PREON box

HIGH QUALITY, FLEXIBILITY AND SPEED IN INDUSTRIAL HALL CONSTRUCTION

 When we refer to our wide-spanning
A standard coverage, we mean it quite literally in
terms of the PREON box. This in-house
solution that developed and patented roof frame sys-
tem ensures the realisation of unsup-
ported spans of up to 100 metres and
sets standards: more. The high level of standardisation
enhances speed, quality and perfor-
The PREON box mance. Then, regardless of a building’s
size, there should be no room for com-
promise.
principle The challenges facing the PREON box
developers were quite clear: Planning
must be a quick and simple process.
And the technical outlay for production,
transport and assembly must be kept to
a minimum. The numerous requirements
were accommodated with a wealth of
know-how and a remarkable degree of
engineering ingenuity, resulting in a pa-
tented solution that sets new standards
in industrial hall construction.
Conventional
framework structure
0m 30 m
Hall span
Vallourec:
Tradition meets innovation
Vallourec is a world leader in the pro-
duction of seamless, hot-rolled tubes
for a broad spectrum of engineering
applications. A key innovation in this
context is the hall system PREON box.
Based on this development, the idea
was expanded and elaborated. Our
planning software, for instance, was
developed specifically for the PREON
box in collaboration with the engineers
from Feldmann + Weynand.
The benchmark in industrial
hall construction
Sometimes big is just better. Nobody
would consider parking a giant Airbus
A380 with a wingspan of almost 80 me-
tres inside a hangar full of columns. Oth-
er buildings, such as logistics facilities,
warehouses, shopping centres, exhibi-
tion halls and leisure centres, can also
benefit from the PREON box and the
large unsupported spans and high load
bearing capacities it offers.
PREON box
100 m
 Vallourec / PREON box /p.3

The modular design

Each PREON box roof truss consists of

three elements: Two identical end sec-
tions and a middle section. All the com-
ponents have square or rectangular top
and bottom cords. And since all the
parts terminate in a headplate, simple
threaded joints ensure fast and efficient
on-site assembly.
Optimised:
The end sections
The end sections consist of roof trus-
ses, whose length and geometry are cal-
culated precisely in line with structural
and economic aspects. The only ma-
terial used is our MSH sections.
The MSH section
Our MSH sections are an integral part of every PREON box solution.
They are hot-rolled and a benchmark for our long-term quality that is
acknowledged around the globe. And there are many more convincing
reasons to choose the:
Outstanding reliability thanks to steel grade S355J2H conforming
to EN 10 210
High load bearing capacity
Ideal corrosion protection
Ease of processing
Aesthetic appearance

Variable: The middle section

The middle section is a frame-type Vier-
endeel girder. Adaptation of the post
distances has also been optimised. The
length is freely selectable and offers the
best possible flexibility with regard to
the overall length of the trusses. Once
again, the basis for success is our MSH
section.

End sections:
Traditional roof trusses
made from MSH sections

Middle section:
Vierendeel girder of
variable length, made
from MSH sections
p.4 / Vallourec / PREON box

The perfect start – using the PREON box planning software

Each project boasts not only high-qual-

ity S355J2H grade steel, but also a
wealth of know-how. And technical
know-how, for example, is also at the
heart of our planning software. This en-
sures your project is tailored to your
individual needs during the planning
stage long before construction com-
mences. The best start for your project
prior to realisation.

The advantages
Providing effective and efficient plan-
ning is all about paying attention to key
details. Your wishes and preferences
are integrated directly into the project
without extensive lead times or other
delays, allowing the accurate simulation
of realistic scenarios. As a result of an
iterative calculation, you receive a cost-
effective structural solution as well as a
reliable cost estimate.

