Zamil Steel Company Limited: Design Manual

PEB DIVISION
ZAMIL STEEL COMPANY LIMITED

PRE-ENGINEERED BUILDINGS DIVISION
DESIGN MANUAL
D M 03 . 10 .0 0
ZAMIL STEEL BUILDINGS
DESIGN MANUAL
PEB DIVISION
P R E F AC E
This revision of design manual has been prepared to account for the changes of ZAMIL STEEL standards
during the last four years since 1999 regarding single skin & Tempcon panels, built-up sections standard
dimensions, serviceability consideration and some standard connections, also this revision of design
manual presents the results of special technical studies carried out in the ZAMIL STEEL PRD department
including finite element studies using most recent software techniques, buckling analysis studies and also
derived formulas using numerical correlation studies. Designers can make use of these studies to enhance
the design process.
This revision of the design manual also resolves some miscellaneous and confusing points that were
reported to PRD department.
The contents of this manual were rearranged and presented in “Adobe Acrobat” format along with
navigation pane to ensure effective and fast use of this manual.
Design/Quote engineers are strongly advised to read this manual as a whole in conjunction with the
standard codes and manuals stated in clause 2.1 page 2-1 of this manual.
The clauses containing the major changes made in this revision of design manual (DM 03.10.00) are as
follows :-
2.4. Serviceability consideration _________ 2-15

3.5. Expansion Joints __________________ 3-8
3.7. Bracing Systems Arrangement_______ 3-11
4.1.2.1. Built up section _________________ 4-3
4.1.2.2. Galvanized primary members______ 4-5
4.3. Flange braces____________________ 4-22
4.6. Standard Anchor Bolts _____________ 4-67
4.7.8. Crane Beam ___________________ 4-74
5.1. Panels___________________________ 5-1
5.2.1.7. Double ‘C’ -sections ____________ 5-27
5.2.2. Design Of Roof Purlins ___________ 5-29
5.2.4. Design Of Eave Struts ____________ 5-35
6.1.2. End wall Rafter Design Concept _____ 6-2
6.2.2. End Wall Posts Design Concept _____ 6-6
7.2.3.1 Top Running Cranes ____________ 7-11
7.3. Bracing Design Notes ______________ 7-13
DM 03.10.00 I
DESIGN MANUAL
PEB DIVISION
P R E F AC E
8.2.1.2.Connection for Lateral Load _______ 8-2

9.1. Design of Joists ___________________ 9-2
9.3. Design of Beams __________________ 9-7
10.11. Egypt Jobs in Non-Free Zone Areas 10-6
12.1. Drainage ______________________ 12-1
Your feedback and comments are highly appreciated for the continuous improvement of this manual.
MTS
AAG
OCT. 2003
DM 03.10.00 II
DESIGN MANUAL
PEB DIVISION
RESPONSIBILLITIES
Design Engineer’s Responsibilities:
1. Reports to his Design Supervisor.

2. Studies and validates contract requirements, given in the Contract Information Form (CIF) and
raises queries and requests for clarifications as necessary.
3. Designs buildings assigned to him using design codes, specifications, procedures and standards of
Zamil Steel together with engineering rationale.
4. Designs all building components satisfying the stability, serviceability and stress requirements
simultaneously under design loads and load combinations.
5. Optimizes the design by utilizing optimizing techniques in order to achieve the most economical and
an adequate design.
6. Plans to finish his work according to the schedules and deadlines assigned. Gives early warning to
his supervisor if the schedules cannot be met.
7. Alerts his supervisor in cases such as special design requirements and non-standard building
configuration.
8. Gives clear instructions to detailing engineers on his jobs in order to make sure that his designs are
understood.
9. Reviews approval and erection drawings and gives final approval on them.
10. Checks other design engineer’s work if checking is assigned to him.
11. Participates in design meetings and suggests improvement of design engineering practices.
Quote Design Engineer’s Responsibilities:
The engineer designing a quote should be efficient in his work. He is required to cope up with the design
accuracy as well as the speed at the same time. His task is not limited only to the design of the building as
it is presented in the C.I.F. Beyond this; he should suggest the optimal building configuration and come up
with the most economical design as well. The ideal and the professional approach that is required from the
quote design engineer is summarized below:
1. Go over the CIF and thoroughly absorb what is requested in terms of dimensions, design loads,
special details etc.
2. Think of the best possible solution that will provide the same shape of the building, but may be with
different bay spacing, different type of frames, different frame orientations, etc. which will produce
the most economical design of the building.
3. Contact the sales representative in charge of the quote and discuss alternative solutions (if any).
4. If approved, design the quotation accordingly and mention the deviations, additions and deletions
clearly in his design summary.
5. The guidelines regarding planning a PEB in order to reach the best and most competitive offer are
outlined in chapter 3.
DM 03.10.00 III
DESIGN MANUAL
PEB DIVISION
T AB L E O F C O N T E N T
CHAPTER 1: MATERIALS ....................................................................................................................................... 1-1

1.1. PLATES ......................................................................................................................................................... 1-1
1.2. COLD FORMED SECTIONS.......................................................................................................................... 1-1
1.3. HOT ROLLED SECTIONS ............................................................................................................................. 1-2
1.4. SHEETING ..................................................................................................................................................... 1-2
1.5. SKYLIGHT PANELS...................................................................................................................................... 1-3
1.6. TRIMS ............................................................................................................................................................ 1-3
1.7. ROUND BARS ............................................................................................................................................... 1-3
1.8. CABLE BRACING ......................................................................................................................................... 1-3
1.9. ANCHOR BOLTS........................................................................................................................................... 1-3
1.10. MISCELANEOUS ........................................................................................................................................ 1-4
1.11. BOLTS ......................................................................................................................................................... 1-4
1.12. NUTS............................................................................................................................................................ 1-4
1.13. WASHERS ................................................................................................................................................... 1-5
1.14. SELF DRILLING SCREWS.......................................................................................................................... 1-5
1.15. RIVETS......................................................................................................................................................... 1-6
CHAPTER 2: STANDARD CODES & LOADS......................................................................................................... 2-1

2.1. STANDARD CODES AND M ANUALS .................................................................................................................... 2-1
2.2. DESIGN LOADS ................................................................................................................................................. 2-2
2.2.1. Dead Load .............................................................................................................................................. 2-2
2.2.2. Live Loads & Collateral Loads ................................................................................................................ 2-3
2.2.3. Roof Snow Load ..................................................................................................................................... 2-4
2.2.4. Wind Load............................................................................................................................................... 2-7
2.2.5. Crane Loads ........................................................................................................................................... 2-8
2.2.6. Seismic Loads ...................................................................................................................................... 2-11
2.3. LOAD COMBINATIONS ..................................................................................................................................... 2-13
2.4. SERVICEABILITY CONSIDERATION .................................................................................................................... 2-15
CHAPTER 3: PLANNING PEB.................................................................................................................................3-1

3.1. M AIN FRAME CONFIGURATION ..........................................................................................................................3-1
3.1.1. Main frame orientation ............................................................................................................................3-1
3.1.2. Main frame types ....................................................................................................................................3-2
3.1.2.1 Clear Span ........................................................................................................................................................ 3-2
3.1.2.2. Multi - Span...................................................................................................................................................... 3-2
3.1.2.3. Lean- T0........................................................................................................................................................... 3-3
3.1.2.4. Mono- slope ..................................................................................................................................................... 3-4
3.1.2.5. Space Saver .................................................................................................................................................... 3-4
3.1.2.6. Roof System..................................................................................................................................................... 3-5
3.1.2.7. Multi- Gable...................................................................................................................................................... 3-6
3.1.3. Roof Slope ..............................................................................................................................................3-6
3.1.4. Eave Height ............................................................................................................................................3-7
3.2. ROOF PURLINS .................................................................................................................................................3-7
3.3. WALL GIRTS ....................................................................................................................................................3-7
3.4. END W ALL SYSTEMS ........................................................................................................................................3-8
3.5. EXPANSION JOINTS ..........................................................................................................................................3-8
3.6. BAY SPACING ..................................................................................................................................................3-9
3.7. BRACING SYSTEMS ARRANGEMENT ................................................................................................................3-11
3.7.1. Bracing for wind and seismic loads in the longitudinal direction ..........................................................3-11
3.7.2. Wind and seismic bracing in P&B endwalls..........................................................................................3-12
3.7.3. Crane Bracing .......................................................................................................................................3-12
3.8. MEZZANINE FLOORS .......................................................................................................................................3-13
3.9. CRANES SYSTEMS ..........................................................................................................................................3-14
DM 03.10.00 IV
DESIGN MANUAL
PEB DIVISION
CHAPTER 4: MAIN FRAMING DESIGN ................................................................................................................. 4-1

4.1. M AIN FRAME DESIGN PROCEDURE AND CONSTRAINTS ...................................................................................... 4-1
4.1.1. ASFAD ................................................................................................................................................... 4-1
4.1.2. Design Constraints................................................................................................................................. 4-3
4.1.2.1. Built up section ................................................................................................................................................ 4-3
4.1.2.2. Galvanized primary members .......................................................................................................................... 4-5
4.1.2.3. Fabrication Limitation....................................................................................................................................... 4-6
4.1.2.4. Shipping Limitation .......................................................................................................................................... 4-7
4.1.2.5. Shot Blast and Paint Line Limitations .............................................................................................................. 4-7
4.1.2.6. Other guidelines............................................................................................................................................... 4-8
4.1.2.7. Optimization..................................................................................................................................................... 4-9
4.2. DESIGN OF JACK BEAMS................................................................................................................................ 4-11
4.2.1. Loads ................................................................................................................................................... 4-11
4.2.2. Connection details................................................................................................................................ 4-12
4.2.3. Design parameters............................................................................................................................... 4-12
4.2.4. Design Procedure ................................................................................................................................ 4-13
4.3. FLANGE BRACES ........................................................................................................................................... 4-22
4.3.1. Brace members requirements.............................................................................................................. 4-22
4.3.1.1. Stiffness requirements ................................................................................................................................... 4-22
4.3.1.2. Strength requirements ................................................................................................................................... 4-23
4.3.2. Spread sheet for checking flange brace system adequacy ................................................................. 4-24
4.4. DESIGN OF RIGID FRAME CONNECTIONS ......................................................................................................... 4-28
4.4.1. Design of Pinned Base Plate ............................................................................................................... 4-28
4.4.2. Design of Fixed Base Plate.................................................................................................................. 4-40
4.4.3. Design of horizontal knee connection .................................................................................................. 4-47
4.4.4. Design of rafter intermediate & ridge splices ....................................................................................... 4-54
4.4.5 Design of Pinned Cap Plate.................................................................................................................. 4-55
4.5. STANDARD FRAME CONNECTIONS CODES ...................................................................................................... 4-58
4.5.1 Anchor Bolt Pattern Codes ................................................................................................................... 4-58
4.5.2 Knee Connections................................................................................................................................. 4-64
4.5.3 Rafter Splice Codes .............................................................................................................................. 4-65
4.6. STANDARD ANCHOR BOLTS ........................................................................................................................... 4-67
4.7. WELDING PROCEDURE ................................................................................................................................... 4-69
4.7.1.Types of Welds and Standard Sizes..................................................................................................... 4-69
4.7.2. Main Frame with Horizontal Knee Connection .................................................................................... 4-70
4.7.3. Vertical Knee Connection .................................................................................................................... 4-71
4.7.4. Interior Columns Connections.............................................................................................................. 4-71
4.7.5. Ridge Splices ....................................................................................................................................... 4-72
4.7.6. Base Plate of Cold-Formed EW Post .................................................................................................. 4-72
4.7.7. Mezzanine Connections....................................................................................................................... 4-73
4.7.8. Crane Beam ......................................................................................................................................... 4-74
CHAPTER 5: SECONDARY MEMBERS DESIGN...................................................................................................5-1

5.1. PANELS ............................................................................................................................................................5-1
5.1.1. Single Skin Panels ..................................................................................................................................5-1
5.1.1.1. Steel Panels .....................................................................................................................................................5-1
5.1.1.2. Aluminum Panels..............................................................................................................................................5-8
5.1.2. Tempcon Panels ...................................................................................................................................5-10
5.1.2.1. Steel Tempcon Panels....................................................................................................................................5-11
5.1.2.2. Aluminum Tempcon Panels............................................................................................................................5-16
5.2. SECONDARY STRUCTURAL FRAMING ...............................................................................................................5-20
5.2.1. Cold Formed Cross Sections Properties and Capacities .....................................................................5-21
5.2.1.1. 200mm depth Z-sections ................................................................................................................................5-21
5.2.1.3. Z-sections overlaps.........................................................................................................................................5-23
5.2.1.4. 120mm depth C-sections................................................................................................................................5-24
DM 03.10.00 V
DESIGN MANUAL
PEB DIVISION
5.2.1.7. Double ‘C’ -sections........................................................................................................................................5-27

5.2.1.8. Eave Strut-section ..........................................................................................................................................5-28
5.2.2. Design Of Roof Purlins .........................................................................................................................5-29
5.2.2.1 Roof Purlins design loads ................................................................................................................................5-29
5.2.2.2. Roof Purlins design concept ...........................................................................................................................5-29
5.2.2.3. Roof Purlins connections ................................................................................................................................5-32
5.2.3. Design Of Wall Girts ............................................................................................................................5-33
5.2.3.1. Wall Girts Design Loads .................................................................................................................................5-33
5.2.3.2. Wall Girt Design Concept: ..............................................................................................................................5-33
5.2.3.3. Wall Girt Connections .....................................................................................................................................5-34
5.2.4. Design Of Eave Struts ..........................................................................................................................5-35
5.2.4.1. Eave strut Design Loads.................................................................................................................................5-35
5.2.4.2. Eave strut Design Concept: ............................................................................................................................5-35
5.2.4.3. Eave Strut Connections: .................................................................................................................................5-36
CHAPTER 6: END WALLS DESIGN ........................................................................................................................6-1

6.1. POST & BEAM ENDWALL RAFTERS ...................................................................................................................6-1
6.1.1. Design Loads: .........................................................................................................................................6-2
6.1.2. Design Concept.......................................................................................................................................6-2
6.1.3. End Wall Rafter Guide Design Tables ....................................................................................................6-3
6.2. ENDWALL POSTS ..............................................................................................................................................6-6
6.2.1. Design Loads: .........................................................................................................................................6-6
6.2.2. Design Concept.......................................................................................................................................6-6
6.3. END W ALL DESIGN SOFT WARE ........................................................................................................................6-9
6.4. DIAPHRAGM ACTION AT P&B END W ALLS .......................................................................................................6-11
CHAPTER 7: BRACING SYSTEM DESIGN............................................................................................................ 7-1

7.1. BRACING STRUCTURAL TYPES ......................................................................................................................... 7-1
7.1.1. X-bracing................................................................................................................................................ 7-1
7.1.2. Portal Bracing:........................................................................................................................................ 7-2
7.1.3. Minor Axis Bending ................................................................................................................................ 7-3
7.2. BRACING SYSTEMS .......................................................................................................................................... 7-4
7.2.1. Wind Bracing.......................................................................................................................................... 7-4
7.2.1.1. Longitudinal bracing:........................................................................................................................................ 7-4
7.2.1.2. Transversal bracing in P&B end walls ............................................................................................................. 7-8
7.2.2. Seismic Bracing ..................................................................................................................................... 7-9
7.2.2.1.Sidewall bracing X-bracing ............................................................................................................................... 7-9
7.2.2.2.Sidewall bracing Portal Bracing ...................................................................................................................... 7-10
7.2.3. Crane Bracing ...................................................................................................................................... 7-11
7.2.3.1 Top Running ................................................................................................................................................... 7-11
7.2.3.2 Underhung...................................................................................................................................................... 7-12
7.3. BRACING DESIGN NOTES ............................................................................................................................... 7-13
CHAPTER 8: CRANE SYSTEMS DESIGN ..............................................................................................................8-1

8.1. CRANES SYSTEMS DESIGN RULES: ...................................................................................................................8-1
8.2. DIFFERENT CRANE TYPES .................................................................................................................................8-2
8.2.1. Top Running Cranes ...............................................................................................................................8-2
8.2.1.1. Bracket System.................................................................................................................................................8-2
8.2.1.2.Connection for Lateral Load ..............................................................................................................................8-2
8.2.1.3. Independent Crane Column..............................................................................................................................8-3
8.2.1.4. Stepped Column...............................................................................................................................................8-4
8.2.1.5. Crane Tower .....................................................................................................................................................8-5
8.2.1.6. Crane Beam Design .........................................................................................................................................8-8
8.2.2. Under hung Cranes / Monorails ............................................................................................................8-12
8.2.3. Jib Cranes: ............................................................................................................................................8-13
8.2.4 Gantry Cranes & Semi-gantry................................................................................................................8-15
DM 03.10.00 VI
DESIGN MANUAL
PEB DIVISION
CHAPTER 9: MEZZANINE FLOOR DESIGN...........................................................................................................9-1

