Handbook for Light Gauge Steel Structure Production – How LGS Done?

Handbook for Light Gauge Steel Structure Production: Light steel structures are an increasingly preferred type of construction in the modern building industry. With features such as durability, lightweight, and eco-friendly materials, these structures stand out for their rapid construction process and flexibility. In this article, we will share a comprehensive guide on producing light steel structures from A to Z, including Wall Panels, Floor Joists, Roof Trusses, and the critical role of light steel structure machines in this process.

Handbook for Light Gauge Steel Structure Production – How Is It Done?

In this section, we will discuss the preparation, production, and assembly stages of light steel structures from A to Z in 9 simple steps.

1. Project Planning and Design
The construction process for light gauge steel structures begins with careful planning and design. First, the project’s purpose is defined, which can be a residential, commercial, or industrial building. Then, architects and engineers gather information about light gauge steel systems to create the building’s design. The structure is designed in 2D and 3D using light gauge steel design software such as Vertex BD, FrameBUILDER MBR, or Strucsoft. The designed data is validated through static analysis, and once approved, it is made production-ready for light gauge steel machines. This data is transferred to the light gauge steel production machines via a flash drive or factory network.

During this phase, the following elements are considered:

• Choosing the Right Steel Thickness, Quality, and Base Size: Factors like the building’s geographic location, number of floors, and exposure to natural loads are evaluated to select the appropriate steel thickness, quality, and base size. For instance, as the number of floors and natural loads increase, the steel thickness and quality should also increase. Wall profiles above the first floor should have reduced base dimensions.
• Designing in Software: After the structure is designed, specific profiles can be removed or additional ones added as needed. Service and utility holes can be applied to the desired locations or panels. The design phase is highly flexible. Once the design is complete, a static analysis, including wind load, snow load, and earthquake resistance, is performed to either reinforce the structure or move to the profile production phase.
• Functional requirements: Understanding the purpose of the building.
• Permits and regulations: Ensuring compliance with local construction codes.

2. Material Procurement
After planning and design, the necessary materials for construction are procured. Light gauge steel structures generally include the following materials:

• Steel Coils or Profiles: These form the framework of the structure and come in various shapes and sizes. Light gauge steel machines can easily produce these profiles.
• Fasteners: Screws, nuts, and other components used to assemble the steel profiles.
• Insulation and Cladding Materials: Essential for fire safety and energy efficiency. Light gauge steel is usually made from galvanized steel, which enhances its resistance to rust and external elements.

3. Cutting, Shaping, and Profile Production
Once the materials are ready, the light gauge steel profiles are automatically shaped and cut according to the project design using light gauge steel machines. This involves automated punching, profile marking, and length cutting. This process is typically done using specialized light gauge steel machines.

• Rollform Machines: These machines are used to shape the steel into desired sections and produce structural components for the building.

4. Assembly Preparation
After cutting and shaping, assembly preparation begins. The locations for assembling the steel profiles are determined, and the necessary equipment is prepared. Additionally, a detailed assembly plan is created to ensure proper construction. Step-by-Step Guide to the Construction of Light Gauge Steel Structures

5. Foundation and Groundwork
Before assembling the light gauge steel structure, a strong foundation is necessary to support the weight and ensure stability.

Types of Foundations:

• Shallow Foundations: Suitable for lighter structures.
• Deep Foundations: Used based on weight and soil conditions. Once the foundation is complete, preparations for assembling the light gauge steel elements begin.

Assembly Process
The assembly phase is one of the most crucial steps in the construction of a light gauge steel structure. The process involves the following steps:

• a. Wall Panel Assembly: After the main frame is complete, the light gauge steel wall panels are assembled. These panels are lightweight wall systems made from steel profiles.
• b. Roof and Flooring: Roof and floor systems are constructed and assembled using steel profiles. This stage increases the vertical and horizontal stability of the structure.
• c. Cladding and Insulation: Once the assembly is complete, external cladding and internal insulation materials are added. This improves energy efficiency and provides an aesthetically pleasing finish.

7. Electrical and Plumbing Installation
After the exterior shell of the building is complete, electrical and plumbing systems are installed. This includes wiring, lighting systems, and water piping.

8. Interior Finishing
The interior finishing phase involves the installation of wall coverings, flooring, interior doors, and other decorative elements. This phase is customized based on the building’s intended use.

9. Inspection and Handover
Once the entire construction process is finished, the building undergoes inspection. Safety, durability, and energy efficiency checks are carried out. After confirming that everything is functioning properly, the building is handed over to the user.

Tüm inşaat süreci tamamlandıktan sonra, bina kontrol edilir. Güvenlik, dayanıklılık ve enerji verimliliği açısından gerekli denetimler yapılır. Her şeyin düzgün çalıştığından emin olduktan sonra bina, kullanıcıya teslim edilir.

