PLANT LAYOUT

ASSIGNMENT 2:- STUDY OF INDUSTRIAL

SHEDS
SWAGAT KUMAR PAL

Industrial Sheds types and functionalities

Industrial sheds come in many different shapes and sizes for many uses, but
after all of the different uses and names, two basic types of sheds are considered
the most popular which are as follows
1. The cold rollformed portal frame shed
2. The structural fabricated steel shed
1. The cold rollformed portal frame shed-

It is the most common type of pre-engineered shed.

It usually arrives as a kit, and the builder assembles it on the owners
property.
The main structure of this kind of shed is called the portal frame.
It contains rolled purlins, batton, girts, brackets, and top hat. These are
popular form of construction for single storey buildings of spans of up
to 30m.
Such buildings typically use cold formed steel channel sections for the
columns and rafters, with joints formed through back-to-back gusset
plates bolted to the webs of channel-sections.

 All types of cold rollformed portal frame sheds have common cladding
and flashings.
CFS (Cold formed steel) is the common term for products made by
rolling or pressing steel into semi-finished or finished goods at relatively
low temperatures.
The use of cold formed steel construction materials has become more and
more popular since its initial introduction of codified standards in 1946.
In the construction industry both structural and non-structural elements
are created from the thin gauges of sheet steel.
The material thicknesses for these thin-walled steel members usually
range from 0.0147 inches (0.373mm) to about inches (25.4mm).
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, and the reason it is so popular,
is that it is extremely efficient, can be easily transported, and can be put
together onsite without a lot of specialised equipment.
An optimization technique that uses a real-coded genetic algorithm is
applied to search for the optimum topography of steel portal frame for a
building.
The advantage of using a real coded genetic algorithm is that a high
precision optimum solution can be achieved easily when the optimization
process works in the continuous search space.
2. A structural fabricated steel shed-

It is similar to the cold rollformed 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.
Structural steel fabrication can be carried out in shop or at the
construction site.
Fabrication of steelwork carried out in shops is precise and of assured
quality, whereas field fabrication is comparatively of inferior in quality.
In India construction site fabrication is most common even in large
projects due to inexpensive field labour, high cost of transportation,
difficulty in the transportation of large members, higher excise duty on
products from shop.
Beneficial taxation for site work is a major financial incentive for site
fabrication. The methods followed in site fabrication are similar but the
level of sophistication of equipment at site and environmental control
would be usually less.
Structural steel passes through various operations during the course of its
fabrication.
The various operations are as follows
Surface cleaning - Structural sections from the rolling mills may require
surface cleaning to remove mill scale prior to fabrication and painting.
Hand preparation, such as wire brushing, does not normally conform to
the requirements of modern paint or surface protection system.
However in some applications manual cleaning is used and depending on
the quality of the cleaned surface they are categorised into Grade St-2 and
Grade St-3.
Blast cleaning is the accepted way of carrying out surface preparation in a
well-run fabrication shop.
Abrasive particles are projected on to the surface of the steel at high
speed by either compressed air or centrifugal impeller to remove rust and
roughen the surface before applying the coating.
By using shot or slag grits, both of which have an angular profile, surface
oxides are removed and a rougher surface is obtained to provide an
adequate key for metal spraying or special paint.
Depending upon the increase in the quality of the cleaned surface, the
blast cleaning is categorised into Grade Sa2, Grade Sa2 and Grade
Sa- 3.
Flame cleaning is another method of surface cleaning.

In this method the surface is cleaned using an oxy-acetylene torch which

works on the principle of differential thermal expansion between steel
and mill scale.
In another method, the steel piece is immersed in a suitable acid and the
scale and rust are removed.
Cutting and Machining - Following surface preparation, cutting to length is
always the first process to be carried out, and this is done by any of the
following methods.
FABRICATION AND ERECTION OF STRUCTURAL STEELWORK
Shearing and cropping Sections can be cut to length or width by cropping or
shearing using hydraulic shears.
Heavy sections or long plates can be shaped and cut to length by
specialist plate shears.
For smaller plates and sections, machines featuring a range of shearing
knives, which can accept the differing section shapes, are available.
Flame Cutting or Burning - In this method, the steel is heated locally by a
pressurised mixture of oxygen and a combustible gas such as propane, which
passes through a ring of small holes in a cutting nozzle.
The heat is focussed on to a very narrow band and the steel melts at
15000 C when a jet of high-pressure oxygen is released through a
separate hole in the centre of the nozzle to blast away the molten metal in
globules.
The desired cuts are obtained quickly by this process.
However due to a rapid thermal cycle of heating and cooling, residual
stresses and distortion are induced and hence structural sections that are
fabricated using flame cutting are treated specially in the design of
structural steelwork.
Arc Plasma Cutting - In this method, the cutting energy is produced
electrically by heating a gas in an electric arc produced between a tungsten
electrode and the work piece.
This ionises the gas, enabling it to conduct an electric current.
The high-velocity plasma jet melts the metal of the work piece.
The cut produced by plasma jet is very clean and its quality can be
improved by using a water injection arc plasma torch.
Plasma cutting can be used on thicknesses up to about 150 mm but the
process is very slow.

