PREFABRICATED STRUCTURES

DEFINITION

 Prefabrication is the practice of assembling components of a structure in a factory or other

manufacturing site, and transporting complete assemblies or subassemblies to the construction site
where the structure is to be located.

 It is combination of good design with modern high performance components and quality
controlled manufacturing procedures.

 This work is carried out in two stages, manufacturing of components in a place other than final
location and their erection in position.
 "Prefabricated building is a type of building that consists of several factory-built components
or units that are assembled on-site to complete the unit. “Prefabricated” are built in:

 Components (panels)

 Modules (modular homes)

 Transportable sections (manufactured homes)

 Mobile homes (houses on wheels)

NEED FOR PREFABRICATION • • •

 Speed

 Quality

 Safety

 Sustainability

 Cost

 Time for change

ADVANTAGES What Are Advantages Of Prefab Over Traditional Construction?

 The process of construction is extremely fast and easy – Prefab construction involves assembling a
lot of manufactured and ready-to-use components. Therefore, if planned well, just after the designs are
finalized and the components are procured, the construction process starts, and depending on the size of
the workforce, the duration can be managed.

 Lightweight – The components of prefab construction are extremely light and can be transported with
ease whereas, in traditional construction methods, the rebar/TMT or bricks used are extremely heavy and
bulky. The lightweight adds to the fast installation process.

 It is non-messy – Traditional construction is very messy and a lot of time, effort, and money go into
housekeeping. Whereas, in prefab construction, it is not the case. As discussed earlier, the components
are procured directly from factories and require only assembling, therefore there is a lot less requirement
for housekeeping.

 It does not require water – Water is one of the key ingredients of good quality traditional construction.
For any construction activities, a lot of water is required at every stage. Whereas in prefab construction
there is a very minimum water requirement.

 Cost-effectiveness and Reusability – The components used in prefab construction consist of cement
boards, PUF panels, MS frames, etc. Now, all these components are extremely durable and they can also
be reused in the future very easily. In fact, the salvage value of these components is far greater than
bricks and concrete which are used in traditional construction. Also, the shorter turnaround time of this
technique makes it all the more cost-effective.
DISADVANTAGES

 Handling and transportation may cause breakages of members during the transit and extra
provision is to be made.

 Difficulty in connecting precast units so as to produce same effect as monolithic. This leads to non-
monolithic construction.

 They are to be exactly placed in position, otherwise the loads coming on them are likely to get
changed and the member may be affected.

 High transport cost

 Need of erection equipment

 Skilled labour and supervision is required.

PRINCIPLES OF PREFABRICATION

 The prefabrication will be done in two stages.

1)Manufacturing at factory condition.

2)Erection of components at required location.

 This requires certain stage of preparation. They are

i)Casting

ii)Curing

iii)Transportation and erection.

 • Casting: - Precast components are casted with controlled cement concrete in moulds of required shape
and sizes. The vibrator is used to vibrate concrete and this removes any honeycombing inside the
components.

• Curing: - After 24 hours of casting, the casted components are released from the mould and transported
to curing tanks. Certain special components like railway sleepers where high strength is required are steam
cured.

• Transportation and erection: - After complete curing is done the components are transported to the site
with heavy trucks and erection will be done using cranes with skilled labor force.
Casting
Curing
Transportation and Erection
MATERIALS

 Structural Insulated Panels (SIPs)

 Insulating Concrete Forms (ICFs)

 Prefab foundation system

 Steel framing

 Concrete framing

 Large modular system

Structural Insulated Panels (SIPs)
 Structural insulated panels (SIPs) are a high performance building system for residential and light
commercial construction.

 The panels consist of an insulating foam core sandwiched between two structural facings, typically oriented
strand board (OSB).

 SIPs are manufactured under factory controlled conditions and can be fabricated to fit nearly any building
design.

 The result is a building system that is extremely strong, energy efficient and cost effective. Building with
SIPs will save you time, money and labor.
Insulating Concrete Forms (ICFs)

 Insulating concrete forms (ICE) are a prefab construction material consisting of hollow EPS (Extended
Polystyrene) foam blocks that are stacked and glued together on-site , creating the form that is filled with
reinforcing bars and concrete.
Prefab Foundation

Precast concrete foundation construction is an off-site

construction technique in which the foundation units are
pre-engineered and manufactured in a controlled
environment. These units as are pre-engineered, their
capacities or the limits are communicated with the
purchaser to produce the desired unit.
Steel Frames
 Prefabricating all of the structural steel and metal components of the building in the factory eliminates the
materials waste common in traditional construction, saving materials cost and also being more
environmentally friendly. (Any excess materials waste at the factory is 100% recyclable steel. )
 MODULAR COORDINATION

 Modular coordination is a concept of coordination of dimension and space, in which buildings and components are
dimensioned and positioned in a term of a basic unit or module, known as ‘ 1 M’ which is equivalent to 100 mm.

 It is internationally accepted by the International Organization for Standardization (ISO) and many other countries.

 The principle objective of modular coordination is to improve productivity in the building industry through
industrialization.
Establishment of Modular Coordination

 In 1936, Albert Farnell Bernis proposed a module for mass-produced building with size of 4 inches during
world war II.

 In 1953, “ European Productivity Agency – E. P. A. ” launch a systematic study of modular coordination

and the general agreement reached in 1955 with the Munich Convention, called for the adoption of a
module with base M = 10 cm, as common denomination for correlating the dimensions of all elements
involved in architecture and building.

