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PLANT LAYOUT

ASSIGNMENT 2
SHAHI EXPORTS PVT. LTD.

SUBMITTED BY:

SUBMITTED TO:

MD SHAD ANWAR

MR. RAMMOHAN

SYMPHONY SATPATHY
TYPES OF INDUSTRIAL SHEDS
The different types of shed are as follows:
Cold Roll Formed Portal Frame Shed

The cold rollformed portal frame shed is the most common type of pre-engineered shed. It usually arrives
as a kit, and the builder assembles it on your property. The main structure of this kind of shed is called the
portal frame. It contains rolled purlins, batton, girts, brackets, and top hat. All types of cold rollformed
portal frame sheds have common cladding and flashings.
In a cold rollformed portal frame shed, the rafters and columns contain purlins which consist of cold rolled
C section. The purlins are connected by fabricated brackets which bolt the assemblies together. Once the
portal frames are stood, the wall and roof members are added.
The main advantages to this type of shed,

Is that it is extremely efficient,


can be easily transported, and
can be put together onsite without a lot of specialized equipment.

Structural Fabricated Steel Shed

A structural fabricated steel shed is similar to the cold roll formed portal frame shed.
The rafters and columns are welded sections such as I beam, H Section, or C channels, and the
ends all have welded cleats and joiners.

This design is for larger sheds and industrial applications. It is extremely popular for warehouses

over 18 metres in width.


Structural steel is very heavy, and requires heavy equipment to assemble. The assembly is fast as
the steel is predrilled and bolts together easily, and the sheds are extremely strong.
Prefabricated Factory Shed

Prefabricated Factory Shed is widely used as a temporary structure for catering various on-site
requirements. Constructed in accordance with industry standards using light weighted well insulated
panels, this factory shed is completely protected from earthquake, adverse weather conditions and any
kind of leakage. With highest structural ability, these are properly insulated with polyurethane/EPS to
restore heat during winter and resist heat during summer time.
Features of Prefabricated Factory Sheds:

Highly appreciated for their excellent aesthetics


Completely protected from natural disasters
Easy to transport due to their light weight
Constructed using well insulated panels

Used for:

Warehouse
Fully equipped kitchen
Manufacturing unit
Warehouse Shed

Warehouse Shed is the ultimate solution for urgent needs of stacking and storage. Best suited for onsite
locations in both cold and hot regions, it is designed and developed in compliance with predefined industry
standards. Moreover, it is manufactured with insulated panels for comfortable temperature inside. Easy to
transport and lift, this, Warehouse Shed does not require any civil foundation and can be placed directly
on targeted site.
Features of Warehouse Sheds:

Leak- proof and can be easily lifted and shifted


Excellent structural stability
Can sustain adverse weather conditions
Best suited for hot and cold regions
Ready to move in structures
No foundation required for construction
Easy to install safety products like smoke detectors and firefighting equipment
Quick to assemble and dismantle

Used for:
Warehouses
Industrial manufacturing unit
Temporary accommodation
Application areas:
Rural development projects
Large scale construction projects
Manufacturing industries

Box Type Sheds

These industrial sheds are constructed using PUF(Polyurethane Foam) / EPS(Expanded Polystyrene
Foam) insulated sandwich panels with PPGI (Pre-Painted Galvanized Iron )sheet.
Features:

These are ready to move in structures.


Constructed using excellent thermal insulation for effective thermal efficiency.
Completely protected against weather conditions, corrosion and other environment conditions.
These structures are light in weight and thus, easy to relocate and lift to any location.
Designed with insulated doors and all other requisite facilities.
Provided with complete electrical and sanitary fittings.

