Truss, I-Beam, Pipe or Modular — Which Steel Structure Is Best for Large Spans?
Designing for large spans is one of the most critical challenges in industrial and commercial construction. Whether it’s a factory shed, warehouse, logistics hub, or manufacturing unit, the choice of structural system directly impacts cost, efficiency, load performance, and long-term usability.
Among the most commonly considered systems are trusses, I-beams, pipe structures, and modular steel systems. Each has its own structural logic, advantages, and ideal use cases. This guide offers a technical yet practical comparison to help architects, consultants, and industrial clients make informed decisions—especially when planning PEB buildings and factory sheds.
Understanding Large Span Requirements
Large-span structures typically range from 20 meters to 100+ meters without intermediate columns. These spans are common in:
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Factory sheds
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Industrial warehouses
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Pre-Engineered Buildings (PEB)
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Aircraft hangars
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Logistics and storage facilities
The primary design goals are:
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Column-free interior space
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Structural efficiency
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Speed of construction
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Optimised steel consumption
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Long-term durability
This is where the choice of steel system becomes crucial.
1. Truss Structures: Lightweight Efficiency for Wide Roofs
What is a Truss System?
A truss is a triangulated framework made of steel members that efficiently distributes loads through tension and compression.
Best Used For:
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Factory sheds with long roof spans
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Industrial buildings where roof loads dominate
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PEB factory sheds and warehouses
Advantages:
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Excellent strength-to-weight ratio
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Reduced steel consumption compared to solid beams
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Ideal for large roof spans (30–80 meters)
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Cost-effective for wide, low-rise structures
Limitations:
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More complex fabrication and detailing
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Increased erection time compared to modular PEB systems
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Not ideal where heavy crane loads are involved
Trusses are a popular choice in traditional factory sheds, especially where roof clearance is more critical than vertical load capacity.
2. I-Beam Structures: Strength and Simplicity
What is an I-Beam?
I-beams (or H-beams) are hot-rolled or built-up steel sections designed to resist bending and shear.
Best Used For:
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Medium-span industrial buildings
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Structures with heavy vertical loads
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Multi-storey industrial facilities
Advantages:
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High load-bearing capacity
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Simple structural behaviour
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Easy integration with cranes and mezzanines
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Faster fabrication for standard sizes
Limitations:
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Heavier steel consumption for large spans
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Becomes uneconomical beyond certain span lengths
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Requires intermediate columns for very wide buildings
For factory sheds with moderate spans, I-beams provide robustness but are often replaced by PEB systems for larger, cost-sensitive projects.
3. Pipe (Tubular) Structures: Aesthetic and Structural Balance
What are Pipe Structures?
Pipe or tubular steel structures use circular or square hollow sections that offer uniform strength in all directions.
Best Used For:
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Architectural industrial buildings
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Canopies and large-span roofs
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Airports, terminals, and modern warehouses
Advantages:
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High torsional resistance
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Clean, modern appearance
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Efficient for curved or complex geometries
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Reduced corrosion surface area
Limitations:
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Higher fabrication cost
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Complex joint detailing
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Requires skilled welding and quality control
Pipe structures are often chosen where design aesthetics and performance go hand in hand, rather than purely cost-driven factory sheds.
4. Modular & PEB Systems: The Industrial Standard for Large Spans
What is a PEB (Pre-Engineered Building)?
A PEB system uses factory-fabricated, built-up steel members designed specifically for the project’s span, load, and usage. These components are then bolted together on-site.
Best Used For:
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Factory sheds
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Warehouses
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Logistics parks
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Industrial plants
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Export-oriented manufacturing units
Advantages:
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Optimised steel usage through tapered sections
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Faster construction timelines
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Column-free spans up to 90 meters or more
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Easy expansion and future modifications
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Lower lifecycle cost
Limitations:
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Requires precise design coordination
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Best executed by experienced PEB manufacturers
This is where Townsklick PEB solutions stand out—offering engineered precision, speed, and scalability for modern industrial infrastructure.
Comparative Overview
| Criteria | Truss | I-Beam | Pipe | PEB / Modular |
|---|---|---|---|---|
| Span Efficiency | High | Medium | High | Very High |
| Steel Optimisation | Good | Moderate | Good | Excellent |
| Speed of Construction | Moderate | Moderate | Slow | Fast |
| Cost Efficiency (Large Spans) | Good | Low | Moderate | Excellent |
| Ideal for Factory Sheds | Yes | Limited | Rare | Yes |
Choosing the Right System: What Architects & Planners Should Consider
When selecting a structural system for large spans, consider:
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Span length and column-free requirement
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Functional load requirements (cranes, storage, machinery)
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Construction timeline
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Future expansion needs
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Overall project lifecycle cost
For most industrial clients today, PEB factory sheds offer the best balance of performance, cost, and speed.
Why PEB Is the Preferred Choice for Modern Factory Sheds
With rising land costs and tighter project deadlines, industries demand structures that are fast, flexible, and efficient. PEB systems meet these demands by combining:
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Custom-engineered steel frames
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Factory-controlled fabrication
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Reduced on-site labour
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Predictable quality and performance
Townsklick’s PEB solutions are designed to meet the evolving needs of industrial infrastructure—whether it’s a manufacturing unit, warehouse, or large-scale factory shed.
Final Thoughts
There is no one-size-fits-all answer when it comes to steel structures for large spans. Trusses, I-beams, pipe structures, and modular PEB systems each have their place.
However, for large-span factory sheds and industrial buildings, Pre-Engineered Buildings (PEB) remain the most efficient, scalable, and cost-effective solution—especially when executed by experienced providers like Townsklick.
Choosing the right structure is not just an engineering decision—it’s a strategic one that shapes how your space performs for decades to come.
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