 In 1972, Malaysia adopted metric system of measure and only in April 1986, modular co-ordination was
introduced in building industry in Malaysia.
Advantages

 Modular coordination make single component in to larger combinations

 Cutting wastages are minimum in the components.

 Base for standardization of mass production of components.

BASIC MODULE

 The fundamental module used in modular coordination, the size of which is selected for general
application to building and its components.

 It is denoted by ‘M’.

 The value of basic module ‘M’ has been chosen as 100 mm for maximum flexibility and convenience.
 The different modules are

i)Basic Module: M

ii)Multi modules: 3 M, 6 M etc. ,

iii)Sub-module: M/2, M/4. etc. ,

 In prefabricated industry a larger modular unit is called as a project module(Mp)

OBJECTIVES OF MODULAR COORDINATION

a)Major Objective:

• The principal objective of modular coordination is to assist the building design, construction professionals in
building industry by standardization in such a way that building components fit with each other, with other
components and with building assembly on site, thereby improving the economics of building.

b)Specific Objectives: Modular coordination

• Facilitates cooperation between building designers, manufacturers, distributors, contractors and authorities.

• Enables building to be dimensionally coordinated so that they can be erected with standard components
without undue restriction on freedom design.

• Permits a flexible type of standardization which encourages the use of number of standardized building
components for the construction of different types of building.

• Optimizes the number of standard sizes of building components.

• Encourages as far as possible the interchangeability of components , whatever the material form or method
of manufacture.
MODULAR AXIS

• In the design of buildings, the modules are made as a grid which consists of parallel lines spaced at the value of
module, M or project module (Mp).

• A grid line taken as the base for setting out the given part of the building is called as modular axis.
 • In prefabricated industry the practice is as follows i)The horizontal co-ordination based on the project
module (Mp)=30 cm. (Note: Larger module unit is called project module) ii)Vertical coordination based on
basic module, M = 10 cm. iii)Floor height in multi storeyed building is fixed as 2. 8 m. But for buildings having
floor less than 15 cm, it may be reduced to 2. 7 m. iv)The c/c distance ‘L’ b/w the load bearing walls are
selected from the following i. e. , n. Mp=2. 7, 3, 3. 6, 3. 9, 4. 5, 5. 1, 5. 4, 5. 7, 6 m

v)The width of staircase measured b/w centre line of walls is fixed as 2. 7 m.

vi)In large multiple projects, the dimensions are used which are the multiples of the project module, Mp=30 cm
Dimensioning of Prefabricates

• The three basic types of unit dimensions are

i)Design or Erection dimension(lm)

ii)Theoretical dimension(l)

iii)Actual dimension(lw)
• The production discrepancy is defined as difference between theoretical dimension(l) and actual dimension (lw).

• If l<lw, the production discrepancy is positive.

• If l>lw, the production discrepancy is negative.

• In drawings (working drawings), theoretical dimensions of the units and the joints b/w them are mentioned.
 Coordination of Prefabricates

i)Three dimensional coordination - Prefabricates are connected to its neighbors in 3 directions (l, b, h). - Eg: Wall panel

ii)Superficial coordination - Unit is joined to other unit in 2 direction only - Eg: l, b of a roof panel

iii)Linear coordination - Unit is connected in one direction only. - Eg: length of beam
Diversity of Prefabricates
• Large prefabricated units have 3 degrees of diversity

i) I Degree of diversity - Differ from each other in basic shape, cross section of material and their
production demand which seperate form work and technology - Eg: wall & floor panel.

ii) II Degree of diversity - Different length or width but can be cast by same methods and using same
form work. - Eg: 16 module wall panel and 18 module floor panel

iii) III degree of diversity

- Difference between the units lies only in the internal details but size or production unit is not effected.
- Those are window openings, service holes, surface treatment etc. ,

• I degree and II degree of diversity affect the capital expenditure.

• III degree of diversity affects the basic size, production method and erection.
• Normally larger units are made in industry.
• If units are large then less work will be on the site and number of joints will also be less.
STANDARDIZATION

• It is defined as the process of adoption of generally accepted uniform procedures,

dimensions, materials or parts that directly affect the design prefabricated product or a facility.

Advantages of standardization:
• Easier in design as it eliminates unnecessary choices.

• Easier in manufacture as there is limited variants.

• Makes use of specialized equipments easier and quicker for erection and completion.

Factors influencing standardization

• To select the most rational type of member for each element from point of production, assembly,
serviceability and economy.
• To limit the number of types of elements and to use them in large quantities.
• To use the largest size to extent as possible , thus resulting in less number of joints.
• To limit the size and number of prefabricate by weight in overall dimension so that it can be handled well by
handling and erection equipment and can be transported easily.
• To have all prefabricates approximately of same weight very near to the lifting capacity of the equipment.
SYSTEM FOR PREFABRICATES

• It is a method of construction of buildings by using prefabricated components which are inter-related in functions.

• The degree of flexibility varies from system to system.

• However in all the system, there is a certain order and discipline.

• The various prefabrication system are

i)Open prefab system

ii)Large panel prefab system

iii)Frame systems

iv)Lift slab systems

v)Box type system

i)Open Prefab System

- This system is based on the use of basic structural elements to form whole or part of building. The standard
prefab concrete components which can be used are prefabricated slabs, prefabricated beams, columns,
precast lintels and sunshades etc. ,

- Foundation for the columns could be prefabricated or conventional cast in-situ depending upon the soil
condition and load.