Metal sheds

A corrugated iron shed. Metal sheds are made from thin sheet metal sheathing (galvanized
steel, aluminium , or corrugated iron) attached to a metal frame. Metal sheds are a good choice when
long-term strength and resistance to fire, rot, or termites is desired. However, metal sheds may rust over
time, particularly if they are constructed from steel that is not galvanized. Since concrete is highly
corrosive so care needs to be taken when assembling your shed to avoid contact with the outside panels.
As well, some types of metal sheds that have thin walls are easily dented, which may makes some types
of thin metal sheds a poor choice for vandal-prone areas or for high-traffic activities such as small
businesses.
In cold climates, metal sheds with thin walls need to have snow and ice cleared from the roof, because the
thin metal may be damaged by a heavy accumulation. Since thin metal sheds weigh much less than wood
or PVC plastic sheds, thin metal sheds are more at risk of being damaged by heavy winds. To prevent
wind damage, thin metal sheds should be attached to a concrete foundation with screws.
In countries where the climate is generally mild, such as Australia, very large metal sheds are used for
many types of industry.
Plastic sheds

Lifetime blow-molded plastic sheds. Plastic shed kits utilizing heavy molded plastics such

as PVC and polyethylene are less expensive than sheet-metal sheds.


PVC resins and high-impact, UV light-resistant polyethylene make plastic outdoor sheds stronger,
lighter, more durable, and more resistant to denting and chipping than wood, and tend to be more

stable.
Plastic shed kits sided with vinyl are typically among the least-expensive types of shed

construction.
Higher-quality sheds use UV-resistant plastic and powder-coated metal frames. Many plastic sheds
are modular to allow for easy extensions, peg-boards, shelving, attic-storage, windows, skylights,

and other accessories to be added later.


Plastic sheds are not susceptible to termite or wood-boring insect damage, and they require little
maintenance. Being rot-proof they do not need to have preservative applied.

Vinyl-sided sheds

An Amish-style vinyl-sided shed. Vinyl-sided sheds are typically built with standard wood framing
construction and oriented strand board (OSB) on the walls covered with standard vinyl siding. Vinyl-sided
sheds never need to be painted, and are maintenance-free. They are stronger than plastic or metal sheds,
and are usually built to conform with the local building codes. They offer good value for money because
they hold up in all weather, including winters with heavy snowfall. Metal, plastic and resin sheds are
cheaper, but they cannot handle the weight of snow in winter (roof caves in). Vinyl sheds also offer the
most colour options.

Industrial buildings are generally designed as enclosures that provide functional space for internal
activities, which may involve use of overhead cranes or suspended equipment as well as provision of
office space or mezzanine floors. Various structural forms have been developed over the last 30 years that
optimize the cost of the steel structure in relation to the space provided. However, in recent years, forms
of expressive structure have been used in architectural applications of industrial buildings, notably
suspended and tubular structures.
A single large hall is the main feature of most industrial buildings. The construction and appearance of an
industrial building provides the design engineer with a wide range of possible configurations in order to
realize the architectural ideas and the functional requirements. Generally, an industrial building has a
rectangular floor space, which is extendable in its long direction. The design of the building has to be
coordinated with functional requirements and the energy-saving concept, including lighting.
The following forms of industrial buildings represent an overview of the possible architectural and
constructional solutions. Exhibition halls, railway stations, airports and sports arenas tend to be special
structures. However, the following general issues are restricted to standard floor plans.
DIFFERENT COMPONENTS OF AN INDUSTRIAL BUILDING
The structural engineer has to consider the following points during the planning and design of industrial
buildings:

Selection of Roofing and wall material


Selection of bay width
Selection of structural framing system
Roof trusses
Purlins, girts and sag rods
Bracing systems to resist lateral loads
Gantry girders, columns, base plates, and foundations

Roofing and wall material


In India, corrugated galvanized iron (GI) sheets are usually adopted as coverings for roofs and sides of
industrial buildings. Light gauge cold-formed ribbed steel or aluminum decking can also be used.
Sometimes asbestos cement (AC) sheets are also provided as roof coverings owing top their superior
insulating properties.
Bay width
In most cases, the bay width may be indicated by owner requirements. Gravity loads generally control the
bay size. Based on both strength and stiffness (L/180) requirements, the maximum economical span is
9m.

