Frameless arched hangars technology. Frame and frameless hangars - advantages and disadvantages
We build frameless arched hangars in Moscow on a turnkey basis from 7-10 days. The term depends on the size of the structure, the availability of insulation, the type of foundation, the availability of engineering and other systems. The experience of our specialists allows us to build not only efficiently, but also quickly.
Construction of a frameless hangar arched video
Frameless hangar price in Moscow
The table shows the order of prices for our construction services. All prices are indicated taking into account work and building materials:
Name of works |
Unit measurements |
Price, rub. |
Preliminary design | m2 | from 250 |
Reinforced concrete base | running m | from 3000 |
Reinforced concrete slab | m2 | from 12 500 |
Frameless hangar | m2 | from 3000 |
Insulation of a frameless hangar, mineral wool (with profiled sheet facing) | m2 | from 1 800 |
Insulation of a frameless hangar, polyurethane foam | m2 | from 1 100 |
Calculating the cost of a frameless hangar online
We suggest using our calculator for self-calculation of the cost of construction in online mode... Please indicate required parameters frameless hangar and get a commercial offer from our company with an estimated cost. Finding out how much a frameless hangar costs is simple and quick.
Construction of frameless hangars in Moscow from SMK Group of Companies
We have been building frameless hangars for more than 10 years using original professional equipment and technology from the American company M.I.C. Industries Inc. We are ready to provide recommendations to our customers. We work honestly and efficiently. We provide an official guarantee for a frameless arched hangar for 5 years. Contact us for construction services and get a competent implementation of your project.
In addition to frameless hangars, we are engaged in the construction of prefabricated frame
Experts of the Ukrainian agricultural market believe that in the coming years there will be a surge in demand for grain storage from small and medium-sized farms. “Most companies with a land bank of more than 5 thousand hectares have their own elevators. The segment of large elevators for large enterprises is saturated. Therefore, the segment of small and medium-sized grain storage facilities is currently developing most actively, ”noted Andrey Kupchenko, grain markets analyst at APK-Inform Agency (). Namely, frameless technologies are perfect for the construction of floor grain storage facilities.
However, many farmers have heard that frameless structures are unreliable and can collapse from strong winds and excessive snow loads. This article contains information that will help the future owner of a frameless structure make an informed choice, which will help to avoid troubles and losses in the future. You will learn about the types of arched hangars and stages of construction, while designers and builders will tell you about the pitfalls of frameless construction. We will also analyze the court case on the collapse of a frameless storage hangar in the Belgorod region. finished products, the construction and operation of which has become a vivid example of unprofessionalism, greed and carelessness!
General information about frameless arched hangars
Frameless arched hangars are a type of pre-fabricated buildings, which are a single self-supporting structure of an arched shape made of rolled galvanized or painted steel with a thickness of 0.8-1.5 mm (see "").
- The width of the arch can be from 3 to 30 m,
- the height of the hangar depends on the span of the arch,
- the length of the building can be any.
There are 3 basic forms of frameless hangar arches. The designer of each of the forms can be modified depending on the specific needs of the agricultural enterprise (see "").
In agriculture, several design solutions for frameless structures are used:
- Usually arches are installed on a strip or slab foundation.
- Also, steel structures can be installed on a base, which can serve as walls of an existing building, concrete blocks or columnar foundation any height.
For example, if the structure of the hangar is designed taking into account the load of grain crops on the walls with a height of 2.5 m, then the arched hangar measuring 15x30 m (450 sq. M) can accommodate 1,000 tons of wheat.
A frameless hangar with an area of 1 thousand square meters accommodates:
- 3 thousand tons of potatoes
- 2 thousand tons of wheat
- 1.2 thousand tons of sunflower
- a pigsty for 500 heads can also be accommodated
The arched shape of the premises allows very efficient use of space when storing bulk materials. However, future owners of granaries should definitely know that it is under no circumstances to pour grain on the steel parts of the structure!
Scope of application of frameless hangars in agriculture:
- Grain and vegetable storage
- Feed warehouses
- Livestock premises
- Production buildings
- Awnings
- Hangars for special equipment and repair shops
- Administrative buildings
Frameless hangars are manufactured directly at construction site, with the help of special mobile complexes. Such complexes produce profiling and corrugation of coiled steel while simultaneously giving the required radius (see ""). Subsequently, the arched element is combined into blocks and connected in the design position with a folding (folding) machine. Then the arched blocks are lifted with a crane and installed on a previously prepared foundation and fixed by spot welding or bolts to the embedded parts of the foundation. Watertightness and tightness of folded joints is an advantage over traditional ways construction and can significantly reduce operating costs.
In separate blocks, we will analyze the court case on the collapse of the arched hangar (see "Case No. А08-7248 / 2013")
The most interesting excerpts from this trial can be found.
