Seismic risk reduction in industrial buildings: interventions and solutions
Reducing the seismic risk of an industrial building does not simply mean “bringing a structure up to code.” It means protecting people, production continuity, equipment, goods, investments, and the property value of the building.
In the case of warehouses, production facilities, logistics centers, and prefabricated structures, seismic safety is a particularly relevant issue: many existing industrial buildings were designed in eras when the seismic classification of the territory, technical standards, and risk awareness were very different from those of today.
For this reason, before choosing an intervention, it is essential to start with a question: what is the actual level of seismic risk of the building?
According to Civil Protection, seismic risk derives from the combination of three factors: hazard, vulnerability, and exposure. In other words, it is not only about how seismic an area is, but also how fragile the building is and what people, activities, and assets are present inside it.
What is meant by seismic risk of an industrial building
Seismic risk measures the expected damage that an earthquake could cause in a given context. In the case of an industrial building, this damage may concern:
- the safety of people;
- the stability of the structure;
- the functionality of columns, beams, roof slabs, and roofing;
- the behavior of connections between prefabricated elements;
- the integrity of cladding, racking, systems, and machinery;
- the interruption of production activity;
- restoration costs and downtime.
Seismic risk does not therefore coincide solely with the “seismic zone” in which the building is located. Two warehouses located in the same area can have very different risk levels, based on the year of construction, the structural system, the state of conservation, interventions carried out over time, and the intended use.
Why prefabricated industrial buildings require specific analysis
Prefabricated industrial buildings have very different structural characteristics compared to traditional civil buildings. They are often made up of load-bearing elements produced off-site and assembled on-site: columns, beams, roof slabs, cladding panels, floors, facade elements.
In the event of an earthquake, the behavior of the building depends not only on the strength of individual elements, but also on the quality and effectiveness of structural connections.
Among the most common critical issues in existing industrial buildings may be:
- beam-column supports not sufficiently restrained;
- absence or inadequacy of restraint devices;
- inadequate connections between roof slabs and beams;
- vulnerability of cladding panels;
- deficiencies in connections between panels and the main structure;
- presence of potentially unstable non-structural elements;
- subsequent modifications not accompanied by a global verification;
- material degradation or loss of efficiency in construction details.
For this reason, seismic risk reduction must be addressed with a targeted engineering approach, starting from in-depth knowledge of the building.
The first step: seismic vulnerability assessment
Before choosing any intervention, it is necessary to perform a seismic vulnerability assessment. This is a technical analysis that allows estimating the structure’s capacity to resist the seismic action expected for the site.
The assessment generally includes:
- Document collection
Analysis of structural documents, original drawings, calculation reports, material certificates, testing records, building permits, and documentation relating to any subsequent modifications. - Geometric and structural survey
Verification of the actual structural scheme, element dimensions, connection layout, and correspondence between design and as-built condition. - Material and construction detail investigations
Tests and verifications useful for defining the mechanical characteristics of materials, the state of conservation, and the quality of connections. - Modeling and structural analysis
Development of a building model to evaluate the seismic response of the structure and identify the main vulnerabilities. - Definition of possible interventions
Identification of the most effective technical solutions based on safety objectives, production requirements, and available budget.
The Technical Standards for Construction currently in force are defined by Ministerial Decree of January 17, 2018, known as NTC 2018, and also govern interventions on existing structures.
Local interventions, seismic improvement, or seismic retrofitting: what are the differences?
Once the assessment is complete, it is possible to establish which technical path to follow. The main categories of intervention on existing buildings are generally attributable to three approaches: local interventions, seismic improvement and seismic retrofitting. The application Circular of NTC 2018 specifically refers to these categories for interventions on existing structures.
Local interventions
Local interventions act on individual parts of the structure, without substantially modifying the overall behavior of the building.
In the case of a prefabricated industrial building, they may concern, for example:
- reinforcement or integration of beam-column connections;
- insertion of anti-overturning devices;
- restraint of roof slabs;
- securing of prefabricated panels;
- reinforcement of secondary elements;
- stabilization of non-structural elements;
- targeted interventions on critical nodes or supports.
These are particularly useful solutions when the structure has localized vulnerabilities and when the objective is to eliminate local collapse mechanisms.