Structural Framing
For the purpose of structural analysis and design, industrial buildings are classified as:

Braced frames
Unbraced frames

In braced buildings, the trusses rest on columns with hinge type of connections and the stability is
provided by bracings in the three mutually perpendicular planes. These bracings are identified as follows:

Bracings in the vertical plane in the end bays in the longitudinal direction
Bracings in the horizontal plane at bottom chord level of the roof truss
Bracings in the plane of upper chords of the roof truss
Bracings in the vertical plane in the end cross sections usually at the gable ends

Purlins, Girts and Eave strut


Secondary structural members such as purlins and girts span the distance between the primary building
structures portal frames or truss-column system). They support the roof and wall covering and distribute
the external load to the main frames or trusses. Purlins form a part of the roof bracing system and girts are
a part of the wall bracing system of the building. The third type of secondary structural member is the
Eave strut. This member is located at the intersection of the roof and the exterior wall and hence acts as
both the first purlin and the last (highest) girt. The buildings eave height is measured to the top of this
member.
Spacing of Purlin
The spacing of the purlins largely depends on the maximum safe span of the roof covering and glazing
sheets. Hence they should be less than or equal to their safe spans when they are directly placed on
purlins.
Plane Trusses
A structure that is composed of a number of line members pin-connected at the ends to form a
triangulated framework is called a truss. In a truss, the members are so arranged that all the loads and
reactions occur only at the joints (intersection point of the members). For common trusses with vertically
acting loads, compressive forces are usually developed in the top chord members and tensile forces in the
bottom chord members. However, it is often necessary to design the various members of a truss both for
tension and compression and select the member size based on the critical force.

Spacing of trusses
The spacing of trusses is mostly determined by the spacing of supporting columns which in turn is
determined by the functional requirements. When there are no functional requirements, the spacing
should be such that the cost of the roof is minimized. It can be shown that an economic system is
obtained when the cost of trusses is equal to the cost of roof covering plus twice the cost of purlins. i.e.
Ct = Cr + 2Cp
Where,
Ct = Cost of the trusses/unit area
Cr = Cost of the roof coverings/unit area
Cp = Cost of the purlins/unit area
Load Combinations for Design
For shed type buildings, the following combinations of loads are considered when there is no crane load:

Dead loads + imposed loads (live loads)


Dead loads + snow loads
Dead loads + wind loads (wind direction being normal to ridge or parallel to ridge whichever is

severe)
Dead loads + imposed loads + wind loads (which may not be critical in most of the cases)

The 3rd combination is considered with internal positive air pressure and internal suction air pressure
separately to determine the worst combination of wind load.
FORMS OF INDUSTRIAL BUILDINGS
The most elementary system used for an industrial building consists of two columns and a beam. This
configuration can be modified in numerous ways using various types of connections between the beams
and columns and for the column base. The types of structures most commonly used in industrial buildings
are portal frames with hinged column bases.
Portal frames provide sufficient in-plane stability, and thus only require bracings for out-of-plane stability.
The figure shows a variety of rigid frames with fixed (a) or hinged (b) column bases.

Fixed column bases may be considered when heavy cranes are used, as they deflect less under
horizontal forces. Hinged column bases have smaller foundations and simple base connections. In
examples (c) and (d), the structure is located partly outside the building, and so details concerning the
piercing of the building envelope have to be designed carefully. The complex details in these types of
structure also serve architectural purposes.
In the second figure, different structures consisting of beam and columns are presented.

The figure (a) shows an example of a structure without purlins that is stiffened by diaphragm action in the
roof and bracings in the walls. In Figure (b), purlins are used, leading to a simple design of the roof
cladding, which has reduced spans and only serves to support vertical loads. The roof is stiffened by plan
bracing. The structure without purlins may offer a more pleasant appearance when viewed from the inside.
Figures (c) and (d) show lattice trusses and cable suspended beams, which may be beneficial to achieve

larger spans, as well as desirable for visual reasons. Arch structures offer advantageous load carrying
behavior as well as having a pleasant visual appearance.
In next figure (a), a building with a three-hinged arch is shown.