9.1. DESIGN OF JOISTS ............................................................................................................................................9-2
9.2. DESIGN OF JOISTS CONNECTIONS .....................................................................................................................9-4
9.3. DESIGN OF BEAMS............................................................................................................................................9-7
9.4. DESIGN OF BEAMS CONNECTIONS .....................................................................................................................9-9
9.5. DESIGN OF COLUMNS .....................................................................................................................................9-14
9.6. DESIGN OF FLOORING .....................................................................................................................................9-16
9.6.1 Mezzanine Deck.....................................................................................................................................9-16
9.6.2. Chequered Plate ...................................................................................................................................9-16
9.6.3. Gratings.................................................................................................................................................9-17
9.7.MISCELLANEOUS ITEMS ...................................................................................................................................9-18
9.7.1. Staircases .............................................................................................................................................9-18
9.7.2. Handrails ...............................................................................................................................................9-18
9.8. SPECIAL CASES..............................................................................................................................................9-19
9.8.1. Roof Platforms ......................................................................................................................................9-19
9.8.2. Catwalk .................................................................................................................................................9-19
9.9. FLOOR VIBRATION...........................................................................................................................................9-20
9.9.1. Vibration due to heel drop impact .........................................................................................................9-20
9 9 2 Vibration due to forcing impact 9-28
CHAPTER 10: SPECIAL DESIGN REQUIREMENTS............................................................................................10-1

10.1. ROYAL COMMISSION:....................................................................................................................................10-1
10.2. SAUDI CONSOLIDATED ELECTRICITY COMPANY (SCECO): ............................................................................10-1
10.3. SAUDI ARAMCO:...........................................................................................................................................10-1
10.4. JEBEL ALI FREE ZONE AUTHORITY (JAFZA).................................................................................................10-2
10.5. DUBAI ..........................................................................................................................................................10-4
10.6. SHARJAH .....................................................................................................................................................10-4
10.7. ABU DHABI...................................................................................................................................................10-5
10.8. VIETNAM: .....................................................................................................................................................10-5
10.9. SHANGHAI CHINA: ........................................................................................................................................10-5
10.10. WIND SPEED IN SAUDI ARABIAN: .................................................................................................................10-5
10.11. EGYPT JOBS IN NON-FREE ZONE AREAS .....................................................................................................10-6
10.12. SNOW LOADS .............................................................................................................................................10-6
CHAPTER 11: SPECIAL BUILDINGS....................................................................................................................11-1

11.1. CAR CANOPIES.............................................................................................................................................11-1
11.2. POULTRY BUILDINGS ....................................................................................................................................11-6
11.3. BULK STORAGE BUILDINGS ..........................................................................................................................11-8
11.4. HANGAR BUILDINGS ...................................................................................................................................11-13
CHAPTER 12: MISCELLANEOUS SERVICES......................................................................................................12-1

12.1. DRAINAGE ...................................................................................................................................................12-1
12.2. NATURAL LIGHTING ......................................................................................................................................12-7
12.3. VENTILATION ..............................................................................................................................................12-10
12.3.1. Ventilation Design Using Air Change Method...................................................................................12-11
12.3.2. Ventilation Design Using Heat Removal Method..............................................................................12-12
12.4. FOOTING .................................................................................................................................................12-14
12.4.1. Spread Footings with hairpin ............................................................................................................12-15
12.4.2 Spread Footings without hairpin ........................................................................................................12-23
DM 03.10.00 VII
DESIGN MANUAL
PEB DIVISION 1. Materials
CHAPTER 1: MATERIALS
Pre-engineered buildings (PEB) system mainly makes use of built-up sections, cold formed members as
well as some hot rolled sections. The materials of these components conform to ASTM (American Society
for Testing and Materials) specifications or equivalent standards. The specifications of materials are
updated as per the current usage and available inventory. In the following table, type, order size, usage and
material specifications are listed for each component of pre-engineered buildings in order to facilitate
design.
1.1. PLATES
Thickness (mm) ORDER SIZE USAGE SPECIFICATIONS
4.0 1500mm W x 6000mm L Webs of built-up sections
5.0 1500mm W x 6000 mm L Webs & Flanges of built-up sections
6.0 1500mm W x 6000mm L
8.0 Webs and Flanges of built-up sections ASTM - A 572 M
10.0 2100mm W x 6000mm L Webs and Flanges of built-up sections, Connection plates GRADE 345 Type 1
12.0
15.0 Flanges of built-up sections Fy = 34.5 kN/cm2
20.0 2100mm W x 6000mm L Fu = 45 kN/cm2
25.0 Connection Plates
30.0
40.0 2000mm W x 6000mm L Connection Plates
50.0
1.2. COLD FORMED SECTIONS
TYPE SECTIONS ORDER SIZE USAGE SPECIFICATIONS

200Z15 COIL 1.5mm T x 345mm W
200Z20 COIL 2.0mm T x 345mm W Purlins & Girts
BLACK COIL 200Z25 COIL 2.5mm T x 345mm W ASTM-A607 GRADE 50
200Z30 COIL 3.0mm T x 345mm W (For Red Oxide Primed)
180C20 COIL 2.0mm T x 390mm W Eave Struts Fy = 34.5 kN/cm2
180C25 COIL 2.5mm T x 390mm W
200C20 COIL 2.0mm T x 390mm W End wall Rafters, F.
Openings,
200C25 COIL 2.5mm T x 390mm W Eave Struts, Wind
Columns
300C2.0 COIL 2.0mm T x 495mm W & Mezzanine joists
200Z22 COIL 2.25mm T x 345mm W ASTM A653 SQ50 Class 1
200Z25 COIL 2.50mm T x 345mm W (Galvanized)
GALVANIZED 180C20 COIL 2.0mm T x 390mm W Eave Struts Fy = 34.5 kN/cm2
200C20 COIL 2.0mm T x 390mm W End Wall Rafters,
200C25 COIL 2.5mm T x 390mm W Eave Struts, Framed
Openings
& Wind Columns
NARROW 120C20 COIL 2.0mm T x 260mm W Space Frame
COILS 120C25 COIL 2.5mm T x 260mm W Chored Members &
GALVANIZED 120C30 COIL 3.0mm T x 260mm W Slide Door Leaves
DM 03.10.00 1-1
DESIGN MANUAL
1.3. HOT ROLLED SECTIONS

TYPE ORDER SIZE USAGE SPECIFICATIONS
I SECTIONS JIS-G3101 SS540 or EN
Wind Columns, Endwall Rafters &
IPEa 200 x 18.4 x 12.0m L 10025- S355JR
Mezzanine Joists
Fy = 34.5 kN/cm2
TUBES 150 mm x 150mm x 4.5mm x 12.0m L
Rigid Frame and Mezzanine JIS-3466 STKR-490
200mm x 200mm x 6.0mm x 12.0m L
Columns Fy = 32.5 kN/cm2
120mm x 60mm x 5.0mm x 8.5m L Space Frame Truss Members
CHANNEL PFC 200 x 75 x 23 x 9.0m L
EN10025-S355JR
PFC 260 x 75 x 28 x 9.0m L Cap Channel for Crane Beams, Stringer
Fy = 35.5 kN/cm2
PFC 380 x 100 x 54 x 9.0m L for Staircase
ANGLES 40mm x 40mm x 3.0mm x 12.0m L
50mm x 50mm x 3.0mm x 12.0m L
60mm x 60mm x 4.0mm x 12.0m L
ASTM 572 Grade 50
60mm x 60mm x 5.0mm x 12.0m L Flange Bracing, X Bracing and Open Web
Fy = 34.5 kN/cm2
60mm x 60mm x 6.0mm x 12.0m L Joist Members
75mm x 75mm x 6.0mm x 12.0m L
100mm x 100mm x 8.0mm x 12.0m L
PIPES 42mm x 2.3mm x 6.6m L Hand Rails/Space Frame Diag. Memb. JIS-G-6344-STK500
Galvanized 48mm x 2.8mm x 6.6m L Space Frame
Fy = 35.5 kN/cm2
89mm x 2.8mm x 6.6m L Diagonal Members
L: Length, W: Width, T: Thickness
1.4. SHEETING
Panel Type Finish/Color Thickness Order USAGE SPECIFICATIONS

Size
Type A: Sheeting Panels for
Bare Zincalume 0.5 Roof, Walls,
Type A ( Hi-Rib)
Mezzanine Deck, Partitions
& Liners
0.6 Type B: Sheeting Panels for
Type B (Hi-Rib+) 0.7 Roof, Walls, ASTM - A 792 M
Partitions & Liners
Coil Type C: Liners Sliding GRADE 345 B
XRW Painted Z/A 0.5 1145 mm Doors, Top & Bottom Layer Coating AZ150
Type C (Lo-Rib)
All Standard Colors W of TCLR, Bottom Layer of
TCHR
XRW Painted Z/A 0.6 Type G: Mezzanine Deck & Fy = 34.5 kN/cm2
Type G (Deep Rib)
Frost White 0.7 Roof Sheeting
XPD Painted Z/A 0.5 Type R: Sheeting Panels for
Type R
Frost White 0.6 Walls, Partitions & Liners
0.7
Alloy Type AA3003
Aluminum Plain
0.70 H26
Aluminum Frost Fy = 16.15 kN/cm2
White
Coil ASTM-A792
Type D & E XRW Painted Z/A 0.5 411 mm GRADE 50B
Partitions, Liners and Soffit
(Sculptured Panel) Frost White W Coating AZ150
Panels
Fy = 34.5 kN/cm2
0.5
Bare Zincalume
0.6
0.5 Coil ASTM-A792
XRW Painted Z/A 0.6 1278 mm GRADE 50B
Type F (5-Rib) Top Layer of TCHR in Roof
Frost White 0.7 W Coating AZ150
and Walls
Fy = 34.5 kN/cm2
0.5
XPD Painted Z/A
0.6
Frost White
0.7
Aluminum Plain 0.70 Alloy Type AA3003
Aluminum Frost H26
White Fy = 16.15 kN/cm2
DM 03.10.00 1-2
DESIGN MANUAL
1.5. SKYLIGHT PANELS
Panel Type Order USAGE SPECIFICATIONS

Lengt
h
Type A ( Hi-Rib) Translucent Panels for Roof, Walls
3250 Translucnet Panels for Roof, Walls
Type B (Hi-Rib)
mm
Type F (5 Rib) Translucent Panels for Roof, Walls ASTM D 3841-86 Type I
2750 Translucent Panels for Roof, Walls Tensile Strength = 10.3kN/cm2, Flexural Strength =
Type G (Deep Rib)
mm 20.7kN/cm2
3250 Translucent Panels for Walls
Type R
mm
1.6. TRIMS
TYPE COLOR ORDER SIZE SPECIFICATIONS

EAVE TRIM Frost White COIL 0.5mm T x 288mm W
CORNE TRIM Bronze Brown
R
GABLE TRIM Frost White COIL 0.5mm T x 326mm W
Bronze Brown ASTM - A792 M
DOWN SPOUTS Frost White COIL 0.5mm T x 350mm W GRADE 345B
Bronze Brown Fy = 34.5 kN/cm2
GUTTERS All Standard Colors COIL 0.5mm T x 563mm W
VALLEY GUTTERS Zinc / Alum COIL 1.0mm T x 1145mm W
1.7. ROUND BARS
ROD DIAMETER ORDER LENGTH USAGE SPECIFICATIONS

16mm 12.0m As Sag Rods ASTM - A 615M GRADE 300
24mm X-Bracing in Roof and Walls Fy = 27.7 kN/cm2
1.8. CABLE BRACING
Strand Diameter ORDER DESCRIPTION USAGE SPECIFICATIONS

Zinc Coated, 7-wire strand Cable Bracing ASTM - A475 - CLASS A
1 / 2 inch (12.70 6 Wire layer eccentrically twisted over one center wire Extra High Strength
in
mm) Coil
Roof and Walls Breaking Load = 119.7 kN
Additional Items: M24 Eye Bolt Class 4.6 Electro Galvanized
Brace Grip 1/2" Diameter x 970mm L ASTM - A475-78 - CLASS A
1.9. ANCHOR BOLTS

BOLT DIAMETER ORDER LENGTH USAGE SPECIFICATIONS
(mm) (mm)
M16 400mm Anchor bolts for End Wall & Partitions Column ASTM A36M or
bases
M20 500mm Anchor Bolts JIS-G 3101 - SS 400
M24 600mm for Main Frame Type J Hot Dip Galvanized
M30 900mm & Mezzanine column bases Fy = 23.5 kN/cm2
M36 1000mm
DM 03.10.00 1-3
DESIGN MANUAL
1.10. MISCELANEOUS

Slide Door Rails Rails (SD/DSD) x 6000 mm L Door Rail Tracks ASTM - A 1
CHEKERED PLATE CH.PL. 5mm T x 2000mm W x 6000mm L ASTM - A 36 Fy = 22.0 kN/cm2
PLAIN GALVANIZED GRAITING Floors in Catwalks,
Mezzanine
GRATINGS BAR 30mm x 3mm @ 30mm CENTER and Twisted & Platforms EN 10025 GRADE 275
BAR 100mm PITCH x 995mm W x 6000mm L
5000 mm HEIGHT - RIGHT
5000 mm HEIGHT - LEFT Australian Standards
ROLL-UP 4000 mm HEIGHT - RIGHT Door Guide For AS-3902
DOOR GUIDE 4000 mm HEIGHT - LEFT Roll-Up Doors
GUIDE TOP TRACK 2.0mm T x 6000mm L Sliding Door T1, T2 Guides
KITS BOTTOM TRACK 3.0mm T x 6000mm L Sliding Door B1 Guides BS - 2989
BOTTOM TRACK 4.0mm T x 6000mm L Sliding Door B1 Guides
1.11. BOLTS
(mm)
M12 35 Secondary Connections DIN 933 Class 4.6 Yellow Chromate
Purlins & Girts Fully Threaded
M12 35 Eave Strut, P&B DIN 933 Class 8.8 HDG
55 Frame Connections Fully Threaded Bolt and Nut
M16 50
70
M20 60 ASTM - A 325 M Type 1 HDG
80 Connections of Primary Sections Fully Threaded Bolt and Nut
M24 70
90 Other Moment Connections
M27 90
110
M30 110
120
M6 16 Ridge Ventilator & Valley Gutters DIN 933 Class 4.6
Stove Bolt Elec. Galvanized Fully
Threaded
M12 36 Framed DIN 933 Class 4.6 Fin Necked Bolt
Openings Elec. Galvanized, Fully Threaded
M12 25 Sliding Doors DIN 933 Class 4.6 Countersunk Bolt
Elec. Galvanized, Fully Threaded
1.12. NUTS
Nut Diameter USAGE SPECIFICATIONS
(mm)
M12 Secondary Connections - Machine Bolt DIN 934 Class 5 Yellow Chromate
M16 For Anchor Bolts
M20 DIN 934 Class 5
M24 For Cable Bracing & Anchor Bolts Electro Galvanized Hex. Nut
M36
M12 DIN 934 Class 8 HDG
M16
M20 High Strength Nut for ASTM – A563M
M24 Main Connections HDG Hexagonal Nut
M27
M30
For Machine Bolts with Valley Gutters & Ridge Ventilator DIN 934 Class 5 Elec. Galvanized
M6
Hex. Nut
DM 03.10.00 1-4
PEB DIVISION
ZAMIL STEEL COMPANY LIMITED

PRE-ENGINEERED BUILDINGS DIVISION
DESIGN MANUAL
D M 03 . 10 .0 0
DESIGN MANUAL
PEB DIVISION
P R E F AC E
This revision of design manual has been prepared to account for the changes of ZAMIL STEEL standards
during the last four years since 1999 regarding single skin & Tempcon panels, built-up sections standard
dimensions, serviceability consideration and some standard connections, also this revision of design
manual presents the results of special technical studies carried out in the ZAMIL STEEL PRD department
including finite element studies using most recent software techniques, buckling analysis studies and also
derived formulas using numerical correlation studies. Designers can make use of these studies to enhance
the design process.
This revision of the design manual also resolves some miscellaneous and confusing points that were
reported to PRD department.
The contents of this manual were rearranged and presented in “Adobe Acrobat” format along with
navigation pane to ensure effective and fast use of this manual.
Design/Quote engineers are strongly advised to read this manual as a whole in conjunction with the
standard codes and manuals stated in clause 2.1 page 2-1 of this manual.
The clauses containing the major changes made in this revision of design manual (DM 03.10.00) are as
follows :-
2.4. Serviceability consideration _________ 2-15

3.5. Expansion Joints __________________ 3-8
3.7. Bracing Systems Arrangement_______ 3-11
4.1.2.1. Built up section _________________ 4-3
4.1.2.2. Galvanized primary members______ 4-5
4.3. Flange braces____________________ 4-22
4.6. Standard Anchor Bolts _____________ 4-67
4.7.8. Crane Beam ___________________ 4-74
5.1. Panels___________________________ 5-1
5.2.1.7. Double ‘C’ -sections ____________ 5-27
5.2.2. Design Of Roof Purlins ___________ 5-29
5.2.4. Design Of Eave Struts ____________ 5-35
6.1.2. End wall Rafter Design Concept _____ 6-2
6.2.2. End Wall Posts Design Concept _____ 6-6
7.2.3.1 Top Running Cranes ____________ 7-11
7.3. Bracing Design Notes ______________ 7-13
DM 03.10.00 I
DESIGN MANUAL
PEB DIVISION
P R E F AC E
8.2.1.2.Connection for Lateral Load _______ 8-2

9.1. Design of Joists ___________________ 9-2
9.3. Design of Beams __________________ 9-7
10.11. Egypt Jobs in Non-Free Zone Areas 10-6
12.1. Drainage ______________________ 12-1
Your feedback and comments are highly appreciated for the continuous improvement of this manual.
MTS
AAG
OCT. 2003
DM 03.10.00 II
DESIGN MANUAL
PEB DIVISION
RESPONSIBILLITIES
Design Engineer’s Responsibilities:
1. Reports to his Design Supervisor.

