Corrosion Resistant Prefabricated Steel Structure with 50 Years Life Cycle and Quick Erection
Pre-engineered steel buildings are steel structures built over a structural concept of primary members, secondary members, roof and wall sheeting connected to each other and various other building components.
These buildings can be provided with different structural and non-structural additions such as skylights, wall lights, turbo vents, ridge ventilators, louvers, roof monitors, doors & windows, trusses, mezzanine floors, fascias, canopies, crane systems, insulation etc., based on the customer's requirements. All the steel buildings are custom designed to be lighter in weight and high in strength.
Pre-Engineered Buildings are the most flexible solutions for contractors and owners. With the advantages of low cost, high durability, perfect quality control and fast erection; PEBs are used for various applications such as factories, warehouses, logistics center, showrooms, shopping malls, schools, hospitals, community buildings, etc.
- Factories
- Workshop
- Warehouses
- Cold Storages
- Steel Mills
- Assembly Plant
- Showrooms
- Supermarkets
- Offices
- Shopping Centers
- Exhibition Halls
- Restaurants
- Logistic Centers
- Multi-purpose Buildings
- Schools
- Hospitals
- Conference Halls
- Laboratories
- Museums
- Stadiums
- Farms
- Utility Shelters
- Pump Stations
- Aircraft Hangars
- Airport Terminals
Price per square meter can be 25%-30% lower than conventional steel buildings. Site erection cost is low because of faster erection times and easier erection process.
All steel components are fabricated at the factory and linked by bolts at the site. So the erection process is fast, step by step, easy to install and requires simple equipment. 60% less construction time required compared with the traditional R.C.C (reinforced concrete) building.
Pre-engineered steel buildings are flexible in any requirement of design, easy to expand in the future and also economically with low transportation costs.
Nowadays, pre-engineered buildings are the green solution for the environment with CO2 reduction, energy efficiency, and recyclability.
Pre-engineered metal buildings consists of following components:
- Primary Members / Main Frames
- Secondary Members / Cold Formed Members
- Roof & Wall Panels
- Accessories, Buyouts, Crane System, Mezzanine System, Insulation, etc.
- Sandwich Panels
Primary members are the main load carrying and support members of a pre-engineered building. The main frame members include columns, rafters and other supporting members. The shape and size of these members vary based on the application and requirements.
Secondary structural framing refers to purlins, girts, eave struts, wind bracing, flange bracing, base angles, clips and other miscellaneous structural parts.
Purlins, girts and eave struts are cold formed steel members which have a minimum yield strength of 345 MPa (50,000 psi) and will conform to the physical specifications of GB/ISO/CE or equivalent.
Standard steel panels are 0.3, 0.4, 0.5 mm or 0.6 mm thick and have a minimum yield strength of 345 MPa. Steel panels are hot dipped and galvanized with zinc or zinc-aluminium coating. The base material is pretreated, before applying a corrosion resistant primer and top coat. The combined thickness of the painted film is 25 microns on the front side and 12 microns on the reverse side.
Other building accessories include anchor bolts, fasteners (bolts, nuts, turnbuckle, expansion bolts), gutters, downspouts, doors, windows, ventilators, skylight panels, louvers and all other building-related materials.
- Verify the receiving documents and quantity of the received material by stores
- Submit the load for QC inspection by stores
- Visual inspection to confirm surface condition and for any damages
- Dimensional inspection checking length, width, depth, thickness etc.
- Verification of supporting documents like MTC
- Preparation of Incoming Material Inspection Report
Preparation of Plates:
- Drawings transferred to storage device using expert software
- Drawings copied into plate processing machine
- Automated machine senses plate length and carries out processing
- Punching of part mark on the plate
- Drilling of plates as per NC files
- Plasma cutting of plates
Preparation of Beams/Tubes:
- Fabrication drawings prepared by design department
- Automated cutting and drilling machine processing
- Transfer from drilling machine to fit-up section
- Fabrication drawings issued by production engineer
- Fabricators collect prepared beams and connection items
- Fix end plates, gusset plates, stiffeners, purlin cleats in appropriate places
- Tack welding for temporary fixation
- QC inspection after fit-up completion
Submerged Arc Welding Procedure:
- Plan jobs to be welded
- Clean welding location free of dust, oil, grease
- Set wire feed and voltage for welding
- Maintain fillet size parameters per GB50661-2011 standard
- Remove spatters and slag after welding
- Grind off burrs, sharp edges and excessive reinforcements
- QC inspection
MIG Welding Procedure:
- Similar procedure to submerged arc welding with MIG parameters
- Maintain fillet size parameters per GB50661-2011 standard
- Post-welding cleaning and grinding
- QC inspection
- Tool Box Talk performed by Foreman for every task
- Working area barricaded with information notices
- ID of fabricated steel recorded for traceability
- Raw material steel sections craned onto "in-feed" rack
- High pressure air cleaning to remove surface dust
- Automated blasting through conveyor system
- Six internally mounted wheels throwing steel shot at high velocity
- Emerges fully cleaned (Grade - SA 2/2.5)
- Full PPE required for personnel
- QC inspection of blasted surfaces before priming
- Ambient conditions checked and recorded (temperature, humidity)
- Surface must be dry and free from oil, grease and soluble salts
- Application by Airless spray preferred
- Paint material checked for conformity with shelf life
- WFT (Wet Film Thickness) readings during application
- Spot checks by QC to verify conformity
Painting System Specification:
- Primer coat: Per project requirement
- Second coat: Per project requirement
- Third coat: Per project requirement
- Touchup at site - after erection
- Receive finished components from painting department
- Store properly job-wise in the yard
- Arrange trucks from contract signed truck companies
- Loading starts after clearance confirmation
- Copies of all documents kept in Job file
With 20 year warranty in the steel building industry, our company maintains strict quality standards for steel buildings. We have acquired ISO9001 and CE certificates. The following standards are strictly followed for design and fabrication:
- GB/T1591-2008/2018
- GB/T11263-2010
- GB/T 2518-2008
- GB/T12754-2006
- GB/T 1228-2006
To ensure the quality of fillet weld, meeting up the technical requirements of welded members and improve the standardization of our fabrication.
This manual applies for the design, fabrication and inspection of fillet weld size.
| Requirement | Specification |
|---|---|
| Minimum fillet weld size | K≥1.5×t (t = thickness of thicker welding member) |
| Maximum fillet weld size | K≤1.2t (t = thickness of thinner welding members) |
| Edge welding | When t≤6mm, K≤t; When t>6mm, K≤t-(1~2)mm |
| Circular/trench holes | K≤(1/3)d (d = diameter of circular hole) |
| Form of fillet weld leg | K (fillet weld size) value | Note |
|---|---|---|
| Fillet weld without groove | K=(0.7~1)t and ≤15mm | For most steel structure buildings |
| Fillet weld without groove | K=(0.5~0.6)t | For strengthening ribs and secondary members |
| Fillet weld with groove (CJP and PJP) | K=t/4 and K≤10mm | For most steel structure buildings |
| Fillet weld with groove (CJP and PJP) | K=t/2 and K≤10mm | Important members (crane beams) |
| Parent metal thickness (t) (mm) | Minimum fillet weld size |
|---|---|
| t≤6 | 3 (minimum 5 for crane beam) |
| 6 | 5 |
| 12 | 6 |
| t>20 | 8 |
Steel plate cutting → H section assembly → Automatic welding → H section strengthening → Assembly → Manual welding → Shot blasting → Painting → Storage
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