- The columns may have hinged or fixed base connections depending upon the type of components used
and method of design adopted
• Two types of open prefab system are

a)Partial prefab open system

b)Full prefab open system

a)Partial prefab open system This system emphasizes the use of prefabricated roofing and flooring and
other minor elements like lintels, sunshades, kitchen sills in conventional building construction.

b)Full prefab open system All structural components are prefabricated

ii)Large panel prefab system

- Based on use of large panel prefab system.

- Components used are prefabricated large panels for walls, floors, roofs, staircases etc. ,

- It is a box like structure.

- Both horizontal and vertical members are load bearing.

- The prefabricated large panel walls can be classified as

a)Cross wall system

b)Longitudinal system
a)Cross wall system - Cross walls are load bearing and facade walls are non load bearing. - Suitable for
high rise buildings

b)Longitudinal wall system - Cross wall is non load bearing and longitudinal walls are load bearing. -
Suitable for low rise buildings.

Prefabricated floors - Depending upon the composition prefabricated floors are classified as
a)Homogeneous floor
b)Non homogeneous floor
- Depending upon the way loads are transferred, the prefabricated floors are classified as
a)One way system
b)Two way system

iii)Frame System

- Components are usually linear elements.

- The beams are seated on the corbels of pillars usually with hinged joints. (rigid connection is also
carried out).

- Joints are filled with concrete at site.

iv)Lift Slab System
- Partially prefabricated in plant (pillars) and partially precasted on site (slabs).

- It consists of one or more high pillars (max 5).

- Up to 30 storey high construction is possible.

- Consists of specially designed joints and temporary joints.

- Slabs are casted on the ground (one on top of another) and then lifted with cranes and elevators.
 Lift-Slab Procedure:
i)Pillars and first package of slabs (Eg: 5 pieces) are prepared at the ground level.

ii)Lifting boxes are mounted on the pillars and a single slab is lifted to first floor level.

iii)Other boxes are sequentially raised to higher position to enable the slabs to be lifted to their required final
position. Slabs are held in relative position (temporary) by pinning system.

v)Box Type System -

In this system room size units are prefabricated and erected at site.

- Toilet and Kitchen blocks could also be similarly prefabricated and erected at site.

- This system derives its stability and stiffness from the box units which are formed by four adjacent walls
which are joined to make rigid connection.
PRODUCTION OF PREFABRICATES

• Stand System

• Conveyor belt or production line system

• Aggregate system
Tilting Table Battery Mould
TRANSPORTATION

• Transportation means taking the prefabricates in a vehicle of wagon or truck from the prefabrication
industry to the place of site work for erection.

• In addition to railway wagons, special transporters are used to carry the prefabricated units from the
factory to the building site.

• These are designed to suit the prefabricate dimensions and weight and convenient method of loading.

• In some places, the lorries are used to transport large prefabricates which are equipped or having power
operated unloading derricks. (cranes or lifting mechanism)

• The following points should be considered for transporting the prefabricates

i) It must be carried out with extreme care to avoid any jerk and distress in elements and handled
/transported in the same orientation as it is to be placed in final position.

ii) It should be properly planned and conformity with traffic rules and regulation.

iii) The size of element decide the mode and size of transport vehicle.

iv) Check the load carrying capacity of the bridges.

 vi) Avoid excessive cantilever projection while transport.

vii) Special care should be taken while moving in curves and uneven roads which may lead to
undesirable stresses.

viii) Before loading, proper base packing materials, proper location and packing must be done over the
other.

Delivery:

i) Delivery of prefabricate elements should be planned according to the general erection sequence to
minimize unnecessary site storage and handling.

ii) Prefabricate elements should be loaded and delivered with proper supports and frames. Cushioning
and tiedowns to prevent damage during transports.

iii) Adequate packing or protection to the edges of prefabricate elements should also be provided to
minimize the risk of damage during transport.
 Handling:

i) Lifting and handling position shall be clearly defined particularly if sections are critical.

ii) It mainly involves the removal of prefabricate elements from mould, transportation to the storage yard and
unloading operation and erection of these element at the job site.

iii) Prefabricate elements are demoulded and transported to the site only when concrete reach required strength.

iv) But these elements haven’t got full design strength and prone to damage during handling.

v) So it has to be carefully handled to avoid excessive stress during handling.

ERECTION

• Erection of building means keeping of prefabricated products in proper and correct position at the site.

• Before doing the erection the setting out should be done and carefully checked with survey
instruments.

• While erection the working of the crane and the correct layout of the crane must be checked.

• Uneveness of the ground, makes it difficult to lay a horizontal crane truck.

• When there is steep slope, high embankment is required and this is costly and technically difficult.

• Prefabricated buildings are erected in convenient sections.

• Sections should be correctly fixed and should be rigid in all directions.

 • The normal sequences of erections are

i)Structural wall units.

ii)Non-structural wall units (partition).

iii)Floor panels, balconies, staircase units.

iv)Specialized pre-fabricates( chimneys, ventilation ducts, sanitary installations).

• The materials required for construction are also lifted by crane and stacked on the floor at the place of work.

