Prefabricated steel building

PREFABRICATED STEEL BUILDING

Prefabricated steel buildings (PEB) are construction projects that utilize pre-manufactured steel components, assembled according to meticulously designed technical and architectural drawings. The process of producing and installing prefabricated steel buildings typically encompasses three primary stages: design, fabrication of steel components, and on-site assembly.

Key components of modern prefabricated steel buildings:

Foundation structure:

• The foundation of prefabricated steel buildings employs reinforced concrete, akin to traditional reinforced concrete structure. This foundation is essential for transmitting loads from above to the underlying stable soil, tailored to the geological conditions and load requirements of the building. Foundation types may include isolated footings, strip footings, or raft foundations, depending on the specific design criteria.
• Before pouring concrete, anchor bolts are precisely installed within the foundation steel framework. This critical step demands high accuracy to facilitate the seamless installation of components such as columns and beams. Common anchor bolts include M22, M24, and M30, with various strength grades like 6.6, 8.8, and 10.9, based on the project's requirements.

Floor slab:

• Factory floors are typically constructed from concrete with a compacted sand base. The thickness of the concrete slab is determined by the expected load and vehicular traffic within the facility. The surface is often treated with epoxy paint or polished to maintain a clean, aesthetically pleasing appearance.
• To enhance stability, various solutions can be applied, including steel-reinforced concrete, non-reinforced concrete, or even concrete piles, depending on the site's geological conditions.

Structural framework: Columns, beams, and trusses

• Steel columns and trusses are integral to the structure of prefabricated steel buildings, designed to ensure load-bearing capacity while spanning significant distances, potentially up to 100 meters, depending on specific project requirements.

• Typically, columns and trusses are designed as H-section steel, available in various cross-sectional configurations or truss forms. Connections between columns and trusses are typically made using high-strength bolts and plates to ensure structural integrity and safety.

Skylights and canopy roofs

• Skylights are positioned at the top of the building to provide natural lighting and enhance ventilation, creating a bright and airy production space.

• Canopy roofs are installed at entryways to provide shade and rain protection. These canopies are generally constructed from steel frameworks, clad with materials such as aluminum and topped with metal roofing or glass, creating aesthetically pleasing and weather-resistant sheltered areas.

Purlins and bracing systems

• The purlin structure and bracing systems are vital for linking and stabilizing the building's frame.
• Galvanized steel purlins are available in C, Z, or U shapes, chosen based on the size of the columns and corresponding load. The spacing between purlins typically ranges from 1 to 1,4 meters. They are connected to trusses using bolts through pre-welded plates on the trusses, supporting the roof system above.
• End bracing, roof bracing, and purlin bracing are designed to enhance structural stability, ensuring safety and integrity from assembly through to operation.

Roofing and cladding panels

There is a wide variety of roofing materials and cladding panels for industrial buildings, with metal roofing often supplemented by insulation layers of air bags or fiberglass. This insulation reduces internal temperatures and significantly minimizes noise within the facility.

Key materials for completing modern prefabricated steel building

Steel frame

The steel frame is an essential foundation for constructing prefabricated steel buildings, chosen based on the intended use of each project. The production and installation of the entire steel structure in a factory setting streamline construction timelines. Additionally, steel's lighter weight compared to concrete alleviates overall load pressure on the building

Roofing sheets

In addition to the steel frame, roofing sheets are widely used to cover and enclose industrial structure such as factories, warehouses, and garages. Their lightweight nature and diverse color options contribute to their increasing popularity. Roofing sheets come in various types, with choices tailored to specific project attributes. Currently, three common types include insulated 3-layer sheets, standard single-layer sheets, and translucent sheets. However, roofing sheets may lack sound insulation, leading to challenges in noise reduction.

Cladding panels

After establishing the main frame and roofing, cladding becomes a crucial component in prefabricated buildings. Historically, bricks were used to ensure structural stability, but the extraction and firing processes can adversely impact the environment and increase material weight and construction time.

To address these concerns, contemporary practices favor cladding panels made from metal, prefabricated materials, or panels as replacements for traditional bricks. These alternatives are significantly lighter, reducing load on the structure.

Advantages and disadvantages of prefabricated steel buildings

a. Advantages

• Material efficiency and reduced construction load due to the lighter weight compared to other materials.

• Rapid and straightforward installation, suitable for various weather conditions.

• Maximization of workshop space with easy scalability for future needs.

• Cost-effective compared to traditional concrete buildings, providing significant time and cost savings for businesses.

• High degree of standardization throughout the construction process.

b. Disadvantages

• Limited fire resistance.

• Susceptibility to corrosion in humid environments.

• Relatively lower durability.

• Higher maintenance costs.

However, these disadvantages have been addressed with modern technologies. For instance:

• Corrosion resistance can be enhanced through galvanization or aluminum plating, reducing maintenance costs.