2. Studies and validates contract requirements, given in the Contract Information Form (CIF) and
raises queries and requests for clarifications as necessary.
3. Designs buildings assigned to him using design codes, specifications, procedures and standards of
Zamil Steel together with engineering rationale.
4. Designs all building components satisfying the stability, serviceability and stress requirements
simultaneously under design loads and load combinations.
5. Optimizes the design by utilizing optimizing techniques in order to achieve the most economical and
an adequate design.
6. Plans to finish his work according to the schedules and deadlines assigned. Gives early warning to
his supervisor if the schedules cannot be met.
7. Alerts his supervisor in cases such as special design requirements and non-standard building
configuration.
8. Gives clear instructions to detailing engineers on his jobs in order to make sure that his designs are
understood.
9. Reviews approval and erection drawings and gives final approval on them.
10. Checks other design engineer’s work if checking is assigned to him.
11. Participates in design meetings and suggests improvement of design engineering practices.
Quote Design Engineer’s Responsibilities:
The engineer designing a quote should be efficient in his work. He is required to cope up with the design
accuracy as well as the speed at the same time. His task is not limited only to the design of the building as
it is presented in the C.I.F. Beyond this; he should suggest the optimal building configuration and come up
with the most economical design as well. The ideal and the professional approach that is required from the
quote design engineer is summarized below:
1. Go over the CIF and thoroughly absorb what is requested in terms of dimensions, design loads,
special details etc.
2. Think of the best possible solution that will provide the same shape of the building, but may be with
different bay spacing, different type of frames, different frame orientations, etc. which will produce
the most economical design of the building.
3. Contact the sales representative in charge of the quote and discuss alternative solutions (if any).
4. If approved, design the quotation accordingly and mention the deviations, additions and deletions
clearly in his design summary.
5. The guidelines regarding planning a PEB in order to reach the best and most competitive offer are
outlined in chapter 3.
DM 03.10.00 III
DESIGN MANUAL
PEB DIVISION
CHAPTER 1: MATERIALS ....................................................................................................................................... 1-1

1.1. PLATES ......................................................................................................................................................... 1-1
1.2. COLD FORMED SECTIONS.......................................................................................................................... 1-1
1.3. HOT ROLLED SECTIONS ............................................................................................................................. 1-2
1.4. SHEETING ..................................................................................................................................................... 1-2
1.5. SKYLIGHT PANELS...................................................................................................................................... 1-3
1.6. TRIMS ............................................................................................................................................................ 1-3
1.7. ROUND BARS ............................................................................................................................................... 1-3
1.8. CABLE BRACING ......................................................................................................................................... 1-3
1.9. ANCHOR BOLTS........................................................................................................................................... 1-3
1.10. MISCELANEOUS ........................................................................................................................................ 1-4
1.11. BOLTS ......................................................................................................................................................... 1-4
1.12. NUTS............................................................................................................................................................ 1-4
1.13. WASHERS ................................................................................................................................................... 1-5
1.14. SELF DRILLING SCREWS.......................................................................................................................... 1-5
1.15. RIVETS......................................................................................................................................................... 1-6
CHAPTER 2: STANDARD CODES & LOADS......................................................................................................... 2-1

2.1. STANDARD CODES AND M ANUALS .................................................................................................................... 2-1
2.2. DESIGN LOADS ................................................................................................................................................. 2-2
2.2.1. Dead Load .............................................................................................................................................. 2-2
2.2.2. Live Loads & Collateral Loads ................................................................................................................ 2-3
2.2.3. Roof Snow Load ..................................................................................................................................... 2-4
2.2.4. Wind Load............................................................................................................................................... 2-7
2.2.5. Crane Loads ........................................................................................................................................... 2-8
2.2.6. Seismic Loads ...................................................................................................................................... 2-11
2.3. LOAD COMBINATIONS ..................................................................................................................................... 2-13
2.4. SERVICEABILITY CONSIDERATION .................................................................................................................... 2-15
CHAPTER 3: PLANNING PEB.................................................................................................................................3-1

3.1. M AIN FRAME CONFIGURATION ..........................................................................................................................3-1
3.1.1. Main frame orientation ............................................................................................................................3-1
3.1.2. Main frame types ....................................................................................................................................3-2
3.1.2.1 Clear Span ........................................................................................................................................................ 3-2
3.1.2.2. Multi - Span...................................................................................................................................................... 3-2
3.1.2.3. Lean- T0........................................................................................................................................................... 3-3
3.1.2.4. Mono- slope ..................................................................................................................................................... 3-4
3.1.2.5. Space Saver .................................................................................................................................................... 3-4
3.1.2.6. Roof System..................................................................................................................................................... 3-5
3.1.2.7. Multi- Gable...................................................................................................................................................... 3-6
3.1.3. Roof Slope ..............................................................................................................................................3-6
3.1.4. Eave Height ............................................................................................................................................3-7
3.2. ROOF PURLINS .................................................................................................................................................3-7
3.3. WALL GIRTS ....................................................................................................................................................3-7
3.4. END W ALL SYSTEMS ........................................................................................................................................3-8
3.5. EXPANSION JOINTS ..........................................................................................................................................3-8
3.6. BAY SPACING ..................................................................................................................................................3-9
3.7. BRACING SYSTEMS ARRANGEMENT ................................................................................................................3-11
3.7.1. Bracing for wind and seismic loads in the longitudinal direction ..........................................................3-11
3.7.2. Wind and seismic bracing in P&B endwalls..........................................................................................3-12
3.7.3. Crane Bracing .......................................................................................................................................3-12
3.8. MEZZANINE FLOORS .......................................................................................................................................3-13
3.9. CRANES SYSTEMS ..........................................................................................................................................3-14
DM 03.10.00 IV
DESIGN MANUAL
PEB DIVISION
CHAPTER 4: MAIN FRAMING DESIGN ................................................................................................................. 4-1

4.1. M AIN FRAME DESIGN PROCEDURE AND CONSTRAINTS ...................................................................................... 4-1
4.1.1. ASFAD ................................................................................................................................................... 4-1
4.1.2. Design Constraints................................................................................................................................. 4-3
4.1.2.1. Built up section ................................................................................................................................................ 4-3
4.1.2.2. Galvanized primary members .......................................................................................................................... 4-5
4.1.2.3. Fabrication Limitation....................................................................................................................................... 4-6
4.1.2.4. Shipping Limitation .......................................................................................................................................... 4-7
4.1.2.5. Shot Blast and Paint Line Limitations .............................................................................................................. 4-7
4.1.2.6. Other guidelines............................................................................................................................................... 4-8
4.1.2.7. Optimization..................................................................................................................................................... 4-9
4.2. DESIGN OF JACK BEAMS................................................................................................................................ 4-11
4.2.1. Loads ................................................................................................................................................... 4-11
4.2.2. Connection details................................................................................................................................ 4-12
4.2.3. Design parameters............................................................................................................................... 4-12
4.2.4. Design Procedure ................................................................................................................................ 4-13
4.3. FLANGE BRACES ........................................................................................................................................... 4-22
4.3.1. Brace members requirements.............................................................................................................. 4-22
4.3.1.1. Stiffness requirements ................................................................................................................................... 4-22
4.3.1.2. Strength requirements ................................................................................................................................... 4-23
4.3.2. Spread sheet for checking flange brace system adequacy ................................................................. 4-24
4.4. DESIGN OF RIGID FRAME CONNECTIONS ......................................................................................................... 4-28
4.4.1. Design of Pinned Base Plate ............................................................................................................... 4-28
4.4.2. Design of Fixed Base Plate.................................................................................................................. 4-40
4.4.3. Design of horizontal knee connection .................................................................................................. 4-47
4.4.4. Design of rafter intermediate & ridge splices ....................................................................................... 4-54
4.4.5 Design of Pinned Cap Plate.................................................................................................................. 4-55
4.5. STANDARD FRAME CONNECTIONS CODES ...................................................................................................... 4-58
4.5.1 Anchor Bolt Pattern Codes ................................................................................................................... 4-58
4.5.2 Knee Connections................................................................................................................................. 4-64
4.5.3 Rafter Splice Codes .............................................................................................................................. 4-65
4.6. STANDARD ANCHOR BOLTS ........................................................................................................................... 4-67
4.7. WELDING PROCEDURE ................................................................................................................................... 4-69
4.7.1.Types of Welds and Standard Sizes..................................................................................................... 4-69
4.7.2. Main Frame with Horizontal Knee Connection .................................................................................... 4-70
4.7.3. Vertical Knee Connection .................................................................................................................... 4-71
4.7.4. Interior Columns Connections.............................................................................................................. 4-71
4.7.5. Ridge Splices ....................................................................................................................................... 4-72
4.7.6. Base Plate of Cold-Formed EW Post .................................................................................................. 4-72
4.7.7. Mezzanine Connections....................................................................................................................... 4-73
4.7.8. Crane Beam ......................................................................................................................................... 4-74
CHAPTER 5: SECONDARY MEMBERS DESIGN...................................................................................................5-1

5.1. PANELS ............................................................................................................................................................5-1
5.1.1. Single Skin Panels ..................................................................................................................................5-1
5.1.1.1. Steel Panels .....................................................................................................................................................5-1
5.1.1.2. Aluminum Panels..............................................................................................................................................5-8
5.1.2. Tempcon Panels ...................................................................................................................................5-10
5.1.2.1. Steel Tempcon Panels....................................................................................................................................5-11
5.1.2.2. Aluminum Tempcon Panels............................................................................................................................5-16
5.2. SECONDARY STRUCTURAL FRAMING ...............................................................................................................5-20
5.2.1. Cold Formed Cross Sections Properties and Capacities .....................................................................5-21
5.2.1.3. Z-sections overlaps.........................................................................................................................................5-23
DM 03.10.00 V
DESIGN MANUAL
PEB DIVISION
5.2.1.7. Double ‘C’ -sections........................................................................................................................................5-27

5.2.1.8. Eave Strut-section ..........................................................................................................................................5-28
5.2.2. Design Of Roof Purlins .........................................................................................................................5-29
5.2.2.1 Roof Purlins design loads ................................................................................................................................5-29
5.2.2.2. Roof Purlins design concept ...........................................................................................................................5-29
5.2.2.3. Roof Purlins connections ................................................................................................................................5-32
5.2.3. Design Of Wall Girts ............................................................................................................................5-33
5.2.3.1. Wall Girts Design Loads .................................................................................................................................5-33
5.2.3.2. Wall Girt Design Concept: ..............................................................................................................................5-33
5.2.3.3. Wall Girt Connections .....................................................................................................................................5-34
5.2.4. Design Of Eave Struts ..........................................................................................................................5-35
5.2.4.1. Eave strut Design Loads.................................................................................................................................5-35
5.2.4.2. Eave strut Design Concept: ............................................................................................................................5-35
5.2.4.3. Eave Strut Connections: .................................................................................................................................5-36
CHAPTER 6: END WALLS DESIGN ........................................................................................................................6-1

6.1. POST & BEAM ENDWALL RAFTERS ...................................................................................................................6-1
6.1.1. Design Loads: .........................................................................................................................................6-2
6.1.2. Design Concept.......................................................................................................................................6-2
6.2. ENDWALL POSTS ..............................................................................................................................................6-6
6.2.1. Design Loads: .........................................................................................................................................6-6
6.2.2. Design Concept.......................................................................................................................................6-6
6.3. END W ALL DESIGN SOFT WARE ........................................................................................................................6-9
6.4. DIAPHRAGM ACTION AT P&B END W ALLS .......................................................................................................6-11
CHAPTER 7: BRACING SYSTEM DESIGN............................................................................................................ 7-1

7.1. BRACING STRUCTURAL TYPES ......................................................................................................................... 7-1
7.1.1. X-bracing................................................................................................................................................ 7-1
7.1.2. Portal Bracing:........................................................................................................................................ 7-2
7.1.3. Minor Axis Bending ................................................................................................................................ 7-3
7.2. BRACING SYSTEMS .......................................................................................................................................... 7-4
7.2.1. Wind Bracing.......................................................................................................................................... 7-4
7.2.1.1. Longitudinal bracing:........................................................................................................................................ 7-4
7.2.1.2. Transversal bracing in P&B end walls ............................................................................................................. 7-8
7.2.2. Seismic Bracing ..................................................................................................................................... 7-9
7.2.2.1.Sidewall bracing X-bracing ............................................................................................................................... 7-9
7.2.2.2.Sidewall bracing Portal Bracing ...................................................................................................................... 7-10
7.2.3. Crane Bracing ...................................................................................................................................... 7-11
7.2.3.1 Top Running ................................................................................................................................................... 7-11
7.2.3.2 Underhung...................................................................................................................................................... 7-12
7.3. BRACING DESIGN NOTES ............................................................................................................................... 7-13
CHAPTER 8: CRANE SYSTEMS DESIGN ..............................................................................................................8-1

8.1. CRANES SYSTEMS DESIGN RULES: ...................................................................................................................8-1
8.2. DIFFERENT CRANE TYPES .................................................................................................................................8-2
8.2.1. Top Running Cranes ...............................................................................................................................8-2
8.2.1.1. Bracket System.................................................................................................................................................8-2
8.2.1.2.Connection for Lateral Load ..............................................................................................................................8-2
8.2.1.3. Independent Crane Column..............................................................................................................................8-3
8.2.1.4. Stepped Column...............................................................................................................................................8-4
8.2.1.5. Crane Tower .....................................................................................................................................................8-5
8.2.1.6. Crane Beam Design .........................................................................................................................................8-8
8.2.2. Under hung Cranes / Monorails ............................................................................................................8-12
8.2.3. Jib Cranes: ............................................................................................................................................8-13
8.2.4 Gantry Cranes & Semi-gantry................................................................................................................8-15
DM 03.10.00 VI
DESIGN MANUAL
PEB DIVISION
CHAPTER 9: MEZZANINE FLOOR DESIGN...........................................................................................................9-1

9.1. DESIGN OF JOISTS ............................................................................................................................................9-2
9.2. DESIGN OF JOISTS CONNECTIONS .....................................................................................................................9-4
9.3. DESIGN OF BEAMS............................................................................................................................................9-7
9.4. DESIGN OF BEAMS CONNECTIONS .....................................................................................................................9-9
9.5. DESIGN OF COLUMNS .....................................................................................................................................9-14
9.6. DESIGN OF FLOORING .....................................................................................................................................9-16
9.6.1 Mezzanine Deck.....................................................................................................................................9-16
9.6.2. Chequered Plate ...................................................................................................................................9-16
9.6.3. Gratings.................................................................................................................................................9-17
9.7.MISCELLANEOUS ITEMS ...................................................................................................................................9-18
9.7.1. Staircases .............................................................................................................................................9-18
9.7.2. Handrails ...............................................................................................................................................9-18
9.8. SPECIAL CASES..............................................................................................................................................9-19
9.8.1. Roof Platforms ......................................................................................................................................9-19
9.8.2. Catwalk .................................................................................................................................................9-19
9.9. FLOOR VIBRATION...........................................................................................................................................9-20
9.9.1. Vibration due to heel drop impact .........................................................................................................9-20
9 9 2 Vibration due to forcing impact 9-28
CHAPTER 10: SPECIAL DESIGN REQUIREMENTS............................................................................................10-1

