Earlier, PEB construction was used only in warehouse/factory building, but with the help of the latest design methods and technology we are now capable of building complex building structures, says Puneet Mathur, Business Head – Building Solutions,  Tata BlueScope Steel Ltd.

How has technological innovations aided faster and safer construction of steel and metal structures and thereby timely completions?
Over the past 10 years, the impact of technology on the construction sector has been evolutionary. Technology has indeed enabled not only pace but also precision. The software enabled designs are the reality of today. They not only fast track the construction process, but also optimise designs from an operational point of view, enabling economy and early occupancy. Tata BlueScope Steel uses advanced software to pass on this advantage to our customers. Progressive construction techniques and installation practices further promise reliability and accuracy.

Pre-engineered Buildings (PEBs) offer offsite fabrication and assembly that further augments quality and productivity. Use of high-end safety equipment reduces fatalities and improves efficiency. Mandatory use of personal protective equipment, SKYWEB II fall protection system and usage of boom lifts for height work along with regular training of erection crew and no tolerance of safety violation safely enable completion of projects, with least damage or wastage. Our construction team is equipped with special tools and tackles, developed by Butler Construction to deliver quality workmanship with superior construction skills and processes ensuring the building are erected on time and with safety and quality.

What are the long-term benefits of your pre-engineered steel structures?
Modern-day requirements demand lighter structures without compromising on functionality. Combining the two, Butler and Ecobuild PEB solutions from Tata BlueScope Steel supplies customised pre engineered steel buildings, designed for long-term benefits – strength, durability, longevity and sustainability. Butler is a premium, globally renowned engineered steel building solution with MR 24 roofing system that offers 10 years leak-proof warranty. Ecobuild is a cost-effective, contemporary building system that can be customised to match various designs, functions, sizes and a host of segment-specific requirements.

Both solutions are accompanied with galvanised purlin and girt known as CEE-plus and ZED plus, that last much longer without regular maintenance, as compared with conventional unprotected structural elements. These solutions combine the practicality of a rigid frame with virtually unlimited design flexibility (seamless expansion). Being modular, they can be easily relocated and enable higher salvage value.

Our safe construction practices are a global benchmark derived from BlueScope Steel, Australia. Right from effective use of risk mitigation techniques, erection methodologies supervised by dedicated construction experts, innovative construction technologies provide long-term benefits. Strength and sustainability make pre-engineered buildings gain an advantage over their nonconventional counterparts. Progressive segments such as warehouses, manufacturing facilities, multi-storey buildings, schools, airports, commercial structures, exhibition and conventions centres etc, derive their efficiencies from what we have to offer.

Our PEB business in India has delivered more than a thousand projects for multinational clients such as Unilever, P&G, Ford, DuPont, Bosch, GE, ColgatePalmolive, Carlsberg, Tata Boeing, Nivea, Reliance, and ITC, to name a few.

What are some of the methods to prevent the oxidation of steel and metals and ensure they remain protected from corrosion?
Our PEB solutions are made from Zincalume steel and Colorbond steel whose coating provides an envelope for the entire building, preventing it from oxidation.

It has greater formidability, which can be readily bent and roll-formed without sacrificing coating adhesion. Zincalume steel combines both galvanic protection of zinc and barrier protection of aluminium. This barrier protection reduces the rate of dissolution of zinc enabling corrosion resistance. To prevent oxidation, primary members are coated with primer and finish coat based on severity and condition of the site location (marine exposure, chemical exposure, etc.) just above the base metal coat, to protect it from external factors such as oxidation. On average, Zincalume steel lasts up to four times longer than galvanised steel under similar environmental conditions. Adequate metallurgical compatibility of various building components and their accessories further augments structural performance. The absence of such know-how usually leads to inappropriate material selection causing a shortfall in structural performance, resulting in leakages, unpleasant aesthetics and ultimately huge replacement costs.

How can PEBs maintain a perfect balance between cost and energy efficiency?
PEBs are inherently green (recyclable and reusable) so far as environmental sustainability is concerned. They are also economically sustainable (due to their long life), as compared to conventional construction methods. PEB construction is 30-40 per cent faster, unlike typical masonry. Wastage is minimum with negligible environmental degradation. There are many components due to which, PEBs can be termed as green buildings. PEBs have skylights and wall lights enabling natural light, cutting down on electricity consumption. The insulation in the roofing system enables thermal efficiency. Natural ventilation in the form of turbo vents, ridge vents, louvres and roof monitor exhaust CO2, hot air and other harmful gases, maintaining a healthy indoor environment. Since all these work on gravity, there is zero energy consumption.

How green is Tata BlueScope Steel’s PEB solution?
At Tata BlueScope Steel, sustainability starts right from the design phase with predesigned/predetermined usage of building materials that optimise resource utilisation, minimising wastage. Being always conscious of the impact on the environment, our manufacturing processes also resonate with the ecological point of view. PEBs supplied by Tata BlueScope Steel are made from Colorbond steel and Zincalume steel – the world’s most advanced pre-painted steel coils. Resilient structures powered by Colorbond steel are lead-free. They are also RoHS compliant and suitable for water harvesting. Colorbond steel with Thermatech technology enhances the roof’s thermal performance and cools down inside temperatures, thus ensuring lesser energy consumption. All our products and solutions are made from 100 per cent recyclable steel. They ensure minimal environmental waste and can be reused and relocated.

What kind of projects are you undertaking in the current market scenario?
For our customers, PEBs are not only confined to industrial or logistics applications, but has also gained importance in diverse applications such as commercial multi-storied buildings those up to G+ 6 (including IT parks), in metro rail projects, stadiums, airport hangers, and Steam Turbine Generator (STG) buildings in power plants, to name a few. Some clients also require PEB vendors to take up civil foundation work along with PEB packages as turnkey solutions, which we are more than willing to offer. With aesthetics, developers are also keen on building eco-friendly structures that cause minimum harm to the environment. PEBs are recyclable and energy-efficient if appropriately insulated.

Adding up further to the environment friendly credentials, there is a greater demand for solar compatible PEB roofing systems that are on the rise. Earlier, PEB construction was used only in warehouse/ factory building, but with the help of the latest design methods and technology, we are now capable of building complex building structures.