• Fire resistance can be improved by using fireproof materials such as ceramic panels, fire-retardant coatings, or concrete encasements, alongside appropriate fire safety equipment to ensure safety.

Strengths and weaknesses of prefabricated steel structure and traditional concrete buildings

Construction method

Traditional reinforced concrete structure require on-site formwork, rebar assembly, and concrete pouring, demanding substantial time and labor. In contrast, the prefabricated steel structure approach allows components like columns, beams, and slabs to be manufactured in a factory and transported for assembly.

Durability

Prefabricated steel structure typically have a minimum lifespan of 30 years. For special projects such as bridges, high-rise buildings, and shopping centers, the steel framework can be engineered to achieve durability requirements of up to 100 years.

Applications

Initially, prefabricated steel structure were primarily utilized for warehouses and industrial projects. Today, however, they are increasingly applied in residential construction, including townhouses, showrooms, cafés, restaurants, high-rise buildings, and shopping centers.

Requirements for prefabricated steel building construction companies

To effectively implement prefabricated steel building solutions, design and construction teams must possess significant experience and expertise while ensuring technical accuracy. The design phase must meet at least four key requirements:

1. Aesthetics and design flexibility: The adaptable steel structure accommodates various architectural styles and investor preferences, enabling the creation of unique and engaging building designs.
2. Load-bearing capacity: Engineers and architects must meticulously calculate various loads, including dead loads, finishing material loads, operational loads, and wind loads, to ensure the design of foundations and frames meets safety and performance standards. The design should also consider potential future expansions.
3. Material optimization and cost efficiency: A compliant prefabricated steel building must meet architectural and load-bearing requirements while also minimizing material costs.
4. Transportation and installation optimization: Many residential prefabricated steel projects are located in urban settings with limited construction space, necessitating careful planning of the construction layout and methods to minimize disruption and maintain safety for surrounding residents and traffic.

The design and installation process for prefabricated steel buildings

The construction of prefabricated steel buildings encompasses 3 fundamental steps:

1. Design: All project components are detailed, from methodologies to material choice. This step is critical for preparing architectural, structural, and MEP (mechanical, electrical, plumbing) drawings.

1. Fabrication of steel components: Components such as columns, beams, deck slabs, and purlins are fabricated in the factory, ensuring quality and readiness for installation.

2. Installation and construction: The prefabricated steel components are transported to the site and assembled, completing the prefabricated steel building.

Construction in urban environments, with more complex conditions than industrial projects, presents significant challenges for many investors. The on-site construction phase is crucial for project success, comprising the following steps:

1. Foundation work and anchor bolt installation: The foundation solution for the steel frame mirrors that of traditional reinforced concrete buildings, which can include isolated footings, strip footings, or pile foundations based on geological characteristics and load requirements. Anchor bolts are precisely positioned before pouring concrete to prepare for future connections with the steel framework.

2. Component production at the factory: This process occurs concurrently with foundation work. Once the foundation concrete is set and reaches necessary hardness, the steel structural components are fabricated in the factory and then transported for assembly, ensuring safety and efficiency during construction.

3. Steel frame erection and cladding installation: After fabrication is complete, the steel structural components are transported to the site for assembly. Assembly is typically supported by cranes, with components connected using high-strength bolts.

4. Finalizing the building, and installing ventilation, electrical, and plumbing systems: The finalization of steel buildings mirrors the finishing processes of traditional reinforced concrete structure, including tasks such as masonry, plastering, tiling, and the installation of doors and sanitary fittings.

Choosing a premier prefabricated steel building construction company in Hanoi, Vietnam

Having over 10 years of experience, LEXFAS COMPANY LIMITED stands as a trusted leader in the design, fabrication, and installation of steel structure in Hanoi, Vietnam.

Our core services:

✦ Design and installation of residential and industrial steel-framed buildings.
✦ Design and installation of steel structure for the construction, transportation, and advertising sectors.
✦ Design and installation of prefabricated steel buildings for warehouses, factories, offices, and parking facilities.
✦ Design and installation of manufacturing facilities for mechanical processing, textiles, and logistics.

OUR COMMITMENTS:
✅ A team of technical advisors trained in the UK, France, and the USA.
✅ High-quality steel materials in production.
✅ Rapid, professional, and safe construction services.
✅ Most competitive price in the market.

Our notable projects: Cam Pha Cement Plant, But Son Cement Line 2, the 7,000 sqm Production Facility of Bac Giang BBG Garment Corporation Joint Stock Company, Cua Dat Hyower Plant (Thanh Hoa), and the 5,500 sqm Space Frame Dome for Sam Nua Trade Center (Laos).

==>> LEXFAS is committed to building a dynamic image and continuously striving for growth in both domestic and international markets.

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