PEB Segment Requirements

Contents

1 What is a PEB?

2 PEB Structures, Applications & Advantages

3 Steel Grades used in PEB

4 HR Plate Processing & TPR (at customer & SPC)

5 Manufacturing of Secondary Components (GP)

6 Testing of PEB Structure

7 Journey So Far (TSJ) and TSK Trial Update

8 Competition Update
9 Future Trends & Disruptions
2
What is a PEB?
Steel: PEB is a pre fabricated structure of a bulding designed over a structural
concept of primary and seconday member, roof, purlins, wall and decking sheets
to form a housed building. PEBs are used for efficient and ecomonical strutures.
They are designed to be light and sturdy at the same time.

*Source: Loya PEB Brochure

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Major Strcutures in a PEB

Major Structures (Primary structures):-

• Columns
• Rafters
• H & I beams
• Crane supporting system
• Angles/ Base Plates/Channels / Bolts
and Fasteners

Support Structures (Secondary

structures):-
• Purlins
• Gutters / Eave Struts
• Side supports
‘Z’ & ‘C’ Purlins
• Claddings, decking sheets
• Roof panels / sheetings

Beams & Columns

*Source: Loya PEB Brochure

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What constitutes a PEB?

Hot rolled plates, sheets

Galvanised (ZS/RS) Sheets of 350 MPA Strength
Pre-painted galvanisged Sheets, coils
Misc (GI and PPGI)

CKD : Complete Knock-down (last process of assembly)

5
Types of Frames used in a PEB

6
Applications

COMMERCIAL OFFICE

INDUSTRIAL AND PROCESSING PLANTS

POWER AND ENERGY

WAREHOUSE

CAR PARKING

RESIDENTIAL

MALLS AND CITY CENTERS

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Advantage of using PEB

The most notable advantages of Pre engineered buildings are :

• Economical & Robust construction
• Fast construction time
• Low maintenance cost
• Infinite choice of layout
• Earth quake resistance
• Ease of future expansion
• Unique aesthetic appeal
PEB is ecomonical and with less weight
• Large clear spans
• Thermal insulated and energy efficient
• Reusability of steel at the end of life cycle.

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 Pre-Engineered Building Vs Conventional buildings

Parameter Pre-Engineered Buildings Conventional Buildings

Each conventional steel structure is
Quick and efficient since standardization of pre-engineered designed from scratch by the consultant,
Design
steel buildings has significantly reduced design time with fewer design aids available to the
Engineer

Weight About 30% lighter through the efficient use of steel More Weight than PEB

Rigid Building pre-engineered steel buildings system uses

Base Material Different Materials used.
almost all steel to meet 50,000 P.S.l. minimum yield.
Foundation Simple design, easy to construct and lightweight Extensive heavy foundation required.

Designed to fit the system, with standardized, interchangeable Every project requires special design for
Accessories (Windows, Doors,
parts, including pre-designed flashing and trims. Mass accessories and special sourcing for each.
Ventilation
produced for economy. Unique fabrication required.

Slow, extensive field labor required.

Easy, fast, step by step. Erection costs and time are
Erection Typically 30% more expensive than pre-
accurately known.
engineered steel buildings.
Outstanding architectural design can be achieved at low cost. Special architectural design requires
Architecture Conventional wall and fascia materials, such as concrete, research and high cost.
masonry and wood, can be utilized.
Delivery 4 - 6 weeks More time than PEB's.
Price per square meter may be as much as 40% lower than
Price High price per square meter.
conventional steel.
Building is supplied complete with cladding and all
Many sources of supply. Required to co-
Sourcing accessories, including erection if required, all from one source
ordinate suppliers and sub-contractors
of supply as Buildings.
Very flexible, tailor made, accepts changes and revisions Changes, revisions and additions can be
Changes on future Needs
easily. Future expansion simple, easy and cost effective difficult due to extensive redesign

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Steel Grades Used in PEB
Hot Rolled Steel:
A typical PEB structure uses hot rolled steel from 4-25 mm thickness in 1500 & 2000 mm
widths. Length may vary from 6 m to 12 m depending of the bed size of the gas / plasma
cutting machine of the customer. Typical grades used are ASTM A572 Gr 50 (Type 1 and 2)
along with IS 2062 E350 A.

Galvanised Steel:
Galvanised steel (PPGI and GP) is used for purlins / gutters / roof panels / decking sheets
from 0.8 to 2.5 mm thickness in slit coil widths as per customer requirements. Zn coating
weights vary from Z120 to Z275 depending on the end customer PEB design.