10.1. ROYAL COMMISSION:....................................................................................................................................10-1
10.2. SAUDI CONSOLIDATED ELECTRICITY COMPANY (SCECO): ............................................................................10-1
10.3. SAUDI ARAMCO:...........................................................................................................................................10-1
10.4. JEBEL ALI FREE ZONE AUTHORITY (JAFZA).................................................................................................10-2
10.5. DUBAI ..........................................................................................................................................................10-4
10.6. SHARJAH .....................................................................................................................................................10-4
10.7. ABU DHABI...................................................................................................................................................10-5
10.8. VIETNAM: .....................................................................................................................................................10-5
10.9. SHANGHAI CHINA: ........................................................................................................................................10-5
10.10. WIND SPEED IN SAUDI ARABIAN: .................................................................................................................10-5
10.11. EGYPT JOBS IN NON-FREE ZONE AREAS .....................................................................................................10-6
10.12. SNOW LOADS .............................................................................................................................................10-6
CHAPTER 11: SPECIAL BUILDINGS....................................................................................................................11-1

11.1. CAR CANOPIES.............................................................................................................................................11-1
11.2. POULTRY BUILDINGS ....................................................................................................................................11-6
11.3. BULK STORAGE BUILDINGS ..........................................................................................................................11-8
11.4. HANGAR BUILDINGS ...................................................................................................................................11-13
CHAPTER 12: MISCELLANEOUS SERVICES......................................................................................................12-1

12.1. DRAINAGE ...................................................................................................................................................12-1
12.2. NATURAL LIGHTING ......................................................................................................................................12-7
12.3. VENTILATION ..............................................................................................................................................12-10
12.3.1. Ventilation Design Using Air Change Method...................................................................................12-11
12.3.2. Ventilation Design Using Heat Removal Method..............................................................................12-12
12.4. FOOTING .................................................................................................................................................12-14
12.4.1. Spread Footings with hairpin ............................................................................................................12-15
12.4.2 Spread Footings without hairpin ........................................................................................................12-23
DM 03.10.00 VII
DESIGN MANUAL
CHAPTER 1: MATERIALS
Pre-engineered buildings (PEB) system mainly makes use of built-up sections, cold formed members as
well as some hot rolled sections. The materials of these components conform to ASTM (American Society
for Testing and Materials) specifications or equivalent standards. The specifications of materials are
updated as per the current usage and available inventory. In the following table, type, order size, usage and
material specifications are listed for each component of pre-engineered buildings in order to facilitate
design.
1.1. PLATES
Thickness (mm) ORDER SIZE USAGE SPECIFICATIONS
4.0 1500mm W x 6000mm L Webs of built-up sections
5.0 1500mm W x 6000 mm L Webs & Flanges of built-up sections
6.0 1500mm W x 6000mm L
8.0 Webs and Flanges of built-up sections ASTM - A 572 M
10.0 2100mm W x 6000mm L Webs and Flanges of built-up sections, Connection plates GRADE 345 Type 1
12.0
15.0 Flanges of built-up sections Fy = 34.5 kN/cm2
20.0 2100mm W x 6000mm L Fu = 45 kN/cm2
25.0 Connection Plates
30.0
40.0 2000mm W x 6000mm L Connection Plates
50.0
1.2. COLD FORMED SECTIONS
TYPE SECTIONS ORDER SIZE USAGE SPECIFICATIONS

BLACK COIL 200Z25 COIL 2.5mm T x 345mm W ASTM-A607 GRADE 50
200Z30 COIL 3.0mm T x 345mm W (For Red Oxide Primed)
180C20 COIL 2.0mm T x 390mm W Eave Struts Fy = 34.5 kN/cm2
200C20 COIL 2.0mm T x 390mm W End wall Rafters, F.
Openings,
200C25 COIL 2.5mm T x 390mm W Eave Struts, Wind
Columns
300C2.0 COIL 2.0mm T x 495mm W & Mezzanine joists
200Z22 COIL 2.25mm T x 345mm W ASTM A653 SQ50 Class 1
200Z25 COIL 2.50mm T x 345mm W (Galvanized)
GALVANIZED 180C20 COIL 2.0mm T x 390mm W Eave Struts Fy = 34.5 kN/cm2
200C20 COIL 2.0mm T x 390mm W End Wall Rafters,
200C25 COIL 2.5mm T x 390mm W Eave Struts, Framed
Openings
& Wind Columns
NARROW 120C20 COIL 2.0mm T x 260mm W Space Frame
COILS 120C25 COIL 2.5mm T x 260mm W Chored Members &
GALVANIZED 120C30 COIL 3.0mm T x 260mm W Slide Door Leaves
DM 03.10.00 1-1
DESIGN MANUAL
1.3. HOT ROLLED SECTIONS

I SECTIONS JIS-G3101 SS540 or EN
Wind Columns, Endwall Rafters &
IPEa 200 x 18.4 x 12.0m L 10025- S355JR
Mezzanine Joists
Fy = 34.5 kN/cm2
TUBES 150 mm x 150mm x 4.5mm x 12.0m L
Rigid Frame and Mezzanine JIS-3466 STKR-490
200mm x 200mm x 6.0mm x 12.0m L
Columns Fy = 32.5 kN/cm2
120mm x 60mm x 5.0mm x 8.5m L Space Frame Truss Members
CHANNEL PFC 200 x 75 x 23 x 9.0m L
EN10025-S355JR
PFC 260 x 75 x 28 x 9.0m L Cap Channel for Crane Beams, Stringer
Fy = 35.5 kN/cm2
PFC 380 x 100 x 54 x 9.0m L for Staircase
ANGLES 40mm x 40mm x 3.0mm x 12.0m L
50mm x 50mm x 3.0mm x 12.0m L
60mm x 60mm x 4.0mm x 12.0m L
ASTM 572 Grade 50
60mm x 60mm x 5.0mm x 12.0m L Flange Bracing, X Bracing and Open Web
Fy = 34.5 kN/cm2
60mm x 60mm x 6.0mm x 12.0m L Joist Members
75mm x 75mm x 6.0mm x 12.0m L
100mm x 100mm x 8.0mm x 12.0m L
PIPES 42mm x 2.3mm x 6.6m L Hand Rails/Space Frame Diag. Memb. JIS-G-6344-STK500
Galvanized 48mm x 2.8mm x 6.6m L Space Frame
Fy = 35.5 kN/cm2
89mm x 2.8mm x 6.6m L Diagonal Members
1.4. SHEETING
Panel Type Finish/Color Thickness Order USAGE SPECIFICATIONS

Size
Type A: Sheeting Panels for
Bare Zincalume 0.5 Roof, Walls,
Type A ( Hi-Rib)
Mezzanine Deck, Partitions
& Liners
0.6 Type B: Sheeting Panels for
Type B (Hi-Rib+) 0.7 Roof, Walls, ASTM - A 792 M
Partitions & Liners
Coil Type C: Liners Sliding GRADE 345 B
XRW Painted Z/A 0.5 1145 mm Doors, Top & Bottom Layer Coating AZ150
Type C (Lo-Rib)
All Standard Colors W of TCLR, Bottom Layer of
TCHR
XRW Painted Z/A 0.6 Type G: Mezzanine Deck & Fy = 34.5 kN/cm2
Type G (Deep Rib)
Frost White 0.7 Roof Sheeting
XPD Painted Z/A 0.5 Type R: Sheeting Panels for
Type R
Frost White 0.6 Walls, Partitions & Liners
0.7
Alloy Type AA3003
Aluminum Plain
0.70 H26
Aluminum Frost Fy = 16.15 kN/cm2
White
Coil ASTM-A792
Type D & E XRW Painted Z/A 0.5 411 mm GRADE 50B
Partitions, Liners and Soffit
(Sculptured Panel) Frost White W Coating AZ150
Panels
Fy = 34.5 kN/cm2
0.5
Bare Zincalume
0.6
0.5 Coil ASTM-A792
XRW Painted Z/A 0.6 1278 mm GRADE 50B
Type F (5-Rib) Top Layer of TCHR in Roof
Frost White 0.7 W Coating AZ150
and Walls
Fy = 34.5 kN/cm2
0.5
XPD Painted Z/A
0.6
Frost White
0.7
Aluminum Plain 0.70 Alloy Type AA3003
Aluminum Frost H26
White Fy = 16.15 kN/cm2
DM 03.10.00 1-2
DESIGN MANUAL
1.5. SKYLIGHT PANELS
Panel Type Order USAGE SPECIFICATIONS

Lengt
h
Type A ( Hi-Rib) Translucent Panels for Roof, Walls
3250 Translucnet Panels for Roof, Walls
Type B (Hi-Rib)
mm
Type F (5 Rib) Translucent Panels for Roof, Walls ASTM D 3841-86 Type I
2750 Translucent Panels for Roof, Walls Tensile Strength = 10.3kN/cm2, Flexural Strength =
Type G (Deep Rib)
mm 20.7kN/cm2
3250 Translucent Panels for Walls
Type R
mm
1.6. TRIMS
TYPE COLOR ORDER SIZE SPECIFICATIONS

EAVE TRIM Frost White COIL 0.5mm T x 288mm W
CORNE TRIM Bronze Brown
R
GABLE TRIM Frost White COIL 0.5mm T x 326mm W
Bronze Brown ASTM - A792 M
DOWN SPOUTS Frost White COIL 0.5mm T x 350mm W GRADE 345B
Bronze Brown Fy = 34.5 kN/cm2
GUTTERS All Standard Colors COIL 0.5mm T x 563mm W
VALLEY GUTTERS Zinc / Alum COIL 1.0mm T x 1145mm W
1.7. ROUND BARS
ROD DIAMETER ORDER LENGTH USAGE SPECIFICATIONS

16mm 12.0m As Sag Rods ASTM - A 615M GRADE 300
24mm X-Bracing in Roof and Walls Fy = 27.7 kN/cm2
1.8. CABLE BRACING
Strand Diameter ORDER DESCRIPTION USAGE SPECIFICATIONS

Zinc Coated, 7-wire strand Cable Bracing ASTM - A475 - CLASS A
1 / 2 inch (12.70 6 Wire layer eccentrically twisted over one center wire Extra High Strength
in
mm) Coil
Roof and Walls Breaking Load = 119.7 kN
Additional Items: M24 Eye Bolt Class 4.6 Electro Galvanized
Brace Grip 1/2" Diameter x 970mm L ASTM - A475-78 - CLASS A
1.9. ANCHOR BOLTS

(mm) (mm)
M16 400mm Anchor bolts for End Wall & Partitions Column ASTM A36M or
bases
M20 500mm Anchor Bolts JIS-G 3101 - SS 400
M24 600mm for Main Frame Type J Hot Dip Galvanized
M30 900mm & Mezzanine column bases Fy = 23.5 kN/cm2
M36 1000mm
DM 03.10.00 1-3
DESIGN MANUAL
1.10. MISCELANEOUS

Slide Door Rails Rails (SD/DSD) x 6000 mm L Door Rail Tracks ASTM - A 1
CHEKERED PLATE CH.PL. 5mm T x 2000mm W x 6000mm L ASTM - A 36 Fy = 22.0 kN/cm2
PLAIN GALVANIZED GRAITING Floors in Catwalks,
Mezzanine
GRATINGS BAR 30mm x 3mm @ 30mm CENTER and Twisted & Platforms EN 10025 GRADE 275
BAR 100mm PITCH x 995mm W x 6000mm L
5000 mm HEIGHT - RIGHT
5000 mm HEIGHT - LEFT Australian Standards
ROLL-UP 4000 mm HEIGHT - RIGHT Door Guide For AS-3902
DOOR GUIDE 4000 mm HEIGHT - LEFT Roll-Up Doors
GUIDE TOP TRACK 2.0mm T x 6000mm L Sliding Door T1, T2 Guides
KITS BOTTOM TRACK 3.0mm T x 6000mm L Sliding Door B1 Guides BS - 2989
BOTTOM TRACK 4.0mm T x 6000mm L Sliding Door B1 Guides
1.11. BOLTS
(mm)
M12 35 Secondary Connections DIN 933 Class 4.6 Yellow Chromate
Purlins & Girts Fully Threaded
M12 35 Eave Strut, P&B DIN 933 Class 8.8 HDG
55 Frame Connections Fully Threaded Bolt and Nut
M16 50
70
M20 60 ASTM - A 325 M Type 1 HDG
80 Connections of Primary Sections Fully Threaded Bolt and Nut
M24 70
90 Other Moment Connections
M27 90
110
M30 110
120
M6 16 Ridge Ventilator & Valley Gutters DIN 933 Class 4.6
Stove Bolt Elec. Galvanized Fully
Threaded
M12 36 Framed DIN 933 Class 4.6 Fin Necked Bolt
Openings Elec. Galvanized, Fully Threaded
M12 25 Sliding Doors DIN 933 Class 4.6 Countersunk Bolt
Elec. Galvanized, Fully Threaded
1.12. NUTS
Nut Diameter USAGE SPECIFICATIONS
(mm)
M12 Secondary Connections - Machine Bolt DIN 934 Class 5 Yellow Chromate
M20 DIN 934 Class 5
M24 For Cable Bracing & Anchor Bolts Electro Galvanized Hex. Nut
M36
M12 DIN 934 Class 8 HDG
M16
M20 High Strength Nut for ASTM – A563M
M24 Main Connections HDG Hexagonal Nut
M27
M30
For Machine Bolts with Valley Gutters & Ridge Ventilator DIN 934 Class 5 Elec. Galvanized
M6
Hex. Nut
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DESIGN MANUAL
1.13. WASHERS
Washer Diameter USAGE SPECIFICATIONS

(mm)
M20 DIN 125 Type A
M24 For Anchor Bolts & Cable Bracing Flat Mild Elec. Galvanized
M36
M12
M16
M20 For High Strength Bolt of ASTM - F436 Type 1
M24 Main Connections Round Hard
M27
M30
ASTM - A48 M Class275 B Cast Iron
M24 Bracing System
HDG Hill Side Washer
DIN 125 Type A Flat Mild Elect.
M12 For Sliding Doors
Galvanized
M6 For Machine Bolt with Valley Gutters & Ridge Ventilator
1.14. SELF DRILLING SCREWS
Description Specifications Usage

SDS Dacromet SPEDEC SD5 T15-5.5 x 25mm Single skin roof fixed at low rib
#5.5x25
SDS Dacromet SPEDEC SD5 T15-5.5x57mm Single skin roof fixed at high rib, gutter strap
#5.5x57
SDS Dacromet SPEDEC SD12-5.5x32mm Mezzanine deck, hot rolled sections
#5.5x32
SDS Dacromet SPEDEC SL2-T-A14-4.8x20 Stitch screws for fastening panel to panel (side lap),
#4.8x20 panel to trims
SDS Dacromet SPEDEC SD5 T15-5.5 x 62mm TCHR-65, TCMD-35, TCLR-35
#5.5x62
#5.5x77
#5.5x107
#5.5x137
SDS Buildex #5.5x25 Buildex 12-14x25mm No.6310-0481- Single Skin non-roof
3CS
SSD Stainless Steel SSD Stainless Steel Screw #5.5x28 Stainless steel single skin fixed at low rib
Screw #5.5x28
SSD Stainless Steel SSD Stainless Steel Screw 5.5x40 Stainless steel screws for mezzanine deck, hot rolled
Screw 5.5x40 sections
SSD Stainless Steel SSD Stainless Steel Screw 4.8x20 Stainless steel stitch screws
Screw 4.8x20
SSD Stainless Steel SSD Stainless Steel Screw 5.5x65 Stainless steel screws single skin roof fixed at high
Screw 5.5x65 rib, gutter strap
SSD Stainless Steel SSD Stainless Steel Screw 5.5x62 TCHR-65, TCMD-35, TCLR-35
Screw 5.5x62
Screw 5.5x77
Screw 5.5x107
Screw 5.5x130
DM 03.10.00 1-5
DESIGN MANUAL
1.15. RIVETS

Pop Rivet Zinc Coated 1/8” SD46BS
Laps of trims, gutter, downspouts,
Pop Rivet Bronze Brown 1/8” SD46BS
Gutter end closure, gutter-downspout connection.
Stainless Steel Pop Rivet 1/8” SSD46SSBS
DM 03.10.00 1-6
DESIGN MANUAL
PEB DIVISION 2. Standard codes & loads
CHAPTER 2: STANDARD CODES & LOADS
2.1. Standard Codes and Manuals

