The pre-engineered buildings (PEB) market in India is on a rapid growth trajectory, driven by the need for quick, cost-effective, and sustainable construction solutions. As urbanisation accelerates, the demand for PEBs is expanding across various sectors, including residential, commercial, and industrial construction. Government initiatives like smart city projects and infrastructure development are boosting the market, while the industrial and warehousing sectors are increasingly adopting PEBs for their flexibility and large, column-free spaces. Additionally, the push for renewable energy has opened new avenues for PEB applications in solar and wind energy projects.
Amidst prevalent misconceptions surrounding PEBs, how can the industry confront them head-on using stringent quality control measures? And in this battle of perceptions, what role does technology play? With advancements like computer-aided design and automated manufacturing, can doubts about the durability and adaptability of PEB finally be eliminated? It’s time to explore how these tools and techniques are reshaping the narrative.
Dispelling the myths
PEBs frequently encounter misconceptions regarding their structural integrity and versatility, which can overshadow their true potential in diverse construction applications. Gaurav Awasthi, Director BD & Marketing, Everest Industries, highlights, “However, PEBs are highly customisable, durable, and suitable for a wide range of applications, including commercial, residential, and industrial projects. With advanced engineering and sustainable features, they offer fast construction, cost-effectiveness, and environmental benefits. By dispelling misconceptions, we can recognise PEBs as innovative solutions for modern construction needs.”
Ravi Ramparia, Principal Architect, Ravi Ramparia Architects, addresses common myths, “They are often perceived as limited to basic, utilitarian structures lacking aesthetic appeal and lower quality and durability. So, we overlook their capacity for customisation and flexibility in various applications beyond temporary structures.”
Prashant Deshmukh, Principal Architect, Prashant Deshmukh Architects, highlights, “People have yet to understand the versatility of PEB. When we talk of the time factor, it is the responsibility of the manufacturer to squeeze the time to design, manufacture and erect. PEB affords flexibility in terms of steel usage and easy erection when done right. The process is streamlined and computer-oriented.”
Addressing misconceptions about pre-engineered buildings is crucial to showcasing their potential in various construction applications. “One common misconception,” Amit Agarwal, Managing Director, Ashtech Prefab (India) Pvt Ltd, believes, “is that PEBs lack design flexibility or aesthetic appeal. However, advancements in architectural design and finishes have expanded the possibilities for visually striking PEB structures, making them suitable for diverse projects including warehouses, factories, offices, and recreational facilities.”
Another misconception is related to durability and longevity. Contrary to belief, PEBs are engineered to withstand environmental challenges and offer excellent performance over their lifespan. They can be designed to accommodate specific load requirements and environmental conditions, ensuring structural integrity and resilience.
Lastly, concerns about customisation and scalability, which seem to be the common thread, are addressed through the flexibility inherent in PEB design. Manufacturers can tailor PEB solutions to meet specific project needs, incorporating features like mezzanines, crane systems, and architectural enhancements without compromising efficiency or cost-effectiveness.
Addressing common challenges, Deshmukh highlights that it starts with the preparation of a GAD (General arrangement drawing) based on the requirements of the client or the architect. “It has to be refined so that all details are covered such as the crane requirements, restriction on spans and column sizes, elevation, cladding material and other details.”
Manufacturers must ensure that processes adhere to the schedule, as any delay in dispatch can disrupt the entire workflow, even if the manufacturing is flawless. Incorporating technology and automation is imperative for streamlining operations.
Building confidence
Quality control is paramount in ensuring the reliability and durability of pre-engineered buildings. To maintain high-quality standards during fabrication and assembly, manufacturers employ stringent quality assurance protocols at every stage of the production cycle. This includes rigorous material testing and precision machining of structural components.
Modern PEB manufacturers leverage advanced technologies to achieve consistent quality and dimensional accuracy. Agarwal elaborates, “Real-time monitoring and inspection processes ensure that any deviations from specifications are promptly identified and rectified, maintaining high standards of quality throughout the production cycle. These rigorous quality control measures ensure that pre-engineered buildings are reliable, durable, and meet all industry standards and codes.”
