AN OVERVIEW OF PRE-ENGINEERED BUILDING SYSTEMS IN

INDIA
1
SAURABH A. SHAH, 2MADHAV B.KUMTHEKAR
1
P.G. Student, Civil Engineering Department, Government College of Engineering, Karad, Maharashtra
2
Professor, Civil Engineering Department, Government College of Engineering, Karad, Maharashtra
E-mail: 1shahsaurabh11@gmail.com, 2kumthekarmb@yahoo.com

Abstract: - In India, Steel has proved its immense dependability as a base material in numerous sectors like building
construction, ship-building, infrastructure, automobiles and many other. Its significance and dependability cannot be
challenged substantially in foreseeable future in all these sectors. It has many luring aspects over conventional construction
such as time-saving, economical, versatility, durable and also eco-friendly which poses threat to global warming conditions
which is increasing at an alarming rate. But, the greatest challenge to the Indian PEB industry is the perception shift from the
conventional construction industry to the pre-engineered building systems. Recently, the expertise from ace private
construction have proved that the precision and cost-effective factor for the structures have increased the level of demand of
Pre-engineered building structures. In spite of such key attractive features, the flourishment of pre-engineered building
observed in India is not as other developed countries. This review is focused on the obstructing issues in pre-engineered
building technology by the new emerging companies in India and the critical success factors that are involved in these
systems. Also, the contribution of pre-engineered building systems in India in the economic growth of country through
various applications is stated briefly.

Keywords: Pre-engineered Building; Pre-Engineered Building Systems; Pre-Engineered Technology; Prefabricated

Buildings; Metal Building Systems; Eco-Friendly Construction

I. INTRODUCTION Intermediate floors of low elevate buildings are

Pre-engineered Steel Buildings utilizes a combination
of built-up sections, hot rolled sections and cold
composed elements which provide the rigid steel
frame work with a covering of single skin sheeting
which is either integrated insulation or insulated
sandwich panels for roofing and wall cladding. It is a
concept which is designed to provide a consummate
building envelope system to accommodate air tight,
energy efficient, optimum in weight and cost and
above all requisite designed as per utilizer's needs.
These Pre-Engineered Steel Buildings can be fitted
and modified with different structural attachments
including mezzanine floors, canopies, fascias, interior
partitions, crane systems etc. The building is made
air-tight by utilization of special mastic beads, filler
divests and trims. This is a very flexible building
system and can be finished internally so that it
accommodates the required function and accessorized
externally to achieve captivating and distinctive
architectural styles. It is most favorable system for
any low-elevate building and offers numerous
advantages over conventional buildings.
Pre-engineered buildings are generally low elevate
building type and hence the maximum eave heights
can go up to 25 to 30 meters which are ideal for
offices, houses, showrooms, shop fronts etc. These
buildings are very economical & expeditious and can
be constructed in less than a half the ordinary time
especially when complimented with other engineered
sub-systems. The most ordinary and economical type
of low-elevate building is a building with ground
floor and two intermediate floors plus roof. The roof
of a low elevate building may be flat or sloped.
composed of mezzanine systems. Single storeyed
houses for living take minimum time for construction
and can be built in any type of geographic location
like extreme cold hilly areas, high rain prone areas,
plain land, extreme sultry climatic zones etc.
II. SUPERIORITY OVER CONVENTIONAL
BUILDINGS
Pre-engineered building systems justifies its
trustworthy value in terms of durability, seismic and
wind resistance and aestheticness of structure. In the
preparation stage itself, cost saving starts. Due to
system engineering and fabrication methodology,
interior financing has increased but it has minimized
the field erection processes. This has benefited in
earlier occupancy of the facility and early start for the
working operations by the client. It has assurance of
factory-built quality which has monotonous finish
quality in fabrication and uniformity in design. These
systems are energy efficient which also gives
watertight roofing systems. It also allows easy
disassembly for future expansion with lowest life
cycle maintenance costs.
