ZAMIL STEEL BUILDINGS

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

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 ZAMIL STEEL BUILDINGS
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.

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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

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T AB L E O F C O N T E N T

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
5.2.1.2. 250mm depth Z-sections ................................................................................................................................5-22
5.2.1.3. Z-sections overlaps.........................................................................................................................................5-23
5.2.1.4. 120mm depth C-sections................................................................................................................................5-24
5.2.1.5. 200mm depth C-sections................................................................................................................................5-25
5.2.1.6. 300mm depth C-sections................................................................................................................................5-26

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T AB L E O F C O N T E N T

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
6.2.3. End Wall Rafter Guide Design Tables ....................................................................................................6-8
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

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T AB L E O F C O N T E N T

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

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 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

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