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LONG PAPER ON
CONSTRUCTION OF PEB
HANGAR
WITH ANNEXE AND SERVICES
AS PART OF MODERNISATION
OF AIRPORT INFRASTRUCTURE
By
ZUBER AHMED
PGPPM
MODULE:M-58
REGN. NO.211-07-31-9628-2131
NATIONAL INSTITUTE OF
CONSTRUCTION MANAGEMENT
AND RESEARCH
SODE, PUNE
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DECLARATION
I declare that the long paper entitled Construction of PEB hangar with annex
and services as part of modernization of airport infrastructure is the bonafied
work carried out by me, under the guidance of Prof. P. Nagarjuna, further I declare that
this paper has not been previously formed the basis of award of any degree, diploma,
associate-ship or other similar degrees or diplomas, and has not been submitted
anywhere else.
Date:
ZUBER AHMED
PGPPM
MODULE:M-58
REGN NO. 211-07-31-9628-2131
NICMAR SODE,Pune
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CERTIFICATE
This is to certify that the long Paper entitled Construction of PEB hangar with annex
and services as part of modernization of airport infrastructure is the bonafied work
carried out by Mr. Zuber Ahmed, in partial fulfillment of the academic
requirements for the award of Post Graduate Program in Project
Management (PGP P M) . T hi s work has been carri ed out under my
gui dance and s upervi s i on.
Date:
Prof. P. Nagarguna
NICMAR SODE, Pune
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ACKNOWLEDGEMENT
I express my sincere and heartfelt thanks to Dr. J .C. Edison, Dean NICMAR SODE,
Pune and Dr. Arun Kumar Co-Ordinator SODE, Pune, for giving me an opportunity to
undertake this research subject for preparing long paper.I also express a deep sense of
gratitude to Prof. P. Nagarjuna, faculty, NICMAR, Pune for his constructive support,
constant encouragement, guidance and channelizing my efforts in the right direction
without which this long paper would not have attained its present form.I also thank
librarians of NICMAR, Pune, for givingus access to the facility whenever required.I
would also like to thank my family and friends who encouraged us constantly throughout
the research period.
(Zuber Ahmed)
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ABSTRACT:
Ha nga r s a r e a l wa ys c o ns i de r e d a s pr e s t i gi o us pr o j e c t s
due t o t he i r operational use, constructional aspects and structural
complexity. Due to recent advancement in concepts, materials and construction
techniques a revolutionary change could be seen world over in conceiving industrial
structures like Hangars, Garages, Workshops, etc not merely as covered shed for
housing aircrafts, specialist vehicles, equipments, etc but as Architectural
Marvels as well. This conceptual change could be seen in almost all ports,
workshops and factory projects. Modern hangars are large sized with respect to span
and height and require most modern f aci l i ti es to s ui t the modern days
ai rcraf ts . A Hangar proj ect constructed during modernization of
airport infrastructure project was also conceived with state-of-the-art
concept of Pr e Engi neer ed Bui l di ng using all modern materials and techniques
which no doubt makes this an ideal project in the category of A Complex
Architectural and Engineering Marvel. The project de ma nde d us e o f
mo de r n t e c hni que s a nd ma t e r i a l s wi t h hi gh de gr e e o f
construction precision, excellent quality control, constant supervision through
experienced executives and regular monitoring up to the highest level. The paper cover
the case study of this hangar constructed as a large span Pre- Engineered Rigid
Frame Structure.
The paper shall depict the evolution of Steel Hangar Structures through a
Gallery of hangar constructed in India over last five decades. Due to revolutionary
change in concept of design, construction techniques and materials
it is now possible to provide large span hangars at considerably faster rate and
lighter in weight. Requirement of Hangar users have also changed
over the years from s i mpl e, s mal l s i zed hangar f or hous i ng
s mal l ai rcraf ts us ual l y concei ved as industrial sheds to considerably
large sized hangars with all modern facilities like repair shops, office accommodations
for the technical staff, testing labs, etc in the form of side annex. The executives
involved in the execution of the project had varied and unique experiences and
challenges during execution of the work which shall be presented in this paper.