ZAMIL STEEL (PEB) standard codes and manuals used in for calculating applied loads and design of
different building’s components are as follows:-
• The standard design codes that govern the design procedures and calculations pertaining to built-
up sections are as follows:
1) AISC: American Institute of Steel Construction, Manual of Steel Construction, Allowable

Stress Design, Ninth Edition 1989.
2) AWS-D1-1-96: American Welding Society, Structural Welding Code Steel Manual 1996.
• The standard procedures for the design of cold-formed sections are based on following code:
3) AISI: American Iron and Steel Institute, Cold Formed Steel Design Manual, 1986 Edition and
1989 addendum.
• For the standard design loads and design practice the design engineer has to refer to the MBMA
manual which is exclusively used for low rise metal buildings.
4) MBMA: Metal Buildings Manufacturers Association, Low Rise Building Systems Manual
1996. The earlier version is of 1986 with 1990 supplement.
The above codes are to be used for the design of buildings by Zamil Steel design engineers unless
otherwise specified in the Contract Information Form (C.I.F).
DM 03.10.00 2-1
DESIGN MANUAL
2.2. Design loads

Zamil Steel pre-engineered buildings are designed to take the following types of loads. ZAMIL STEEL
Standard design loads is as per MBMA 1996. But the designer must always follow the loads mentioned in
the C.I.F. that may require design loads as per building code other than MBMA.
2.2.1. Dead Load

This includes the self-weight of rigid frames and imposed dead load due to secondary elements like roof
sheeting, purlins, insulation, etc.
Following are some standard dead loads (in kN/m2):
Purlin + Panel (0.5mm): 0.10

Purlin + Panel (0.5mm) + Liner (0.5mm) 0.15
Purlin + Mark Series Roof 0.15
Purlin + Tempcon Panel 0.15
These loads are pertaining to steel panels. The exact weights of all types of panels & purlins are given
in chapter (5)
Mezzanine Dead Loads (in kN/m2):
Table 2.1. Mezzanine Dead Loads
Dead Load Type Load in kN/m2

75mm Thick Concrete Slab 1.80
0.6mm Thick Mezzanine Deck 0.06
Joists (LL < 5.0 kN/m2) 0.15
Joists (LL > 5.0 kN/m2) 0.20
Beams (LL < 5.0 kN/m2) 0.15
Beams (LL > 5.0 kN/m2) 0.20
50mm Screed 1.20
25mm Ceramic Tile + 25 Grout 1.20
Vinyl Tile 0.05
Carpet 0.05
200mm Hollow Block Wall with Plasteron
3.50*
both sides ( per unit wall area )
200mm Reinforced Block Wall with
5.00*
Plaster(per unit wall area )
* Loads should be Verified by customer
DM 03.10.00 2-2
DESIGN MANUAL
2.2.2. Live Loads & Collateral Loads

Roof Live Loads
The roof live load depends on the tributary area of rigid frames. Refer to table 3.1 and Section 3 of MBMA
1996 for live loads. For built-up frames minimum uniformly distributed live load on roof is 0.57kN/m2 and
1.0 kN/m2 on roof and purlins as per MBMA 1996. However MBMA 1986 allows the use of 0.57kN/m2 as
live load for roof and purlins where ground snow load is less than 0.57kN/m2 (*). Roof live loads as per
other building codes should be verified before proceeding in your design. Some customers/consultants
may require pattern loading in live load applications.
Collateral Loads
Collateral loads are included in roof live loads that arise due to sprinklers, ducts, lighting fixtures and
ceilings. These loads are outlined in Table C2.4.1.2 of Section C2 of MBMA Manual. Following are some of
the collateral loads (in kN/m2).
Ceiling (Gypsum Board) 0.15

HVAC Duct 0.05
Lighting Fixtures 0.05
Sprinklers 0.15
Mezzanine Live Loads:

For Deck Panel: A Live Load of 0.50 kN/m2 has to be considered to account for concreting and curing (in
addition to dead load) when designing the mezzanine deck panel.
For Floor Live Loads Of Different Occupancy or Use refer to Table 8.1 of Section 8 of MBMA 1996 Manual.
Also commonly used occupancies are summarized in table (2.2) :-
Table 2.2. Commonly Used Occupancies Loads
2
Occupancy Or Use Uniform Load (Kn/m ) Concentrated (Kn)
Fixed 2.87 -
Assembly areas
Movable 4.79 -
Operating rooms 2.87 4.45
Hospitals
Wards 1.92 4.45
Light 5.99 8.90
Manufacturing
Heavy 11.97 13.34
Offices 2.39 8.90
Computer Rooms 4.79 8.90
Class rooms 1.92 4.45
School Classrooms
first corridors 4.79 4.45
Light 5.99 -
Storage
Heavy 11.97 -
Retail 4.79 4.45
Stores
Wholesale 5.99 4.45
*
Low rise building systems manual MBMA1986 – Section C3.1
DM 03.10.00 2-3
DESIGN MANUAL
Reduction in Mezzanine Live Load:

i) MBMA 1996:
For A1 > 37.2m2 (400 ft2) and L0 > 4.79kN/m2 (100 psf) reduction in live load is applied as given:
 4.57 
L = L 0  0.25 +
 A 1 

where,
L = reduced design live load in kN/m2
L0 = unreduced uniform design live load (kN/m2) of area supported by the member
A1 = influence area in m2 which is:
- 4x tributary area of a column
- 2x tributary area of a beam
- panel area for a two-way slab
Minimum L:
L > 0.5L0 for members supporting one floor
> 0.4L0 for members supporting two or more floors.
ii) MBMA 1986:
For members supporting more than13.9m2 (150 ft2) and Live Load > 4.79 kN/m2 reduction in live
load is calculated as:
R = r (10.8A-150)
where,
R = Reduction in percent
r = Rate of reduction equal to 0.08 percent
A = Area of floor supported by the member in m2
Maximum R:
R < 0.4 for members receiving load from one level only
< 0.6 for other members
< 23.1 (1+D/L)
Where,
D = Dead load in kN/m2 for the area supported by the member
L = Unit live load in kN/m2 for the area supported by the member.
2.2.3. Roof Snow Load
i) MBMA 1996
Snow loads, if any, on roofs are to be applied as per Section 4 of MBMA 1996 which depends on the
geographical locations, roof slope and building geometry.
The roof snow load pf are determined as:

pf = Is C pg
where: pg = ground snow load

Is = Importance factor as per Table 4.1.1(a)
C = Roof Type Factor 0 for roof slope θ > 70o and as per Table 4.1.1(b) for θ < 70o
DM 03.10.00 2-4
DESIGN MANUAL
The roof snow load has to be checked for the following situations (if prevailing)
Check for:
1) Minimum Roof Snow Loads

pf values should be checked with Minimum Roof Snow Loads given as:
For slope < 15o:
i) When pg < 20 psf ----- Min pf = Is pg
ii) When pg > 20 psf ----- Min pf = Is x 20
2) Unbalanced Roof Snow Loads
i) Gable Roofs: (but not applicable for Clear Span & mono-slope frames)
2.5o < slope < 15o --- 0.5pf on one slope and pf on the other slope
15o < slope < 70o --- Cu pf on one slope and no load on the other slope
Cu as per Table 4.2.1 of MBMA Manual
ii) Multi-Gable Roofs:

For slopes > 2.5o roof snow loads shall be increased from 0.5pf at the ridge to Cm pf at the valley. The
maximum height of snow at the valley need not exceed the elevation of the snow at the lower adjacent
ridge.
Cm as per Table 4.2.2 of MBMA Manual
Height of snow = Snow Load (kN/m2) / D (in kN/m3)

D (Density) = 0.435pg + 2.243 < 4.805kN/m3.
3) Partial Snow Loads
Partial loading has to be checked for multi-span frames and purlins.
For Multi-span Framing:
Load on Exterior Modules = pf

Load on Interior Modules = 0.5 pf
For roof purlins:
Load on Exterior Bays = pf

Load on Interior Bays = 0.5 pf
4) Drifts on Lower Roofs
Procedure:
Step-1: Check the need of drift loads
Drift Loads need to be considered if:
DM 03.10.00 2-5
DESIGN MANUAL
hr −hb
> 0.2
hb
Where hb = Height of uniform snow on lower roofs ( pfl / D )

hr = Difference in height between the upper and lower roofs
Step 2: Calculate drift height
Calculate drift height for both windward (lower) and leeward (upper) cases.
Leeward Drift:
h d = 0.43 3 Wb 4 p g + 10 - 1.5 ≤ (h r − h b )
where: Wb = Roof size along the drift for upper roof > 7.62m (25ft)
hb = Height of uniform snow on lower roofs ( pfl / D )
hr = Difference in height between the upper and lower roofs
Windward Drift:
h d = 0.5 x 0.43 3 Wb 4 p g + 10 - 1.5 ≤ (h r − h b )
where: Wb = Roof Size along the drift for lower roof
Take the larger hd of above.
Step 3: Calculate Width of Drift Wd:
For hd < (hr – hb ) :
Wd = 4 hd
For hd > (hr – hb ) :
4h d2
Wd =
hr − hb
DM 03.10.00 2-6
DESIGN MANUAL
Step 4: Calculate Maximum Intensity pt:
pt = D (hd + hb )
Note: If upper roof slope > 10o extra drift of 0.4hd (sliding drift) has to be considered. However the
total drift of 1.4hd shall not exceed (hr –hb ).
ii) Snow Load as per MBMA 1986
The roof snow load shall be determined in accordance with the formula:
pf = 0.7 pg
Roof snow loads in excess of 0.96kN/m2 (20 psf) may be modified when roof angle ‘a’ is greater than
30o according to the formula:
pf = 0.7 cs pg
 a - 30  o o
cs = 1 −   for 30 < a ≤ 70
 40 
=0 for a > 70 o
where,
cs = Slope reduction factor
a = Roof angle in degrees
Note: Drift load calculations as per MBMA 1986 are similar to as per MBMA 1996.
2.2.4. Wind Load

The wind loads are determined in accordance with Section 5 of MBMA 1996. Wind loads are governed by
wind speed, roof slope, eave height and open wall conditions of the building. Zamil Steel buildings are not
designed for a wind speed less than 110 km/h. Wind design pressure p depends on Importance Factor Iw ,
velocity pressure q and pressure coefficient GCp as per the following formula:
p = Iw q (GCp)
where velocity pressure q is evaluated as:
q (kN/m2) = 2.456 V2 H2/7 10-5
Where V = Wind velocity in km/h

H = Eave Height (min as 4.57m)
= Mean height for roof slope angle > 10o
DM 03.10.00 2-7
DESIGN MANUAL
GCp values are given for Rigid Frames for transverse and longitudinal directions in Tables 5.4(a) and
5.4(b) of MBMA 1996 Manual respectively. For secondary members GCp values are either evaluated
from the formulae given in Tables 5.5(a) through 5.5(f) or directly obtained from the summarized
Tables 5.7(a) & 5.7(b). Iw is importance factor taken from table 5.2(a) of MBMA 1996 manual.
Open Wall Conditions: GCp values largely depend on the open wall conditions. Buildings are thus
defined as Enclosed, Partially Enclosed and Open Buildings.
Partially Enclosed Building: A building in which:

1) the total area of openings in a wall that receives positive pressure exceeds 5% of that wall area
2) the total area of openings in a wall that receives positive pressure exceeds the sum of the
areas of openings for the balance of the building envelope ( walls and roof ) and
3) the density of the openings in the balance of the building envelope does not exceed 20%
This can be expressed as:
Ao > 0.05 Ag and

Ao > Aoi and
A oi
< 0.20
A gi
Where: Ao = Total areas of openings in a wall that receives positive external pressure
Ag = The gross area of that wall in which Ao is identified
Aoi = Total area of openings in building envelope - Ao
Agi = Building Envelope Area - Ag
Examples of Partially Enclosed Buildings:

1) Building with one side wall or one end wall fully open for access.
After applying the above criteria, it is found that this situation satisfies all the criteria mentioned for
partially enclosed building and thus, should be treated as partially enclosed building.
2) Building with two opposite walls fully open.
This situation may be regarded either as partially enclosed building or open building. If open wall area
is 80% of the total wall area then it is regarded as open building. Otherwise it should be treated as
partially open building which is the normal case.
Open Building: A building in which at least 80% of all walls are open
Enclosed Building: A building neither defined as Partially Enclosed building nor as an open building
Note: In MBMA1986 ‘Importance Factor’ Iw does not appear in the formula i.e., its value is set to 1.0,
while as per MBMA 1996, Iw is read from table 5.2(a) of the manual.
2.2.5. Crane Loads

Crane Loads are determined using the crane data available from the crane manufacturer and in
accordance with Section 6 of MBMA. Crane data includes wheel load, crab weight, crane weight,
wheel-base, end hook approach (used when two cranes operate in one aisle) and minimum vertical
and horizontal clearances.
DM 03.10.00 2-8
DESIGN MANUAL
Wheel Load:
Wheel Load (WL) for top running crane: (Assuming 2 end truck wheels at one end of bridge)
WL = 0.25BW + 0.5(RC+HT)
where,
WL = maximum Wheel Load
RC = Rated Capacity of the crane
HT = weight of Hoist with Trolley
BW = Bridge Weight
For an under-hung monorail crane, the maximum wheel load may be calculated as:
WL = RC + HT
Vertical Impact:
Top running crane: WL (maximum wheel load) used for the design of crane runway beams, their
connections and support brackets shall be increased by 10% for pendant operated bridge cranes and
25% for cab-operated bridge cranes. Vertical impact shall not be required for the design of frames,
support columns and foundations.
Wheel Load with vertical impact for top running crane:
WL = 0.25BW + 0.5(RC+HT) x I
where, I = vertical Impact (1.1 or 1.25)
Wheel Load with vertical impact for under-hung monorail crane:
WL = (RC + HT) x I
Underhung Monorail crane: Vertical impact is 25%; maximum wheel load WL = 1.25 x (RC+HT)
Lateral Force:
Lateral Wheel Load = 0.2x(RC + HT) / 4 = 0.05(RC+HT)
Longitudinal Force per side wall:
Longitudinal loads are calculated as 10% of the wheel load. Longitudinal crane bracing is designed to
resist this force.
For top running crane:

Longitudinal Wheel Load = 0.1x2x[0.25BW + 0.5(RC+HT)] = 0.2x[0.25BW + 0.5(RC+HT)]
For monorail crane: Longitudinal Wheel Load = 0.1x(RC+HT)

A detailed procedure of crane beam analysis has been provided in Section 6.5 of this manual. The
crane beam reactions are then used as applied loads on the main frame.
DM 03.10.00 2-9
DESIGN MANUAL
Allowable Fatigue Stress Range:

Use appropriate allowable stress range in the crane beam design program following the steps given
below:
Step1: Determine the Crane Service Classification using the following table:
Table 2.3. CRANE SERVICE CLASSIFICATION
Service Usage No. of Lifts per hour Speed Service

Classifications
Repair Shops, Light
assembly operations,
B 2-5 Low Light
Service and Light
Warehousing
Moderate Machine 5-10 Moderate Moderate
C
Shops
Heavy Machine
shops, Foundaries,
Heavy
D Fabricating Plants, 10-20 High Speed Duty
Steel Warehouses,
Container Yards, Mills
Step2: Determine AISC Loading Condition using the following table:
Table 2.4. Loading Condition for Parts and Connections Subjected to Fatigue
Service Class AISC Loading Condition

R < 0.5 R > 0.5
B 1
C 1 2
D 2 3
where,
R = TW/(TW+RC) For Under-hung monorail cranes
R = TW/(TW+2RC) for Top Running cranes
TW = Total Weight of the crane including bridge + hoist with trolley
Step3: Select the Allowable Stress Range for an appropriate crane-supporting member According the
table next page :
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DESIGN MANUAL
Table 2.5. ALLOWABLE STRESS RANGE (kN/cm2)
AISC Loading Condition