Advantages of frameless arched hangars
Frameless technology makes it possible to build hangars in record time. It will take 10-15 days to build an arch for a grain warehouse with an area of 1 thousand square meters. Artem Bilyk, head of the Engineering Center of the Ukrainian Center for Steel Construction (USSS), noted that this technology makes it possible to construct not only arched structures, but also temporary circular granaries in an incredibly fast time: literally in 3-4 days it is possible to build storage facilities for 2-3 thousand cubic meters. tons of grain, which is successfully used by farmers in the United States and other countries.
Also among the advantages of frameless construction are:
- Combination of supporting and enclosing structures
- Span up to 30 m and the absence of internal columns or trusses, which allows full use of the entire internal area of the room
- Production directly on site, which minimizes transport costs
- One compact raw material type - sheet steel coil
- Possibility of fast and effective thermal insulation by spraying up to 70 mm of polyurethane foam
- Seam tightness and minimum operating costs
- Various shapes, adaptability for purpose, the possibility of inserting windows and gates
V agriculture frameless hangars are successfully used as floor grain silos, which have a number of advantages over silo elevators. Firstly, the floor storage can be used both for storing grain and for other purposes, while the silo can only be used for storing grain. In addition, corn, soybeans and other crops are better stored in the floor warehouse, there is less drop height of the grain during loading, which prevents injury. Secondly, there is more condensate in the silos, as it is metal. In floor-standing warehouses, there is no metal contact. This often uses internal retaining structures that separate the interaction of the grain with the enclosing structure.
Prices for frameless arched hangars and granaries
But still, the main advantage of arched structures is the price of frameless hangars. Usually companies declare that the cost of erecting arched hangars is about 2-2.5 times less than frame structures (see "").
Savings in the construction of arched hangars is achieved due to:
- lack of a frame, which reduces the metal consumption of the project;
- the use of lightweight (cheaper) foundations, which, moreover, the customer can build on their own;
- minimum logistics costs.
However, the cost of construction for different companies operating in the frameless construction market may differ by a factor of 5 (see ""). Having monitored the Internet at the beginning of summer 2017, I found that the minimum price for the construction of arched hangars was 400 UAH / sq.m. True, it is worth noting that the companies do not indicate what is included in this price - only an arch without a foundation and a gate, what kind of metal is used, etc. I found a more or less intelligible offer for May 2017 on the website of the Industrial Systems company, where the construction of a frameless grain warehouse with an area of 1.08 thousand square meters (60x18 m) will cost about UAH 2.15 million, or almost 2 thousand UAH / sq.m (see "").
Quite often, the price of a frameless structure, announced on the websites of companies and at preliminary negotiations, increases over time for various reasons. The expert warns: “Some contractors are disingenuous, initially declaring a low price per square meter of the future hangar, then including additional expenses for the rental of lifting equipment, delivery of equipment and materials, accommodation and meals for workers, etc. ".
According to operators
For example, the cost of renting cars, crane work, crew travel to the construction site, security can be up to 15% of the total cost of construction. More detailed information on the cost of building frameless arched hangars and prices for the materials required for this is located.
Floor grain silos, built using frameless technology, outperform silo elevators. For example, the construction of a silo elevator will cost at least 3 times more (based on the price for 1 ton of storage; see "Arithmetic for building an elevator. How to build cheaper?") Than a ready-made floor warehouse with mechanization, built using frameless technology, with conveyors and all the necessary equipment.
A non-mechanized floor-type grain warehouse, the design of which does not provide for the presence of transport mechanisms, with a gallery without conveyors in any design, will cost in the range of $ 13-14 per storage cube. According to the latest estimates, a semi-mechanized grain warehouse, which has added top loading, upper conveyors, towers, lighting, increases the price of a grain warehouse by another $ 4-5 per cubic meter of storage. If you also install unloading, then the price of a floor grain storage will increase by another $ 4-5, depending on the task. Experts noted that the price of a mechanized grain storage without thermometry will cost about $ 25 per cubic meter of stored products. The maximum is a grain storage with aeration, with transport, with temperature and humidity sensors, everything that you can think of - the cost of such a grain storage will be about $ 30 per cubic meter of stored products. A set of metal structures for a silo without a foundation and without installation will cost at least $ 60 per cubic meter of stored products (see "").
Source: "Industrial Systems"
Ruslan Dashkevich, commercial director of Industrial Systems LLC, told the magazine Grain Storage and Processing (No. 9 for 2016) that when building from scratch, the cost per cubic meter of storage of a non-mechanized warehouse and a mechanized warehouse is the same. The difference is that a mechanized warehouse requires more investment at a time. That is square meters, if you count, will be more expensive, but the price for a storage cube will be the same. An agricultural producer can choose for himself: to build 1000 square meters of mechanized warehouse or build 2000 square meters of non-mechanized one (see ""). It will be the same money and the same capacity. Mechanized warehouses hold more products per square meter. It makes no sense to do mechanization with a small load per square meter. “A frameless hangar, built simply on a foundation, on a reinforced concrete wall, can be mechanized in the future, but it is unprofitable and expensive (see“ ”),” Ruslan Dashkevich noted.