Needless to say, the availability of rele-

vant materials is always taken into ac- The benefits of the PREON box
count. Necessary modifications can be
made directly and immediately produce
an adjusted result. Faster: Process
Faster quotation process thanks to
planning software
Industrial production for fast and
simple assembly, and the shortest
Highly standardised, possible construction period
Reduced cutting and welding de-
mands
yet individual enough Just-in-time delivery without de-
lays or holdups in the supply of
to match your steel (production at our own steel
and tube mills)
expectations Planning software saves up to
20% on materials and cuts the
process time by up to 30% com-
pared to conventional project ex-
ecution
Greater: Flexibility
Freely selectable ground plan de-
sign; the PREON box adapts to
your needs
Easy adaptation of the middle sec-
tion in response to structural chal-
lenges
Effective spanning of large dis-
tances from 30 metres to over 100
metres
Planning, handling and assembly
all from a single source upon re-
quest
Higher: Quality
Highest load-bearing capacity
thanks to hot-rolled MSH sections
Long-term, durable quality (long
life cycle)
Patented, modular solution
Comprehensive quality
management
Conforms to all applicable
standards
Pleasing aesthetics
Larger: Cost savings
Cost-effective realisation thanks to
standardised products
Less material costs due to weight
reduction
Reduced cutting and welding de-
mands
Iterative calculation and efficient
measurement algorithms through
the planning software ensure opti-
mum utilisation of materials
 Vallourec / PREON box /p.5

The five strong pillars for cost-effective

and sustainable construction

Cost-effective, fast and of the highest

quality. Our clients have a clear under-
standing of how their project should
evolve. We meet their demands with a
clear strategy that rests on five pillars
of sustainable and cost-effective con-
struction.

Planning
Suggestions instead of corrections:
A successful project begins with in-
depth consultation. If requested, design
and structural engineers, as well as oth-
Careful planning er experts, will provide you with theoreti-
cal and practical advice from start to fin-
ish.

Production
Everything from a single source:
Industrial production
As a global market leader we manufac-
ture products at our own steel and tube
mills throughout Europe. This helps to
prevent delays and holdups. What is
more, all tube production stages take
place under industrial conditions at our
plants. This ensures optimum condi-
tions for subsequent work on site, en-
hancing cost, time and quality objec-
tives.

Execution
Construction site advantages:
Our dedicated team of production and
project managers and project supervi-
sors work hand in hand, guaranteeing
Precise execution leading-edge production processes at
our plants. And since this know-how
extends beyond the factory gate, you
can be sure that all the processes are
coordinated perfectly. You therefore
profit from quick and simple assembly.

Quality Additional columns are simply not re-

quired with the PREON box. We are

assurance
From start to finish:
Seamless quality assurance
covered by a number of certifications
which we – from production to installa-
tion – naturally comply with as standard
procedure. The comprehensive monitor-
ing of all processes ensures the highest
quality and full compliance to dead-
lines.

Logistics
A new era:
Inconsistencies are not an option. This
applies to both the accuracy of the
Mature logistics PREON box elements and the agreed
deadlines. We therefore view construc-
tion logistics as an integral part of our
reliability. This is the only way to guar-
antee adherence to very tight produc-
tion and construction schedules, and to
profit from the finished structure at the
earliest possible date. We can proudly
claim that all projects to date have been
completed, often against all expecta-
tion, ahead of schedule.
p.6 / Vallourec / PREON box

It is always best to ask someone who knows best:

An expert commentary

Companies will, of course, lay claim to

many achievements in pursuit of suc-
cess. Fortunately, we can back up our
claims with solid results and expert
reports. For example, from Dr. Stefan Vierendeel section
Herion, who is an expert for hollow sec-
tions and hollow section designs, and
the managing director of the Karlsruhe
Competence Centre for Tubes and Hol-
low Sections. He also works at the Fig. 1: Transverse force distribution across a single-span girder
Karlsruhe Institute of Technology (KIT)
as a research officer and coordinates
specific research projects in this field.