Savings are also achieved in terms of minimal
wastage as there is minimum sand and cement
wastage. A poor man can be provided with a home
engendered under rigorous quality control and having
a longer life span, with more preponderant safety
against natural disasters like earthquakes and
cyclones. It allows you to mould your dream structure
in the shape you want. It allows much liberty to the
designers, consultants, architects and builders to

Proceedings of 27th IRF International Conference, 24th May 2015, Pune, India, ISBN: 978-93-85465-17-8
53
 An Overview Of Pre-Engineered Building Systems In India
achieve the aesthetic design along with the strict
codes of the building in most economic manner
In nutshell, the benefits may be summarized as under:
 Increased speed of construction, more
expeditious return on investment.
 Ensured quality of material, design and
construction
 Unlimited architectural possibilities
 Enhanced Durability and seismic reliability
 Easy construction, maintenance and
refurbishing
 Increased Life cycle performance and cost
competitiveness
 Environment–friendly structures
 Better value for MAZUMA
 Cleaner and unencumbered sites
 Sustainability in construction through reuse
of most materials
 Suitability for Hilly regions and other
geographically arduous areas
 Hassle Free
 Optimized design of steel reducing weight
 Better Earthquake & Wind pressure
resistant.
 Energy efficient roof and wall system
utilizing insulations.
 Easy integration of all construction materials
 The building can be dismantled and
relocated facilely.
 Future extensions, expansion modification
can be facilely accommodated without much
hassle.
 Faster distribution and erection, preserving
around 30-40% of project time
 Column-free large clear spans, up to 90m.
 Virtually maintenance free
 Single-source responsibility
 Lighter weight; savings in substructure cost
of 10-20 percent
 Insulated from sound and heat, as per the
requisite
 Better rainwater harvesting through gutters
and down-take arrangements
 Overall economy
PEB has multifariousness in all types of building but
the most prevalent applications are in industrial,
institutional and commercial types of buildings. In
India, most of the construction of pre-engineered
building is in construction of warehouses and
industrial sheds. Recently, the focus is shifted to rural
areas along with urban, individual housing projects
and mass housing projects, farmhouses, slum re-
organisation projects and rehabilitation projects and
other various sectors. Aspect of being earthquake
resistant have wide recent applications of PEB with
appreciable acceptance. PEB concept has played a
major role in the infrastructure of the country. Single
Proceedings of 27th IRF International Conference, 24th May 2015, Pune, India, ISBN: 978-93-85465-17-8
54
storeyed building takes minimum time for
construction and it has so flexibility that it can be
built in any type of geographic location like high rain
prone areas, extreme climatic zones etc.
III. COMPONENTS OF PEB
Fig. 1. Components of PEB building
3.1. Main Framing
It is also called primary framing members which
includes a basic rigid steel frame. This steel frame
comprises of tapered/straight columns or rafters as
per the design requirements. These unit members are
turned into built-up members by fabricating steel
plates into the 'I' or 'H' sections. Finally, the frame is
erected on site by bolting other sections on the site
itself followed by cranes.
3.2. Secondary frames
These are cold-formed members. Purlins, girts and
eave struts are the basic examples of secondary
framing members. Preparation of these members does
not involve welding process but involves the press
bending process of the HR steel coil giving it the
optimum shape as per design and aesthetics (Z- or C-
shape) and dimension.
3.3. Roof and Wall panels
The thickness of Roof and Wall panels is in the range
of 0.47mm to 0.55mm. It is made up of Zincalume or
Galvalume coils which are generally metallic plain or
color coated profiled steel sheets. To make
galvanized steel, the base steel is applied with zinc
coating varying with minimum mass of 120 gsm/ m2
to maximum of 275 gsm/ m2 (total of both sides) are
available with permanent color coating or coating of
zinc - aluminum (zinc 45%, aluminum 55%) is
applied on base steel of total mass of 150 gsm/m2
(total of both sides). The color coating is available in
two ways of which one is distinct option of polyester
paint coating like conventional modified polyester,
silicon modified polyester and super polyester
coatings and another option is poly vinyl fluoride
which is special organic coatings. These coatings
provides good resistance or all kinds of environment
hazards. This metal roof panels can be manufactured
 An Overview Of Pre-Engineered Building Systems In India
to any desired length with a constant width but only
has conveyors restrictions hence it is customarily kept
upto 12 meters. To eliminate water ingress, general
overlap joint considered is 15 cm to 20 cm.