Disadvantages of frameless arched hangars
A significant problem of frameless construction in Ukraine is a very vague regulatory and technical base. Only on 05.05.2016 in the Ministry of Agrarian Policy was signed a Decree on the inclusion of prefabricated hangars, developed in accordance with TU U 45.6-32821424-001: 2012 (developed by Industrial Systems LLC), into State Register technical means for agro-industrial complex Ukraine (). Unfortunately, it was not possible to find a description of this TU on the Internet (see Russian TU 5283-147-02494680-2004), and representatives of the Industrial Systems company, referring to their busyness, did not find time to answer the questions that were poisoned to them in the preparation of this articles.
“When choosing a company engaged in the construction of frameless hangars, the customer should pay attention to whether the contractor has documentation for the products - hangars - TU, Enterprise Standard and its level of elaboration. For example, in Russia, only a few companies have technical specifications developed design organizations", - said the expert.
Many experts complain about the lack of reliable and proven miscalculations of the stability of such structures (see ""). Igor Khoroshilov, a design engineer at Starplast, warns that in a classical calculation, a frameless structure should collapse in the first year of operation. But they stand! The reason is that due to the corrugation of the profile, the laws of section reduction change, the stability of the section to the load increases, and the classical calculation is not applicable. I heard that there were attempts to calculate it "from scratch", but the results were still negative - the building with such arch thicknesses should have collapsed, if we take into account the snow loads generally accepted for our climatic zone. But here they are. They are destroyed only when violations become egregious: the thickness is less than 1.2 mm, the span width is more than 24 m, the length of the building is more than 70 m. ", - added Igor Khoroshilov (see" ").
Deputy general director on the scientific and technical policy of LLC "Ukrinstalkon named after V.M. Shimanovsky", Vladimir Adrianov noted that frameless arched structures are unstable and require special attention to ensure their safety, reliability and, preferably, durability. Therefore, the customer must:
- involve a firm (enterprise) of a supplier of structures with sufficient experience and, preferably, with the provision of a certificate (declaration) for compliance with normative and technical documentation (NTD), according to which the structures will be manufactured;
- installation of structures is commissioned by a specialized construction organization with the necessary work experience;
- ensure the operation of frameless arched hangars made of folded metal structures, taking into account the requirements of the current standard of Ukraine for the inspection of buildings and structures made of metal structures.
The customer should pay attention to the qualifications and experience of the companies and their construction teams. Director of Angaryugstroy Andrey Zdot noticed that now even farms are buying roll-forming machines and trying to build arched hangars. Then some time comes and they call us with a proposal to sell these machines, as they begin to understand that the construction of frameless structures is, first of all, specialists and practitioners.
V construction company"Iveco-Bud", which is engaged in the construction of frame structures, believe that frameless arched structures are not repairable in case of any damage to their self-supporting surface. After all, unpredictable external loads and soil shrinkage or light foundation nobody canceled. The frameless structure is assembled into a single whole during the installation process and can be replaced, if necessary, also only as a whole. However, specialists from companies building frameless structures said that arches are quite amenable to repair and galvanized metal can be easily cut, sewn, make an opening, etc.
Valeriy Dryuk, the deputy general director of the company "Sunward-Ukraine", confidently declares that when operated in a non-aggressive or slightly aggressive environment, the frameless arched building will serve for more than 30 years. If necessary, the building can be dismantled and erected in a more convenient place or lengthened, and in case of mechanical damage to the metal structures, it can be replaced by elements.
The shape of the arch does not always allow full use of the internal volume of the room when it comes to storing bulk or bulk objects.
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1. Preparatory work:
Includes preparation of the construction site, engineering survey, the choice of the optimal type of foundation. If desired, the foundation can be made by the customer independently, which further reduces the cost of work. The profile guides are attached to the foundation.
2. Profiling of steel.
The production of arched and straight profiled panels from galvanized steel 1.2 mm is carried out directly at the construction site using a roll forming machine. The arcuate profile of the required length is connected into arched elements of five strips ("five") with a width of 1.5 m by rolling.
3. Installation.
The resulting arches are lifted by a crane, installed in guides and fixed in them, and then connected to each other (rolled). Then the end walls with valves and gates are installed.
4. Thermal insulation.
For the insulation of arched hangars, rigid polyurethane foam (PPU) is used, which meets the most stringent requirements for thermal insulation and has a number of advantages over other heaters:
- durability (half-life of polyurethane foam is 250 years) during this time it will not lose its thermal insulation qualities;
- this insulation is neutral to water, solvents, and other aggressive media;
- in addition to heat insulation of the storage facility, the PPU serves as the protection of the storage metal against corrosion, which further extends the service life of the hangar;
- quality material is flame retardant. It does not ignite from a short circuit or a match, do not even burn with welding. However, it can burn, but only if there is a very high temperature or a large fire site.
PPU has the lowest thermal conductivity coefficient. Only 3 cm of PU foam replaces 1 meter brickwork made of silicate bricks.