Wall Construction in Light Steel Structures:

1. Interior Wall Paint and Primer
The innermost layer of the light gauge steel wall system consists of interior wall paint, which provides an aesthetic and hygienic surface. A primer used before painting helps make the wall more durable and enhances paint performance.

2. Satin Plaster
Plaster is the final layer that smooths the wall surfaces. This layer contributes to the aesthetic appearance of the interior design.

3. Mesh + Adhesive Application (Kalekim)
A combination of mesh and adhesive (Kalekim) is used to strengthen the wall system and prevent cracks. This provides durability to the surface and helps the wall last longer.

4. Drywall (White or Green)
Drywall acts as an interior wall covering material in light gauge steel wall systems. Green drywall, thanks to its moisture-resistant properties, is preferred especially in wet areas.

5. 11 mm OSB Panel
Oriented Strand Board (OSB) provides structural support in the wall system. It is lightweight, durable, and easy to install. It can be used in both the interior and exterior layers to increase the system’s rigidity.

6. Light Gauge Steel Frame
The light gauge steel skeleton serves as the main load-bearing element of the wall. Steel material provides excellent strength and flexibility. Additionally, its standardization in manufacturing allows for cost and time savings in projects.

7. Stone Wool (5 cm, 120 kg/m³ Density)
Stone wool, used as an insulation material, offers high performance in sound and thermal insulation. Its fire-resistant properties also make it an important safety component.

8. 11 mm OSB Panel
Oriented Strand Board (OSB) provides structural support in the wall system. It is lightweight, durable, and easy to install. It can be used in both the interior and exterior layers to increase the system’s rigidity.

9. Gypsum Board Panel (Boardex)
Boardex is a moisture- and water-resistant gypsum board used for exterior applications. It enhances durability in outdoor conditions and extends the lifespan of the building.

10. XPS or EPS Insulation Foam
Extruded polystyrene (XPS) or expanded polystyrene (EPS) foam provides high thermal insulation. This layer improves the energy efficiency of the wall system, creating a comfortable indoor climate in buildings.

11. Exterior Cladding Material
The final layer is the exterior cladding material, which defines the aesthetic appearance of the building. It can be applied using options such as bricks, composite panels, or wood.

Floor Construction in Light Steel Structures:

Components of the Floor Structure:

The flooring system used in multi-story light gauge steel buildings has a layered structure. These layers consist of various materials, each serving a different purpose. Here are the details of these layers:

1.Joists and Truss Beams Joists and truss beams, which form the main skeleton supporting the entire floor system and the upper floor load, are the fundamental elements in floor construction in light gauge steel structures. Joists serve as a layer that carries the weight of the structure and ensures stability. Although lightweight, joists provide high durability, allowing the weight of the upper floors and roof to be transferred effectively to the ground floor panels in multi-story buildings.

2. Trapezoidal Sheet Placed on top of the joists, the trapezoidal sheet forms the mold for pouring the C25-C30 concrete. The trapezoidal sheet is fastened to the joists at regular intervals. Its corrugated shape allows for better adhesion of the poured concrete to the surface. This layer enhances the durability of the flooring system, creating a strong floor in conjunction with the concrete.

3. C25-C30 Concrete and Steel Mesh Reinforcement It is necessary to lay steel mesh within the trapezoidal sheet; otherwise, the concrete will crack, break, and fail to provide the required strength. After the steel mesh is laid, C25-C30 concrete should be poured with a minimum thickness of 8-10 cm. This application prevents the floor from vibrating, swaying, and bending. One of the most common concerns in light gauge steel structures is floor deflection, squeaking, and trembling. This application addresses these issues, providing additional thermal and sound insulation.

4. Screed Concrete If underfloor heating will be used, after laying the heating pipes and polystyrene, a water test is conducted, and a screed concrete layer (5-6 cm) is applied, making the floor ready for the final flooring. If underfloor heating is not required, a 2-3 cm screed concrete layer is applied, preparing the floor for the final finish.

5. Adhesive Mortar Adhesive mortar is a specialized bonding material used in construction to securely fix tiles, bricks, or other building components in place. This type of mortar is formulated to provide a strong and durable bond between surfaces, ensuring structural stability. It is especially ideal for applications requiring precision and strength, such as tile installation, stonework, or the bonding of insulation panels.

6. Flooring Adhesive mortar is also used to firmly secure ceramic, marble, or other building elements in construction. This type of mortar is formulated to provide a strong and durable bond between surfaces, ensuring structural integrity. It is ideal for applications that require precision and durability, such as ceramic tiling, stonework, or bonding insulation panels. If wood flooring is preferred, a necessary underlay or foam (available with thermal insulation) is laid over the screed, and parquet is applied over it. This layer ensures the floor is presented to the end-user in the most suitable and comfortable way. In addition to its aesthetic appeal, it also provides durability against wear and tear from everyday use.