STRESS CATEGORY
1 2 3
Up to Up to Up to
LOADING CYCLES 100,000 500,000 2,000,000
1) B/U Runway Beams 33.8 20.0 12.4
2) B/U Brackets 33.8 20.0 12.4
3) Full penetration Groove Welded Splice on 24.1 14.5 9.0
Runway Beams
4) Base Metal @ Welded Transverse 24.1 14.5 9.0
Stiffeners
5) Bracket Flange Connection to Frame 15.2 9.0 5.5
Columns
6) Bracket Stiffener Connection to the Frame 15.2 9.0 5.5
Column
7) Bracket Stiffener Connection to the Frame 15.2 9.0 5.5
Rafter for Underhung Cranes
8) Bracket Web Connection to Frame 10.3 8.3 6.2
Column
11) A325 Bolts in tension 16.6 16.6 16.6
2.2.6. Seismic Loads

i) MBMA 1996
Seismic forces are evaluated using Equivalent Lateral Force Procedure as outlined in Section 7.4 of
MBMA 1996. As per this method seismic base shear V is determined in accordance with the following
equation:
V = Cs W
where,
2.5C a
Cs (The Seismic design coefficient) =
R
Ca (Seismic Coefficient) as defined in Table 7.4.1.1 (MBMA 1996)
R (Response modification factor) as defined in Table 7.3.3 (MBMA 1996)
W = Total Dead Load
Note: The total dead load includes:
1) In buildings with storage type of live loads, 25% of such live loads to be included in total dead load.
2) The actual partition weight or a minimum weight of 0.5kN/m2 of floor area, whichever is greater
must be added.
3) Total operating weight of permanent equipment.
4) Roof snow load has to be included in case it is greater than 1.5kN/m2. Snow load can be reduced
by 80% if approved by the local building official.
The lateral seismic force Fx induced at any level shall be determined as follows:
wx h x
Fx = n
V
∑wh
i =1
i i
k
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Where :
wi and wx = The portion of the total gravity load of the building W assigned to level i or x.
hi and hx = The height from the base to level i or x.
k = An exponent related to the building period. (For Low Rise Buildings k = 1)
The Main frames and P&B frames are designed for lateral seismic forces. Longitudinal bracing shall
be designed for an additional seismic force in addition to the wind force.
ii) MBMA 1986

Base Shear V:
V = 0.14ZKW
Where,
V = The total lateral seismic force or shear at the base

K=1.0 for moment resisting frames
Z=0.1875 for Zone I
Z=0.375 for Zone II
Z=0.75 for Zone III
Z=1.00 for Zone IV
W = the total dead load including collateral loads and partition loads where applicable.
Note: In case live load is of storage type, include 25% of live load in dead load. Also where the snow load is
1.5kN/m2 (31psf) or greater, 25% of the snow load shall be included with the total dead load.
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2.3. Load combinations

The Load Combinations as given in Section 9 of MBMA 1996 shall be considered in the design of all
buildings unless special combinations are requested in the C.I.F. The following two load combinations are
always considered for any building.
1. DL + LL
2. DL + WL
Building with Cranes

3. DL + CR
4. DL + CR + 0.5 WL
5. DL + CR + 0.5 LL (applicable as per MBMA 1974 only)
Building in Snow Zones

6. DL + SL
7. DL + CR if Pf ≤ 0.62kN/m2
DL + CR + 0.5SL if 0.62 kN/m2 < Pf < 1.48 kN/m2
DL + CR + 0.75SL if Pf ≥ 1.48 kN/m2
8. DL + SL + 0.5 WL
9. DL + 0.5 SL + WL
Building with Mezzanine

Mezzanine Load is added to all previous load combinations where applicable.
Building in Seismic Zones

10. [(0.9-0.5Av)*DL] + EL
11. [(1.1+0.5Av)*DL] + [(0.5)*FL] + [( R )*SL] + EL
Where Av : Effective Peak Velocity Related Acceleration [ Refer Figure 7.1.4(a) page 1-7-2
of MBMA ‘96]
R = 0 for ground snow < 30 psf (1.436 kN/m2)
R = 0.2 for ground snow > 30 psf (1.436 kN/m2)
Note: For FL>4.79kN/m2 use coefficient of FL as 1.0
DL includes total weight of bridge plus hoist with trolley in the presence of crane
For MBMA 1986 the load combinations are:

10. DL+EL
11. DL+SL+EL
11a. DL+EL+CR
Buildings in High Temperatures Variation Zone

12. DL + TL
13. DL + LL + TL
14. DL + WL or EL + TL
15. DL + SL + TL
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where,
DL = Dead Load
LL = Live load plus applicable Collateral Load
WL = Wind load
EL = Seismic Load
CR = Crane load plus applicable Collateral Load
SL = Snow load plus applicable Collateral Load
TL = Thermal load
FL = Floor Live Load (Mezzanine Live Load)
Notes :
1. Whenever the building geometry or loading is not symmetric, wind and seismic loads applied left
and right both should be considered in their corresponding combinations.
2. When load combination 2 is applied on frames, exclude collateral loads, special roof dead loads
(such as roof units), and the mezzanine dead load from `DL'.
3. The allowable stresses for Load Combinations including wind load or seismic load should be
increased by 33% as per AISC. 9th Edition, Section A 5.2. of Part 5.
4. Seismic loads should be calculated according to Section 7 of MBMA 1996.
5. Load Combinations 12, 13, 14 and 15 are not stated in the MBMA 1996 Manual. However if the
engineer feels that the temperature loads may seriously affect the building, he can check these
combinations and if found of little effect, they must be deleted from the calculations and should be
used only if required in the CIF.
6. Load combinations including crane or mezzanine are only applicable when the main members
supporting the crane or mezzanine are directly connected to the structure.
7. If more than one crane is present, the following loading, where applicable, is to be considered in
`CR' (as per Section 6.3 of MBMA 1996 & Table 6.3) as follows:
a) Multiple cranes bumper to bumper in the same frame span (aisle):
i) Consider any single crane producing the most unfavorable effect.

ii) Consider any two adjacent cranes, with simultaneous vertical wheel loads and 50% of
the lateral load from both cranes OR 100% of the lateral load for either one of the cranes
whichever is critical.
b) Multiple crane aisles each with single crane:
i) Consider single crane in any aisle producing the most unfavorable effect.
ii) Consider any two aisles with simultaneous vertical wheel loads and 50% of the lateral
load from both cranes or 100% of the lateral load for either one of the cranes whichever is
critical.
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c) Multiple cranes in multiple aisles:
i) Consider single crane in any aisle producing the most unfavorable effect.
ii) Consider any two adjacent cranes in any one aisle, with simultaneous vertical wheel
loads and 50% of the lateral load from both cranes or 100% of the lateral load for either
one of the cranes whichever is critical.
iii) Consider any two adjacent aisles each with one crane, with simultaneous vertical wheel
loads and 50% of the lateral load from both cranes or 100% of the lateral load for either
one of the cranes whichever is critical.
iv) Consider any two adjacent cranes in any aisle, and one crane in any other nonadjacent
aisle with simultaneous vertical wheel loads and 50% of the lateral load from three cranes
or 100% of the lateral load for any one of the three cranes whichever is critical.
8. Although loading combinations have been stated for Cranes and Mezzanine loads together, Zamil
Steel Building Co. strongly recommends that such situations of rigid frame supporting both the
crane and mezzanine be avoided whenever possible. (i.e. provide an additional separate support
for the mezzanine or crane as the solution). This will eliminate any undesirable vibration in the
mezzanine floor due to the operation of the crane.
9. These loading conditions must be specified on calculation sheets. In case customer load-
specifications to be used, the above-mentioned criteria will be overruled.
2.4. Serviceability consideration

In addition to strength considerations as stipulated in various building and design codes, due
consideration must also be given to deflection and vibration limitations. Standard codes of practice
do not impose clear and rigid criteria for limiting the deflection of various structural members
leaving it to the professional design engineer’s judgment. Zamil Steel has adopted a conservative
policy on defining deflections based upon its extensive building design experience. One good
reference available on this subject is “Serviceability Design Considerations for Low-Rise Buildings”
published by AISC. The currently adopted deflection limitations by Zamil Steel are illustrated in the
tables next page.
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Table 2.6. Serviceability Consideration

1. S t a n d a r d B u i l d i n g
Structural Element Deformation Max Limit Loading
Main Frame Span/150 DL+LL Or DL+SL
Jack Beams Span/240 DL+LL Or DL+SL
Roof Purlins Vertical Span/150 DL+LL Or DL+SL
Span/240 DL+LL
Mezzanine Beam/Joist
Span/360 LL
Main Frame E.Height/45 DL+WL
End Wall Columns Horizontal Height/90 WL
Wall Girts Span/90 WL
2. B u i l d i n g s W i t h B l o c k w a l l s
Main Frame Sapn/150 DL+LL Or DL+SL
Roof Purlins Vertical Sapn/150 DL+LL Or DL+SL
Span/240 DL+LL
Span/360 LL
Main Frame E.Height/(45+R*55)(1) DL+WL
Wall Girts Sapn/90 WL
3. B u i l d i n g s W i t h G l a z e d w a l l s
Main Frame sapn/150 DL+LL Or DL+SL
Roof Purlins Vertical Sapn/150 DL+LL Or DL+SL
Sapn/240 DL+LL
Sapn/360 LL
Main Frame E.Height/(45+R*205)(2) DL+WL
Wall Girts Sapn/90 WL
4. B u i l d i n g s W i t h C r a n e s
Main Frame Span/150 DL+LL Or DL+SL
Roof Purlins Span/150 DL+LL Or DL+SL
Span/240 DL+LL
Span/360 LL
Relative deflection of adjacent frames at
Vertical Bay/225 CR
point of support of UHC or MR beam
Rigid Frame Rafters supporting UHC or MR
Sapn/500 CR
beams running laterally in the building
Span/600 Crane Class(3) A,B,C
Crane Beam Span/800 Crane Class(3) D
Span/1000 Crane Class(3) E,F
Main Frame Carrying Pendant Operated E.Height/100 DL+WL O DL+CR
Main Frame Crarrying Cab Operated E.Height/240 DL+WL O DL+CR
Wall Girts Span/90 WL
Crane Beam Span/400 CR
(1)
RW= (block height)/(Eave height)
(2)
RG= (Glazed height)/(Eave height)
(3)
Cranes class according to CMAA
Note: The maximum eave height to be considered while using this table is 9m. For EH>9m different limitations have to be used.
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DESIGN MANUAL
PEB DIVISION 3. Planning PEB
CHAPTER 3: PLANNING PEB
Planning of the PEB buildings (low rise metal buildings)(1) and arranging different building components is a
very important step for the designer before proceeding with the design of each component.
The Following building configurations are significantly affecting the building Stability and Cost:-
1) Main Frame configuration (orientation, type, roof slope , eave height)

2) Roof purlins spacing
3) wall girts (connection & spacing)
4) End wall system
5) Expansion joints
6) Bay spacing
7) Bracing systems arrangement
8) Mezzanine floor beams/columns (orientation & spacing)
9) Crane systems
Some of the above configurations may be governed by customer requirements stated in (CIF) but generally
the optimal configuration guide lines are outlined in this chapter.
For cases when considerable saving in building cost can be achieved by changing some of the input
configuration stated in (CIF) without affecting the building end use it should be reported to the sales
representative in charge.
3.1. Main Frame Configuration
Main frame is the basic supporting component in the PEB systems; main frames provide the vertical
support for the whole building plus providing the lateral stability for the building in its direction while lateral
stability in the other direction is usually achieved by a bracing system.
The width of the building is defined as the out-to-out dimensions of girts/eave struts and these extents
define the sidewall steel lines. Eave height is the height measured from bottom of the column base plate to
top of the eave strut. Rigid frame members are tapered using built-up sections following the shape of the
bending moment diagram. Columns with fixed base are straight. Also the interior columns are always
maintained straight.
3.1.1. Main frame orientation

Building should be oriented in such a way that the length is greater than the width. This will result in more
number of lighter frames rather than less number of heavy frames, this also will reduce the wind bracing
forces results in lighter bracing systems.
(1)
The characteristics of the low rise metal buildings are as per section A15 of MBMA 96
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3.1.2. Main frame types

There are Several types of main frames used in ZAMIL STEEL for PEB buildings, The choice of the type
of main frame to be used is dependant on :-
1) Total width of the building.

2) The permitted spacing between columns in the transversal direction according to customer
requirements and the function of the building.
3) The existence of sub structure (RC or masonry )
4) The architectural requirements of the customer specially the shape of the gable.
5) The type of rain drainage (internal drainage availability).
6) Any customer special requirements.
The available types of main frames are clear span, multi span, lean-to, mono-slope, space saver, roof
system and multi-gable. Description and usage of each type are as follows
3.1.2.1 Clear Span

Clear Span rigid frames are single gable frames and offer full-width clear space inside the building without
interior columns. This type of frame is extensively used anywhere an unobstructed working area is desired
in diverse applications such as auditoriums, gymnasiums, aircraft hangars, showrooms and recreation
facilities.
The deepest part of the frame is the knee, the joint between the rafter and the column, which is generally
designed as horizontal knee connection. An alternate design of knee joint is as vertical knee connection
that is employed for flush side-wall construction. Clear Span rigid frames are appropriate and economical
when:
i) Frame width is in the range 24m-30m.
ii) Headroom at the exterior walls is not critical.
3.1.2.2. Multi - Span
When clear space inside the building is not the crucial requirement then Multi-Span rigid frames offer
greater economy and theoretically unlimited building size. Buildings wider than around 90m experience a
build up of temperature stresses and require temperature load analysis and design. Multi-span rigid
frames have straight interior columns, generally hot-rolled tube sections pin connected at the top with the
rafter. When lateral sway is critical, the interior columns may be moment connected at the top with the
rafter, and in such a situation built-up straight columns are more viable than hot-rolled tube columns.
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Multi-Span rigid frame with an interior column located at ridge requires the rafter at ridge to have a
horizontal bottom flange in order to accommodate horizontal cap plate.
Multi-Span rigid frame is the most economical solution for wider buildings (width > 24m) and is used for
buildings such as warehouses, distribution centers and factories. The most economical modular width in
multi-span buildings is in the range 18m-24m. The disadvantages of such a framing system include:
• The susceptibility to differential settlement of column supports,

• locations of the interior columns are difficult to change in future
• Longer un-braced interior columns especially for wider buildings.
• Horizontal sway may be critical and governing the design in case of internal columns pined with
rafter.
3.1.2.3. Lean- T0
Lean-To is not a self-contained and stable framing system rather an add-on to the existing building with a
single slope. This type of frame achieves stability when it is connected to an existing rigid framing. Usually
column rafter connection at knee is pinned type, which results in lighter columns. Generally columns and
rafters are straight except that rafters are tapered for larger widths (> 12m). For clear widths larger than
18m, tapered columns with moment resisting connections at the knee are more economical. Lean-To
framing is typically used for building additions, equipment rooms and storage.
For larger widths “Multi-Span-Lean-To” framing can be adopted with exterior column tapered and moment
connected at the knee.
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DESIGN MANUAL
3.1.2.4. Mono- slope
Mono-Slope or single-slope framing system is an alternative to gable type of frame that may be either
Clear Span or multi-span. Mono-Slope configuration results in more expensive framing than the gable
type.
Mono-Slope framing system is frequently adopted where:
i) Rainwater needs to be drained away from the parking areas or from the adjacent buildings
ii) Larger headroom is required at one sidewall
iii) A new building is added directly adjacent to an existing building and it is required to avoid:
• The creation of a valley condition along the connection of both buildings.
• The imposition of additional loads on the columns and foundations of the existing building.
For larger widths “mono-slope-multi-span” framing will be more economical when column free area inside
the building is not an essential requirement.
3.1.2.5. Space Saver
Space Saver framing system offers straight columns, keeping the rafter bottom flange horizontal for ceiling
applications with rigid knee connection. Selection of Space Saver is appropriate when:
i) The frame width is between 6m to 18m and eave height does not exceed 6m.
ii) Straight columns are desired.
iii) Roof slope of < 0.5:10 are acceptable.
iv) Customer requires minimum air volume inside the building especially in cold storage ware houses.
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3.1.2.6. Roof System

A Roof System framing consists of beam (rafter) resting onto a planned or an existing substructure. The
substructure is normally made of concrete or masonry. The rafter is designed in such a way to result in
only vertical reaction (no horizontal reaction) by prescribing a roller support condition at one end. The
roller supports are provided at one end by means of roller rods.
If the roller support condition is not properly achieved in reality and only slotted holes are provided at one
end then a horizontal reaction HR has to be considered for the design of supporting system. HR is
calculated as:
HR = µVR
Where,
µ = Coefficient of friction between steel and steel
VR = Vertical reaction at that end.
A Roof System is generally not economical for spans greater than 12m although it can span as large as
36m. This is due to fact that the Roof System stresses are concentrated at mid-span rather than at the
knees.
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3.1.2.7. Multi- Gable

Multi-Gable buildings are not recommended due to maintenance requirement of valley region, internal
drainage and bracing requirement inside the building at columns located at valley. Especially in snow
areas, Multi-Gable framing should be discouraged. However for very wide buildings this type of framing
offers a viable solution due to:
• reduced height of ridge and thus the reduced height of interior columns, and
• temperature effects can be controlled by dividing the frame into separate structural segments
Thus, Multi-Gable buildings are more economical than Multi-Span buildings for very wide buildings. Multi-
Gable frames may be either Clear Spans or Multi-Spans. The columns at the valley location should be
designed as rigidly connected to rafters on either side using a vertical type of connection.
3.1.3. Roof Slope