It also has a major advantage for the designers as it
allows roofing with minimum pitch which is a rare
case in convetional buildings. This happens due to
joint-less run of roofing as it has flexibility in cutting
of lengths. Slopes as shallow as 1:20 are possible
which allows sufficient drainage of water thereby
improving long term performance of the panels.
These profile steel sheets are conventionally
categorized into two types depending upon the type
of fine-tuning arrangement followed. These two types
are Through Fastened and second one is Standing
Seam. Installation of this type of roofing & cladding
system can provide 30 years or more of trouble-free
accommodation in most environments.
3.4. Insulations
These buildings can be properly insulated by
providing fibrous insulation slabs/rolls of non-
combustible Rockwool, Aluminum foil laminated,
placed over a metal mesh bed created between the
purlins, and then the roofing steel sheet fixed over it.
The siding walls can also be insulated by providing a
double skin profile steel sheet wall cladding having
Rockwool Insulation slab sandwiched in between and
held in position withthe help of 'Z' spacers in between
the two profile steel sheets. In similar pattern a
double skin insulated roofing system can also be
erected.
3.5. Sandwich Panels
Sandwich panels are generally adopted for thermally
efficient roof and wall claddings for buildings which
is especially suited in high altitude areas and cold
storages. It is an alternative to the pre-fabricated
insulated panels. It generally comprises of two-single
skin panels with polyurethane foam insulation in
between. It is extensively adopted in non-residential
andresidential buildings which also has good
insulation properties and noise reduction properties.
3.6. Crane systems
Various types of crane systems which are used in pre-
engineered buildings are overhead EOT cranes, semi-
gantry cranes, wall mounted cranes, mono rails and
under slung cranes for material and equipment
handling operations inside. The loads are considered
while erecting of these buildings and generally
adopted as 1MT to 250 MT. Maintenance platforms
and ladders are equipped along with carne runway
beams which is none other than built-up sections
strengthened with channels which serves as a gantry
girders.
3.7. Mezzanine Systems
Mezzanine systems are provided in several
commercial buildings and high-rise structures to
Proceedings of 27th IRF International Conference, 24th May 2015, Pune, India, ISBN: 978-93-85465-17-8
55
increase the floors which serves different functions
for the different buildings. These systems are nothing
but the built-up beams which supports built-up, hot-
rolled sections or the cold-formed elements which as
a whole supports metal deck. Metal deck is generally
a concrete slab finished surface. Also, the steel
checkered plates are adopted as top surface. It is
generally adopted for office space which supports
goods or for the horizontal circulation from one
compartment of the buildings to another.
3.8. Bracing Systems
Bracings provide stability to the structure against
wind, seismic forces or others such disturbing forces.
It comprises of rods, pipes, angle sections or cables
with an eye bolt and an adjusting nut at both ends
which is located near the outer flange of columns or
rafters and affixed at the web of the rigid frame.
3.9. Paints and finishes
Paints and finishes protect the surface deterioration
which happens due to the interior environment and
exterior environment of the structure. In general,
synthetic enamel and epoxy based paints are used for
painting and finishing purposes as per the
recommendation of architect/client.
3.10. Accessories, Attachments etc.
Accessories and attachments are governed by the
functional requirements and architectural aesthetics
of the structure. Hence, they are supplied in ready fit
condition. Also, the ventilation systems and lighting
systems are to be designed and attached by consulting
an expert.
