Collaboration blog between Venwiz and Arcedges Building India LLP: On understanding the advantages of using pre-engineered buildings in manufacturing.
In today’s manufacturing landscape, flexibility, efficiency and cost-effectiveness are critical. Pre-engineered buildings, or PEB, have quickly become a popular solution for building workshops or warehouses. Unlike traditional construction, which involves on-site fabrication and extended timelines, PEBs use pre-fabricated components If you are planning to use PEB steel structures for your next plant, here are some advantages of pre-engineered buildings you should know about.
Table of Contents
- What are pre-engineered buildings?
- Components of pre-engineered buildings
- Advantages of pre-engineered buildings in manufacturing
- Case Studies
- Venwiz and Arcedges Building INDIA LLP: A Partnership for PEB Structures
- About Arcedges Building INDIA LLP
- Venwiz: Your Gateway to Unmatched Business Success
What are pre-engineered buildings?
Pre-engineered buildings, or PEBs, are steel buildings manufactured off-site, with their components pre-cut and pre-engineered to fit together easily, while assembling on-site. These buildings are typically low-rise structures (two stories or less), used for commercial applications such as manufacturing, warehousing, fitness centres, and hangers.
Components of pre-engineered buildings
We can broadly classify components of PEBs into:
- Primary Frame
- Secondary framing
- Accessories
Primary Frame
The primary frame forms the core structure of the building, consisting of steel elements and includes:
- Main Frame: Composed of tapered columns and rafters, also known as built-up members. PEB manufacturers fabricate the sections using advanced technology, with welded flanges. The frame is assembled by bolting the splice plates of the connecting sections.
- Columns: Vertical members providing structural support made of steel and designed to withstand bending, bulking, and shear forces.
- Rafters: These are sloping structural members that extend from the ridge to the wall plate. Rafters support the roof deck and associated loads.
Secondary Frame
The secondary components offer additional support and stability to the structure, including:
- Purlins: These horizontal, secondary cold-formed members run along the building’s length. They support roof panels and transfer roof loads to the primary frame.
- Girts: The girts run vertically along the building’s walls, support wall panels and transfer wall loads to the primary frame.
- Eave Struts: These horizontal members connect columns at the eave level, providing extra support and stability.
- Cleats: These small steel plates connect secondary framing components like purlins and girts to the primary frame, ensuring a secure and stable structure.
Accessories
These members improve the functionality and durability of the PEB:
- Ventilators: These replace contaminated indoor air with fresh outside air.
- Paints and Finishing: Manufacturers use modern high-speed coil painting lines to produce pre-painted steel, ensuring optimal surface preparation, paint application, and curing.
- Crane System: This system facilitates lifting and moving heavy objects within the building.
- Mezzanine Floors: These create additional usable space within the building.
- Bolts: Workers use bolts to connect various PEB components, ensuring structural integrity.
- Insulation: This improves energy efficiency and thermal comfort.
Advantages of pre-engineered buildings in manufacturing
Cost Effectiveness
One of the main benefits of PEBs is that they are cost-effective. Traditional construction involves expensive material costs, labour expenses, and prolonged construction times which can escalate the budget. The design, manufacturing, and erection are reduced because we use standard sections and connections. CAD/CAM processes are used to design and produce structural components with a high strength-to-weight ratio, minimising raw material costs and waste, resulting in lower construction times by more than half due to reduced construction time and skill required. PEBs are 20% more cost-effective than traditional buildings.
Quick assembly
PEBs are made from pre-fabricated components and are manufactured in a controlled factory setting. The components need to be assembled on-site. Traditional construction is tedious including site preparation, foundation work, structural elements, and finishing work. With PEB buildings, a small shed can take days to build. The speed of construction is 40% faster than that of traditional buildings.
Flexibility and scalability
re-engineered steel buildings are inherently versatile, designed for easy and economical modifications before, during, and after construction to accommodate various expansions. Typically, expanding a PEB involves removing one end of the building, erecting a new framework, and adding a matching roof and wall panels. Despite common misconceptions, PEBs offer significant design flexibility. We can customise PEBs to meet the unique requirements of different projects, thanks to advanced computer-aided design (CAD) software that enables intricate designs while maintaining structural integrity. PEBs are up to 80% more flexible than traditional buildings
Low maintenance
PEBs are made from high-quality steel. This makes them robust and capable of handling different operating conditions. They are low maintenance when compared to other materials like wood and concrete. This translates to long-term saving
Durability
Steel is one of the strongest materials available boasting the highest strength-to-weight ratio of any construction material—approximately 25 times greater than wood. Interesting steel frames are lighter than wooden frames. Steel can withstand extreme weather conditions such as strong winds, cyclones, rainfalls, and earthquakes. Steel is also not vulnerable to terminates, creepings, cracks, splitting, rotting, or fire. Metal building structures are often treated with special coatings like galvalume, which protect the paint and surfaces from rust. Reputable manufacturers usually provide extended warranties on their paint and coatings lasting decades.
