Light Steel Factory and Warehouse Construction: How?

Light Steel Factory and Warehouse Construction: Industrial buildings are at the heart of commercial activities such as production and storage. Large warehouse and factory constructions must meet the highest standards in terms of both durability and functionality. In this context, light steel building systems offer an ideal solution for modern industrial projects. Light steel systems provide a fast, flexible, and durable construction process thanks to the precision profiles produced by rollform machines. In this article, we will discuss the applications, advantages, and technical details of light steel systems in large warehouse and factory construction.

1. Light Steel Factory: The New Standard in Industrial Construction

Light steel systems are structures made using cold-formed steel profiles and a modular design approach. In industrial projects, wide spans and heavy load-bearing requirements are commonly encountered. Light steel buildings offer significant advantages in large warehouse and factory construction by addressing these needs:

• Wide Spans: Steel profiles increase the distance between columns, allowing for more efficient use of interior space.
• Durability: Light steel provides high strength against both heavy loads and external factors (wind, snow loads).
• Quick Installation: Thanks to prefabrication, on-site labor and time are minimized.

2. Light Steel Solutions for Factory and Large Warehouse Construction

2.1. Structural Design
The use of light steel structures in industrial projects (Light Steel Factory) provides advantages that start at the design stage. Projects designed with precise engineering software (such as Vertex BD) are transferred to the site in an optimized manner.

• Beams and Columns: Light steel profiles, manufactured with base sizes ranging from 100 mm to 250 mm, can carry heavy loads.
• Roof Systems: Lattice joists are commonly used in roofs to support large areas.
• Modularity: Since parts are produced in factories, quick assembly on-site is possible.

2.2. Material Selection
In industrial projects, the durability of the materials used is of critical importance. Light steel structures are made from galvanized sheets. This coating prevents rust and extends the lifespan of the structure.

• Standards: Materials that comply with international standards such as ASTM A653 or EN 1090 are used.
• Thicknesses: For columns, a sheet thickness of 3-4mm is recommended, for roof beams 1.6-2.5 mm, and for wall panels, 1.2 mm thickness is advised.

3. The Contribution of Rollform Technology

Rollform machines play a critical role in the production process of light steel structures. Leading companies like UNBAK Machinery use advanced technologies in the production of profiles for industrial projects.

Advantages of Rollform Machines:

• Fast Production: Ability to produce thousands of meters of profiles per day.
• Precision: Precision and smooth profile production with 33 years of rollform experience.
• Variety: The ability to produce profiles of different thicknesses and widths from the same machine.

4. Technical Details: Light Steel in Large Warehouse and Factory Designs

4.1. Roof Systems
In light steel factory and warehouse projects, roof systems are typically designed to support wide spans. Light steel trusses or sandwich panels provide both durability and energy efficiency. Roof systems used to support large spans include:

• Trusses: Offer a lightweight and high-strength solution for larger spans.
• Sandwich Panels: Provide thermal and waterproof insulation.

4.2. Wall Panels
Light steel wall panels are used both as load-bearing elements and partition walls. These panels can offer an aesthetic appearance with various cladding options. Light steel wall panels are made from galvanized sheets, offering long-lasting and aesthetically pleasing solutions. They are used both as load-bearing walls and for partitioning within the building.

4.3. Floor Systems
Light steel structures are lightweight, reducing the load on the foundation. This helps lower foundation costs and accelerates the construction process. Floor systems often use the technique of pouring concrete over steel sheets. This method enhances load-bearing capacity and optimizes costs.

4.4. Column Systems
Light steel offers an ideal solution for large-scale structures such as factories and warehouses. The use of steel columns in these types of buildings provides significant advantages in terms of durability, load-bearing capacity, and flexibility. Steel columns in light steel factories form the main structural elements that support the building and allow for wide spans. This creates spacious interior areas where machinery and storage can be easily placed.

Steel columns can be produced in various shapes and sizes. Typically, columns are made in C or Z-profile shapes, which are both lightweight and durable. Moreover, steel columns can be integrated with prefabricated systems, allowing for quick and efficient assembly. This results in a significant reduction in construction time and costs.

In addition to supporting the structure, steel columns also offer high resistance to external factors such as wind and snow loads. They provide a safe structural solution against natural disasters, such as earthquakes. One of the key benefits of steel columns is that they make the building more flexible and modular. As a result, the building can be easily expanded or modified if necessary.

The material thickness of columns is determined by the size of the building and the load it needs to support. For small and medium-sized structures, a thickness of 1.5 mm to 2.5 mm is typically used, while larger projects may require thicknesses of 3 mm or more. This ensures that the required load-bearing capacity for any warehouse or light steel factory structure is met.

Rollform Machines in Steel Construction
Rollform machines play a critical role in the production of light steel structures. These machines shape steel sheets into specific profiles, creating the desired columns, roof beams, wall panels, and other structural components. Thanks to rollform machines, steel profiles are produced quickly and precisely and can be sent directly to the construction site. The advantages of rollform machines include speed, reduced labor costs, and high production capacity. Additionally, the steel components produced using rollform machines are durable and maintain their structural integrity over time without deformation.

Rollform machines further accelerate the assembly of light steel structures. Steel columns and other components are produced according to predefined measurements, making it easier to assemble pre-prepared panels. This accelerates the construction process, leading to savings in labor and costs. Moreover, rollform machines allow for the production of custom profiles tailored to specific requirements, which enhances the flexibility and functionality of the structures.

5. Advantages of Light Steel Structures in Industrial Projects

5.1. Fast Construction Process
Modular building components are quickly assembled on-site, speeding up the construction process by 30-50%. This efficiency helps meet tight deadlines and reduces overall project timelines.

5.2. Flexibility
Light steel systems can be customized to meet the needs of various industries. For example, a textile factory can be designed with large warehouse spaces and office floors, offering versatile solutions for different operational requirements.

5.3. Low Cost

• Material Optimization: Efficient use of materials leads to reduced waste and cost savings.
• Lower Labor Requirements: Fewer labor resources are needed due to the ease of assembly and prefabricated components.
• Operational Savings: Faster delivery times result in operational cost savings, allowing businesses to start operations more quickly.

Light steel structures offer both technical and economic benefits in large warehouse and factory construction. Precision profiles produced with rollform machines provide durable, flexible, and sustainable solutions. For industrial projects where speed, cost, and longevity are key considerations, light steel structures are the ideal choice.