Roof Construction in Light Steel Structures:

In light steel structures, the roofing system has a multi-layered design, with each layer serving a different function. This layered system maximizes the thermal, acoustic, and water insulation of the interior while enhancing the roof’s durability. Here are the standard layers used in a light steel roof:

1. Steel Frame (Primary Support)
   The steel frame forms the primary skeleton of the roof, providing a strong and durable foundation for the structure. This lightweight steel frame reduces the overall weight of the roof structure while offering robust support. It helps ensure the roof remains stable for years and provides resistance to natural disasters.
2. 11mm OSB Board
   The 11mm-thick OSB board placed on the steel frame adds rigidity to the roof. The OSB board creates a structural bond between the layers, enhancing the roof’s durability. It also provides a smooth surface for the placement of additional insulation layers.
3. 5cm, 120 kg/m³ Density Rock Wool
   Placed on the OSB board, the 5cm thick and 120 kg/m³ density rock wool provides thermal and acoustic insulation. Rock wool improves the building’s energy efficiency by offering high insulation and prevents external sounds from entering the interior. This layer maintains interior comfort in both hot and cold weather conditions.
4. 15mm OSB Board (Second Layer)
   The second layer of 15mm OSB board placed on the rock wool protects the insulation layer and further increases the roof’s rigidity. This layer supports the water insulation membrane and maintains the roof’s structural integrity.
5. Waterproof Membrane
   The waterproof membrane applied on top of the OSB layers protects the roof against water. This layer prevents rain, snow, and moisture from penetrating the roof, protecting the structure. Waterproofing significantly enhances the durability and longevity of the roof, especially in rainy regions.
6. 5×10 Double-Sided Batten Frame
   A 5×10 cm double-sided batten frame is added to create an air gap that helps in ventilation and prevents moisture buildup under the roofing material. This frame also provides additional support for the tile covering and enhances the durability of the overall roofing structure.
7. Concrete Tile Covering
   The concrete tiles on the top layer of the roof provide an aesthetic appearance while ensuring high resistance to external weather conditions. Concrete tile covering protects all layers of the light steel structure, maintaining the structural integrity of the building and ensuring waterproofing.

Static Analysis in Light Gauge Steel Structures

Another important factor in the static  calculations of  gauge steel structures is the precision of rollform machines, which produce steel profiles. Rollform machines precisely shape steel sheets and bring them to the desired dimensions. These machines enable the production of highly accurate steel profiles, ensuring that every structural element fits perfectly into place. This enhances the reliability of static calculations.

Rollform technology plays a crucial role in producing the profiles that form the structural backbone of gauge steel buildings. These profiles are selected and optimized based on the results of static calculations. Additionally, the proper installation of rollformed profiles contributes to making  gauge steel structures more resistant to earthquakes and other external forces.

Compared to prefabricated structures, light gauge steel buildings offer several significant static advantages:

1. Lighter and More Flexible Material: Light gauge steel structures are lighter than prefabricated buildings made of materials like concrete or wood. As a result, they behave more flexibly under external forces, such as earthquakes, reducing the risk of damage.
2. Higher Durability: Steel is particularly strong in terms of tensile strength. Materials used in prefabricated structures are comparatively weaker in this regard, making gauge steel structures more durable in the long run.
3. Precision Manufacturing and Assembly: The steel profiles produced by rollform machines adhere to much stricter manufacturing standards compared to prefabricated building components, resulting in more reliable static calculations.
4. Fast and Safe Construction: While the assembly of gauge steel structures is faster than that of prefabricated buildings, accurate static calculations ensure a safe structure. In contrast, the quick assembly process in prefabricated buildings can sometimes lead to less meticulous attention to static calculations.

Key Considerations for Static Calculations in Light Gauge Steel Structures

When performing static calculations for light gauge steel structures, several important factors must be considered:

• Building Location: The design should account for external factors such as wind, earthquakes, and snow loads.
• Load-Bearing Capacity of Structural Elements: The proper selection of steel profiles directly affects the stability of the building.
• Correct Material Usage: The quality of the steel profiles produced by rollform machines enhances the accuracy of static calculations.

The Use of Magnesium-Coated Steel in Light Steel Structures

Galvanized vs. Magnelized Steel: Why Magnelized Steel is More Suitable for LGSF: Why Magnelized Steel is More Suitable for LGSF: In the construction world, materials matter greatly. Especially in light steel frame (LGS) systems, the type of steel used plays a crucial role in the durability, corrosion resistance, and overall performance of the structures. Two steel coating types frequently discussed in the industry are galvanized steel and magnelized steel. While both options have their own advantages, magnalized steel is emerging as the superior material for light steel structure projects due to its enhanced properties.