HR Plates for PEB Purlins - GP

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PEB – HR Plate Processing (1/2).
A typical PEB HR plate process map is shown below.

Critical Parameters for Steel

• Flatness after plasma/gas torch
cut(refer next slide)
• Dimensions
• Thickness Tolerances
• Yield Strength
• CEq as per IS standard for welding

*Source: TBSL Document 11

PEB – HR Plate Processing (2/2)
Gas Torch cutting Submerged Arc Welding Shot Blasting

Gas Torch Cutting (No Bow) SAW Welding of Web and Flange Shot Blasting

Gas Torch Submerged

Tack Welding Piercing
cutting Arc Welding

Quality check
Shot Blasting
and dispatch

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PEB - Tech process requirements (1/2)
To meet strict requirements of PEB segment. Thickness / customer specific TPR
Development is a must for all Tata Steel SPC (Steel Processing Centre). A sample flatness
requirement of PEB HR Plates is shown below.

*Source: TBSL TDC and TPR Document

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PEB - Tech process requirements (2/2)
To meet strict requirements of PEB segment. Thickness / customer specific TPR
Development is a must for all Tata Steel SPC (Steel Processing Centre). A sample flatness
requirement of PEB HR Plates is shown below.

Critical shape related parameters:

• Cross bow : 3 mm / metre width (i.e; 6 mm max for 2m wide plates)

• Camber : 2 mm / m in mill edge supplied sheets
• Flatness / Longitudinal Bow:

• After gas torch cutting / plasma cutting : Bow after cutting is critical.

*Source: MB Phenix TDC

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Process of PEB - HR Plate Processing at SPC

Critical Quality Checks at SPC

o Slit bow test (to check for flatness / bow in sheets)
o Leveller calibration from time to time to ensure processing with minimal residual stress.
o Presence of a crown kill roll in the CTL machine
o Packing of HR Plates (minimum 700 mm distance between wooden dunnages)

Warpage Measurement at SPC

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Manufacturing Process secondary components (Purlin channels )

RM (Mostly in Slit Roll press and

Roll forming Unit
coil form) working rolls

Pressing and
forming through Punching as per the
Quality check and
Working roll as per CNC data and moved
dispatch
the profile required out of the roll forming
( Z or C)

16
Manufacturing Process secondary components (Roofing sheet)

PPGI Coil (Mostly in Slit coil form) Roll forming Unit

Roll press and working rolls &

Quality check and dispatch
punching

Roofing Sheets

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 Testing of a PEB Structure

PEB Structures (Web & Flanges) are tested for integrity of plate & welds as below:

As per AWS D1.1

• Ultrasonic testing (sample inpection)

• Weld DP testing
• Visual inspection

All the tests are done in presence of the end client.

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 Critical Customer Requirements - HR
• Grade : ASTM A572 Gr 50 and IS 2062 E350 A and C
• Thickness Tolerance on the negative side
1. Most customers want lower side thickness upto -0.3 mm (as per ASTM)
2. For thicker plates > 12 mm a positive tolerance is accepted upto +0.3 mm

• Shape Tolerances
1. Cross bow and Longitudinal Bow is critical to ensure good shape of sheets after
plasma cutting. Most customers demand 6 mm max cross bow across width & long
upto 15 mm in most cases.
2. Camber in mill edge sheets of 1.5 mm / m to ensure not half plasma cut sheets.
3. Minimal residual stress after levelling is necessary.

Cross bow in CTL Plate

Warpage (bow) after plasma/gas cut
Convex Bow in Coil
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TSPDL TSK Trial : 20 mm x 1800 mm

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TSPDL TSK Trial : Customer end processing

• Customer used 2 plates and cut 350 mm and 400 mm webs from the plate
• Oxy acetylen flame torch cutting was used (multi torch)
• Full plate of 12 m was cut in a single gas cut and no significant bow was observed.
• Picture shows the pictures taken during trial

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 Competition Scenario in West

• ESSAR
1. Supplies from HSM & Plate mill route
2. UT tested plates are supplied for > 16 mm (if customer desires)
3. Grades are mostly peritectic with Type 1 & Type 2 alloying.
4. Offers dual certification in TCs – both IS 2062 E350 & ASTM A572 gr 50

All plates are levelled and cut at their Hazira Unit.

• JSW Bellary
1. Supplies from HSM-2 mill
2. Supplies in peritectic Type 1 alloying

All plates are levelled and cut at their Bellary Unit. JSW used to cut plates at SKM Taloja as
well but discontinued the practice since last 8-10 months.

• JSPL Raigarh
1. Supplies material in plate from from their plate mill.
2. Mostly supplied in 2500 mm widths in thicker sections (> 16 mm) & UT tested

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 Future Trends in PEB Market

Case Study: Use of high strength steels for steel structures.