The use of steel structures in various types of buildings/accommodation is
not uncommon, e.g.aircraft hangars,covered garages,storage accommodation
auditoriums, towers,etc. Most of these structures commonly consist of elements s uch
as beams , col umns , trus s es & portal f rames whi ch are
bas i cal l y two- dimensional from the point of view of analysis as well as
design. Inter-connecting members in the third dimension (for example
purlins) are usually of secondary character, present merely for the purpose of
transferring load and not contributing to the ri gi di ty of the s tructure. A
s tructural arrangement i n whi ch there i s i ntegrated l oad
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s hari ng i n al l the three di recti ons wi l l obvi ous l y have more
advantage, since every part of the structure makes an effective contribution. Such
structures are known as Space Structures and are gaining importance in its use all over
the world due to various advantages over traditional structures. The
study shall present some insight in the advantages of use of P EB
system for hangar construction as part of any major airport modernization project.
TABLE OF CONTENTS
Title page 1
Certificate 2
Declaration 3
Acknowledgement 4
Abstract 5
Contents 6
List of Tables
List of figures
CHAPTER Page No.
I. INTRODUCTION. 7
II. NEED OF PEB WITH RESPECT TO CONVENTIONAL
R.C.C. STRUCTURE.
11
III. COMPLETE HISTORY AND EVOLUTION OF PEB
STRUCTURE.
13
IV. CONCEPT AND METHODOLOGY OF PEB
STRUCTURE SYSTEM.
20
V. IMPORTANCE OF PEB STRUCTURE SYSTEM 28
VI. ADVANTAGES AND LIMITATIONS OF PEB
STRUCTURE SYSTEM.
31
VII.CASE STUDY WITH APPLICATIONS OF THE PEB
SYSTEM.
41
VIII.SUMMARY FINDINGS, CONCLUSIONS AND
RECOMMENDATIONS.
76
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CHAPTER - I
INTRODUCTION
1.1 GENERAL:
Today, the Indian construction industry is in full bloom and so is the real estate sector.
With the demand for both residential and commercial segments increasing, there is a
need to get the projects completed on time so as to minimize extra costs. Also, with a
major emphasis being laid on the infrastructure as well as the current boom in the
commercial buildings, developers are now looking towards other options so as to meet
the deadlines and curtail the expenditure.
This is where the prefabricated or the prefab industry comes in. To name it as the 'fast-
food' of construction industry would not be wrong as this has now come across as the
most viable option for instant completion of projects for various endeavors.
The pre-engineered building technology, which entered the Indian construction arena
during the late nineties has over a period of time gained widespread acceptance among
the end users and is steadily making inroads in the construction and infrastructure
projects across the country. This is largely due to the fact that PEB-based construction
technique is offering the most innovative, hi-tech, and quicker methods of construction
ensuring efficient, cost effectiveness and speedy completion of projects, which is
perhaps the pre-requisite for the construction sector to meet tight construction
schedules and demanding deadlines.
Drawing overwhelming response from construction and infrastructure builders, due to
heightened construction activities currently going on across the country, the global
players in the PEB industry have not just set up their shops but also launched multi-
prong brand building initiatives by holding technical seminars, exhibitions and events
displaying their products to popularize the benefits of PEB brands. In the process, they
have been able to create awareness informing people that under the PEB systems
buildings are built keeping the, eco-friendly environs, aesthetic value, designing,
durability, energy efficiency, cost effectiveness and speedy completion of the
construction projects in mind.
With increased emphasis on the on-going green buildings ensuring sustainable
construction, the PEB structures are created with a high proportion of recycled content
making them lighter by about 30% than the conventional steel buildings. They contain
higher degree of fire and dust resistant and are maintenance free. As a result today the
PEB system is the most preferred choice among the architects, builders, developers
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and industrialists. The experts in the field are unanimous in their view that the PEB
industry in India is currently heading to achieve growth trajectory of about 35% per
annum.
Kirby Building Systems is one of the world's largest producers of quality steel buildings
and has been operational since 1976. The company recognized the need of customers
and the potential in the Indian market and was the first to set up a mega manufacturing
facility in India near Hyderabad in 1999. Since then it aggressively promoted the use of
PEB concept in India.
Generally, steel structures and specifically PEBs market have, on the domestic front,
surpassed the GDP from both the Indian steel industry and the Indian construction
sector. Over the next 2-3 years, the industry is optimistic about a 15 to 20% annual
growth, resulting in doubling of the market over five years.The sector is going
international as companies move to tie up with multinationals for upgrading offerings to
their customers. "Technical association and J V's with leading PEB companies in
Europe, USA and Middle-east are quite useful in terms of engineering excellence,
product quality and superior products range.
1.2 BACKGROUND:
Construction is an activity, which cuts across almost all sectors of the economy. It is an
activity, which transforms various resources into economical and social infrastructure
and facilities. It includes all phases of the process of transformation viz. planning,
designing, financing, procurement, construction, operations etc. The construction sector
is an essential contributor to the process of development. It usually accounts for three
percent to eight percent of a developing countrys Gross Domestic Product.