3.11. High Strength materials
The ordinary construction utilizes the steel having
nominal yield stress of approximately 250 MPa
whereas the PEB construction uses steel of yield
stress approximate to 340 MPa. This recent change in
grade of structural steel is due to the revision of
IS2062:2006. There are reliable manufacturers for
these steel manufacturers like TATA, SAIL, etc. who
are manufacturing these in India. New materials like
Fe540B gives yield stress of around 410 MPa which
has thickness lower than 20 mm and the galvalume or
zincalume roofing and wall sheets having strengths in
the range of 550MPa.
Steel is popular in construction due to the flexibility it
provides in design, its material strength, unorthodox
geometry and volume to weight ratio. Also,
economical fabrication can be done along with easy
erection.
IV. CRITICAL SUCCESS FACTORS AND
ISSUES OF PEB IN RECENT MARKET
SCENARIO
There are some critical success factors analyzed over
a period of time which are posing threat to the
 An Overview Of Pre-Engineered Building Systems In India
flourishment of this metal building systems. They are
as follows:
Fig. 2. Critical Success factors
Increased Technical Competence
Technical competence is the critical base and a
necessity for surviving in the industrial competition.
Mostly, the companies which cannot invest in their
own in-house R&D section, they are mostly forming
an alliance with reputed companies in order to offer
more quality products. Hence, rather than investing in
thier own R&D, that much amount is utilized in
buying of products and rewarding the companies with
the profit associated with the members. PEB
construction is not recommended for high rise
buildings as it is not the ideal choice for the factory
buildings to sustain very high dead loads and live
loads. Hence, the engineering expertise offer low-rise
factory buildings and its aesthetic requirement with
large spanning capacity and other operational uses so
as to place the company in a better competition to
handle competition.
Standardization and Modularization
All projects have a primary aim to be achieved, i.e.,
to build a structure fulfilling the customers
specifications. So, to extract the profit out by
fulfilling the customer's need, you need to develop
some production strategies like standardisation and
modularization of the building components. It aslo
enables better transportation planning which adds to
the benefits of standardization and modularization.
Closer alignment between manufacturing arm and
other supply chain partners
There is repetitive process of manufacturing and
supplying. Hence, the manufacturing arm and supply
arm should create a harmonial relationship. This
arises the need of Supply chain management which
will help to strengthen the alliances with sub-
contractors and raw-material suppliers which would
result in reduction of logistics cost for the company.
This will bring overall economy to the project.
Price Competitiveness
Steel fabrication can be done with expensive
machineries as well as low cost machineries too. This
allows open competition and no barrier like condition
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56
for new comers. Hence, no single company has a
clear brand advantage as the competition on price
ranges from Rs.75-95/kg. Hence, major deciding
factor is the delivering charges charged by the
companies. So its a major decisive concern.
End user needs
End user needs are to be identified well and derive
benefits out of it, you need to develop and modify the
production and supply chain strategies to stay in
forefront of the competition. This can be done
collaborating with supply chain partners, taking their
regular customer feedback and forging strategic
alliances with the large builders to forecast their own
product demand.
Develop suitable marketing strategies
To develop marketing strategies, it is essential to
know the market restrainer for PEBs. After
identifying the market restrainer's, it should be
mitigated by educating public about the benefits of
PEBs. To appeal the customers with attractive
marketing strategy to various residential customers
which would open an entirely new dimension for
them. This will promote the brand awareness as well
as trust over the company which would be a major
differentiating factor.
Issues in PEB:
There are few issues in PEB which are discovered
over a large period of time thorough examination
during erection and under seismic conditions as stated
below:
Fire Protection
Fire protection systems is still a major issue of
concern for steel structures when compared to
concrete or other construction materials. The smaller
members and thermal mass of the steel structures
makes it more hazardous. The catastrophic failure of
WTC tower in USA due to fire caused by burning of
aviation fuel and sudden escalation of temperature
lead to devastation of structure which is still a rigid
part of memory. Structural cost of building comprises
of good share of fire protection systems. Hence,
engineers are challenged to reduce the cost of fire
protection systems and also to assure adequate
resistance to devastating situations caused due to fire.
