TRIM: Sheet metal flashing used to cover the intersection of
the roof and the endwall of a building.
REACTIONS: The resisting forces at the column bases of a frame,
holding the frame in equilibrium under a given loading condition.
REINFORCING STEEL: The steel bars placed in concrete to help
carry the tension, compression and shear stresses, as well as
temperature stresses.
REVISION: A significant change in building design, building order,
or product worthy of notation.
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ROOF SLOPE: The angle that a roof surface makes with the
horizontal. Usually expressed in units of vertical rise to 10 units of
horizontal run.
ROOF SNOW LOAD: The load induced by the weight of snow on
the roof of the structure.
SV: Space Saver building – a single gable clear span with straight
columns and flush girts to offer maximum clearances.
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SLEEVE NUT: A long, slender nut normally used to join two brace
rods of the same diameter together. (Also known as coupling).
SLIDE DOOR: A single or double leaf door, which opens
horizontally by means of overhead trolleys.
SLOT: A long hole used for the access for the movements.
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WICKET DOOR: The small door in the main Roll-up or slide doors.
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Chapter – 3
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EXTERIOR CLADDING
Provides a weather tight envelope and transfers structural loads like wind and live
loads to the supporting secondary framing.
SECONDARY FRAMING
“Z” shaped roof purlins and wall girts are used for the secondary framings. They are
lighter than the conventional hot-rolled “C” shaped sections. At the roofs with
appreciable slope over 0.4/10, proper purlin orientation Nesting of these “Z” shaped
members at the supports at the frame locations allows them to act as continuous
members. This doubles the strength capacity of the “Z” shaped members at the laps and
supports where the maximum internal stresses normally occur.
Whenever purlins are stabilized by roofing or top flange, they are considered laterally
supported only for downward loads, which produce mostly compressive stresses in the
purlin’s top flange. But when wind produces upward forces, the bottom flange acts
mostly I compression. There, the purlin is unbraced
Purlins and girts receive the loads from the roof and wall covering and transfer to
the main building frames.
Purlins and girts provide lateral bracing to the building columns and rafters
preventing lateral buckling of the compression flanges.
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MAIN FRAMES
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ENDWALL FRAMING
The function of endwall framing is to resist all loads supplied to the building’s endwalls
and to support wall girts. In buildings with expandable endwalls, a regular interior frame
is provided. In buildings where endwalls are non expandable, light end frames are
provided supporting the vertical loads and contains wall girts, with or without wall cross
bracings. The endwall girts may have a flush or by-pass inset.
WIND BRACING
Roof and wall x-bracing provides longitudinal stability to the building. Portal
frame bracings or minor axis moment resistance may also be used, if the openings
are required.
Transfers the wind load acting on building end walls to the foundations.
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Chapter – 4
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.
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.
Our study shows that in India the use of PEB will reduce total construction time on a
project by at least 50%. This will allow faster occupancy and earlier realization of
revenue.
DESIGN
Since PEB’s 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.
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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.
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.
ARCHITECTURAL VERSATALITY
Buildings can be supplied with various types of fascias, canopies, and curved eaves and
designed to receive pre-cast concrete wall panels, curtain walls, block walls and other
wall systems.
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Chapter – 5
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Project: Loco Sheds for Delhi Metro Rail Corporation, Courtesy: Kirby Building Systems
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Project: Delhi Metro Rail Corporation Stations, Courtesy: Kirby Building Systems
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Project: North Eastern Council Assembly Buildings, Courtesy: Kirby Building Systems
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Project: Loco Sheds for Delhi Metro Rail Corporations, Courtesy: Kirby Building Systems
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Project: North Eastern Council Assembly Buildings, Courtesy: Kirby Building Systems
Project: Tata Holset Admin & Plant Bldg, Courtesy: Kirby Building Systems
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Project: Tata Holset Admin & Plant Bldg, Courtesy: Kirby Building Systems
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Chapter – 6
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Chapter – 7
The pre-engineered building manufacturers operate through network of Sales Offices and
Certified Builders. The Builders are contractors who have been pre-qualified and certified
by the PEB manufacturer and who have an exclusive contract with the manufacturer to
sell and erect the buildings in a specific geographic region. Some builders also provide a
turnkey service including civil works, mechanical and electrical services and finishing
works when required by owner. The builder may either sign contract directly with the
owner or with a general contractor appointed on the project. The owner may directly
order the building from Kirby for supply only or through a Kirby builder for supply and
erection.
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Chapter – 8
DESIGN CYCLE
The design cycle consists of the following steps:
• Set up section sizes and brace locations based on the geometry and loading
specified for the frame design.
