Cold formed steel buildings

Cold formed steel is thin but very strong steel formed by rollers, presses, and dies at ambient temperature. Due to being formed while cold, the metal does not lose its hardness or shape.

We are surrounded daily by cold-formed steel. Automobiles, appliances, dwellings, and other structures use CF steel. Framing, as well as roof and wall cladding, use cold-formed steel in construction.

What are cold-rolled steel buildings?

Cold formed steel buildings are pre-engineered clear-span buildings that use c-channels for their primary framing’s columns and rafters instead of rigid frames or hot-rolled sections, as other metal building systems might use.

Durability and strength

Cold-formed metal buildings are very strong, and the manufacturing process results in consistently well-shaped, straight members. CF steel doesn’t shrink, warp, or crack as wooden framing members can.

Resistance to corrosion and pests

CF steel consists of coated or galvanized coils and sheets, which makes it resistant to moisture. Steel’s natural properties prevent it from being damaged by termites and other pests.

Longevity of structures

Although 50 years is commonly published, the lifespan of a cold-formed steel building is virtually endless when fabricated and installed correctly. Like wood and other materials, cold-formed steel’s unique properties do not lessen over time.

Reduced foundation costs

Concrete is the single most expensive material in construction. With c-channel buildings being lighter in weight than other types of metal, the footings are smaller, and less rebar is required. Minimizing foundation costs by as much as 30%.

Environmental benefits

Cold formed steel fabrication leaves the smallest footprint on our environment. The coils and sheets are created from recycled steel and formed at room temperatures instead of the extreme temperatures of furnaces. This reduces carbon emissions. With each piece fabricated to specific dimensions, CF building kits leave little waste.

Sustainability and recyclability

Steel is recyclable, and the steel bought today contains recycled steel. So, cold formed steel is a sustainable resource that gives back to itself.

Energy efficiency

Cold-rolled steel buildings are tightly sealed and easily insulated, making them energy efficient. They can also meet the standards of Energy Star, LEED, and other environmental benchmarks.

Cost-effectiveness

Cold form steel structures are the most economical building solution available. First, steel is sold by the pound. 

Since cold-formed is lightweight and easier to produce than other types of metal, it’s cheaper to purchase.

Next, their lightweight uses smaller footings, reducing concrete expenses.

Cold form building kits arrive with components precut to the proper length. Each piece is ready to be bolted or screwed together. These pre-fabricated benefits reduce labor costs and material waste.

Finally, CF buildings are virtually maintenance-free, so the savings continue throughout the life of the building.

Versatility in design and applications

Cold form framing is available in several profiles, making it versatile for architectural design and construction. 

Its clean, consistent form works well with glass, wood, and other materials to create complex, modern structures. It’s also simple enough to be used in basic applications, like steel-framed garages.  

Fire resistance and safety

CF steel’s fire resistance is unmatched by materials like wood. Steel doesn’t burn, and its melting temperature is around 2,470°. A dry, wooden 2”x4” can ignite at temperatures as low as 200°.

In the event of a fire, steel’s higher melting temperature allows time for occupants to make their way to an exit.

While cold-form buildings fit a broad span of applications from aesthetically appealing commercial buildings to garages and other low complexity needs, they work best when:

• They are 40’ wide or less
• Their maximum height is 20’ or less
• Their roofs are gabled
• Used for low-complexity designs

Not used in applications where cranes, hangar doors, mezzanines, and other significant loads exist

Cold form buildings are versatile and cost-effective, making them suitable for various applications. These popular structures, from agricultural storage and workshops to retail spaces and residential garages, demonstrate durability, flexibility, and quick assembly.

CF steel buildings are a type of pre-engineered metal building (PEMB). The supplier custom designs them to fit customers’ needs and fabricates them in their shop.

The metal components are delivered pre-cut to length with drilled connection holes. It can be easily assembled following the manufacturer’s erection drawings.

Initial costs vs. long-term savings

As a PEMB, CF has a higher initial cost due to the design and manufacturing processes. However, the speed and ease of the erection process quickly offset the higher initial cost. Framing members are already cut to length and ready for connections, reducing labor rates.

Additionally, metalrequires little to no maintenance and is resistant to rot, termites, and other destructive factors that wood or other materials experience. Also, property insurance costs less for CF structures due to their structural integrity.

As shown, the higher initial cost of steel is brief compared to the long-term savings.

Cost comparison with other building materials

CF metal members cost more than wooden members, but that is the extent to which wood is less expensive. Wooden members are heavier and more challenging to handle while installing, requiring more workers.

Each piece of wood requires measuring and cutting on the job site. This takes time, which increases labor costs. It also increases safety risks for the workers.