A good reduction in rigid frame weight can be achieved by using steeper slopes for Clear Span frames of
large widths.
Example: Consider Clear Span building of width 42m and eave height of 6m:
With slope 0.5:10 ---- Frame Weight = 3682 Kg
Higher roof slopes may result in heavy frames in the case of Multi-Span frame buildings due to the longer
interior columns.
Higher roof slopes help reduce the deflection in wider span buildings.
In the areas of high snow higher roof slopes (slopes > 1:10) help reduce the snow loads if snow load
governs.
Higher roof slope tends to increase the prices of fascias since fascias are designed to cover the ridge. Also
increased height of fascias cause the rise in frame weight due to additional wind forces from fascias.
However roof slope starts from 2:10 needs sag rods between purlins thus adding to the price of the building.
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Optimum roof slopes:

• Multi-Span Buildings: 0.5:10
• Clear Span, Width up to 45m: 1.0:10
• Clear Span, Width up to 60m: 1.5:10
• Clear Span, Width > 60m: 2.0:10
3.1.4. Eave Height

Eave height is governed by:
• Clear height at eave (head clearance)
• Mezzanine clear heights below beam and above joist
• Crane beam / Crane hook heights
Minimize eave height to the bare minimum requirement since the eave height affects the price of the
building by adding to the price of sheeting, girts and columns. If columns are unbraced eave height affects
the frame weight significantly. Also higher eave heights increase the wind loads on the building.
If eave height to width ratio becomes more than 0.8 then the frame may have a fixed based design in order
to control the lateral deflection.
3.2. Roof Purlins
Roof purlins are to be arranged according to the following guide lines as applicable:-
1. 900 mm between first roof purlin and the eave strut
2. Intermediate spacing in case of single skin panels not exceeding 1750 mm(*).
3. Intermediate spacing in case of Tempcon panels not exceeding 2000 mm(*).
4. Equal intermediate roof purlin spacing are preferred satisfying the following conditions :-
• The minimum distance between any purlin line and end wall column position is 150 mm.
• The minimum distance between any purlin line and main frames splices is 150 mm.
5. If Zamil Steel Standard skylights(1) are required the lighter weight solution of the following is to be
used :-
• Provide an extra run of purlins at the skylight location.
• Provide standard 1.5m spacing over the span where skylights exist and use wider spacing at
other spans.
3.3. Wall Girts
Our standard practice is to have:

• Endwall girts as flush with end wall columns (columns spacing is around 5m-6m), which provides a
diaphragm action in the P&B endwalls and avoids the need of endwall bracing.
• Side wall girts as by-framed (by-pass) that allows lapping of the girts and larger main frames
columns spacing can be used.
If there are no customer special requirements (special wall openings, block walls, etc.) wall girt spacing are
as follows:-
2250mm(*) form finish floor level (to allow for recent or future erection of ZAMIL STEEL standard personal
doors), then girt spacing not exceeding 2000mm(∗)
(1)
Zamil Standard skylight can only fit to 1.5m purlin spacing, available length of 3.25m can span over 2 purlins.
(∗)
Panel strength must be checked for any used spacing
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DESIGN MANUAL
3.4. End Wall Systems
The standard end wall are designed as post & beam (all connections are pinned) the lateral stability is
provided by the diaphragm action (see clause 6.4.) in the absence of this shear diaphragm wind bracing are
required (see clause 7.2.1.2. of this manual).
End rigid frame are used in case of:-
1) Future extension is intended or if stated clearly in the (C.I.F.), in this case only wind posts are
required.
2) Crane running to the endwall
3) Open for access condition prevails at the endwall
4) X-bracing is not allowed at endwall in the case of by-framed end wall.
3.5. Expansion Joints
The maximum length of the building without any expansion joint can be calculated using following formula.
∆ max
L=
KE∆ T
Where ∆max = Maximum Allowable Expansion in cm.

L = Length of building in cm.
E = Coefficient of linear expansion (0.0000117/ oC)
∆T = Temp. Difference in oC
K = 1.0 for building w/o air-conditioning
= 0.7 for building w / air-conditioning
= 0.55 for building w / heating and air-conditioning
Example: Calculate the maximum length when expansion joint is required for the following locations:
Dhahran, Jeddah and Riyadh
Consider 2.8-cm expansion slot, which is derived from purlin expansion joint detail
Note: 2mm expansion per purlin connection, assuming 14 bays gives: 14 x 2 = 2.8cm
Solution:
Temperature difference in Saudi Arabia:

Dhahran - 35 oC ) Based on "Engineer's Guide to Solar Energy"
Jeddah - 30 oC ) By Yvonne Howell & Justin A. Bereny - page 175
Riyadh - 40 oC )
I Dhahran Area
1) Building without air-conditioning (K = 1.0)

2 .8
L= = 6837cm ≈ 68m
1x 35x 0.0000117
2) Building with air-conditioning (K = 0.70)

6837
L= = 9767 cm ≈97m
0.70
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DESIGN MANUAL
3) Building with heating and air-conditioning (K = 0.55)

6837
L= = 12431 cm ≈ 124m
0.55
II Jeddah Area
1) Building without air-conditioning

2 .8
L= = 7977cm ≈ 79m
1x 30 x 0.0000117
2) Building with air-conditioning

7977
L= = 11396 cm ≈ 113m .
0.70
3) Building with heating and air-conditioning

7977
L= = 14504 cm ≈ 145m
0.55
III Riyadh Area
1) Building without air-conditioning
2 .8
L= = 5983 cm ≈ 59 m
1x 40 x 0.0000117
2) Building with air-conditioning

5983
L= = 8547 cm ≈ 85m
0.70
3) Building with heating and air-conditioning
5983
L= = 10878 cm ≈ 108m.
0.55
3.6. Bay Spacing
For standard loads the most economical bay spacing is around 8m. The standard loads are:
Live Loads on roof Wind Speed

and frame (kN/m2) (km/h)
0.57 130
For greater loads than standard loads the economical bay spacing tends to decrease.
For buildings with heavy cranes (crane capacity > 10 MT) the economical bay spacing ranges between 6m
and 7m.
Smaller end bays than interior bays will taper off the effect of higher deflection and bending moment in end
bays as compared to interior bays and help reduce the weights of purlins/girts in the end bays. This will
avoid the need of nested purlins/girts in the end bays and result in uniform size of purlin/girt sizes.
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DESIGN MANUAL
1.13. WASHERS
Washer Diameter USAGE SPECIFICATIONS

(mm)
M20 DIN 125 Type A
M24 For Anchor Bolts & Cable Bracing Flat Mild Elec. Galvanized
M36
M12
M16
M20 For High Strength Bolt of ASTM - F436 Type 1
M24 Main Connections Round Hard
M27
M30
ASTM - A48 M Class275 B Cast Iron
M24 Bracing System
HDG Hill Side Washer
DIN 125 Type A Flat Mild Elect.
M12 For Sliding Doors
Galvanized
M6 For Machine Bolt with Valley Gutters & Ridge Ventilator
1.14. SELF DRILLING SCREWS

SDS Dacromet SPEDEC SD5 T15-5.5 x 25mm Single skin roof fixed at low rib
#5.5x25
SDS Dacromet SPEDEC SD5 T15-5.5x57mm Single skin roof fixed at high rib, gutter strap
#5.5x57
SDS Dacromet SPEDEC SD12-5.5x32mm Mezzanine deck, hot rolled sections
#5.5x32
SDS Dacromet SPEDEC SL2-T-A14-4.8x20 Stitch screws for fastening panel to panel (side lap),
#4.8x20 panel to trims
#5.5x62
#5.5x77
#5.5x107
#5.5x137
SDS Buildex #5.5x25 Buildex 12-14x25mm No.6310-0481- Single Skin non-roof
3CS
SSD Stainless Steel SSD Stainless Steel Screw #5.5x28 Stainless steel single skin fixed at low rib
Screw #5.5x28
SSD Stainless Steel SSD Stainless Steel Screw 5.5x40 Stainless steel screws for mezzanine deck, hot rolled
Screw 5.5x40 sections
SSD Stainless Steel SSD Stainless Steel Screw 4.8x20 Stainless steel stitch screws
Screw 4.8x20
SSD Stainless Steel SSD Stainless Steel Screw 5.5x65 Stainless steel screws single skin roof fixed at high
Screw 5.5x65 rib, gutter strap
Screw 5.5x62
Screw 5.5x77
Screw 5.5x107
Screw 5.5x130
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DESIGN MANUAL
Some buildings require bay spacing more than 10m in order to have a greater clear space at the interior of
the building in Multi-Span buildings. Such a situation can be handled by providing jack beams (see clause
4.2.) that support the intermediate frames without interior columns. Thus the exterior columns will have bay
spacing of say 6m while the interior columns are spaced at 12m. Intermediate frames allow the purlin to
span for 6m as shown in the Figure next page
Estimation of economical bay spacing:
Example No. 1
Building Length = 70m

No. of Interior bays = (70-12)/8 = 7.25 Use 7 @ 8m
Size of End bays = (70-8x7)/2 = 7m
Bay Spacing: 1 @ 7 + 7 @ 8 + 1 @ 7
Example No. 2
Building Length = 130m --- Needs an expansion joint

No. of Interior bays = (130-24)/8 = 13.25 Use 14 @ 7.5m
Size of End bays = (130-14x7.5)/4 = 6.25m
Bay Spacing: 1 @ 6.25 + 7 @ 7.5 + 1 @ 6.25 + Exp. Jt + 1@ 6.25 + 7 @ 7.5 + 1 @ 6.25
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3.7. Bracing Systems Arrangement
Bracing is a structural system used to provide stability in a structure in a direction where applied forces on
that structure would otherwise make it unstable. Whether it is a force due to wind, crane or seismic
applications, the bracing system will always eventually transmit that load down to the column base and then
to the foundations. The rules of arranging different types of bracing systems are as follows:-
3.7.1. Bracing for wind and seismic loads in the longitudinal direction
1. In long buildings, braced bays shall be provided in intervals not to exceed five bays.
2. Although there is a diaphragm action available in Zamil Steel Buildings roof, this action is not as of
yet quantitatively determined. Therefore, the Design Engineer shall not take diaphragm action into
consideration, until a future revision to this rule is made.
3. A braced bay shall not be located in the end bay of a building if the endwall system at the end is a
post and beam frame. If an exception to this is necessary, the design engineer must design the
endwall members as either built-up or hot-rolled sections.
4. Sidewall bracing shall be generally placed in the same bays of roof bracing. This may not be
possible at times due to openings in the sidewalls. In such cases, sidewall bracing shall be placed in
bays adjacent to those containing the roof bracing with a consideration that load transfers to the
adjacent bays.
5. Roof rod bracing shall not cross the ridgeline.
6. Cables / rods braces shall not exceed 15m in length. If a cross bracing contains rods longer than
15m, then the bracing should be broken to two sets of bracings with a strut member between them
so that the rod/cable lengths shall not exceed 15 m.
7. Roof bracing shall be comprised of ASTM A 475 Class A extra high strength cables or ASTM A 572
Grade 36 rods or ASTM 572 Grade 50 angles.
8. Sidewall bracing shall be comprised of any one of the following types:

• Cables
• Rods or angles.
• Portal frame with / without rods or angles.
9. There shall be only one type of bracing in the same sidewall. Do not mix different type / material in
the same sidewall.
10. It is preferable to use only one type of wall bracing in the whole building otherwise the lateral loads
(especially seismic loads) will not be divided equally between bracing lines, For cases when this will
result in excessive weight for bracing system advanced calculation (rather than those described in
clause 7.2.1.1.) is to be done to determine the force that will be carried by each type depending on
its stiffness and location.
DM 03.10.00 3-11
DESIGN MANUAL
3.7.2. Wind and seismic bracing in P&B endwalls

1. Endwall bracing is not required for a fully sheeted P&B endwall with flush girt construction. If P&B
endwalls have by-framed girts then this endwall needs bracing.
2. If required, bracing in P&B endwalls shall comprise cables or rods, unless otherwise specified by the
customer. In such a case the endwall members shall be either built-up or hot-rolled members.
3. If an endwall requires bracing and the customer requests that no bracing to be placed in the plane of
the endwall, then it is recommended that the load in the plane of the endwall is transferred back to
the first rigid frame through additional roof bracing in the end bay.
4. In wide buildings, if endwall bracing is required, it shall be provided in intervals not to exceed five
endwall sections.
3.7.3. Crane Bracing

1. In crane buildings, bracing has to be designed for longitudinal crane loads for top running or under-
hung cranes. The bracing shall be placed in intervals not to exceed five bays.
2. Longitudinal bracing for top running cranes shall be comprised of any one of the following types.
• Rods (for cranes with a capacity of 15 tons or less)
• Angles (for cranes with capacity exceeding 15 tons)
• Portal frame with rods (or angles)
• Portal frame without rods (or angles)
3. Longitudinal bracing for top running cranes shall be of only one type in the same longitudinal plane
of a building.
4. Longitudinal bracing for underhung cranes shall consist of either rods or angles.
5. Lateral bracing for underhung cranes (attached to crane brackets), if any shall consist of either rods
or angles.
6. Whenever a brace rod is used for crane bracing, the minimum diameter of that rod shall be 19mm.
7. A brace rod shall not exceed 15m in length. If angle are used the critical slenderness ratio of a
bracing angle shall not exceed 300.
DM 03.10.00 3-12
DESIGN MANUAL
3.8. Mezzanine Floors
The following guide lines are to be considered while planning mezzanine floor:-
1. Most economical mezzanine column spacing is around 6m. Mezzanine columns should be aligned
with rigid frame column and wind column grid lines.
2. Generally aligning joists with the shorter panel side results in lighter weight for mezzanine floor.
3. Clear height above mezzanine joist and below mezzanine beam must be maintained preferably
between 2.5m-3.0m and not to be less than 2m.
4. Top landing requirements in mezzanine staircases is governed by the relative orientation of the
staircase to the building orientation as shown in the following Figure.
5. Maximum number of rises in a single straight flight without mid-landing is 15. If the number of rises
exceeds 15 then mid-landing must be provided. Remember the rise varies between 160mm to
200mm but preferably a rise of 175mm is commonly used.
6. The choice of single or double flight should be based on the mezzanine layout, available space and
customer’s requirements.
DM 03.10.00 3-13
DESIGN MANUAL
3.9. Cranes Systems
The following guide lines are to be considered while choosing the crane structural system:-
1. Avoid top running cranes running in the transverse directions since it requires extra supporting
system.
2. Top running cranes are the most economical option as compared to underhung cranes.
3. Use bracket as Crane runway beam support when vertical loads < 250kN. Otherwise use a
separate crane column or a stepped column. Stepped columns are more economical than separate
crane column especially for larger eave height buildings.
4. Underhung cranes are employed in case where the crane span is smaller than the building aisle
width.
5. Underhung crane capacity should be limited to 10MT and under-hung monorail crane capacity
should not exceed 5MT for a reasonably economical design of frame.
DM 03.10.00 3-14
DESIGN MANUAL
PEB DIVISION 4. Main framing design
CHAPTER 4: MAIN FRAMING DESIGN
4.1. Main Frame Design Procedure and Constraints
Main frame method of design, the choice of haunch depths, haunch lengths and splice location has a
significant effect on the economy of the building as a whole. In house special software (ASFAD) is used for
the design procedure.
4.1.1. ASFAD
Design and analysis of rigid frames is carried out using an in-house developed software ASFAD. This
package was developed to satisfy the requirements of the Pre-Engineered Steel Buildings industry using
C++ language utilizing the latest programming, analysis and design techniques. It has many features to
facilitate design of various elements and to ensure the economy, safety, uniformity and high quality of the
structural designs. Refer to the computer aids manual for detail information and user guidelines on this
software. However some features are outlined here.
Structural modeling is based on dividing the Structure into Members, which connect to each other at
common points called Nodes. Following are few examples of node numbering:
The method used for the analysis of a Structure is the Stiffness Matrix Method.
DM 03.10.00 4-1
DESIGN MANUAL
Members may have variable properties along their lengths. Such Members are called non-prismatic
elements and the stiffness coefficients for such Members are calculated by numerical integration
techniques.
End forces at nodes due to intermediate member loading are also calculated by the same numerical
integration techniques.
The numerical integration technique is based on the Energy Method which is achieved by dividing a
Member into Segments (Members are broken into Sections and Section are broken into Segments). The
accuracy of this method depends on the length of Segment and number of Segments in the Member.
Analysis results for different models have proven that the use of a 0.5 meter segment and a minimum of 10
segments per member lead to very accurate and acceptable results.
Loading is defined by specifying various Load Cases, Load Categories & Load Conditions.
Example: The Load Condition “Dead + Wind + Crane”
Load Categories Dead Wind Crane

in a + +
Load Condition
Load Cases Dead Wind right Crane-1

within Wind left Crane-2
Category Wind end Crane-3
Crane-4
Dead + Wind right + Crane-1