• Calculate moments, shears, and axial forces at each analysis point for each load
combination.
• Compute allowable shear, allowable axial and allowable bending stress in
compression and tension at each analysis point.
• Compute the corresponding stress ratios for shear, axial and bending based on the
actual and allowable stresses and calculate the combined stress ratios.
• Decide the optimum splice locations and check to see whether the predicted sizes
conform to manufacturing constraints.
• Using the web optimization mode, arrive at the optimum web depths for the next
cycle and update the member data file.
• At the end of all design cycles, an analysis is run to achieve flange brace
optimization.
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, heights and slopes.
• Frames with different support conditions viz. Pin supports, fixed supports,
sinking supports, supports with some degrees of freedom released etc.
• Unsymmetrical frames with off-centric peaks, unequal modules, varying
slopes etc.
• User specified purlin and girt spacing & flange brace locations.
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FRAME LOADING
Frame Design can handle different types of loading as described below:
• All the building dead loads due to sheeting, purlins etc., and the self weight of the
frame.
• Imposed live loads on the frames with tributary reductions as applicable.
• Collateral loads such as false ceiling, light fixtures, A/C ducting loads, sprinkler
systems, and any other suspended loads of similar nature.
• Wind loads input as basic wind speed or basic wind pressure will be converted to
design wind pressure as per the building code specified by the user and shall be
applied on different elements of the frame as per the coefficients corresponding to
the user defined building code. The standard building codes like MBMA, UBC,
ANSI, ASCE etc., are built in to the program and the program can automatically
pick the coefficients for these codes. For special codes, however, the program
offers the option for the user to input the coefficients as required.
• Crane and non-crane special 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 desired by the user.
• Seismic loads corresponding to 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 the differential temperature
value in Centigrade and specifying the appropriate coefficient for thermal
expansion.
• Load combinations with appropriate load factors can be specified by the user as
desired.
DESIGN CODES
Following design codes are used as applicable to the project:
IS Indian Standards
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DESIGN CRITERIA
Longitudinal Stability Wind load on building end walls is transferred through roof
purlins to braced bays and carried to foundations through
diagonal bracing.
DESIGN SOFTWARE
Kirby uses the following main design software for the Design for pre-engineered
buildings:
PACE II: proprietary design software specifically developed in U.S. for PEB and
customized to Kirby standards.
COMPUFRAME: Design software developed in U.S. for frame analysis and design.
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DESIGN PROCESS
The frame data is assembled based on the 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 the member section properties are
computed. The overall joint stiffness matrix is generated based on the above frame data
by summation of the individual stiffness matrices considering all possible displacements.
The load vector is then generated based on the loading data and the unknown
displacements are obtained by inverting the overall joint stiffness matrix and multiplying
with the load vector.
Knowing the free joint displacements, the member end actions are obtained by back
substitution. The axial, shear and bending forces are then transformed to the section
neutral axis and the additional moment created by the eccentricity of the thrust is added
to the moment value. These values are generated for different load combinations and the
final design checks are performed.
The allowable stress values are computed as per the AISC specification with due
consideration for the web depth/thickness ratios and the flange width/thickness ratios
with the appropriate correction factors as per AISC. For computation of the allowable
bending stresses, the effective un-braced lengths for each segment are used based on the
brace point locations defined by the user. The effective length factor K is used for
calculating the slenderness ratios in order to compute the allowable axial stresses. The
coefficients for bending are calculated based on the end conditions for each member and
the corresponding end moment values. The stress ratios are then computed as
actual/allowable stresses and are then combined to check that the total aggregate value is
under unity.
The joint displacements and support reactions are reported for various load cases and
combinations along with the clear heights at haunch and peak to check for clearances.
A detailed connections report is generated based on the forces acting at all the splice
joints and designed as per the specifications of AISC. The connections used in the super
structure for all the main frame splices conform to the specifications of ASTM A 325 for
High strength friction grip bolts. The anchor bolts will be of ASTM A 307 material
Grade 36.
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SERVICEABILITY CRITERIA
Unless otherwise specified by client, the serviceability criteria are based on MBMA and
AISC specifications and standard industry practices. Following are the brief extracts
from these specifications.
Mezzanine supporting Beams & Joists: L/240 max. Under Dead & Live load
L/360 max. under LL only
When client requires the serviceability criteria as per IS codes, the design deflections will be
compiled accordingly.
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Chapter – 9
The manufacture of the building is done in accordance with relevant American Codes.
Welding is performed by pre-qualified welders using approved welding processes as per
structural welding code AWSD1.1 published by the American Welding Society. The built-up
sections are welded in an automatic Conrac welder using submerged arc welding process. The
splice plates and other attachments are welded by the Innershield or CO2 welding process.