Precision cuts and knowledge of proper framing practices require skilled workers. CF building kit components are pre-fabricated and ready to bolt or screw together on-site.

So, while wood is cheaper per piece, labor demands make it more expensive overall. But, wood’s additional costs do not stop there.

Wood requires ongoing maintenance to prevent mold, rot, and termite infestation. Additionally, as wood dries, it becomes easier to ignite. It’s also not as durable as steel in harsh weather environments. These issues lead to higher property insurance costs for wooden structures.

Factors influencing the overall cost

In a nutshell, a project’s total cost has more variables than just material cost. Labor, construction time, and insurance premiums require consideration to evaluate overall cost accurately.

CF buildings and most red iron (RI) buildings are pre-engineered building systems (PEMB). Both provide construction advantages over wood and other construction materials. However, there are stark differences between the two products and their ease of use. Let’s take a closer look.

Materials

Cold-formed steel members begin as galvanized or pre-primed coils ranging in thickness from 10-gauge to 18-gauge, or roughly a little more down to a little less than one-eighth of an inch. A machine shears the coils to their required lengths. Next, they are passed through rollers and dies, forming them into C, Z, or U-sections, hat channels, angles, and other shapes.

As the name implies, cold-formed steel’s shaping occurs at room temperature. Minimum welding is required.

RI, sometimes called hot-rolled steel, begins as a solid slab or billet. A furnace heats the billet to extreme temperatures over 2,000°. While hot, the billet passes through rollers, which apply pressure, forming them into I, C, and other shaped members, each having different structural properties.

Rigid frames are another building system sometimes referred to as red iron. Rigid frame assemblies consist of two flanges and a web welded to form an I-shape. Cut flat plates of metalform the flanges and web.

RI production involves shop and field welding, increasing lead times due to extended fabrication processes.

Construction

The physical weight difference between CF and RI affects every aspect of construction, from delivery to installation to safety.

CF building components are bundled and delivered to the job site on pallets. Red iron, which is much heavier, usually requires many more deliveries so that the trucks comply with DOT laws.

Once unloaded, the kit components are light enough for workers, forklifts, or other small equipment to move it. Due to its weight, red iron requires a crane to offload and move each piece of it throughout the erection process.

Another key difference between CF and RI is how they assemble. CF workers can hold or clamp pieces while screwing or bolting them together.

RI connections may require welding or bolting for assembly. In either case, the heavy members are suspended in the air by a crane while the worker is on a lift, trying to connect them.

RI construction creates more safety risks and physical challenges for workers, who have to wrestle the heavy beams incrementally into place for the connection while both are in the air.

Foundations

The columns of CF structures are light in weight and support less loads than RI columns. Therefore, the concrete footings beneath them are smaller than those under red iron columns. 

The footings and foundation can be poured simultaneously for CF buildings. However, red iron requires at least two pours due to the substantial size of its footings. The footings are poured first, and later, the remaining concrete is poured.

Costs

We’ve already addressed many ways CF costs less than RI, like cost per pound, shipping charges, job site labor, concrete, and property insurance. But there are layers of other expenses to consider

CF buildings are produced more quickly in the supplier’s manufacturing facility since it is primarily an automated process requiring little human labor. It’s thin enough to be sheared to length and have its holes punched and requires little welding.

Red iron, on the other hand, requires more attention from shop workers. It’s too thick to shear, so it must be cut by hand, which is slower. Its thickness also requires connection holes to be drilled instead of punched. Again, this is slower.

Additionally, some RI beams require multiple plates, which means workers must handle and cut more pieces. Once cut, these plates need welding together.

Time spent by shop employees is a cost passed down to the customer.

Due to the weight, RI construction requires a crane for the project’s duration, so equipment rentals cost more.

CF projects are generally smaller in size and require fewer workers. A smaller labor crew not only saves on physical labor costs but also saves on Workman’s Compensation insurance.

The user-friendliness of CF construction reduces construction time. This is helpful to owners with construction loans, as their exposure to interest fees is minimal.

Cold-formed construction provides many savings opportunities from beginning to end.

Cold-formed steel buildings check all the boxes on everything important to a construction project: quick deliveries, easy installation, structural integrity, cost-efficiency, low maintenance, environmentally friendliness, and safety.

Still, some people will default to wood for their project because of the misconception that wood is cheaper. Before you make a decision, do your due diligence. Here’s why:

A 2019 study by R.A. Smith, Inc. found that wood and steel cost about the same once all expenses, including insurance, are considered.

So why not make it easier on yourself and have a better structure that is simple to erect and requires less maintenance?

 

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For a comprehensive list of  PEMB terminology, see our steel building glossary page.