Commercial Fabrication
STAAD-Pro engineered PEB warehouses, showrooms, cold-storage buildings and mezzanine floors — column-free spans to 90 m, fast fabrication, turnkey erection anywhere in India.
Engineered Steel Buildings for Warehouses, Retail & Cold Storage
- STAAD.Pro Limit State Design analysis
- Column-free clear spans up to 90 m
- Wind & seismic design included
- Eave heights up to 14 m
- PIR sandwich panels for cold-storage (80–200 mm)
- Mezzanine floors for 3–10 kN/m² live loads
- Shop output up to 80 T/week
- High-strength bolted connections, match-drilled
- Turnkey: frame + cladding + doors + mezzanine
- 3–5 days erection per 1,000 m² of floor area
Prayag Fab Solutions designs and builds Pre-Engineered Buildings (PEBs) and conventional steel-framed commercial structures for logistics, retail, cold-storage, light manufacturing, and mixed-use occupancies. All structural frames are analysed in STAAD.Pro using Limit State Design methodology, ensuring that every column, rafter, and bracing member carries load safely while minimising steel tonnage — and therefore project cost.
Building Types We Deliver
- Logistics & distribution warehouses — clear-span portal frames from 15 m to 90 m wide, eave heights to 14 m, with dock-leveller pits, overhead-door openings, and fire-compartment walls designed into the structural scheme from day one.
- Showrooms & retail units — architecturally expressed steel frames with glazed curtain-wall interfaces, cantilevered canopies, and integrated mezzanines for display and back-office use.
- Cold-storage & controlled-atmosphere stores — insulated PEB envelopes with 80–200 mm PIR sandwich panels, vapour barriers, and structural detailing that accommodates differential thermal movement at every joint.
- Multi-story mezzanine floors — steel-framed intermediate floors in existing buildings, designed for live loads from 3 kN/m² (office) to 10 kN/m² (pallet-racking storage), with metal-deck composite slabs or steel chequer plate to suit the application.
- Insulated wall & roof systems — trapezoidal single-skin, standing-seam, or composite sandwich panels supplied and installed as part of the complete building package.
Engineering & Design
Every building starts with a structural analysis model in STAAD.Pro that accounts for dead load, imposed load, wind (regional wind speed up to Vb 50 m/s), seismic, and snow load where applicable. Foundation load schedules and column base-plate reaction drawings are issued to the civil contractor, eliminating the coordination gaps that cause programme delays.
Fabrication & Speed
Tapered portal-frame rafters and columns are fabricated from flame-cut plates on our automated welding lines, achieving a shop output of up to 80 tonnes per week. Primary connections use high-strength M20/M24 bolts with match-drilled end-plates — reducing site-erection time to typically 3–5 days per 1,000 m² of floor area. Secondary purlins and girts are cold-formed Z- or C-sections, pre-cut to length and delivered in erection sequence.
Turnkey Delivery
We offer design-supply-erect contracts covering: structural steel frame, roofing and cladding, gutters and downpipes, ridge ventilators, personnel doors and overhead doors, mezzanine stairs and guard-rails, and anchor-bolt setting-out plan. The client gets a single-point responsibility for the building envelope — no coordination between separate steel and cladding sub-contractors.
Commercial Fabrication — What We Deliver
Every capability is supported by in-house equipment, qualified procedures, and documented quality records.
PEB Warehouses
Tapered portal-frame columns and rafters, eave struts, ridge beams, and crane runway girders are fabricated from high-grade structural plate on our automated sub-merged-arc welding (SAW) lines. Flanges are CNC flame-cut for dimensional accuracy; end-plates are drilled on our radial-arm drill to ±0.5 mm hole-position tolerance so that field bolting goes together first time. Shop primer is applied to precision blast-cleaned surfaces before despatch.
Showrooms & Retail
Retail and showroom structures demand visual impact as well as structural integrity. We fabricate exposed steel frames in hollow sections (SHS/RHS), round CHS columns, and feature trusses that become part of the architectural language. All welds are ground flush and filled before a high-build polyurethane coating is applied in the client's specified colour. Cantilevered canopies use welded plate brackets engineered to carry the design wind uplift.
Cold-Storage PEBs
Cold-storage buildings require structurally continuous insulated envelopes with no thermal bridges. We supply and install 80–200 mm PIR-core sandwich wall and roof panels with interlocking joints, factory-applied colour-steel facings, and site-sealed perimeter flashings. Vapour-barrier continuity at panel junctions is detailed in our construction drawings so that the refrigeration plant can achieve specified chamber temperatures without condensation or frost risk.
Mezzanine Floors
Intermediate mezzanine floors are fabricated as bolted steel frameworks of UC columns, UB primary beams, and secondary joists at 1.2–1.5 m centres. Composite metal deck (0.9 mm galvanised steel + light concrete screed) or heavy-duty open-bar grating is installed to suit the occupancy. We design for pallet-racking point loads, forklift wheel loads, and vibration serviceability (natural frequency > 8 Hz for office areas).
Insulated Wall Panels
For controlled environments, we supply factory-made insulated wall panels (single-skin with insulation and liner, or composite sandwich) with a full range of factory-formed corner pieces, window surrounds, and door head-flashings. Panel-to-structure attachments are designed to transfer wind load without compromising the insulation layer, and all penetrations — for MEP services — are supplied with purpose-made insulated sleeve flanges.
Turnkey Site Erection
Our erection team handles complete building erection from foundation anchor-bolt survey through to ridge-cap installation. We mobilise with mobile cranes (12–50 T), cherry pickers, and modular scaffold as required. Daily progress photos and toolbox-talk records are maintained. A practical-completion handover pack with photographic as-built evidence, coating inspection report, and bolt-tension records is issued on handover.
A Four-Stage Engineering Discipline
Site Survey & Brief
Our estimator visits site to verify soil conditions (for foundation loading), check access and craneage constraints, confirm building orientation for prevailing wind, and agree floor-level datum. A Building Information Brief — occupancy, design live load, eave height, clear span, door positions, future expansion provision — is signed off by the client before engineering commences.
Engineering & Design
STAAD.Pro model is built for wind, seismic, and gravity load combinations. Member sizes are optimised to minimise tonnage. Foundation load schedule, column base-plate drawings, anchor-bolt setting-out plan, and 3-D rendering are issued to the client for review and sign-off. Any structural changes required by the client are incorporated before fabrication drawings are released.
Shop Fabrication
Primary steel is CNC-cut, drilled, assembled, and welded on our SAW lines. Secondary purlins and girts are roll-formed to length. Roofing and cladding panels are procured from approved panel manufacturers. All material is dispatched in erection sequence with piece-marks matching the erection drawing — nothing arrives on site before it is needed.
Site Erection
Our erection crew sets out anchor bolts from the structural engineer's setting-out plan (± 3 mm column grid), erects columns, rafters, and bracing, and then installs purlins, girts, and cladding from ridge down. Roof and wall panels are sealed with compatible silicone sealant at all side-laps and end-laps. On completion, a walk-through snagging inspection is conducted with the client and all items are closed before the final handover is signed.
Recent Commercial Fabrication Projects
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They engineered our cold-storage PEB from concept to commissioning. The design-build discipline was refreshing.
Explore Our Other Disciplines
Industrial Structures
Heavy structural steel for plants, mills, conveyor gantries, and crane beams — designed, fabricated, and erected in-house with full surface protection and project-specific engineering.
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