Dr. Stefan Herion: Roof trusses are

girders subject to bending that have to
take up transverse forces and moments
resulting from their own weight and roof Fig. 2: Moment distribution in 06/06 with a variable distance between posts
loads. With increasing spans, plane lat-
tice girders capable of transmitting the
loads via a system of tension and com-
pression bars are therefore mainly used.
In addition to their static load advan-
tages, trusses are superior to all other
structures in terms of weight, produc-
Fig. 3: Moment distribution in 06/06 with a constant distance between posts
tion costs and aesthetics.

„ An extremely
cost-effective
By comparison, Vierendeel girders have
the advantage of a greater range of
spans and simpler production. Straight
Perfectly combined:
Roof trusses and Vierendeel
sections and lower dimensional accura- girders
and versatile cy are sufficient for Vierendeel girders.
However, Vierendeel girders are less ca- Dr. Stefan Herion: By using a Vier-

”
solution pable of transmitting shear forces.
Therefore, with the PREON box girder
the Vierendeel section is only applied in
the middle area exposed to lower shear
forces (Fig. 1).
Another advantage of the Vierendeel
girder is that the distances between
the posts can be adapted to the actual
load, which has a particularly positive
effect on moment transfer. Consequent-
ly, the version with variable post dis-
tances in Fig. 2 shows a lower moment
Y < X than the version with a constant
distance between posts in Fig. 3.
endeel girder with a variable post dis-
tance in the middle section of the girder
and a plane lattice at both ends of the
girder, the PREON box girder combines
the advantages of both systems. This re-
sults in a structure which is very efficient
thanks to its adaptation to the distribu-
tion forces and its large range of spans.
PREON box represents an extremely
cost-effective and versatile solution for
industrial building construction.

Dr. Stefan Herion,

Karlsruhe Institute of Technology (KIT)
 Vallourec / PREON box /p.7

DIN and ISO instead of IFS, ANDS or BUTS: The standards

Hot-rolled and cold-rolled sections have

completely different structural character-
istics, which are taken into account in
the European standards. We only use
our own hot-rolled sections as they offer
outstanding welding characteristics and
greater load bearing capacity. The long-
term quality of these sections is recog-
nized worldwide. And since a material is
only as good as the production process-
es, all Vallourec production facilities are
certified to ISO 9001. You can therefore
rely on Vallourec quality management
and on the compliance of it products
with all aspects of the relevant standards
– no ifs, ands or buts about it.

Applicable standards and quality standards for PREON box

➜ MSH SECTIONS: ➜ DESIGN: • Eurocode 1: Actions on structures

• EN 10 210-1: Hot finished structural hol-
low sections of non-alloy and fine grain
steels
Part 1: Technical delivery conditions
• EN 10 210-2: Hot finished structural hol-
low sections of non-alloy and fine grain
steels
Part 2: Tolerances, dimensions and sec-
tional properties
➜ WELDING:
Qualification certificate in accordance
with DIN 18 800, Part 7
➜ FIRE SAFETY:
With regard to fire safety, the industrial
building guideline and Eurocode 1 apply
• Eurocode 1: Actions on structures
Part 1-1: General actions
(densities, self-weight and imposed loads
for buildings)
German version EN 1991-1-1:2010
• Eurocode 1: Actions on structures
Part 1-2: General actions
(actions on structures exposed to fire)
German version EN 1991-1-2:2010
• Eurocode 1: Actions on structures
Part 1-3: General actions (snow loads)
German version EN 1991-1-3:2010
• Eurocode 1: Actions on structures
Part 1-4: General actions (wind actions)
German version EN 1991-1-4:2010
Part 1-6: General actions
(actions during execution)
German version EN 1991-1-6:2010
• Eurocode 3: Design of steel structures
Part 1-1: General rules and rules for
buildings
German version EN 1993-1-1:2010
• Eurocode 3: Design of steel structures
Part 1-8: Design of joints
German version EN 1993-1-8:2010
• Eurocode 8: Design of structures for
earthquake resistance
Part 1: General rules, seismic actions
and rules for buildings
German version EN 1998-1:2010

• Eurocode 1: Actions on structures Inclusive of national annexes in all cases.