Alternatively, the structure can be elevated on columns or integrated in a truss structure, as in Figure (d).
The forms of buildings with primary and secondary structural elements described above are all directional
structures, for which the loads are carried primarily on individual directional load paths. Spatial structures
and space trusses are non-directional structures; they can be expanded, but would become heavy for long
spans. The next figure shows some examples of spatial structures.

PORTAL FRAMES
Steel portal frames are widely used in most of the European countries because they combine structural
efficiency with functional application. Various configurations of portal frames can be designed using the
same structural concept as shown in figure.

Multi-bay frames can also be designed, as in Figure (e) and (f), either using single or pairs of internal
columns. In addition to the primary steel structure, a wide range of secondary components has also been
developed, such as cold formed steel purlins, which also provide for the stability of the framework. These
simple types of structural systems can also be designed to be architecturally more appealing by using
curved members, cellular or perforated beams etc. Innovative structural systems have also been
developed in which portal frames are created by moment resisting connections using articulations and
ties.
LATTICE TRUSSES
Long span industrial buildings can be designed with lattice trusses, using C, H or O sections. Lattice
trusses tend to be beam and column structures and are rarely used in portal frames. Various
configurations of lattice trusses are illustrated in Figure.

The two generic forms are W or N bracing arrangements. In this case, stability is generally provided by
bracing rather than rigid frame action. However, columns can also be constructed in a similar way, in order
to provide in-plane stability. Using lattice structures, a comparatively high stiffness and load bearing
resistance can be achieved while minimising material use. Besides the ability to create long spans, lattice
structures are attractive and enable simple service integration. A pinned structure is an idealisation used in
design. Moment-resisting connections can be designed using bolted or welded connections. The resulting
additional internal forces are accounted for in the design of the lattice members, when the lattice truss
acts to stabilise the building against lateral loads.
SUSPENDED STRUCTURES
By using suspended structures, longspan buildings with high visual and architectural quality can be
realised. The division into members that are predominantly subject to either tension or compression
permits the design of lightweight structures. However, structures that save on materials use do not
necessarily lead to economic solutions. Particularly in space structures, the joints may be very complex
and more time consuming to construct and install. Therefore, possible applications of this type of structure
are industrial buildings that also serve architectural purposes rather than merely functional buildings.
Suspended structures can be designed by extending columns outside the building envelope. Suspended
structures accomplish longer spans, although the suspension cables or rods also penetrate the building
envelope, and can be obstructive to the use of the external space.
Lattice and suspended structures is complex and are not covered in detail in this Best Practice Guide.

FIRE SAFETY
Even though the general context of fire safety regulations is the same throughout Europe, national
differences do exist. For example a single-storey industrial building in the Netherlands with a compartment
size of 50 x 100 m has no requirements concerning fire resistance, whereas in France, a fire resistance of
30 minutes is required in many cases, and in Italy the requirement is possibly as high as 90 minutes. At
the design stage, the following fire safety issues should be addressed:

Means of escape (number of emergency exits, characteristics of exit signs, number of staircases,

width of doors).
Fire spread (including fire resistance and reaction to fire).
Smoke and heat exhaust ventilation system.
Active fire fighting measures (hand extinguishers, smoke detectors, sprinklers, plant fire brigade).
Access for the fire brigade.

Fire resistance requirements should be based on the parameters influencing fire growth and development,
which include:

Risk of fire (probability of fire occurrence, fire spread, fire duration, fire load, severity of fire, etc.).
Ventilation conditions (air input, smoke exhaust).
Fire compartment (type, size, geometry).
Type of structural system.
Evacuation conditions.
Safety of rescue team.
Risk for neighboring buildings.
Active fire fighting measures.