Manufacturers continually strive to improve PEB components’ quality and efficiency through innovations to achieve ‘better and smaller’ solutions. To enhance quality, advanced materials and fabrication techniques ensure components meet or exceed industry standards while minimising waste and maximising resource utilisation. By embracing lean manufacturing principles and integrating automation technologies, production processes can be optimised to achieve smaller footprints, reduce material consumption, and enhance overall efficiency.
Additionally, Awasthi shares, “Ongoing research and development efforts focus on improving design methodologies, enhancing structural performance, and integrating sustainable practices to create PEB components that are both better in quality and smaller in environmental footprint. Through these innovative approaches, manufacturers drive continuous improvement in construction, delivering structures that are more durable, cost-effective, and environmentally friendly.”
Ramparia suggests a few measures to maintain high-quality standards during the fabrication and assembly processes:
– Implement a robust quality management system (QMS) compliant with industry standards.
– Conduct stringent inspections and testing of raw materials and components.
– Invest in advanced, well-maintained manufacturing equipment and automated assembly lines.
– Establish rigorous inspection and testing protocols, including non-destructive and destructive testing methods.
– Employ and train highly skilled personnel in quality control and manufacturing processes.
Maintain detailed documentation and traceability throughout the manufacturing process.
– Conduct regular internal and external audits, and continuously improve based on quality data analysis.
– Foster a strong quality-focused culture across the organization, emphasizing adherence to standards.
Simulating Success
The integration of advanced software tools has transformed the entire design process, allowing for comprehensive 3D modelling and visualisation of PEB structures. These tools enable precise coordination between architects, engineers, and fabricators, facilitating seamless collaboration and reducing design errors.
Moreover, design software such as STAAD.Pro, Tekla Structures, and Autodesk AutoCAD streamline the detailing and documentation of PEB components, optimizing the manufacturing process. These tools enable accurate material takeoffs, precise fabrication drawings, and efficient production planning, leading to enhanced productivity and cost savings.
Erection is often the most critical phase, and companies without an in-house team rely on erection contractors, who may lack familiarity with the products they are assembling. Deshmukh suggests technology as the answer, “There is no programming in the erection process. It is a different agency, the manufacturer’s job is done once it is dispatched. So, there is no control over the erection process. There has to be more concentration on how to recoup the lags by incorporating software.”
Awasthi shares that digital technologies are significantly influencing the design and engineering of pre-engineered buildings by revolutionising processes and enhancing efficiency. “Tools such as BIM, parametric design software, advanced structural analysis tools, and virtual reality (VR) are enabling architects and engineers to create precise and optimised building designs, streamline collaboration, and improve construction methodologies. Prefabrication and modular construction techniques are also benefiting from digital advancements, allowing for faster project timelines, better quality control, and reduced costs.”
For Deshmukh, it depends on the software being used and the codes being followed. “There is software made specifically for metal buildings. Codes, too, differ such as the American code and the Indian code which makes for a comparatively heavier structure. Similarly, regular software like STAAD.Pro is more steel-consuming than the ones created for metal buildings. PEB companies have developed their own software to support efficient design which is based on market research and specific requirements. I do believe that software like STAAD.Pro has room for improvement to suit loading conditions while meeting the requirements of the stakeholders.”
In light of the evolving landscape and advancements in PEBs, it’s clear that these structures are far more than basic, utilitarian solutions. With enhanced customisation options and the ability to cater to permanent, sophisticated needs, PEBs challenge outdated notions and set new benchmarks in construction.
Quote
“We overlook their capacity for customisation and flexibility in various applications beyond temporary structures.”
Ravi Ramparia, Principal Architect, Ravi Ramparia Architects
“There has to be more concentration on how to recoup the lags by incorporating software.”
Prashant Deshmukh, Principal Architect, Prashant Deshmukh Architects
“With advanced engineering and sustainable features, they offer fast construction, cost-effectiveness, and environmental benefits.”
Gaurav Awasthi, Director BD & Marketing, Everest Industries
“Advancements in architectural design and finishes have expanded the possibilities for visually striking PEB structures, making them suitable for diverse projects.”
Amit Agarwal, Managing Director, Ashtech Prefab (India) Pvt Ltd