In the context of liberalization of the Indian economy, domestic and foreign investment
is likely to flow into various infrastructure projects in a big way. This is more so, taking
into consideration the conferring of industry status to the construction sector by the
Government of India.
Fluctuations in construction demand affect the economy in many ways. They affect the
demand for labour and materials as well as the lag time taken to supply the industrys
output. Backward and forward linkages affect the working of a wide range of operations.
In fact, construction industry has been ranked among the top four out of twenty
economic sectors in terms of inter sectoral linkages. These linkages together with a high
value added output ratio, indicates that construction provides a substantive growth
stimulus throughout the economy. Its importance as an agent for development is
enhanced by its ability to provide gainful employment for a large number of people.
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1.3 OBJECTIVES OF STUDY:
The paper shall depicts the evolution of Steel Hangar Structures through a Gallery of
hangar constructed in India over last five decades. Due to revolutionary
change in concept of design, construction techniques and materials it is now
possible to provide large span hangars at considerably faster rate and
lighter in weight. Requirement of Hangar users have also changed
over the years from simple, small sized hangar for housing small aircrafts
usually conceived as industrial sheds to considerably large sized hangars with all
modern facilities like repair shops, office accommodations for thetech
nical staff, testing labs etc in the form of side annex. The executives involved in the
execution of the project had varied and unique experiences and
challenges during execution of the work which shall be presented in this
paper. So the objectives of the study can be summarized as:
To understand Evolution of technologies in construction of
large hangars over past 05 decades.
To analyze Latest technology i.e. PEB system being used in
Hangar construction, and its advantages and importance over conventional
system.
To Prepare a case study of a Large span Hangar covering all relevant
aspects of planning, material and construction management etc.
1.4 LITERATURE REVIEW:
There is a lot of literature available on steel structure as the steel is the main
construction material world over. However in India we have mostly concrete intensive
construction instead of steel intensive construction due to cheap availability of labour.
PEB system being new concept to India not many books are available on the subject,
however a lot of material and data is available on internet and write-up available in
structural journals and relevant IS codes like BIS-800 etc. has been used.
1.5 METHODOLOGY OF STUDY:
The study requires detailed study of conventional system of Hangar Construction and
the PEB system and their applicability. The following method of study has been adopted
for conducting the study:
Literature review regarding conventional and PEB system of Hangar
construction from various published material.
Interviews with experts in the field of PEB steel construction.
Websites related to the PEB construction.
Case study after discussion and collection of data for an already completed
project.
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1.6 SCOPE AND LIMITATION OF STUDY:
The study shall present some insight in evolution of technologies in construction of large
hangars over past 05 decades and the advantages of use of PEB system for hangar
construction as part of any major airport modernisation project. The project demanded
use of modern techniques and materials with high degree of construction precision,
excellent quality control, constant supervision through experienced executives and
regular monitoring up to the highest level. The study shall cover the case study of this
hangar constructed as a large span Pre-Engineered Rigid Frame Structure. Although,
the scope of the subject is enormous, the study shall have following limitation:
Application of the proposed study is mainly suitable to steel intensive
construction
Time and monetary constraints may limit the depth of penetration of the
study.
The data required for case studies are many times confidential which
limits the study to certain extent.
1.7 SCHEME OF CHAPTERIZATION:
The study shall consist of following 08 Chapters:
In Chapter 1 will be an introduction chapter. This chapter highlights the
importance of construction sector. It also deals with the importance of the
concept and study of PEB structures.
In Chapter 2 will be an introduction to PEB providing the need of PEB with
respect to conventional R.C.C. Structure.
In Chapter 3 will give the complete history and evolution of PEB structure.
In Chapter 4 will give the detail description of concept and methodology of PEB
structure system.
In Chapter 5 will give the detail description of importance of PEB structure
system.
In Chapter 6 will give the detail description of advantages and limitations of PEB
system.
In Chapter 7 will be case study giving the detail description of Application of the
PEB system. I have covered the case study of a 70 meter clear span hangar
constructed at Airport under modernization of airport infrastructure project
covering following issues:
(a) Project definition concept and scope and cost.
(b) Project institutional framework with role and responsibility matrix.
(c) Project planning and phasing.
(d) Project execution and related issues.
In Chapter 8 will be summary findings, conclusions and recommendations.
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CHAPTER - II
NEED OF PEB WITH RESPECT TO
CONVENTIONAL R.C.C. STRUCTURE
2.1 WHY PEB SOLUTION:
Such buildings are detailed and designed in advance and manufactured in a
quality controlled environment.
