Fair Cost for Industrial/Warehouse Buildings (without cranes)
Interactive Excel web-sheet calculator for estimate and break-up details (civil & structural works) for new industrial or warehouse projects. Costing compared for four different types of industrial structures.
An excel worksheet is embedded below. Building dimensions and other input can be provided on grey cells which are permitted to be edited. Details of cost for different types of industrial building will be provided as output. We use an in-house dynamic programming routine for optimal design of the building for given sizes. The costing is intended to help organizations and individual industrialists to add value to Front-End decisions, such as selection of type of structure, budgetary costing and contracting decisions. We will shortly publish the provisional Bill of Quantities in other posts. Other cases, such as sheds with cranes and non-industrial buildings also will be published shortly. Do stay tuned. To report queries that are not covered here, please mail to email@example.com
Note: Details of four types of sheds are presented below. Description of all four types are given after the worksheet.
Mobile users, please double tap on the cells to edit
Type 1: Pre-Engineered Building Shed with Full Height Cladding
Many modern buildings are of Pre-Engineered building type. The general methodology of construction is not entirely new; it derives from a conventional type of construction called rigid portal frames. The advent of high strength plates, modern welding techniques, patented corrosion-resistant (galvalume) steel sheets, turbo-ventilators and integral louvres, has changed the face of steel buildings. It is now possible to pre-design and fabricate the building in entirety. The marked pieces are literally assembled at the site, making the construction process especially quick. Typically a PEB building can be constructed including foundations and civil work in 2-3 months if there are no space constraints at site.
PEB construction is not exactly cheaper compared to other methods. But, they have evolved to be internationally accepted standard in terms of quality, aesthetics and building specifications. Design of PEB steel structures, as per National Codes such as Indian, European or American Codes turn to be expensive. Many industrial buildings in the private sector are hence constructed according to the recommendations of Metal Building Manufacturers Association MBMA, which is lenient in some respects. Where buildings are likely to be insured, it is advisable to follow the regulations of the respective national codes.
Type 1 Industrial shed, comprises of PEB industrial sheds with full height cladding – without masonry works above plinth level. Entire building skin comprises of steel galvalume sheet cladding, rolling shutter frames and louvre windows are built into the cladding sheets.
Type 2: Pre-Engineered Building Shed with Cladding above 8-10 feet blockwork
See general description of PEB Buildings above
Type 2 Industrial structures are PEB sheds with masonry walls to 8-10 feet height above plinth level and steel sheet cladding above. This type of construction is preferred internationally because it provides the comfort of thermal and sound insulation at working heights of building users. It permits the use of conventional windows and rolling shutters, providing increased thermal comfort. Type 2 sheds are slightly costlier than Type 1 sheds, and their completion time takes one or two fortnights more than Type 1 sheds.
Type 3: Truss Building Shed with Full Height Cladding
Truss structures have been conventionally used in most industrial buildings before the advent of PEB structures. Nevertheless, truss structures remain a very economical alternative to PEB structures, and can accommodate all advantages of PEB components, such as galvalume sheets and louvres. Truss structures can be constructed in a comparable time period as a PEB building, if there are no space limitations at the site. Maintenance and cleaning is often cited to be a difficult drawback of truss structures.
Type 3 sheds are truss buildings with full height cladding. The results can also be used for partial blockwork to a height of 8-10 feet and cladding above with marginal variations in cost (usually on the lower side). Marginal variations are also applicable for variations in truss configuration and lattice-type sheds.
Type 4: Truss Building Shed with Full Height Blockwork
See general description of truss Buildings above
Type 4 sheds are the most conventional type of construction, where entire skin of the building is constructed in masonry blockwork. Although this method calculates to the lowest price in most cases, the construction is slow, typically requiring about 20-day cycle for every 3-4 m of building height (depending on position of tie beams), in addition to fully clad truss building. This type of construction does not employ any modern contrivances used in PEB Buildings.
Assumptions used in this spreadsheet
- Material and labour rates are applicable to Tamil Nadu, South India as on 1 Oct 2020. We will update the rates periodically, and shortly put up options to interactively select project location.
- All load calculations are based on Indian Codes. Structural design is as per both Indian Codes and MBMA recommendations.
- Wind load locations 50m/s are considered in calculations. There may be marginal variations for other wind zones
- Rafter or truss spacing is optimized by the spreadsheet to value between 5.5-7.5m
- Galvalume sheets (0.47mm bare roofing and 0.5mm TCT cladding) are used in calculations and costs. Alternate details for insulation sheets are being prepared
- Purlins shall be cold-formed Z sections.
- Diagonal bracing is assumed to be possible at all locations.
- It is assumed that moderately good soil (with SBC capacity of about 12T/sqm) is present at about 2-2.5m from existing ground level. The result shall be revalidated with soil investigations
- Cost estimation is based on 200mm solid block (8″ CMU) for masonry below plinth level and 200mm hollow block (8″ CMU) above plinth.
- Assumed that water and power are available free at the site, there are no space constraints and no access issues into the site.
- About 20% wall area (or corresponding cladding area at working level) is considered as window openings. Every 6th bay, is regarded as rolling shutter openings. Loading-bay platforms and canopy are not considered in the calculations. The same may be regarded as an additional area.
- Costs that are common in all the types such as cable trays, electrical works, lighting and other utilities are not included in the calculations.