• In large panel buildings, where two external and one internal wall panels meet at common joint, the external
panels are erected first and the joint between them is sealed or covered and then the internal wall panel is
placed.
ERECTION PREPARATION:

i)Check the crane access to site and erection platform to prevent cranes or trucks damaging the concrete
floors during access.

ii)Obtain verification that the erection platform can support the erection loads.

iii) Ensure the locating dowels and levelling shims are correctly located.

iv)Clear the site for truck.

v)Ensure sufficient space is available for precast propping or panel bracing.

vi)Builder must ensure that adequate temporary base restraint is provided for any prefabricate element to
prevent sliding failure at the base.

vii)Check lifting inserts are in their correct location and recesses are cleaned in preparation for lifting.
Types of Cranes

1)Stationary Cranes
a)Guyed derrick crane
b)Climbing crane
c)Tower crane with fixed base

2)Cranes on rails

a)Portal crane
b)Tower cranes

3)Mobile crane moving on ground

a)Truck mounted
b)Crawler mounted
a)Guyed derrick crane Climbing Crane

• Used on framed buildings for erection of

floor panel, columns and slab strips.
Tower Crane
Portal Cranes
Tower Cranes on rail Truck Mounted Crane
Crawler Mounted Crane
Prefabricated construction Vs Precast construction

 Precast construction is the manufacturing of products in a pre-made cast or mold and then,
after being cured in a controlled environment, transporting it to the construction site for final
assembly.

 Prefabricated construction is the assembly of pre-made components for construction of

structures required for industrial use, and then transporting these complete assemblies to the
final location.Both of these construction types have their advantages and disadvantages.
Prefabricated construction Vs Precast construction…

Precast construction

•Precast construction isn’t as eco-friendly as prefabricated construction. The assemblies required are made on
precast molds. The materials used thus depend upon the size of the molds. If the size of the required product
is less than the mold dimensions, then there is a significant wastage of the materials that can or cannot be
used for other applications. It renders the entire production process inefficient in terms of energy, raw
materials, and labor.

•Precast products are financially expensive. The raw materials required depend on the mold size. Thus, if there
is no mold available for your product dimensions, you will have to build it in a larger mold. This will increase the
price of the product due to the extra raw materials needed. Also, the costs per unit framework are fixed as per
the mold size required for the task.

•Precast construction is limited regarding design. Due to the pre-determined nature of the molds, there are a
few variations that can be achieved from this method. The size, shape, layout, and other features that can be
customized in terms of prefabricated constructions is not available in precast products.

•The process of making a component using the precast construction takes a longer time. The parts are made
stage by stage and require sufficient time for the mold to set completely. If the product dimensions differ from
the mold size, extra time would be added to bring the mold to the required size.
Prefabricated construction Vs Precast construction ….

Prefabricated construction

•Prefabricated buildings are eco-friendlier than their precast counterparts. The assemblies are built as per
the requirements specified for the project. Thus, the quantity of raw materials used to build the products
aligns with the requirements, so as to generate minimal waste while completing the task. The process of
creating the assemblies thus becomes energy-efficient and sustainable.

•Financially, prefabricated buildings are cost-effective. The amount spent on the materials required is cut
down. The orders can be customized as per the quantity. The transportation of these products also
become easy as the individual components, rather than a hefty final assembly, needs to be transported to
the final site for the installation. Prefabricated construction offers flexibility and better control in the process
of building the components. The size and dimension of the assemblies can be customized as per your
requirements.

•You havea variety of shapes and designs to choose from when you get a structure manufactured by this
method. This adds to the aesthetics of the final product, making it appealing.

•The final assembly of the structure is done on-site. This makes it easier for the individual pieces to be built
simultaneously, resulting in shorter construction time.
 Prefabricated Industrial Steel Structure Workshop/Warehouse Design

• Prefabricated steel structures (PEBs) are custom-made steel structures based on customer structural
and architectural requirements.

• Prefabricated steel construction is the most flexible option for contractors and owners.

• With its significant advantages such as low cost, high durability, good quality control and quick
installation, prefabricated steel structures have been widely used in factories, warehouses, shopping
malls, exhibition halls, shopping centers, schools, hospitals and other civil buildings.
Prefab Steel Structure
Prefab steel structure is an ideal option to erect industrial buildings which is pre-engineered in order to
meet the standards of designing buildings. All the main components of this steel structure construction are
pre-engineered including pre-punched, pre-drilled and pre-welded, and then set up at the desired location.
We offer robust steel structures to ensure these buildings can stand the test of time as well as harsh
weather conditions.

Source : https://steelmillcranes.com/prefab-steel-structure/
• Steel Structure is the first choice for the construction of logistics
warehouses, made of super anti-corrosion high
strength Galvanized Sheet,which is safe and reliable.

• The Steel Frame Warehouse are widely used in the factories,

warehouses, shopping malls, schools, hospitals, community
buildings and several more, and it's connected by welding or
high-strength bolts on the construction site. The construction is
relatively simple to installation through the drawings. It can
saving labor costs, and fast to built, the logistics warehouse can
be used in advance, reducing investment costs. Furthermore,
the reduced cost and time required for Steel Structure
Construction, ease of installation and relocation.

• The building of the house also can be 100% recycled, even

other supporting materials of Prefabricated Steel Frame can
also be recycled. All materials are green building materials that
meet the requirements of the ecological environment and are
beneficial to health.
What Are The Types Of Prefab Steel Structures?

• Heavy steel structure

It is an ideal option to construct various industrial buildings, such as steel workshops, warehouses and
factories. The heavy steel structure building has high strength and long service life. In addition, if you require
an overhead crane system to be installed inside your facility, we also offer a range of overhead cranes and
runway systems.

• Light steel structure

It uses thin sheets of steel that have been bent to form C-sections or Z-sections. The light steel structure is
able to create more useful building space, reduce building height, and also has better appearance and lower
cost.