Seismic improvement
Seismic improvement aims to increase the overall safety of the building, without necessarily reaching the levels required for a new construction.
It is often the most suitable solution for existing industrial buildings where the goal is to concretely reduce seismic risk, improving the overall behavior of the structure and addressing the main critical issues.
It may include:
- reinforcement of connections between prefabricated elements;
- improvement of column response;
- stiffening or bracing;
- restraint systems for roofing and cladding;
- localized reinforcements on load-bearing elements;
- solutions to improve the distribution of seismic actions;
- integrated interventions on the main structure and secondary elements.
Seismic retrofitting
Seismic retrofitting aims to bring the building to a safety level compliant with that required for new constructions, in the cases and with the methods provided by regulations.
It is a broader and more structural intervention, often required in the presence of significant modifications, such as vertical extensions, structurally connected expansions, or changes in use that involve significant load increases.
In the industrial context, retrofitting may be necessary when the building is substantially transformed or when the client voluntarily chooses to achieve the highest performance level.
Which interventions to choose to reduce seismic risk
There is no one-size-fits-all intervention for all buildings. The choice depends on several factors:
- structural type;
- year of construction;
- presence or absence of effective connections;
- intended use;
- building use class;
- occupancy level;
- value of assets present;
- required production continuity;
- ability to operate during activity;
- client’s safety objectives;
- available budget and timeframe.
Below is an overview of the most relevant interventions for industrial buildings.
- Securing structural connections
In prefabricated warehouses, connections between structural elements are often the most delicate point. In the event of an earthquake, beams, slabs, panels, and other components must be able to correctly transfer actions without losing support or generating overturning mechanisms.
Interventions may include:
- additional mechanical connections;
- restraint systems;
- brackets;
- plates and metal devices;
- restraints between roofing elements and beams;
- anti-overturning systems for prefabricated panels.
This type of intervention is often a priority because it allows reducing potentially critical vulnerabilities with targeted works and, in many cases, compatible with the company’s operational continuity.
- Reinforcement of columns, beams, and structural nodes
When the analysis reveals deficiencies in load-bearing elements, it may be necessary to intervene on columns, beams, or nodes.
Solutions may vary based on material, geometry, and level of structural deficit:
- jacketing;
- confinement;
- steel reinforcements;
- composite material reinforcements;
- increase in local ductility;
- improvement of element load-bearing capacity;
- interventions on connection nodes.
The objective is to increase the building’s capacity to dissipate and resist seismic actions, reducing the risk of brittle collapses or local mechanisms.
- Stabilization of panels and cladding
In prefabricated industrial buildings, cladding panels can represent a critical element. Even when they do not perform a primary load-bearing function, their detachment or overturning can generate significant risks for people, vehicles, goods, and production continuity.
Interventions may include:
- verification of existing anchors;
- replacement or integration of connections;
- anti-overturning devices;
- restraint systems;
- reinforcement of fixing points;
- verification of interferences with plant elements or openings.
The safety of non-structural elements is a central issue in production facilities, because even apparently “secondary” damage can cause operational downtime, partial unusability, or risks for workers.
- Bracing and stiffening systems
In some cases, to improve the overall behavior of the building, it may be necessary to insert bracing or stiffening systems.
These interventions serve to:
- improve the distribution of horizontal actions;
- increase overall stability;
- reduce displacements and deformations;
- improve the box-like behavior of the building;
- limit torsional mechanisms or structural irregularities.
The design of these systems must be accurate, because improperly calibrated stiffening can modify the dynamic behavior of the building and generate stress concentrations.
- Interventions on industrial roofing
The roofs of industrial warehouses are often made up of prefabricated elements resting on main beams. In the absence of effective connections, seismic action can generate sliding, loss of support, or local instabilities.
Interventions may concern:
- connection of slabs to beams;
- restraint devices;
- verification of supports;
- reinforcement of connections;
- control of skylights, sheds, systems, and superstructures;
- assessment of additional loads, such as photovoltaic systems or technical installations.
This aspect is particularly important when systems, lifelines, solar panels, or other elements that can modify loads and structural behavior are present on the roof.