Part 1-5: General actions
(thermal actions)
German version EN 1991-1-5:2010
p.8 / Vallourec / PREON box

PREON box in practice

Production shop,
steel industry,
St. Saulve, France

Length: 154 m
Span: 39 m
Ground area: 6,000 m2
Ridge height: 25.6 m
Eaves height: 20.7 m
Hollow section tonnage: 564 t
Year of construction: 2006

Production shop,
steel industry,
Düsseldorf, Germany

Length: 171 m
Span: 47 m
Ground area: 8,000 m2
Ridge height: 19.8 m
Eaves height: 16.7 m
Hollow section tonnage: 604 t
Year of construction: 2006

Production shop, mechanical

engineering industry,
Duisburg, Germany

Length: 120 m
Span: 24 m
Ground area: 2,900 m2
Ridge height: 15 m
Eaves height: 14.2 m
Hollow section tonnage: 260 t
Year of construction: 2006
 Vallourec / PREON box /p.9

Three-bay production shop,

steel industry,
Changhzou, China

Length: 144 m / bay

Span: 30 m / bay
Ground area: 13,000 m2
Ridge height: 16.5 m
Eaves height: 15.5 m
Hollow section tonnage: 533 t
Year of construction: 2006

Warehouse,
Witten,
Germany

Length: 48 m
Span: 23 m
Ground area: 1,100 m2
Ridge height: 17 m
Eaves height: 16 m
Hollow section tonnage: 57 t
Year of construction: 2007

Production shop, metal-

working industry,
Hohenlimburg, Germany

Length: 200 m
Span: 35 m
Ground area: 7,000 m2
Ridge height: 17 m
Eaves height: 16 m
Hollow section tonnage: 160 t
Year of construction: 2006
p.10 / Vallourec / PREON box

Production shop, plant

engineering, Mönchenglad-
bach, Germany

Length: 181 m
Span: 24 m
Ground area: 4,400 m2
Ridge height: 20 m
Eaves height: 19 m
Hollow section tonnage: 540 t
Year of construction: 2007

Two-bay production shop,

steel industry, St. Saulve,
France

Length: 1 x 270 m / 1 x 189 m

Span: 1 x 45 m / 1 x 35 m
Ground area: 19,100 m2
Ridge height: 22.5 m
Eaves height: 17 m
Hollow section tonnage: 1,870 t
Year of construction: 2007

Seven-bay warehouse and

logistics building, steel trade,
Düsseldorf, Germany

Length: 128 m / bay

Span: 32 m / bay
Ground area: 29,000 m2
Ridge height: 14 m
Eaves height: 13.7 m
Hollow section tonnage: 1,150 t
Year of construction: 2008
 Vallourec / PREON box /p.11

Production shop, aircraft

construction, Saint-Nazaire,
France

Length: 200 m
Span: 60 m
Ground area: 12,000 m2
Ridge height: 28 m
Eaves height: 21.3 m
Hollow section tonnage: 1,400 t
Year of construction: 2009

Seven-bay production shop,

steel industry, Jeceaba,
Brazil

Length: 700 m / bay

Span: 2 x 35 m / 5 x 50 m
Ground area: 130,000 m2
Ridge height: 33.5 m
Eaves height: 27 m
Hollow section tonnage: ~ 15,000 t
Year of construction: 2011

Ten-bay production shop,

Changhzou,
China

Length: 327 m / 205 m / 60 m

Span:
5 x 24 m / 1 x 40 m / 1 x 42 m
1 x 22 m / 1 x 18 m / 1 x 16 m
Ground area: 43,000 m2
Ridge height: 14 m / 28.5 m / 11.5 m
Eaves height: 13 m / 27 m / 10.5 m
Hollow section tonnage: ~ 3,400 t
Year of construction: 2012
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Phone +49 (211) 960-3594

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