• Large span steel structure

The large-span prefabricated steel structure building has the advantages of strong load-bearing capacity,
good extension performance, high rigidity and convenient construction. It can meet the needs of a variety of
building heights and planes.
Heavy Steel Structure Building Large-Span Industrial Steel Structure
Common Applications Of Prefab Steel Structure Frame

The applications of prefabricated steel structure is almost endless:

•Industrial buildings

•Manufacturing facilities

•Warehouses

•Steel sheds

•Workshops

•Welding shops

•Equipment storage buildings

•Hangar
Pre-Engineered Steel Frame Prefab Steel Structure Workshop Industrial Steel Structure Building

Prefabricated Steel Structure Factory

 The Main Parameters of the Prefabricated Steel Structures

1.Width-length-height of prefabricated steel structures: Developed by the owner’s needs, with no size
restrictions.

2.Roof slope: The slope of the roof affects the roof drainage problem. Typical roof slope is i = 15%

3.Between columns: The distance from the axis of the column along the long side of the structure to the
axis is defined as the column, which is determined by the length and use of the prefabricated building.

4.Load: including live load, dead load, additional load, wind load, deflection limit, internal crane system, etc.
 Key Specifications/Special Features:

1.Significantly reduce costs

Precast steel structures can reduce costs from 20% to 30% compared to traditional buildings. Minimize the
weight of the part subjected to less load to reduce the amount of steel.

2. Durability
Prefabricated steel structures are durable and resistant to heavy rain, strong winds, and large earthquakes.

3. Quick installation
Prefabricated steel structures can be installed quickly because each project has assembly details, components
that have been machined and detailed installation instructions.

4. Flexibility
Prefabricated steel structures can have a small or no column inside to facilitate the storage of large quantities
of equipment, installation of cranes and internal activities.
In addition, prefabricated steel structures are flexible, easy to expand, and economical and transportation costs
are low.

5. Energy saving
Currently, prefabricated steel construction is a green solution that can reduce CO2, energy savings, and more.
 The Components Of Prefab Steel Structure Construction
• A wide range of ready made structural steels are available to construct the industrial buildings, such as I-beam, C-shaped
steel and angle sections. They can be designed and constructed into any kind of form, and using any type of material to
meet your project’s specifications.

• The industrial steel structure buildings are very flexible since a range of joining methods are available to erect your
buildings, such as bolting, welding and riveting. What’s more, they can be easily modified, strengthened and extended for
future uses. We use high quality components and optimal design to ensure you end up with the perfect solution.
Components Of Prefab Steel Frame Structure

Main component: steel columns (H-shaped equal sections, variable sections), steel beams (I-beam), wind-
proof columns and runway beams.

Steel Columns And Beams Crane Runway Beam

Secondary component: purlins (C-shaped sections, Z-shaped sections), bracing system (horizontal
bracing, vertical bracing).

Vertical Bracing
Horizontal Bracing
Envelop material: color steel tile (0.8mm or less), sandwich panel (50mm, 75mm, 100mm, 150mm). In order to
strengthen the insulation, a combination of color steel tile, insulation cotton and steel mesh is available. Lighting
panels are generally added to the roof to save energy as well as enhance indoor lighting.

Sandwich Panel Color Steel Tile Combined Insulation Method

Features of prefabricated steel structure buildings:

1.Superior seismic performance

Compared with the traditional building structure, the steel structure building structure is a flexible
structure. Buildings with the same fortification intensity and the same site will bear less seismic force,
and the earthquake disaster caused by it will be reduced accordingly. The application of steel
structure housing in the earthquake zone will reduce the number of people. Casualties and property
losses have considerable comprehensive benefits.
Features of prefabricated steel structure buildings …

2. Flexible layout and increased effective use area

The use of steel structure allows large spans to be achieved under the premise that the
cross-section is not too large. This makes the building function highly flexible and can be
flexibly arranged according to the needs of residents, which is conducive to meeting the
needs of modern homes and adapting to the modern housing market. need. Moreover, the
steel structure is adopted, the cross-section of beams and columns is small, and the use
area of the residents is increased at the same time
Features of prefabricated steel structure buildings …

3.Lightweight and high strength

Steel structure houses have the advantages of high strength and light weight, and
generally can reduce the weight of the building by about 1/3. For example, the strength
of steel is G550, and the strength of concrete is C25. The ratio of the strength of the two,
the bearing capacity of the steel structure is twice that of the concrete for the same
quality component; correspondingly, the weight of the steel component is the same for
the same bearing capacity. It's half of concrete. On the other hand, due to the light
weight and high strength of the steel structure, the same weight of the building, the steel
structure component section is small, the net height is large, and the building height can
be saved. The steel structure has more layers than concrete, which not only increases the
building area, but also Brings good economic benefits.
Features of prefabricated steel structure buildings …

4.Steel structure building energy saving and environmental protection

The main body of the steel structure building is steel components, and the wall material is
thermal insulation mortar, which can not only meet the requirements for energy saving, but
also can be recycled. It is a green and environmentally friendly recycling building that meets
the requirements of sustainable development. The thermal resistance can reach a brick wall
thickness of about 1m. In a country like my country with a large population and high energy
consumption, the promotion and application of steel structure housing is the ultimate choice.
 Features of prefabricated steel structure buildings …

5.High degree of industrialization, short construction period

• Steel structure building is a structural form that uses steel plates or section steels,
processed into components, and then installed. The production precision is high and the
production cycle is short. A large number of bolt connections are used during
installation, which has good assembly properties, which greatly shortens the
construction period, and this advantage also makes the built steel structure easy to
disassemble, with small losses and easy recycling.