Sustainability
Steel can be a sustainable choice. Steel is recyclable, and PEBs often require less material compared to conventional structures.
Case Studies
Project Name: PGP Glass (J-266) A Towering Achievement in PEB Construction
PGP Glass (J-266) is a stunning example of innovative and precise Pre-Engineered Building (PEB) construction. This 30-meter-tall masterpiece is a testament to our dedication, teamwork, and relentless pursuit of excellence. It’s more than just steel and concrete and is a symbol of our commitment to pushing boundaries and reaching new heights.
Overcoming Challenges
The project presented several challenges: geographical limitations, space constraints, and the ambitious height target.
Building Success Through Collaboration
Through clear communication and strong teamwork, we successfully navigated these obstacles.
A Lasting Legacy
PGP Glass (J-266) is not just a structure; it’s a landmark that will inspire future generations.
Project Name: VBL, Kota, Project Overview 61,000 Sq.m
The PEB (Pre-Engineered Building) project by Arcedges for Varun Beverages Ltd. (VBL) in Kota, Rajasthan, was a landmark endeavour in expanding VBL’s production capabilities. This ambitious project faced numerous challenges during its execution. Below is an overview of the primary challenges encountered and the solutions implemented to address them:
Regulatory Compliance and Approvals
Challenge:
Navigating through a complex regulatory framework required for such a large-scale industrial project was daunting. The project needed approvals for environmental clearances, construction permits, and operational licenses, all of which involved rigorous scrutiny from various government bodies.
Solution:
Arcedges and VBL set up a dedicated team to handle regulatory compliance. This team worked closely with local and state authorities to ensure all necessary permits were secured promptly. They employed consultants to streamline the documentation process and ensure adherence to the latest regulatory requirements, thereby mitigating potential delays.
Supply Chain Disruptions
Challenge:
The global pandemic caused significant disruptions in the supply chain, affecting the timely procurement of critical materials like steel, which is essential for PEB structures.
Solution:
To counteract these disruptions, Arcedges diversified its supplier base and established relationships with multiple vendors to ensure a steady supply of materials. They also implemented just-in-time inventory management to reduce the impact of supply delays and adjusted project schedules to accommodate material availability.
Labour Shortages and Management
Challenge:
The pandemic led to a shortage of skilled labour as many workers returned to their hometowns. Ensuring the health and safety of the workforce on-site was also a significant concern.
Solution:
Arcedges introduced robust health and safety protocols, including regular health screenings, provision of PPE, and enforcing social distancing measures. They also offered incentives to retain and attract skilled labour and invested in training programs to upskill the available workforce, ensuring the project could continue without significant interruptions.
Technical and Engineering Complexities
Challenge:
PEB construction requires precise engineering and alignment of pre-fabricated components. Any inaccuracies in the design or assembly could result in structural issues or delays.
Solution:
Arcedges leveraged advanced design software and technologies for precise engineering and 3D modelling to pre-visualize the assembly process. They conducted rigorous quality checks and coordinated closely with on-site teams to ensure that all components were manufactured and assembled to exact specifications. Regular on-site inspections helped identify and rectify any issues early in the construction process.
Environmental and Sustainability Concerns
Challenge:
The project needed to adhere to strict environmental standards, which included minimizing the ecological footprint and incorporating sustainable practices.
Solution:
Arcedges implemented several green initiatives, such as integrating energy-efficient systems, rainwater harvesting, and waste recycling practices into the project design. They also used eco-friendly construction materials and adhered to sustainable building practices to reduce the environmental impact of the construction activities.
Financial Constraints and Investment Risks
Challenge:
The financial implications of the project were significant, especially during the economic uncertainty caused by the pandemic. Managing the budget while maintaining high standards was crucial.