All Possible Dead + Wind left + Crane-1

Load Case Dead + Wind left + Crane-2
Combinations Dead + Wind left + Crane-3
Dead + Wind left + Crane-4
Dead + Wind end + Crane-1

As shown in the above example categorizing Load Cases makes one Load Condition sufficient to
specify all possible 12 Load Case combinations rather than specifying each of them individually.
DM 03.10.00 4-2
DESIGN MANUAL
Design Codes for checking of stresses using ASFAD are:-
AISC Ninth edition 1989

BS 5950 Part 1: 1990
BS 5950 Part 1: 2000
Egyptian code ECP97
Egyptian code ECP2001
Eurocode 3
All the Sections within a Member are checked segment by segment and the most critical point within the
section is reported for bending & axial stresses, shear stresses & deflections.
Since Members are non-prismatic elements the critical buckling Load is determined for the whole member
using numerical integration techniques. This will simulate the actual buckling behavior of the non-prismatic
member accurately rather than analyzing the Member at each segment individually that does not take into
effect the interaction of all segments when they behave as one member.
Auto design of built up Section dimensions (widths and thicknesses) are available for some codes but in
general user defined dimensions are checked for stresses according to specified code, some limitations
must be taken into consideration while choosing the dimensions of the built up section to be checked as
indicated below.
4.1.2. Design Constraints

4.1.2.1. Built up section
Geometrical limitation were established to achieve the following targets

1. Ease shop fabrication
2. Limit the reduction of allowable stresses due to high (width / thickness) ratios resulting in non
economical designs.
3. To ensure sound designs and optimize material cutting and minimize material waste
Table 4.1 illustrates the used web plates and flange plates used and the accepted combination between
them to form a built up sections, this table is called plate 7
DM 03.10.00 4-3
DESIGN MANUAL
Table 4.1 Built Up Geometry Limitation
PLATE 7
Web Depth
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800
(mm)
Min Web
4 5 6 8 10
Thick. (mm)
Flange size
125X5
125X6
125X8
150X5
150X6
150X8
150X10
175X6
175X8
175X10
175X12
200X6
200X8
200X10
200X12
225X8
225X10
225X12
225X15
250X8
250X10
250X12
250X15
300X10
300X12
300X15
300X20
350X12
350X15
350X20
350X25
NOTES:
• Hatched areas are not to be used.
• Upon manual design designer must consider provision of clause G2 of AISC 9th Edition. Page 5-51.
• Upon special depths, the following limitations have to be checked.
hw t w ≤ 180
t f t w ≤ 2 .5
hw w f ≤ 5
where hw = web depth, tw = web thickness, tf = flange thickness and wf = flange width.
• The above dimensions are not applicable for galvanized members
DM 03.10.00 4-4
DESIGN MANUAL
4.1.2.2. Galvanized primary members
The following limitation should be considered

The maximum dimensions of built up or hot rolled piece are 830x750x9500mm (including any welded parts
like gusset plates, bracket)
The maximum weight of any one piece 1050kg
* For special cases where larger dimensions/weights can not be avoided out side galvanized must be
sought, extra charges should be accounted be estimate department.
Built up cross sections to be conformed
Table 4.2 Galvanized Built Up Geometry Limitation
PLATE 8
Web Depth
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800
(mm)
Min Web
5 6 8 10 12 15 20
Thick. (mm)
Flange size
125X5
125X6
125X8
150X6
150X8
150X10
175X8
175X10
175X12
200X8
200X10
200X12
225X10
225X12
225X15
250X10
250X12
250X15
300X12
300X15
300X20
350X15
350X20
350X25
NOTES:
• Hatched areas are not to be used.

• For regular design refer to limitations of PLATE 7.
• Upon special depths, the following limitations have to be checked.
hw t w ≤ 100
w f 2t f ≤ 13
w f t f ≥ 0.25hwt w
where hw = web depth, tw = web thickness, tf = flange thickness and wf = flange width
DM 03.10.00 4-5
DESIGN MANUAL
4.1.2.3. Fabrication Limitation
Conrac is an automatic welding machine, which welds the web to the top and bottom flanges with single
side fillet welding with one head fixed at one flange (straight) and the other head movable in order to
fabricate tapered built-up sections. Following are the size limitations of built-up members welded by this
machine.
Size Limitations:
1) Minimum web thickness = 3mm; Maximum web thickness = 12mm
2) Minimum flange thickness = 5mm; Maximum flange thickness = 25mm
3) Minimum web depth = 180mm; Maximum web depth = 1500mm
4) Minimum flange width = 125mm; Maximum flange width = 380mm
5) Minimum member length = 1500mm; Maximum member length = 16000mm
6) Minimum Fillet Weld Size = 3mm; Maximum Fillet Weld Size = 8mm
Fillet weld size depends upon the material thickness (see clause 4.7.1.)
7) If the sizes are out of the above ranges manual welding has to be undertaken.
8) Width of continuous Flange should be constant along the one welded piece. Also top and bottom
flange widths must be same.
9) Variation of thickness at any butt weld splice of continuous Flange / Web within the one welded
piece should be limited to maximum 6mm.
10) Maximum thickness of a flange that can be bent is 19mm
11) One of the flanges (normally top) of the built-up member must be straight.
12) Butt web splices must be perpendicular to the straight flange.
13) Maximum bend angle for the flange is 28.44o (normally top flange bends at peak while bottom
flange is straight in multi-span building frames)
14) In relation to the straight flange the maximum slope that welding head can follow at the other
flange is 15o.
The previous rules should be respected in the design of built up section to be fabricated using conrac
machine those rules are illustrated in the sketch next page:-
DM 03.10.00 4-6
DESIGN MANUAL
(BUS) CONRAC FABRICTION LIMITATION
L1
Feild Splice Plate Feild Splice Plate
STRAIGHT FLANGE
TF2
TF1
HW2
H W1 H W2
H W1
MAX 28.44
TF4
TF4
TF3
FLANGE BENT
MAX 15
WEB BUTT WELD

1. 3mm ≤ (Tw1 , Tw2) ≤ 12mm
2. 5mm ≤ (TF1 , TF2 , TF3 ,TF4 ) ≤ 25mm
BTF1 BTF2
TF1
3. 180mm ≤ (HW1 , HW2) ≤ 1500mm

TF2
4. 125mm ≤ (BTF1 , BBF1 BTF2 , BBF2 ) ≤ 380mm

S(mm)
HW2
TW2 5. 1500mm ≤ L1 ≤ 16000mm

6. 3mm ≤ S ≤ 8mm
H W1
TF4
BBF2
TW1
7. BTF1 = BBF1 = BTF2 = BBF2
SEC. 2-2 8. │TF2 - TF1│ ≤ 6mm , │TF3 - TF4│ ≤ 6mm
& │ Tw1 - Tw2 │≤ 6mm
BBF1 9. TF4 ≤ 19mm
TF3
SEC. 1-1
4.1.2.4. Shipping Limitation
Maximum fabricated out-to-out length of the piece is 12m for transportation by truck and 11.7m for
transportation by dry cargo container.
4.1.2.5. Shot Blast and Paint Line Limitations
• Maximum built-up member length = 15,000mm

• Maximum built-up member width = 392mm (for paint line); 800mm (for shot blasting)
• Maximum built-up member depth = 1500mm
• Maximum built-up member weight = 2MT
DM 03.10.00 4-7
DESIGN MANUAL
4.1.2.6. Other guidelines
1. At Knee connection column depth and rafter depth should be the same as applicable if not the
difference to be limited at ± 200mm.
2. For main column at Crane Bracket zone , preferably the depth of that column to be constant starting at
a minimum distance of 150 mm below the bracket, and extending all the way up to the top of the
column.
3. In a tapered section, the minimum difference in web depths at start and end should be 100 mm.
• Minimum base plate thickness = 12 mm

• Minimum base plate width = 220 mm
• Minimum splice plate thickness = 10 mm
• Minimum splice plate width = 200 mm
• Minimum Anchor bolt diameter = 20 mm (except end-wall post = 16mm)
• Minimum splice bolt = 16 mm
DM 03.10.00 4-8
DESIGN MANUAL
4.1.2.7. Optimization
The following rules should be followed to produce the most economical frame profiles. These rules result in
lighter frames while satisfying fabrication, shipping and erection limitations.
1. Minimize number of splices in the columns and rafters by providing maximum possible lengths
regardless of the material savings that can be produced otherwise. Section lengths should be
multiple of 3m i.e., 3m, 6m, 9m and 12m in order to reduce the scrap.
2. In case of different bay spacing avoid using more than 3 frames.
3. Different frame should be adopted if saving of 5% on all frames with a minimum of 1.0ton is
ascertained.
4. When different frames have to be used due to different bay spacing, maintain the same web cuts for
all such frames.
5. Minimize the number of different flange widths in a frame. Maximum different widths of flanges in all
the frames should preferably be less than three.
6. As much as possible maintain uniformity in the base plate detail and anchor bolt sizes for all the
frames.
7. Try to locate the splices at the locations where the bending moment is least and/or where the depth
is least in a frame.
8. Try to follow the shape of bending moment diagram for the controlling load combination in the
configuration of the frame by maintaining the stress unity check ratios closer to 1.
Controlling Deflections:
Lateral Sway ∆h:
If lateral sway ∆h exceeds the prescribed limit (normally EH/45) then check the EH/Width ratio. If H/B > 0.75
then fixing the base would result in more economical frame. If H/B<0.75 then increase the web depth at
knee of both column and rafter (difference between knee depth of column and rafter < 200mm)
In multispan frames before going for the option of fixing the exterior column at base, check whether fixing
the tops of interior columns control the lateral sway. If not then fix the exterior column bases.
Vertical Deflection ∆v:
If Vertical deflection ∆v exceeds the prescribed limit (normally Span/180), increase the web depth at knee of
both column and rafter (difference between knee depth of column and rafter < 200mm). A slight increase in
the rafter depth at ridge will also help control the vertical deflection.
Stress Unity Checks:
Combined Stress Unity Check:
f a f bx f by
+ + ≤ 1 .0
Fa Fbx Fby
Where fa, fbx and fby are actual axial, major axis bending and minor axis bending stresses respectively. Fa,
Fbx and Fby are corresponding allowable stresses. If combined stress unity ratio exceeds 1.0, check whether
DM 03.10.00 4-9
DESIGN MANUAL
vertical deflection/lateral sway limits are satisfied. If not first control the deflection/lateral sway. If deflections
are under control and still the section fails in combined unity check then check the allowable stresses:-
1. If allowable stresses of top and/or bottom flanges are much lower than 0.6Fy then it implies that the
member is not properly braced then try one of the following:-
• For rafters and exterior columns (with sheeted side walls) adding flange braces(1) with roof purlins or
wall girts will adjust the allowable stresses for the unbraced flange.
• For exterior columns (without sheeted side walls) then providing strut tubes adequately connected to
bracing system at an appropriate height would reduce the unbraced length and adjust the allowable
stress.
• For interior I-section columns they can also be braced by means of strut tubes if allowed and
adequately connected to bracing system.
• For interior I-section columns that brace points can not be added in the design then stress ratios can
be improved by increasing flanges width or by minor adjustment in the flange thickness.
• For columns connected with mezzanine beams/joists columns are considered braced at mezzanine
level.
• For columns supporting top running crane beam the columns are considered laterally braced at the
level of carne beam top flange(2).
2. If allowable stresses are sufficiently high and still the section is failing in unity check, then unity check
ratio can be improved by increasing the following in the given order:-
• Increasing the web depth

• Increasing the flange width
• Increasing the flange thickness
Shear Stress Unity Check:
If Shear stress unit ratio fv/Fv > 1.0 increase web thickness.
Slenderness Ratio Check:
The slenderness ratio (KLu)/r of a member under compression must be less than 200. Usually in the minor
axis this ratio may exceed the limit. Increasing the flange width in comparison to web depth would improve
the slenderness ratio.
K = Effective length factor

Lu = Unbraced Length
r = Radius of gyration (√I/A)
Note: While optimizing keep in mind to satisfy clauses from 4.1.2.1 to 4.1.2.6
(1)
Refer for clause 4.3.1. for flange brace requirements
(2)
Refer to clause 7.2.3.1. for connection details
DM 03.10.00 4-10

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PEB DIVISION

ZAMIL STEEL COMPANY LIMITED

2.4. Serviceability consideration _________ 2-15

8.2.1.2.Connection for Lateral Load _______ 8-2

Design Engineer’s Responsibilities:

1. Reports to his Design Supervisor.

Quote Design Engineer’s Responsibilities:

CHAPTER 1: MATERIALS ....................................................................................................................................... 1-1

CHAPTER 2: STANDARD CODES & LOADS......................................................................................................... 2-1

CHAPTER 3: PLANNING PEB.................................................................................................................................3-1

CHAPTER 4: MAIN FRAMING DESIGN ................................................................................................................. 4-1

CHAPTER 5: SECONDARY MEMBERS DESIGN...................................................................................................5-1

5.2.1.7. Double ‘C’ -sections........................................................................................................................................5-27

CHAPTER 6: END WALLS DESIGN ........................................................................................................................6-1

CHAPTER 7: BRACING SYSTEM DESIGN............................................................................................................ 7-1

CHAPTER 8: CRANE SYSTEMS DESIGN ..............................................................................................................8-1

CHAPTER 9: MEZZANINE FLOOR DESIGN...........................................................................................................9-1

CHAPTER 10: SPECIAL DESIGN REQUIREMENTS............................................................................................10-1

CHAPTER 11: SPECIAL BUILDINGS....................................................................................................................11-1

CHAPTER 12: MISCELLANEOUS SERVICES......................................................................................................12-1

1.2. COLD FORMED SECTIONS

TYPE SECTIONS ORDER SIZE USAGE SPECIFICATIONS

1.3. HOT ROLLED SECTIONS

Panel Type Finish/Color Thickness Order USAGE SPECIFICATIONS

1.5. SKYLIGHT PANELS

Panel Type Order USAGE SPECIFICATIONS

TYPE COLOR ORDER SIZE SPECIFICATIONS

1.7. ROUND BARS

ROD DIAMETER ORDER LENGTH USAGE SPECIFICATIONS

1.8. CABLE BRACING

Strand Diameter ORDER DESCRIPTION USAGE SPECIFICATIONS

1.9. ANCHOR BOLTS

TYPE ORDER SIZE USAGE SPECIFICATIONS

ZAMIL STEEL COMPANY LIMITED

2.4. Serviceability consideration _________ 2-15

8.2.1.2.Connection for Lateral Load _______ 8-2

Design Engineer’s Responsibilities:

1. Reports to his Design Supervisor.

Quote Design Engineer’s Responsibilities:

CHAPTER 1: MATERIALS ....................................................................................................................................... 1-1

CHAPTER 2: STANDARD CODES & LOADS......................................................................................................... 2-1

CHAPTER 3: PLANNING PEB.................................................................................................................................3-1

CHAPTER 4: MAIN FRAMING DESIGN ................................................................................................................. 4-1

CHAPTER 5: SECONDARY MEMBERS DESIGN...................................................................................................5-1

5.2.1.7. Double ‘C’ -sections........................................................................................................................................5-27

CHAPTER 6: END WALLS DESIGN ........................................................................................................................6-1

CHAPTER 7: BRACING SYSTEM DESIGN............................................................................................................ 7-1

CHAPTER 8: CRANE SYSTEMS DESIGN ..............................................................................................................8-1

CHAPTER 9: MEZZANINE FLOOR DESIGN...........................................................................................................9-1

CHAPTER 10: SPECIAL DESIGN REQUIREMENTS............................................................................................10-1

CHAPTER 11: SPECIAL BUILDINGS....................................................................................................................11-1

CHAPTER 12: MISCELLANEOUS SERVICES......................................................................................................12-1

1.2. COLD FORMED SECTIONS

TYPE SECTIONS ORDER SIZE USAGE SPECIFICATIONS

1.3. HOT ROLLED SECTIONS

Panel Type Finish/Color Thickness Order USAGE SPECIFICATIONS

1.5. SKYLIGHT PANELS

Panel Type Order USAGE SPECIFICATIONS

TYPE COLOR ORDER SIZE SPECIFICATIONS