• Gr 70 (490 Mpa) steel usage in place of Gr 50 (345 Mpa steel) in steel structures of a high
rise building in Mexico City.
• Possible to have material and weight saving upto 14-20% in steel structures if Gr 70 is
used in place of Gr 50 by reducing the effective lengths of the columns.
• CO2 emissions can be reduced, by using lower amounts of steel and lighter sections.
• Not all structures of a building can be converted to Gr 70 (due to design constraints)
although it is possible to reduce thickness & weld lengths in Gr 70.

*Source: DESIGN OF REFORMA 509 WITH HIGH STRENGTH STEEL

(Stuart Smith et al;)

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 Disruptive Technologies – 3D printing

Advantages:
• 3D printing is done using super-size printers which use a special concrete and composite
mixture that is thicker than regular concrete, allowing it to be self-supporting as it sets.
• Do not have same constraints as conventional construction methods.
• Can be hollow, created space for building services inside the structure.
• Low cost of labor, on site construction printing and assembly.
• Customised design.

Challenges:
• Currently more expensive than current construction methods.
• Printers are large and difficult to place at site.
• Only a limited type of materials, composites have been tried.

Chinese Company, Wunsun, claims it built 10 houses in a day for $5,000 per house.

http://www.huffingtonpost.in/entry/3d-printed-houses_n_5773408

Video: 3D printing disruptive technology.

*Source: ConstructionPROS.com

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THANK YOU!

25
BACK UP

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Customer Requirements – West (Major Customers)
Parameter Zamil TBSL Phenix Loya PEB Everest
Grade ASTM A572 Gr ASTM A572 Gr 50 ASTM A572 Gr 50 IS 2062 E350 IS 2062 E350
50 Type 1 & 2 Type 1 & 2 Type 1 & 2
Yield Strength 345-400 MPa 345 MPa Min 350 MPa Min 350-410 Mpa 350 Mpa min
Tensile Strength 450 Mpa min 450 Mpa Min 490 Mpa Min 490 Mpa min 450 Mpa min
Potential 1800 500 2500 350 1250
(t/month)
Flatness Critical Critical Critical Critical Critical
Thickness -0.3 mm / +0 mm -0.3 mm / 0.5 mm -0.3 mm / + 0.2 -0.3 / +0.2 mm As per IS
Tolerance mm
Dual Yes No Yes No No
Certification
(both ASTM and
IS reqd onTC)
Camber 2 mm / metre 2 mm / metre 1.5 mm / metre 2 mm/ metre --
Out of 1% of width max 1% of width max 1.5 mm / m of 1% of width max 1% of width
Squareness width

Surface As per TPR As per TPR As per TPR As per TPR As per TPR
Width / Length +20/-0 mm +20/-0 mm +20/-0 mm +20/-0 mm +20/-0 mm
+5 / - 0 mm +5 / - 0 mm +5 / - 0 mm +5 / - 0 mm +5 / - 0 mm

*Zamil Steel requires lower YS material (345-400 Mpa); We have guaranteed 345-450 MPA
*Source: Customer visits / DPCRs / Customer TDC Documents 27
Customer Requirements (GP)–West (Major Customers)
Parameter Zamil TBSL Loya PEB Everest
Grade ASTM A 653 ASTM A 653 S350 Class ASTM A 653 S350 ASTM A 653 S350
S350 Class 1 1 Class 1 Class 1
Yield Strength 350 Mpa min 350 Mpa min 345 Mpa min 350 Mpa min

Tensile Strength 450 Mpa min 450 Mpa Min 450Mpa Min 450 Mpa min

Coating Type RS / ZS both OK RS / ZS both OK RS Only --

Coating (GSM) Z120 & Z275 Z120 to Z275 275 275

Thickness Tolerance -0.1/+0 mm +/- 0.04 mm A s per IS As per ASTM

Width Tolerance As per TPR As per TPR +1 mm / -0 mm

Telescopicity 5 mm max 5 mm max -- --

Packing Prefers eye to Prefers eye to sky -- --
sky
Surface As per TPR As per TPR As per TPR As per TPR
Width +1/-0 mm +2/-0 mm +1/-0 mm +1/-0 mm

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Customer Requirements – North (Major Customers)
Parameter Interarch Kirby Richa Jindal Everest Modern