Solution:
Arcedges and VBL conducted thorough financial planning and risk assessments to ensure the project stayed within budget. They implemented cost-saving measures without compromising on quality and closely monitored expenses throughout the project. Regular financial reviews helped them stay aligned with their budgetary constraints.
Community and Stakeholder Engagement
Challenge:
Engaging with the local community and addressing their concerns related to environmental impact, land use, and employment were crucial for the smooth execution of the project.
Solution:
Arcedges and VBL maintained transparent communication with local stakeholders, including community leaders and residents. They organized regular meetings to address concerns and provide updates on the project’s progress. Additionally, they prioritized hiring from the local workforce, thus fostering goodwill and reducing potential conflicts.
Logistical Challenges
Challenge:
Transporting large pre-engineered components to the site in Kota required careful planning to avoid damage and ensure timely delivery.
Solution:
Arcedges developed a detailed logistical plan that included route planning, securing necessary transportation permits, and coordinating with local authorities to facilitate the movement of oversized loads. They employed specialized transport vehicles and techniques to handle large and heavy components safely and efficiently.
Conclusion
Despite these challenges, the successful completion of the PEB project by Arcedges for VBL in Kota is a testament to their meticulous planning, problem-solving capabilities, and effective execution. The new facility not only boosts VBL’s production capacity but also sets a benchmark for future PEB projects in the region.
Venwiz and Arcedges Building INDIA LLP: A Partnership for PEB Structures
Venwiz, India’s leading digital platform for industrial service discovery and procurement, and Arcedges Building India LLP, a prominent PEB (pre-engineered building) solutions provider, join forces to empower businesses. Venwiz’s strength lies in its comprehensive database of over 25,000 pre-vetted vendors, making it easier for businesses to find the right partner for their PEB needs. Through Venwiz’s user-friendly platform, companies can efficiently connect with PEB specialists like Arcedges Building India LLP.
About Arcedges Building INDIA LLP
Arcedges Building (India) LLP is a prominent player in the PEB (pre-engineered building) turnkey solutions market across India. Established in 1988, their journey began as a consulting firm. In 2016, they took a strategic leap by setting up their first manufacturing plant with a capacity of 50,000 metric tons per annum. Their commitment to quality is reflected in their ISO 9001:2015 accreditation.
Arcedges Building designs manufactures, and installs high-quality pre-engineered buildings that meet international standards. Their manufacturing facility is strategically located in Himmatnagar, Gujarat, approximately 100 kilometres from Ahmedabad.
In a brief period, they have undertaken projects across India and even ventured into exports to the African continent. Their impressive clientele list includes companies from China, Germany, Japan, America, and Britain.
Process and equipment
- SSR Lifting Machineries
- 360° Standing Seam Machineries
- OXY-FUEL & Plasma Cutting
- Shearing Machineries
- Plate Joining with 5’M Width
- Shot Blasting with 8 Blasting Heads/12M Conveyer
- H-Beam Welding line with hydraulic straightness (3M)
- H-Beam Welding line with hydraulic straightness (2M)
- C-Z Inter-Changeable, Double Layer Roll Forming
- C-Frame Press
- Threading Machine
- 5-Axis CNC Break with Auto Crowning
- Hydraulic Decoiler
Quality checks
Arcedges Building’s carry out vigorous testing at every stage of manufacturing. Some of the quality equipment and testing include:
- Hardness Testing Machine
- GSM Testing
- Ultrasonic Testing
- DFT (Dry Film Thickness) Testing
- SA (Surface Appearance) Testing
- DP (Destructive Pull) Testing
- Elongation Testing
…and many more testing equipment
Successful projects
| S.no | Client name | Industry/Sector | Project description |
|---|---|---|---|
| 1 | Varun Beverages Limited, Jabalpur | FMCG and Beverages | Area: 27,870.16 m² |
| 2 | Varun Beverages Limited, Gorakhpur | FMCG and Beverages | Area: 1,00,000 Sq.m. |
| 3 | Pidilite Grupo Puma Manufacturing Ltd | Architecture, Urban | Area: 3297.5 Sq.M |
Guest Author
Mr. Mahendra Singh is the CEO of Arcedges. He has over two decades of experience in PEB & steel structures. He has worked with leading companies across functions of project management, sales & key account management. A rich experience of domestic & international projects at his side Mahendra brings valuable expertise in managing the overall operations at Arcedges. He is a civil engineering graduate & known for bringing technical solutions to any challenging situation out of his knowledge & experience of erection, project management & technical sales.
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Further reading