• The project cost is slightly higher than concrete or equivalent

• The cost of steel structure materials is higher than that of concrete, but its construction
period is short, the use area is large, and the number of floors can be increased under
the same conditions. The project cost of steel structure residences is slightly higher or
equivalent to concrete, and the actual economic benefits are significant, making steel
structure residences It has become the first choice for high quality and low price, and
the best choice for replacing masonry structure houses in the future.
Features of prefabricated steel structure buildings …

6.The project cost is slightly higher than concrete or equivalent

The cost of steel structure materials is higher than that of concrete, but its construction
period is short, the use area is large, and the number of floors can be increased under the
same conditions. The project cost of steel structure residences is slightly higher or
equivalent to concrete, and the actual economic benefits are significant, making steel
structure residences It has become the first choice for high quality and low price, and the
best choice for replacing masonry structure houses in the future.
Advantages Of Prefab Steel Structure /Pre Engineered Steel Structure
• Large span
A wide range of structural steels make it possible to create a large-span building.

• Ready for quick and efficient assembly

Since all the main components of prefab steel frame building are pre-cut, pre-drilled and pre-welded in the
manufacturer’s factory, and then set up at the desired location, it has short construction period.

• Low cost
It has low cost as compared to other building forms, such as concrete construction.

• Excellent fire resistance and corrosion resistance

It can resist harsh weather conditions, such as strong wind and heavy snow.

• Good seismic performance

Due to the plasticity or ductility of structural steel, it will not suddenly crack when subject to great force, but slowly
bend out of shape or deform. Therefore, it performs far better in earthquake than other materials.

• Environmentally friendly
The structural steel can be recycled without pollution.

• Custom design
The steel workshops can be made to take any kind of shape and clad with any type of material to your specific
requirements.
Advantages Of Prefab Steel Structure /Pre Engineered Steel Structure…

• Other Advantages

 Ventilation and cooling: roof fan and clerestory on the ridge can be designed for general
steel buildings to enhance indoor ventilation. However, for large-span, high steel structure
building, it is better to install large exhaust fans on the roof.

 Anti-seepage and waterproof: to prevent seepage, the screw mouth is sealed by gasket,
and then use concealed fixing. Besides, take sealant or welding at the joint of the plate

 Sound insulation: fill the roof layer with sound-proofing material, or apply heat-reflective
coating on the metal tile surface.

 Lighting: use lighting panels or lighting glass at specific locations on the roof to improve
indoor lighting. The joints of dormer and roof panels take waterproof treatment.
Prefab Steel Structure Factory And AQ-QD 50 Ton Overhead Crane
Prefabricated Shed Steel Structure And 10 Ton Overhead Crane
 Specifications Of Single-Story Ready Made Steel Structures
•Overall length: according to your requirements
•Column spacing: 6m, 7.5m, 9m, 12m, or based on requirements
•Span: 9-36m (take a multiple of 3). Single span, double span and multi-span are available.
•Building height: 4.5-9m (without overhead crane system). If overhead cranes are required, the building height is
determined by the desired crane specifications, such as rated load capacity and lifting height.
•Overhead crane: 1 ton to over 300 tons capacity. Single girder, double girder, top running, and underhung
system are available for you to choose from.
•Wall and roof insulation: available
•Door and window: PVC or aluminum alloy; sliding door or roll up door.
•Note: the price of prefab steel structure building does not include that of doors and windows.

Single-Story Prefab Steel Structure Factory

How Do You Erect A Prefab Steel Structure Building?

Installation Process

The installation process of ordinary prefab factory steel structure is as follows:

Foundation – erect steel columns – installation of tie rods – installation of steel beams – installation of
crane runway beams – support between columns – purlin installation – color panel installation – roof
panel installation.
Installation Precautions

•When the foundation is handed over, strictly check the position and elevation of the anchor bolts and embedded
parts, and it is strictly forbidden to have large errors.

•When steel structure elements enter the site, check their dimensions and screw hole positions in accordance
with the drawings.

•When erecting the steel column, strictly control the elevation, axis position and verticality of the steel column.
Gas cutting and reaming is strictly prohibited during installation. After the verticality of the steel column is
corrected, fasten the bolts in time. The tightening sequence starts from the middle and goes symmetrically to
both sides.

•After the steel column is installed, the tie rod must be installed in time.

•The axis position and verticality of the steel beam should be strictly controlled during installation, and it is strictly
forbidden to exceed the tolerance.

•When installing the crane runway beam, pay attention to its elevation and the height difference between the two
adjacent beams. The joint parts of the crane beam are strictly prohibited to be misplaced.
Installation Precautions…

•When installing the support between columns, purlins, braces, and corner braces, protect the main body
to prevent the paint from being knocked off; pay attention to the direction of the purlin and the spacing of
the brace during installation; welding of the brace is strictly prohibited; after installation, check whether
there is paint falling off. If found, touch up the paint in time.

•When installing the roof panel, the steel plate should be prevented from folding in half. The focus of the
laying of the profiled steel plate is the treatment of the edges and corners. Before processing the edges
and corners, make the edge and corner templates carefully, and then cut off the corners.

•The cornice (rock wool/slag wool) must be sealed with colored boards or corner aluminum and sealing
materials to prevent the core material from being exposed, which will seriously affect the quality and
service life of the board.

•The overlap of roof panels must meet the design and specification requirements to avoid leakage.
 Industrial Roof Trusses: Understanding and Designing
What are Trusses?

Trusses are triangular formation of metal sections, usually used to span large lengths in space instead of solid
girders. The external load apply mostly axial forces on the members in a truss.