Grade ASTM A572 ASTM A572 Gr ASTM A572 Gr ASTM A572 Gr ASTM A572 Gr ASTM A572 Gr
Gr 50 Type 1 50 Type 1 & 2 50 Type 1 & 2 50 Type 1 & 2 50 Type 1 & 2 50 Type 1 & 2
&2
Yield 345 min 345 MPa Min 345 MPa Min 345 MPa Min 345 MPa Min 345 MPa Min
Strength
Tensile 420 Mpa min 450 Mpa Min 450Mpa Min 450 Mpa min 450 Mpa min 450 Mpa min
Strength
Flatness Critical Critical Critical Critical Critical Critical

Thickness -0.3 mm / +0 -0.15/+0.15 mm -0.3 mm / +0 As per ASTM As per ASTM As per ASTM
Tolerance mm mm
Dual No No Yes No No No
Certification
(both ASTM
and IS reqd
onTC)
Out of 1% of width 1% of width max 1% of width 1% of width 1% of width --
Squareness max max max

Surface As per TPR As per TPR As per TPR As per TPR As per TPR As per TPR
Width / +20/-0 mm +20/-0 mm +20/-0 mm +20/-0 mm +20/-0 mm +20/-0 mm
Length +10 / - 0 mm +10 / - 0 mm +10 / - 0 mm +10 / - 0 mm +10 / - 0 mm +10 / - 0 mm

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Customer Requirements (GP)–North (Major Customers)
Parameter Interarch Kirby Richa Jindal Everest

Grade ASTM A 653 class ASTM A 653 class ASTM A 653 class ASTM A 653 class ASTM A 653 class
50 50 50 50 50
Yield Strength 350 Mpa min 350 Mpa min 345 Mpa min 350 Mpa min 350 Mpa min

Tensile 450 Mpa min 450 Mpa Min 450Mpa Min 450 Mpa min 450 Mpa min
Strength
Coating (GSM) 275 275 275 275 275

Thickness As per ASTM -- A s per IS -- As per ASTM

Tolerance
Surface As per TPR As per TPR As per TPR As per TPR As per TPR
Width +1/-0 mm +2/-0 mm +1/-0 mm +1/-0 mm +1/-0 mm

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Customer Requirements – South (Major Customers)
Parameter Nikitha Alpha Karthik Roofings PEB Structural Raksga Engg
Industries
Grade ASTM A572 Gr ASTM A572 Gr 50 ASTM A572 Gr 50 IS 2062 E350 ASTM A572 Gr 50
50 Type 1 & 2 Type 1 & 2 Type 1 & 2 Type 1 & 2
Yield Strength 345-400 MPa 345 MPa Min 350 MPa Min 350-410 Mpa 345 MPa Min

Tensile Strength 450 Mpa min 450 Mpa Min 490 Mpa Min 490 Mpa min 450 Mpa Min

Flatness Critical Critical Critical Critical Critical

Thickness -0.3 mm / +0 mm -0.3 mm / 0.3 mm -0.3 mm / + 0.2 -0.3 / +0.2 mm -0.15/+0.15 mm

Tolerance mm
Dual No No No No No
Certification
(both ASTM and
IS reqd onTC)

Camber 3 mm / metre 3 mm / metre 3 mm / metre 3 mm/ metre 3 mm/ metre

Out of 1% of width max 1% of width max 1% of width max 1% of width max As per TPR
Squareness
Surface As per TPR As per TPR As per TPR As per TPR +20/-0 mm
+10 / - 0 mm
Width / Length +20/-0 mm +20/-0 mm +20/-0 mm +20/-0 mm ASTM A572 Gr 50
+5 / - 0 mm +5 / - 0 mm +5 / - 0 mm +5 / - 0 mm Type 1 & 2

*Source: Customer visits / DPCRs / Customer TDC Documents 31

PEB Segment – Specific TDCs

Grade HSM TSCR TSK Thick Range Width range Vertical

TDC TDC TDC

HG13 HG13 5-7.99 mm 900-1500 mm IPPE

(upto
10
mm)
ASTM A572 Gr 50 Type 1 HG27 - - 8.0-12.0 mm 900-1500 mm IPPE

HG14 HG14 - 2.5-4.99 mm 900-1500 mm IPPE

- HR34 - 2.5-4.99 900-1500 mm BPRS

- HR35 - 5.0-10.0 mm 900-1500 mm BPRS

HG16 HG16 HG16 5-7.99 mm 900-1500 mm IPPE

(TSK 2050 mm*)
ASTM A572 Gr 50 Type 2
HG24 HG19 HG19 8.0-12.0 mm 900-1500 mm IPPE
(TSK 2050 mm*)
- - HM79 12.01-16 mm 900-2050 mm IPPE

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 Competition Scenario in West

• ESSAR Mill TCs (Type 2)

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