Prefabricated steel structures, also known as pre-engineered metal buildings, are designed, fabricated, and assembled using standard components. As the name suggests, these components are put together off-site and then transported to the construction site, allowing for faster, more efficient construction. These structures consist mainly of the roof, structural subsystems, and exterior frames (walls and deck panels). Their strength, customizability, versatility, sustainability, and cost-effectiveness give them an edge over structures made using other materials and techniques.

Key applications of prefabricated steel structures
Compared to traditional construction techniques, prefabricated (prefab) steel structures offer various benefits, including reduced labor costs, less wastage, and quicker construction times. That is why it is widely used across industries to create:

1. Warehouses and distribution centers
The basic structure of prefab steel buildings and their strength in housing heavy equipment and machinery make them ideal for storage spaces like warehouses and distribution centers.

2. Manufacturing facilities
Pre-engineered buildings are highly customizable and can serve as the ideal solution for manufacturing facilities and factories. Based on one’s needs, they can include large open spaces, house cranes, and other larger machinery, build mezzanine floors, and create room for other specialized infrastructure. Prefab buildings are also commonly used as industrial plants as they are known to ensure a safe working environment for one’s team.

3. Industrial workshops
Like factories and manufacturing units, prefab buildings can also be used to build industrial workshops due to their versatile design and strength.

4. Cold storage
Pre-engineered structures offer stellar insulation properties, making them ideal for high-capacity cold storage units for perishable goods like food, pharmaceuticals, and chemicals.

Challenges of choosing prefabricated steel structures
While there are clear advantages of using prefabricated steel structures, like their durability, sustainability, shorter construction times, and clear interior spans, they also present some challenges.

1. Poor ventilation
As a non-porous material, steel does not allow air to pass freely. While this makes the material an excellent choice for insulation, it can increase the risk of issues such as increased condensation, mildew, and mold growth inside the structure. Luckily, there are ways to circumvent this issue.

• Installing louvers allows air to flow into and out of the building for improved ventilation.
• Using a vapor barrier prevents moisture from getting into the structure.
• Mounting fans can improve air circulation and reduce moisture content indoors.

2. High thermal conductivity
Steel structures present another challenge in terms of their heat transfer capabilities. This can make it difficult to maintain a standard temperature indoors, especially in areas with extreme weather. To resolve this issue, most companies rely on spray foam insulation for metal buildings. This creates a barrier between the metal and the heat and prevents thermal conductivity.

3. Issues with expansion
After the structure is constructed, it can be challenging to dismantle and expand a steel structure, presenting a problem for growing facilities. For most prefab steel buildings, the only way to expand is by building in a direction parallel to the ridge of the existing building, that is, by adding length to it. While it may not be possible outright to carry out large-scale structural changes, one way to add space to a prefab steel building is by creating a multi-story structure (more floors) and expanding vertically.

Innovations in prefabricated steel structures
Throughout history, innovation has been at the heart of metalworking. The same holds true for steel structures, with many companies investing heavily in research and development to create better, more efficient, and sustainable solutions. Some of the most recent innovations in this field include:

1. Improved reinforcement
Precision engineering aids are being used in the manufacturing processes of steel bars to provide more strength and ductility and reduce the risk of corrosion. The industry has also seen the introduction of product features like rib-on-rib, which improve steel and cement bonding to offer improved strength and load-bearing capacity, even in extreme weather conditions.

2. Sustainable coatings and building materials
Over the last few years, there have also been developments in surface treatment technology (such as zinc-rich paints and epoxy coatings) that can be used to increase the lifespan of steel structures. Another revolutionary trend has been the use of recycled steel for construction practices to reduce carbon emissions and meet long-term sustainability goals. According to some sources, this recycling feature can substantially reduce water and air pollution.

3. Lightweight steel framing
The industry has also seen a noticeable shift to lightweight steel framing, which offers additional flexibility with design choices and creates larger open spaces. Additionally, the material provides more strength and durability, making it a top choice for those looking for a sustainable and environmentally friendly construction material.