BUILDING PHYSICS
Thermal insulation
The main purpose of thermal insulation in industrial buildings is to ensure an adequate indoor climate
depending on the use of the building. During the heating season, one of the main functions of the building
envelope is to reduce the heat loss by means of effective insulation. This is particularly true for buildings
with normal indoor temperatures, such as retail stores, exhibition halls and leisure centers; it is true to a
lesser extent for buildings with low indoor temperatures, such as workshops and warehouses.
For large panels, thermal bridges and air tightness of joints have a major influence on the energy-balance
of the building. The thermal insulation has to be placed without gaps and the building envelope must be
sealed and made airtight at longitudinal and transverse joints.

In the summer, the role of the building envelope is to reduce the effects of solar gain on the interior space.
The summer heat reduction depends on the total area and orientation of openings, as well as the
effectiveness of solar protection measures.
Condensation risk
Thermal and moisture protection are linked closely, because damage arising from high local humidity is
often the result of missing or improperly installed thermal insulation. On the other hand, lack of moisture
protection can lead to condensation in the construction, which in turn affects the effectiveness of the
thermal insulation.
In multi-skin roof or wall constructions, condensation risk has to be controlled by installing a vapour barrier
on the inner skin of the structure. Wall constructions that are vapour proof on both sides, like sandwich
panels, prevent diffusion. However, the humidity in the internal space also has to be regulated by air
conditioning.
Acoustic insulation
The minimum requirements exist on the sound insulation of buildings. In addition, for industrial buildings, it
may be necessary to limit values of acoustic emissions from particular machinery. In steel framed
buildings, acoustic insulation is mainly achieved by the construction of the building envelope. All measures
of acoustic insulation are based on the following physical principles:

Interruption of transmission, e.g. by using multi-skin constructions.


Sound absorption, e.g. by using perforated sheeting or cassettes.
Reducing response by increasing the mass of a component.

For single sound sources, a local enclosure or isolation is recommended. In order to reach a high level of
acoustic insulation, special sound-absorbing roof and wall cladding are effective. For multiskin panels the
level of sound insulation can be controlled by varying the acoustic operating mass. Due to the complexity
of this issue, it is recommended to consult the specialist manufacturers.
FLOORS
In most cases, the floors for industrial buildings are used for vehicles or heavy machinery. They are
designed to support heavy loads and have to be flat. Concentrated loads due to vehicles, machines,
racking and containers have to be considered, depending on the application. Most industrial buildings
have a concrete floor with a minimum thickness of 150 mm on top of a layer of sand or gravel, which is
also at least 150 mm thick. For large floor areas, a sliding layer between the base layer and the concrete
is required, typically using two layers of synthetic material.

LIGHTING
Requirements for the lighting of industrial buildings depend on the type of use. The concept and
arrangement of openings to provide natural lighting permit diversity in architectural design. Rooflights and
gable glazed roofs are common, along with lightbands in the faade (Figure). Openings for natural lighting
can serve as smoke and heat outlets in case of fire.

Well-designed natural day lighting can have a significant impact on a buildings carbon emissions.
However, too much natural day lighting can result in excessive solar gain in the summer, leading to
overheating, and increased heat loss through the envelope in the winter. The decision to utilize natural
daylight within a building and the type of day lighting selected has important implications for the overall
building design.
VENTILATION
Natural ventilation reduces the reliance on air conditioning systems, which in turn means a reduction in
the buildings CO2 emissions. The effectiveness of natural ventilation depends on the size and orientation
of the building. Roof vents are a common option for natural ventilation in buildings without suitably large
openings, however these need to be carefully positioned so as to maximize their performance. Hybrid
ventilation systems are now popular in industrial buildings. They use predominantly natural ventilation, but
with mechanically driven fans to improve predictability of performance over a wider range of weather
conditions.

Mechanical Heat and Ventilation Recovery (MHVR) systems use the heat from the exiting warm stale air
to heat up the fresh cool air as it enters the building. The warm air is vented out of the building alongside
the incoming fresh air, allowing heat transfer from the exiting to the incoming air. Although this heat
transfer will never be 100% efficient, the use of MHVR systems can significantly reduce the amount of
energy required to warm the fresh air to a comfortable level.

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