All butt welds are full penetration welds. Stage inspections are carried out at various stages in
the manufacturing process and results documented. The welds are subject to NDT tests
including Dye penetrant inspection (DPI), Magnetic particle Inspection (MPI),Ultrasonic
Testing (UT) or Radiography, as required by contract specifications. A 100% visual and
dimensional check is performed on all members. Manufacturing tolerances are in accordance
with MBMA and AWS specifications.
The standard surface treatment for fabricated steel is mechanical wire brushing to SSPC ST3
and application of one coat of red oxide prier to a nominal dry film thickness of 25 microns.
However Kirby offers various types of surface preparation and epoxy paint systems to suit the
corrosive conditions at site and contract requirements. Kirby has blast cleaning facility to
achieve a white metal finish to Swedish standard SA3 and airless spray facility to apply any
specified paint system. Upon request Kirby will recommend the optimum paint system to suit
ambient conditions at site.
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Chapter – 10
SITE ERECTION
Kirby provides Erection drawing and procedures manual, which includes all the information
required for the site assembly of the building. The erector must use the proper tools and
equipment and sequence of erection as specified in Kirby manual. The high strength bolts at
the primary connections are pre-tightened to specified tension or torque as shown in the
erection drawings. The method of tightening may be either using a calibrated tension or
torque wrench or turn-of-the-nut method as specified in AISC Manual. Erection should
always start with a braced bay and the red steel must be fully plumbed before starting
cladding erection. Erection tolerances are as set forth in AISC Code of Practice except
individual members are considered plumb and aligned if the deviation does not exceed 1:300
as per MBMA specifications.
Chapter – 11
WARRANTY
Kirby provides a standard one-year warranty from date of shipment against defective
materials and workmanship. Extended warranty on cladding can be provided based on the
type of coating specified and the requirement of the contract.
Chapter – 12
CONCLUSION
The foregoing is a brief overview of the Pre-Engineered building system. For further details,
you may please refer to the Kirby Technical Manual and other company brochures.
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11. BSI 6399: Part 3: 1988, Code of practice for imposed roof loads (snow loads)
12. BSI 6399: Part I: 1984, Code of practice for dead and imposed loads.
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KIRBY is the premier producer of steel buildings in the Middle East and South West
Asia. Over the years KIRBY has earned a remarkable reputation for providing cost
effective solutions for buildings manufactured to the highest standards and suited to all
environments. KIRBY operates from all the major cities of India. The manufacturing
facilities have a production capability to produce hundreds of custom designed steel
buildings each year.
KIRBY people are all dedicated to provide buildings specifically designed to your
requirements. Skilled structural engineers familiar with state-of-the-art technology are
part of the KIRBY team. Our professionals use the very latest in computerized
engineering design and drafting systems, permitting the selection of the most
economical and efficient framing systems, as well as accurate design and drawings.
Other skilled technicians also use computerized systems for estimation, inventory
control, job tracking, scheduling and accounting applications. Courtesy of the computer,
quotations are provided in just a few days for even the more complex projects.
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These framing systems are available in a variety of sidewall heights, bay spacings, and
loading conditions, including seismic loads. The high quality and attractive Kirby-Rib
Roof Panel and Kirby Architectural Wall Panel complement the various framing
systems. For those clients requiring special Architectural features, Kirby offers a
complete line of fascias, canopies, roof overhangs, parapet walls, and curved panels.
Kirby offers rock wool blanket insulation and a wide variety of accessories such as
skylights, wall lights, roof vents, wall louvers, windows, personnel doors and sliding
doors. Kirby buildings are ideally suited for a wide range of uses, such as
manufacturing, warehouses, supermarkets, auto agencies, commercial buildings,
recreational buildings, camps workshops, and agricultural buildings.
Research and development of new products used in the buildings play a particularly
important role within the company. KIRBY is constantly improving its products. We
listen to our clients when we consider new product lines and product improvements.
The stamp represents KIRBY’S commitment to Total Quality Control. Every major
fabricated steel section must be approved before it is stamped by one of our qualified
inspectors. KIRBY uses the latest test methods, including ultrasonic and radiographic
equipment. In addition, the Total Quality Control System ensures that all purchased
materials received are exactly to our high quality specifications and that it is
manufactured exactly to KIRBY’s Quality Control Standards.
KIRBY appoints, trains and certifies a highly experienced team of local builders who
work closely with the company to offer the client efficient and economical construction
service. KIRBY builders also become involved in much more than merely erecting a
building. Many are capable of offering complete turnkey construction services.
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