Cold Sawing - When a section cannot be cut to length by cropping or

shearing, then it is normally sawn.

All saws for structural applications are mechanical and feature some
degree of computer control.
There are three forms of mechanical saw - circular, band and hack.
The circular saw has a blade rotating in a vertical plane, which can cut
either downwards or upwards, though the former is more common.
Band saws have less capacity.
Sections greater than 600 mm X 600 mm cannot be sawn using band
saws.
The saw blade is a continuous metal edged, with cutting teeth, which is
driven by an electric motor.
Hack saws are mechanically driven reciprocating saws. They have
normal format blades carried in a heavy duty hack saw frame. They have
more productivity than band saws.

Punching and Drilling - Most fabrication shops have a range of machines,

which can form holes for connections in structural steelwork.
The traditional drilling machine is the radial drill, a manually operated
machine, which drills individual holes in structural steelwork.
But this method has become too slow for primary line production.
Therefore, larger fabricators have installed NC (Numerically Controlled)
tooling, which registers and drills in response to FABRICATION AND
ERECTION OF STRUCTURAL STEELWORK.
These can drill many holes in flanges and webs of rolled steel sections
simultaneously.
It is also possible to punch holes, and this is particularly useful where
square holes are specified such as anchor plates for foundation bolts.
While this method is faster compared to drilling, punching creates
distortion and material strain hardening around the holes, which increase
with material thickness.
Its use is currently restricted to smaller thickness plates.
In order to reduce the effect of strain hardening and the consequent
reduction in ductility of material around punched holes, smaller size (2
mm to 4 mm lesser than final size) holes are punched and subsequently
reamed to the desired size.
Straightening, Bending and Rolling - Rolled steel may get distorted after
rolling due to cooling process.

Further during transportation and handling operations, materials may

bend or may even undergo distortion. This may also occur during
punching operation.
Therefore before attempting further fabrication the material should be
straightened.
In current practice, either rolls or gag presses are used to straighten
structural shapes.
Gag press is generally used for straightening beams, channels, angles, and
heavy bars. This machine has a horizontal plunger or ram that applies
pressure at points along the bend to bring it into alignment.
Long plates, which are cambered out of alignment longitudinally, are
frequently straightened by rollers.
They are passed through a series of rollers that bend them back and forth
with progressively diminishing deformation.
Misalignments in structural shapes are sometimes corrected by spot or
pattern heating.
When heat is applied to a small area of steel, the larger unheated portion
of the surrounding material prevents expansion. Upon cooling, the
subsequent shrinkage produces a shortening of the member, thus pulling
it back into alignment. This method is commonly employed to remove
buckles in girder webs between stiffeners and to straighten members.
It is frequently used to produce camber in rolled beams.
A press brake is used to form angular bends in wide sheets and plates to
produce cold formed steel members.

Fitting and Reaming - Before final assembly, the component parts of a

member are fitted-up temporarily with rivets, bolts or small amount of
welds.
The fitting-up operation includes attachment of previously omitted splice
plates and other fittings and the correction of minor defects found by the
inspector.
In riveted or bolted work, especially when done manually, some holes in
the connecting material may not always be in perfect alignment and small
amount of reaming may be required to permit insertion of fasteners.
In this operation, the holes are punched, 4 to 6 mm smaller than final
size, then after the pieces are assembled; the holes are reamed by electric
or pneumatic reamers to the correct diameter, to produce well matched
holes.
There are a lot of other kinds of sheds, and a lot of other uses, but heartily
these two frame constructions are recommended as the basis of any shed:
domestic, commercial, or industrial.

Other varieties of Industrial Sheds

2.