Depending upon how the force is applied, trusses can be designed in the following two ways:

Plane Trusses: where the external load is placed on the plane of the truss.

Space Trusses: where the external load can be applied to any three-dimensional space within.

How are Trusses Built?

Trusses mostly consist of axially loaded members to support loads. The reason for this that when steel members
are subjected to axial forces, they perform better in bearing that load, than members that are in flexure. This is
because the cross-section of such a system is uniformly stressed under axial forces.

Trusses are very common in most architecture. Mostly used to span long distances, they are well suited to
bear the load of single-storey industrial buildings.

They can also be designed to bear gravity loads in long span floors. For the same reason they are also
mounted to bear loads of long span bridges.
Planar truss
Space frame truss
A planar truss is a truss in which all
In contrast to a planar truss which lies in a two-
the members lie in a two-dimensional plane. This
dimensional plane, a space frame truss is a three-
type of truss is typically used in series, with
dimensional framework of connected triangles.
the trusses laid out in a parallel arrangement
to form roofs, bridges, and so on.
Applications

Trusses are used in

• Roofs of Single Storey Industrial Buildings

• Long Span Floors and Roofs Of Multistory Buildings Buildings, to resist gravity gravity loads

• Trusses are also used in Walls and Horizontal Planes of Industrial Buildings to resist Lateral Loads and
to provide Lateral Stability
 Types of Industrial Roof Trusses:

There are several types of industrial roof trusses, depending upon how the span is made, quality of elegance, and demands
of the building particular and venting systems.
 Different Types of Roof Trusses
King Post Truss
• King post trusses are the simplest roofing truss.
• Common uses: Home additions, garage construction, short-span projects
• Span: 5 to 8 meters
• King post trusses are the most basic type of truss. It uses the fewest truss members - two top chords, one
bottom chord, a central vertical post called the king post, and two webbing chords.
• Because king post trusses are made with few materials and a simple design, they come at a lower price
point than many other trusses. However, this also means that king post trusses cannot span long
distances, so they are better suited for smaller-scale projects.
Queen Post Truss
• Queen post trusses are well-suited for larger residential projects.
• Common uses: Residential home construction, home additions
• Span: 8 to 12 meters
• Queen post trusses are similar to king post trusses in that they have a simple, yet sturdy design. Instead of
having one king post in the center, this type of truss will have two queen posts that are connected by a straining
beam.
• The additional posts in a queen post truss make them slightly more expensive than a king post truss.
• The two vertical queen posts allow queen post trusses to span greater spans than king post trusses, which
means they can be used for larger projects.
Fink Truss
• Fink trusses are the most common truss for residential projects.
• Common uses: Residential home construction
• Span: Up to 14 meters
• Fink trusses are the most common truss seen in residential roof construction. The webbing in fink trusses has a
‘W’ shape, giving them a great load-carrying capacity. The position of the webbing allows for some storage
space and can accommodate things like water tanks if need be.
• They are also considered one of the most cost-effective roof trusses available, especially because they can
span far distances.
Howe Truss

A kind of truss having upper and lower members, a combination of steel and wood or both. One thing that
makes this truss extraordinary is that it has a very wide span, as it can cover anything from 6-30 meters. This
is very useful for a wide range of project types.
 Pratt Truss
The prat truss is the most popular steel truss since it is very
economical. It includes vertical and diagonal members that slope
down towards the center (opposite of Howe Truss). Pratt truss
can cover lengths ranging between 6-10 meters.
Fan Truss

A simple design made out of steel. Most projects with larger span of around 10-15 meters uses this kind of truss.
 North Light Roof Truss
Have a wide set of lattice girders that include support
trusses. North light truss is the oldest, and most
economical kind of truss. These are found in industrial
buildings, drawing rooms and large spaces, with a span
of 20-30 meters.
 Quadrangular Roof Trusses
Type of truss having parallel chords and an arrangement of
web members of tension diagonals and compression
verticals. It is mostly encountered in auditoriums or railway
sheds.
Parallel Chord Roof Truss

Constructed with two chords running parallel to each other and supported by reinforcing trusses in between the
top and bottom chords. This roof truss reduces the condensation problems and mold conditions since they create
a vapor barrier.
Raised Heel Roof Truss

Provides a cost-effective way to meet more stringent energy efficiency codes and improve the energy
efficiency of your building envelope. Raising the truss higher greatly simplifies attic ventilation and it leaves
ample room for insulation above exterior wall top plates
 Scissor Roof Truss
• Scissor trusses can create vaulted cathedral ceilings.
• Common uses: Residential home construction projects that require vaulted ceilings
• Span: Up to 22 meters
• Scissor trusses make it possible to create vaulted ceilings. The bottom chords of scissor trusses are sloped,
creating the dramatic ceiling in the room below. Scissor trusses combine the speed and convenience of using
pre-engineered wood trusses, while still getting the aesthetic benefit of high ceilings.

• You can install scissor trusts in one part of your

home, and use other types of trusses in other areas
of your home where you don’t want vaulted ceilings.
What’s great is that from the outside, your roof will
look uniform, even if one area has high ceilings.