- Structural monitoring and control over time
Seismic risk reduction does not end with the intervention. For the most strategic industrial buildings, it may be useful to integrate structural monitoring systems capable of controlling the building’s behavior over time.
Monitoring allows:
- observing significant structural parameters;
- detecting anomalies or variations over time;
- supporting maintenance decisions;
- improving knowledge of the building;
- managing industrial real estate assets more consciously.
In a production context, monitoring can become part of a broader strategy of predictive maintenance and risk management.
How to choose the correct intervention: performance-based approach and production continuity
For a company, the choice of intervention does not depend only on structural engineering. It also depends on the ability to reconcile safety, timeframes, costs, and operational continuity.
A good seismic risk reduction project should therefore answer very concrete questions:
- Can the building remain operational during the works?
- Can the interventions be carried out in phases?
- Which production areas need to be cleared?
- Which systems interfere with the works?
- Which operations generate less impact on activity?
- What is the relationship between investment and risk reduction?
- Is a local intervention, improvement, or retrofitting preferable?
- Can the intervention be integrated with maintenance, energy efficiency, or property redevelopment?
In the industrial sector, design must therefore bring together two levels: structural safety and business operations.
Seismic risk reduction and property value
Investing in seismic risk reduction does not only mean preventing damage. It also means increasing the technical, functional, and asset value of the building.
An industrial building that has been verified, monitored, and improved from a seismic standpoint can offer significant advantages:
- greater safety for workers and visitors;
- reduced risk of production downtime;
- better insurance and asset management;
- greater property attractiveness;
- better compliance with safety requirements;
- ability to plan maintenance and investments more rationally;
- protection of business continuity.
In a market where logistics, production, and operational continuity are increasingly strategic, seismic safety becomes a competitive factor.
The role of Manini Service in seismic risk reduction
Seismic risk reduction of an industrial building requires specialized skills, diagnostic capability, knowledge of prefabricated systems, and an integrated approach to structural retrofitting.
With Manini Service, Manini Prefabbricati supports companies, property owners, and industrial asset managers in all phases of the process:
- preliminary building analysis;
- vulnerability assessment;
- definition of intervention priorities;
- design of technical solutions;
- execution of interventions;
- monitoring and maintenance over time.
The objective is to identify the most effective solution for each building, avoiding standardized approaches and building an intervention plan consistent with the actual conditions of the structure and the operational needs of the company.
Seismic risk reduction in industrial buildings cannot be entrusted to generic interventions. Each structure has a history, a construction system, a level of vulnerability, and a specific role within the production activity.
To choose the correct intervention, it is necessary to start from an in-depth technical assessment, distinguish between local interventions, improvement, and seismic retrofitting, and define a strategy capable of combining safety, operational continuity, and investment sustainability.
For a company, protecting its industrial building means protecting people, production, value, and the future.
Do you want to know the seismic risk level of your industrial building?
Manini Service can support you with a dedicated technical analysis and a customized intervention plan to improve the safety and reliability of your structure.
SEO / AEO FAQ
What is seismic risk?
Seismic risk is the measure of expected damage that an earthquake can cause in a given context. It depends on the seismic hazard of the area, the vulnerability of the building, and the exposure of people, assets, and activities present.
How is the seismic risk of an industrial building reduced?
Seismic risk is reduced through a technical assessment of the building and the subsequent design of targeted interventions, such as reinforcement of connections, securing of panels, improvement of structural nodes, bracing, seismic retrofitting, or structural monitoring.
What is the difference between seismic improvement and seismic retrofitting?
Seismic improvement increases the safety level of the existing building without necessarily reaching that required for a new construction. Seismic retrofitting, on the other hand, aims to bring the structure to the safety levels required by regulations for specific conditions and interventions.
When is it necessary to perform a seismic vulnerability assessment?
It is advisable to perform a seismic vulnerability assessment when the building is old, when structural or functional modifications are planned, when new loads are installed on the roof, when operational risk needs to be reduced, or when the actual safety level of the structure needs to be known.
Can seismic interventions be carried out without stopping production?
In many cases yes, provided the interventions are specifically designed and planned. In industrial buildings, it is often possible to proceed in phases, working on delimited areas and reducing the impact on production activity.
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