1. Warehouse shed
Warehouse Sheds comprise high quality fabrication
finish based steel structure sheds that come with wide span, single span or
multiple span choices.
Various types of warehouse sheds include the construction of wooden sheds,
metal sheds, and pressure treated sheds, windowless sheds, bike sheds, log
cabins, summerhouses, plastic sheds, arbours and arches, greenhouses,
playhouses, storage sheds and so on.
The scope for steel kit industrial warehouse shed is almost limitless.
A large list of extras upgrade the warehouse collection which include dividing
walls, mezzanine floor, roof insulation, roof ventilation, personal access doors,
motorised roller doors, sliding doors and Windlocks.
Wide Span warehouses sheds are made from super strong steel which are cost
effective and allow for much shorter turnaround times as well as offer
outstanding value.
Prefabricated steel roof frame shed
These shades come up with a lot of advantages.
In
the

method of prefabrication, the practice of assembling components of a structure

in a factory or other manufacturing site, and transporting complete assemblies
or sub assemblies to the construction site where the structure is to be located,
is done. The steel frames are accurately engineered to fit simultaneously, with
one end skidding into the other.
No exceptional fasteners are required, and fewer employees are required to
entire the process.

 No cutting, retaining, and hammering simultaneously long, hefty and bulky

planks.
Since the steel is accurately slashed while manufacturing, there is no on location
waste (no require to yield for somewhat longer timber to confirm they are long
sufficient which you then slash down to size).
Since fewer employees are required, that is less salaries to yield if we are
having the construction gathered by somebody else.
Recyclable is an environmental benefit of steel buildings using in construction.
Steel is the most recycled material in the world.
Most manufacturers use recycled steel in all of their steel building materials.
Energy efficiency is one element that points to an environmentally friendly
building.
Steel buildings fit this description in many different ways such as
Window placement, Tinted Windows, Insulated Frames, Vapour Retarders
between the foundation and concrete slab.
Steel frame buildings are conspicuously more blaze resistant than a wood
framed constructions, steel is furthermore unaffected by termites, bugs or
rodents as well as mold or fungi.
It does not have to be treated with chemicals like timber does, and a steel frame
building is well grounded and less probable to be hit or impaired by lightning.
A steel frame building does not age and worsen like wooden structures manage
over time, so as a homeowner we dont have to concern about any feeble spots.
Steel is corrosion resistant, it is dimensionally steady and it furthermore
continues directly, no anxieties about distorting with climate changes.
Steel has one of the largest powers to heaviness ratios of any building material,
so is large for a garage kit.
Steel will not ever buckle, divide, distort, rotate, chink, rot or splinter. All this
power, yet it is furthermore weighs less than timber, producing it simpler to
handle, proceed round and construct with particularly when lifting partitions
and roofs.
3. Polycarbonate roof aluminium shed

Aluminium Roofing Solutions offered by Rooves 360 is a quality product

for Industrial Roofing from Hindalco, A Fortune 500 Company.
Aluminium sheets for industrial applications offer versatility in terms of
usage which makes Aluminium Roofing Sheets a wise choice.
Aluminium roofing sheets can be used in various ways to build a variety
of industrial structures such as:

INDUSTRIAL ROOFING
Industrial Buildings and Sheds
Warehouses and Logistic Centre
Airports and Aircraft Hangers
Barracks and Makeshift Habitats
Cold Storage Chain
Insulation for Boilers
Cladding and Wall Panels
Insulated Sandwich Panels, etc.
Besides this, the durability and cost effectiveness of aluminium sheet
make it the ideal choice for industrial applications.

Rooves 360's Polycarbonate & PVC Roofing solutions comes from the
stable of PALRAM Industries a global leader in manufacturing of semifinished extruded thermoplastic sheets, panel systems, and finished
products.

PALRAM sheets, manufactured mainly from Polycarbonate and PVC, are

designed to suit a diverse range of industrial applications.
INDUSTRIAL ROOFING
Palram sheets for Industrial applications (PALRUF) possess high
resistance to chemicals, fire and impact and are ideal for roofing, siding
and cladding applications where the performance of alternatives would
deteriorate and fail over time.
These sheets are especially suitable for corrosive environments such as
seaside and chemical industries.

INDUSTRIAL ROOF LIGHTING (DAY LIGHTING)

SUNTUF by Palram combines optimal light transmission, weather
resistance, complete blocking of harmful UV rays and many other benefits.
The 'Metal Match" profile matching technology allows us to quickly adapt
SUNTUF to any metal profile.

Products

Polycarbonate Sheets

Polycarbonate Sheets

Aluminium Roofing Sheets

Polycarbonate Sheets


Polycarbonate Sheets

Polycarbonate Sheets

Aluminium Roofing Sheets

Figure 1.Prefabricated light steel metal

shed

Figure 2.prefabricated portal shed