Every manufacturing operation is carried out through advanced technologies
such as sophisticated welding techniques, standardization of components, etc.
Pre engineered construction system also facilitates mass production.
The construction is faster than the conventional method.
Such buildings are detailed and designed in advance and manufactured in a
quality controlled environment.
2.2 NEED OF PEB:
India has the second fastest growing economy in the world and a lot of it, is attributed to
its construction industry which figures just next to agriculture in its economic contribution
to the nation. In its steadfast development, the construction industry has discovered,
invented and developed a number of technologies, systems and products; one of them
being the concept of Pre-engineered Buildings (PEBs). As opposed to being on-site
fabricated, PEBs are delivered as a complete finished product to the site from a single
supplier with a basic structural steel framework with attached factory finished cladding
and roofing components. The structure is erected on the site by bolting the various
building components together as per specifications. PEBs are developed using potential
design software. The onset of technological advancement enabling 3D modeling and
detailing of the proposed structure and coordination has revolutionized conventional
building construction.
PEBs have hit the construction market in a major way owing to the many benefits they
possess. They exemplify the rising global construction, technology and while they
oppose the practice of conventional building construction they simultaneously have
taken it to a higher level too. Worldwide, they are a much used concept with studies
revealing that 60% of the non-residential low-rise building in USA are pre-engineered;
for India the concept has been gaining momentum and the scope of growth is
guaranteed looking at India's huge infrastructural requirements. Studies already validate
that India has the fastest growing market in the PEB construction segment. The scope
of using PEBs ranges from showrooms, low height commercial complexes, industrial
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building and workshops, stadiums, schools, bridges, fuel stations to aircraft hangers,
exhibition centers, railway stations and metro applications. While we are still to see
PEBs being used in residences in India, one can see their optimal use in warehouses,
industrial sheds, sports facilities, etc. The Delhi Airport and the metro projects of Delhi,
Bengaluru and Mumbai are also examples of PEB applications.
A PEB system in totality consists of a structural system, sandwich panels, roofing,
exterior facade and accessories. The PEB concept based on a proper design usually
involves a thorough project information data including complete details like building
parameters, grade of steel, secondary member details, paint coat on steel members,
welding, anchor bolts steel grade, roof & wall liner / panel, insulation, sky light, gutters,
facia, mezzanine, ridge ventilation to name a few. Following this input, the drawings for
General Arrangement, Anchor Bolt & Template Fabrication & Erection are prepared.
2.3 COMPARISON PEB V/S CONVENTIONAL:
PEB Buildings Conventional Building
Aesthetically appealing appearance. Special aesthetic design required
Reduced time because of international
design standards & codes using standard
sections and connections.
Increased design time due to scratch and
availability of less design aids.
Higher resistance to seismic forces due
to low weight flexible frames.
Rigid heavy weight structures not suitable
for seismic zones.
30% less PEB steel structures weight
through efficient use of steel.
High weight due to excessive safety factor
and heavy RCC work.
Factory controlled quality. Every project to be fabricated at site.
Lower initial cost of PEB steel buildings
(cost per square meter about 30% less
than the conventional) and faster delivery
Special design and features developed for
each project at higher costs.
Simple Foundation, easy to construct and
light weight of PEB structures.
Extensive heavy foundation.
Span size may be designed up to 40m. Span size with limitation of beam width
may be limited to 10-15 m.
Average delivery time 6-8 weeks. Average delivery time 22-28 weeks.
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CHAPTER - III
COMPLETE HISTORY AND EVOLUTION OF
PEB STRUCTURE SYSTEM
3.1 HISTORY OF PEB STRUCTURE SYSTEM:
In early 1900s - Concept of metal buildings originated in U.S.
- Simple industrial structures using truss rafters, straight columns, sectional roofs
& wall.
- Wedge pins for connections.
In 1940s - Mass production of Nissen and Quonset housing and storage
Modules for:
- US army during world war II.
- Metal building system recognized as a favourable method of construction over
conventional methods.
Late 1950s & early 1960s
- Computerized design allowed buildings to be tailored to individual Customer
requirements.
- Roll forming lines allowed continuous span cold rolled Z-purlins.
- Colour coated panels and factory insulated panels improved Architectural
appearance.
- Major increase in design possibilities contributed to the boom in metal buildings.

The term Pre-Engineered Buildings came into existence.
In 1990s - Today Pre Engineering metal buildings dominate the low rise building
market.