Buckling
Buckling and stability are also the major issue of
concern in PEB. Due to this, maximum eave height is
limited generally to 25m to 30m and also stability is
critical due large clear span.
Micro Cracks
With progressing time, it is observed that increasing
yield stess, operating stress levels, emphasis on
plastic and ultimate capacity and the use of welded
construction have resulted in increased frequency if
 An Overview Of Pre-Engineered Building Systems In India
initiation of micro-cracks which causes fracture in
bridges and other industrial buildings. This micro
cracks and its crack growth is more hazardous in
seismic areas.
Welding
Presently, welded constructions are more dominant
over PEB constructions which utilizes bolting
process. PEB construction as stated earlier utilizes
higher grade of steel which poses difficulty for the
welding operations. This does not affect the ductility
and other aspects of structural system but do spoil the
aesthetic appearance. Recently, the use of fully
automatic and semi-automatic submerged arc welding
results in increase in welding speed apart from the
good quality. Few key features have enhanced the
easiness and operational efficiency like elimination of
fumes, smoke or any visible arc column. This ensures
better quality and wide range of applications.
Ductility from seismic considerations
Seismic design is very important in civil engineering
structures. Steel as a material itself has many benefits
like its stiffness, material strength and ductility.
Welding process for steel structures also affect its
seismic performance and it is concluded that new
methods to improve inelastic seismic performance is
to be investigated.
V. FUTURE ASPECTS LEADING TO
ECONOMIC GROWTH
Steel is preferred construction material because of is
merits like quality, aesthetics, economy and
environmental conditions. This can play a major role
in filling the gaps for shortage of housing,
educational institutions, railway stations, airports,
industrial buildings etc.
Warehousing industry
Manufacturing sector will be gaining tremendous
growth in India in upcoming years. Also, logistics
will be gaining equal demand in it. The addition in
capacity to the cold store and warehousing would also
trigger investment in PEB market in India. Many
experts feel that warehousing industry would be the
primary driver for PEBs in India in the immediate
future as the automobile industry had reached a level
of maturity.
Manufacturing industry
India's manufacturing industry could touch US$ 1
trillion by 2025 (McKinsey and Company). The
elevating demand in the country for manufacturing
and establishing low-cost plants in India by MNCs
are two reasons for this possible development.
Retail Industry
Proceedings of 27th IRF International Conference, 24th May 2015, Pune, India, ISBN: 978-93-85465-17-8
57
India's retail market is expected to target prodigious
amount of Rs. 47 trillion by 2016-17, which is
increasing at the compounded annual growth rate
(CAGR) of 15%.
Residential Construction
India will become the world's third largest
construction market by 2025 which adds about 11.5
million homes a tear to become a $1bteillion a year
market.
Metro Rail Projects
Metro Rail Projects are new to India and hence many
state governments have initiated metro rail projects to
get relief from the congested traffic on road. A
ballpark figure is estimated for the projected demand
arising from these projects in several cities is 176250
MT.
Other applications
Most attractive feature of PEBs is that they provide
large clear span. Hence, this advantage will be taken
by airport hangars, railway stations, SEZs and fuel
stations also.
CONCLUSIONS
In this era of competition, it is important to build
economic structures which provide good integrated
system performance. Steel is suitable for all types of
taller, bigger, longer span and especially for
geometrically complex structures. Most attractive
economy in civil engineering construction can be
achieved by optimum use of steel of high grade and
composite form of construction with improved
materials. But, there are some aspects that are needed
to be addressed in the immediate future:
1. PEBs needs a huge initial investment.
2. Indian education has most of the focus on RCC
buildings in course curriculum and hence
advancement in steel construction is ignored.
3. Fire-fighting protocols in steel buildings have
to improve as per the customer's concern.
4. IS codes should be modified as the sections
selected are found to be heavier mostly.
Hence, Pre-engineered building has a wide scope
future in India as they are still not preferred today.
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 An Overview Of Pre-Engineered Building Systems In India
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