• Keep in mind that scissor trusses do come at a

higher cost than other types of trusses - sometimes
up to 30% more than standard truss types.
Attic Truss
Attic trusses allow for storage space and sometimes even added living space.
Common uses: Residential home construction projects that require an attic or additional loft living space
Span: Up to 25 meters
One downside to many trusses is that the webbing can often limit attic space. This can be a dealbreaker for
homeowners looking for additional storage or living space. Luckily, there are attic trusses, which are built to
allow for attic space.
Attic trusses look similar to queen post trusses, but the two vertical posts are spaced further apart to allow for
attic space. The wider the building structure is, the bigger the attic space will be. The steeper the roof pitch is,
the taller the attic ceiling will be.
Gable Truss
• Gable trusses act as the ‘bookends’ to your roof.
• Common uses: Residential gable roof construction
• Span: Varies depending on roof design
• Gable trusses are usually used in combination with other types of trusses. The gable truss serves as the
‘end cap’ for the roof. They have two top chords, one bottom chord, and multiple vertical posts. Gable
trusses are built on each end of the roof framework to support roof sheathing.
• Gable trusses will cost anywhere from 25% to 50% more than standard-style trusses.
The Basic Components of a Roof Truss
The Basic Components of a Roof Truss…
•Apex – Highest point where the sloping top chords meet.

•Bearing – Structural support of trusses (usually walls) normally with a timber wall plate.

•Bottom Chords (BC) – the lowest longitudinal member of a truss.

•Cantilever – part of structural member that extends beyond its support.

•Cantilever Strut – web that joins the bottom chord above the bearing point to the top chord of a cantilevered
truss.

•Chord – main members that form the outline of the truss and subject to relatively large axial forces and bending
moments.

•Clear Span – horizontal distance between interior edges of supports.

•Heel – point on a truss which top and bottom chord intersect.

•Joint – point of intersection of one or more web(s) with a chord.

•Nail Plate – galvanized steel plate punched to form a nail pattern integral with the plate and used to connect
timber members.
The Basic Components of a Roof Truss…

•Node (node point) – point of intersection of two or more members that make up the panels of a truss.

•Nominal Span – horizontal distance between outside edges of the supports (wall plates) – usually the tie beam
length.

•Overhang – extension of the top chord of a truss beyond the bearing support.

•Panel – truss segment defined by two adjacent joints or nodes.

•Plumb Cut – vertical cut to the end of the top chord to provide for vertical (plumb) installation of the fascia or gutter

•Splice Point – Top and bottom chord splice

•Square Cut – perpendicular to the edges of the chord

•Stub End – a truss type formed by the truncation of a normal triangular truss.

•Top Chord or Rafter – a horizontal member that establishes the upper edge of a truss

•Web – members that join the top and bottom chords to form a triangular pattern
The Basic Components of a Roof Truss…
Advantages of Truss
1.Less expensive.
2.More accuracy.
3.Quicker construction.
4.Greater strength.
5.Diy friendly.

Disadvantages of Truss
1.Big weight and size.
2.Limitations in-ceiling design.
3.No future alternations possible.
4.No room for storage or conversion.
ASSIGNMENT
1ST SHEET : ON STEEL ROOF TRUSS / TUBULAR ROOF TRUSS

2ND SHEET : ON NORTH LIGHT TRUSS

REFER FOR ASSIGNMENT
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PORTAL FRAMES

Source - https://www.steelconstruction.info/Portal_frames
Source - https://havitsteelstructure.com/specification-of-portal-
steel-frame-buildings/
 Portal frames
• Portal frames are generally low-rise structures, comprising columns and horizontal or pitched rafters,
connected by moment-resisting connections.

• Resistance to lateral and vertical actions is provided by the rigidity of the connections and the bending
stiffness of the members, which is increased by a suitable haunch or deepening of the rafter sections.

• This form of continuous frame structure is stable in its

plane and provides a clear span that is unobstructed by
bracing.

• Portal frames are very common. They are very efficient

for enclosing large volumes, therefore they are often
used for industrial, storage, retail and commercial
applications as well as for agricultural purposes.
• A portal frame building comprises a series of transverse frames braced longitudinally. The primary
steelwork consists of columns and rafters, which form portal frames, and bracing. The end frame (gable
frame) can be either a portal frame or a braced arrangement of columns and rafters.

• The light gauge secondary steelwork consists of side rails for walls and purlins for the roof. The
secondary steelwork supports the building envelope, but also plays an important role in restraining the
primary steelwork.

• The roof and wall cladding separate the enclosed space from the external environment as well as
providing thermal and acoustic insulation. The structural role of the cladding is to transfer loads
to secondary steelwork and also to restrain the flange of the purlin or rail to which it is attached.
Cross-section showing a portal frame and its restraints
Principal components of a portal framed building
Types Of Portal Frames

Pitched roof symmetric portal frame

Generally fabricated from UB sections with a substantial

eaves haunch section, which may be cut from a rolled
section or fabricated from plate. 25 to 35 m are the most
efficient spans.

Pitched roof symmetric portal frame

Lancashire Waste Development
Portal frame with internal mezzanine floor

Office accommodation is often provided within a portal

frame structure using a partial width mezzanine floor.
The assessment of frame stability must include the effect
of the mezzanine; guidance is given in SCI P292.
Crane portal frame with column brackets

Where a travelling crane of relatively low capacity (up to say 20 tonnes) is required, brackets can
be fixed to the columns to support the crane rails. Use of a tie member or rigid column bases may
be necessary to reduce the eaves deflection.
The spread of the frame at crane rail level may be of critical importance to the functioning of the
crane; requirements should be agreed with the client and with the crane manufacturer.
Tied portal frame In a tied portal frame the horizontal movement of the
eaves and the bending moments in the columns and
rafters are reduced. A tie may be useful to limit spread in a
crane-supporting structure.
The high axial forces introduced in the frame when a tie is
used necessitate the use of second-order software when
analysing this form of frame.