- Precision roll forming lines for the cladding and sectional members.
- Auto production lines for the structural sections.
- High quality paint system for steel and cladding.
- MBMA statistics show, About 60% of low rise industrial and commercial in the
U.S.A. use the P.E.B. system.
3.2 HANGARS AS PEB STRUCTURE SYSTEM:
Hangars are always considered as prestigious projects due to their operational use and
constructional and structural complexity. Due to recent advancement in the concepts,
materials and construction techniques a revolutionary change could be seen world over
in conceiving industrial structures like Hangars, Garages, Workshops etc not merely as
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covered shed for housing aircrafts, specialist vehicles, equipments etc but as
Architectural Marvels as well. This conceptual change could be seen in almost all the air
ports, workshops and factory projects. Modern hangars are large sized with respect to
span and height and require most modern facilities to suit the modern days aircrafts.
Hangar project at Bangalore was also conceived with state-of-the-art concept of Pre-
Engineered Building using all modern materials and techniques which no doubt makes
this an idle project standing in the category of A Complex Architectural and
Engineering Marvel. The project demanded use of modern techniques and materials
with high degree of construction precision, excellent quality control, constant
supervision through experienced executives and regular monitoring up to the highest
level. In this project executives have had varied and unique experiences and challenges
during execution of work which have been documented in this report.
Pre-engineered buildings are the state-of-the-art steel solution to developing an efficient
and cost-effective infrastructure. PEBs offer ultimate design flexibility and an extremely
short construction time (right from initial design to completion). They are supplied as a
fully finished product along with steel structure, building accessories and roof cladding.
They require no onsite fabrication or welding they can simply be bolted together as
per specifications. PEBs are best suited for warehouses, sports halls, factories,
workshops, distribution centers, cold storages, supermarkets, aircraft hangars or any
ground +two-storey construction.
3.3 EVOLUTION OF STEEL STRUCTURE AND HANGARS IN INDIA:
In India, the use of steel structures in various types of buildings/accommodation is not
uncommon, e.g. aircraft hangars, covered garages, storage, auditoriums, towers, etc.
Most of these structures commonly consist of elements such as beams, columns,
trusses & portal frames which are basically two dimensional from the point of view of
analysis as well as design. Interconnecting members in the third dimension ( for
example purlins) are usually of secondary character, present merely for the purpose of
transferring load and not contributing to the rigidity of the structure. A structural
arrangement in which there is integrated load sharing in all the three directions will
obviously have more advantage, since every part of the structure makes an effective
contribution. Such structures are known as Space Structures and are gaining
importance in its use all over the world due to various advantages over traditional
structures.
Among various structures developed by Civil Engineers in aircraft hangars are
considered important from operational point of view. These hangars are of span varying
from 30m to 70m and cover large spaces. Traditional arrangement for covering such
structures with trusses and purlins was being adopted in MES till recent years. The
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requirement of steel in such structures was as high as 100 kg/m2 to 150 kg/m2
depending upon the span and spacing of trusses. The modern trends for covering large
spaces with much reduced requirement of steel are Pre-Engineered Rigid Frame
Structures, Space Structures and Tensile Structures.
A Gallery of hangar structures constructed at Bengaluru since inception of the base can
be seen in Photographs P1 to P8 for understanding the evolution of Steel Hangar
Structures over last five decades. Due to revolutionary change in concept of design,
construction techniques and materials it could be possible now to provide large span
hangars at considerably faster rate and lighter in weight. Requirement of users have
also changed during this period from simple, small sized hangar for housing small
aircrafts usually conceived as industrial sheds to considerably large sized hangars with
all modern facilities like repair shops, office accommodations for the technical staff,
testing labs, etc in the form of side annex.
P-1 : SW TYPE HANGAR(1965)
SPAN 49.9m, HEIGHT 9m
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P-2: LATTICE FRAME TYPE HANGAR (1965) SPAN 28.25m, HEIGHT 8.5m
P-3 : TRADITIONAL TRUSS TYPE HANGAR (1998) SPAN 70m, HEIGHT -11m
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P-4, P-5:BOWSTRING GIRDER TYPE HANGAR (1993) SPAN 60m HEIGHT- 11m
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P-6:LIGHT WEIGHT TWIN HANGAR-TUBE SECTIONS (1996) SPAN 35m HT.- 6m
P-7 : PRE ENGINEERED BUILDING HANGAR (2003) SPAN 40m x 3, HEIGHT 8m
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P-8 : PRE ENGINEERED BLDG HANGAR (2003) SPAN 60m, HEIGHT - 10m