In this blog post, we will explore the main differences between galvanized and magnelized steel, and explain why magnelized steel is increasingly considered the optimal choice for light steel frame construction.

1. What is Galvanized Steel?

Galvanized steel is steel that has been coated with zinc. This coating is applied through a process called galvanization, where the steel is dipped into molten zinc, creating a zinc layer on the surface. The zinc coating protects the steel from corrosion by acting as a barrier against external elements, preventing rusting.

Key advantages of galvanized steel include:

• Corrosion resistance: The zinc layer provides good protection against corrosion, particularly in regular outdoor environments.
• Cost-effective: Galvanized steel is relatively affordable and easy to produce.
• Durability: It offers long-lasting performance and requires little maintenance over time.

However, galvanized steel does have some weaknesses. In environments with high humidity or saltwater exposure, the zinc coating can gradually wear off, leaving the steel vulnerable to rust.

2. What is Magnelized Steel?

Magnelized steel is an advanced steel material coated with a zinc, magnesium, and aluminum alloy. This coating significantly enhances the steel’s corrosion resistance, outperforming traditional galvanized steel. The magnelized coating creates a stronger barrier and ensures that the steel lasts much longer, even under extreme conditions.

Magnelized steel offers several key benefits:

• Higher corrosion resistance: The zinc-magnesium-aluminum alloy provides excellent protection, even in harsh environments.
• Longer lifespan: The coating on magnelized steel lasts much longer than that of galvanized steel, requiring less maintenance.
• Eco-friendly: Because the coating is thinner, it uses fewer raw materials, reducing environmental impact.

3. Differences Between Galvanized and Magnelized Steel

The differences between galvanized and magnelized steel become especially clear when considering corrosion resistance and longevity. Below is a comparison of the two materials:

How Light Gauge Steel Frame Machines Works?

Light steel structure machines are rollform machines designed to produce steel structural elements. These machines primarily take steel coils and shape, cut, and punch them into steel profiles. The working process of the machines can be explained in the following steps:

1. Steel Coil Feeding: The machines are fed with galvanized steel coils. These steel coils are directed to the rollform stations via the machine’s automatic feeding system. Proper feeding of the steel into the machine is a critical step for the accurate and error-free production of the profiles.
2. Forming: The steel progresses through the rollform stations, where it is gradually shaped into the desired profile at each station. Rollform machines use a series of shaping molds to gradually bend and shape the steel into its final form. At this stage, one of the most important functions of light steel structure machines comes into play: turning the steel into profiles of precise dimensions and geometries. Proper and symmetrical light steel profiles are crucial for the structure’s durability and ease of assembly.
3. Cutting and Punching: After the profile is formed, the machine cuts the steel to the desired lengths and punches holes where necessary for assembly. The cutting process is usually performed with a highly precise system, ensuring that profiles are produced without any defects. Additionally, if certain mounting points require holes or slots, the machines can integrate this process as well, eliminating the need for additional steps during installation.
4. Ready-to-Assemble Parts: The steel profiles produced are ready to be sent directly to the assembly site. These parts, being lightweight, are easy to transport and can be quickly assembled. Light steel structure machines produce all the necessary steel components for structures with high speed and precision, significantly reducing construction time.

Advantages of Light Steel Structure Roll Form Machines and Computer-Aided Design

Light steel structure machines and CAD software offer numerous advantages in the construction process. Some key advantages provided by these machines are as follows:

1. Fast Production and Assembly: Light steel structure machines have the capacity to produce profiles in a short time, allowing structures to be assembled quickly. The precision designs created in CAD software enable error-free production, speeding up the overall process.
2. Flexible and Precise Design: CAD software provides flexibility and detailed control during the design phase. This allows for customized solutions tailored to different projects. The software allows structural elements to be planned down to the smallest detail, and light steel machines produce profiles in the exact dimensions and shapes required by these plans.
3. Durability and Efficiency: Both the designs created on the computer and the light steel profiles produced by the machines ensure that structures are long-lasting and durable. Steel materials’ resistance to fire, corrosion, and other external factors makes light steel structures safe and long-lasting.
4. Cost-Effective and Environmentally Friendly Solutions: The use of CAD software results in less material waste and reduced labor costs in construction projects. Additionally, light steel structure machines use recyclable steel, making them ideal for sustainable and environmentally friendly construction projects.

How Light Gauge Steel Frame Machines Works? Light steel structure machines and computer-aided design software are revolutionizing modern construction technology. Offering fast, flexible, and durable solutions, these technologies make construction projects both more economical and environmentally friendly. As light steel structures are expected to be used in a wider range of projects in the future, the importance of these machines and software in the construction sector continues to grow every day. How Light Gauge Steel Frame Machines Works?

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