How Long Does It Take to Build a Light Steel Structure Workshop?

The Standard Light Steel Structure Workshop Timeline (Design to Handover)

When designing and constructing a typical light steel structure workshop, the total length of time from start to finish generally runs between 6 to 12 weeks depending on size and complexity. Time frames for the three major phases of work according to industry standards are as follows:

- Phase 1: Design and permitting – 2 to 4 weeks

- Phase 2: Offsite manufacturing – 4 to 8 weeks

- Phase 3: Onsite assembly and finishing – 2 to 5 weeks

The traditional construction methods of time-consuming workflows, precision, and bolt-up connections are contrasted with designs that allow parallel workflows and factory-offsite construction, resulting in a building that is strategically completed before the end of the construction contract.

The three critical stages of light steel structure construction consist of a tightly coordinated sequence of phases with clearly defined outcomes and time expectations that do focus construction scheduling. These expectations allow building owners to formulate coordinated strategies for all stakeholders involved.

Pre-Construction: Design, Engineering & Permitting

During this phase, functional requirements of the building are converted into a signed-off, buildable, for construction documentation of a building. This phase begins with the practice of structural engineering (load, deflection, and bracing) for compliance to ASCE 7 and the provisions of local building codes. The design team, in parallel, develops construction drawings that provide bolt anchors, roof slope, and structural connection details. Following the conclusion of the design phase, building construction permits are filed with local or state authorities. While the permitting process has a 2 to 4 week variance, it is important to note that this phase will set the boundaries of the construction for the fabrication and erection workflows.

Offsite Fabrication: Manufacturing of Light Steel Components

Fabrication begins under controlled conditions once we have finalised the designs. Automated CNC systems for punching, cutting, and robotic welding enable us to manufacture components that include, but are not limited to, cold-formed C- and Z- sections, rafters, purlins, and girts, with tolerances of ±1 mm. Unlike field-welded options, consistency of dimensions and quality are ensured, and the process avoids delays due to adverse site conditions. Weld quality is ensured by AWS D1.3 standards, and dimensional checks are conducted at various points before items are packaged. For medium-sized workshops of approximately 30 m x 20 m, the best suppliers can provide fully traceable, ready-to-assemble kits that take only 2-3 weeks to manufacture, depending on the size of the order and the level of automation on the assembly line.

Onsite Assembly: Foundation, Erection & Finishing

Fabrication and site work happen simultaneously at the best of times. After footing and pier foundations are completed, the structural frame is erected in the order of columns, rafters, roof purlins, and lateral bracing. For a standard single-story workshop, skilled crews and a mobile crane erect the complete primary frame in 5-10 workdays. The enclosure systems, which includes sandwich panels and insulation, and doors, follow to provide a weather-tight seal, usually within days. Final touches of MEP and interior work end the phase, bringing the total time on site to between 2-5 weeks, which is entirely dependent on the weather and how well the subcontractors are coordinated.

Key Factors That Speed Up or Slow Down Light Steel Structures Projects

Design and Construction Complexity

The complexity of the design will dictate construction speed and the cost per square meter. For example, New Zealand Reports: “Multi-level designs, non-conventional spans greater than 24 m, or complex roof designs, all require additional modelling, peer review, and longer permitting cycles. Elements such as these take more time to engineer and increase the incidence of requests for revisions.” By contrast, built light steel kits use design, engineering, and architecture to ready components that meet code requirements and are certified to the AISC and AISI S240 standards. These kits are likely subject to fast track permitting processes and eliminate iterative drawing approvals. This can reduce the duration of the pre-construction phase by 2 to 3 weeks. When considering design changes, an owner should first consider if the functional purpose of the design changes outweigh the potential benefits a built kit may offer in terms of performance, cost, and time.

External Stress Factors: Weather, Labor, Supply Chains, Site Preparedness

While the process of building light steel structures exposes workers to less weather than timber or concrete, timber and steel construction still relies heavily on site and foundation preparation, and crane lifts that are especially sensitive to long-term rain and winds, or extreme cold weather. Critical long path activities can also be delayed by a shortage in skilled labor for certified steel erecting, or certified weld inspection. The recent volatility in supply chains presents challenges to the lead times for specialty coatings or materials, and custom hardware for firesafe construction. Also, site work can hinder or stop the construction process: unprepared land, poor access, and not having resolved utility conflicts can all result in rework and costly delays. Some of the tools used to limit scope changes are site surveys, staged procurements, and buffer days in the master construction schedule. These days will be allocated during the construction season that has the most volatility.

Reliable Methods to Reduce Light Steel Structure Workshop Delivery Time

It is possible to make construction schedules for light steel workshops more efficient without the need for compromises or taking shortcuts on quality. Time savings can be achieved through process optimization and collaboration in advance. The following two strategies have proven applicable and effective in over 60 commercial projects.

Integrating Workflows across Phases

Offsite fabrication of light steel components allows for the foundation and structure to be built at precisely the same time. The process of design, permitting, fabrication, and erection can be simplified and shortened. For instance, concrete footing can be cast in the first week of finalizing a design, along with a provisional layout of the anchor bolts. The kit can be delivered just days before erection begins. Along with connections that are designed to be pre-engineered, as well as systems designed for modular panels, projects can routinely attain a weather-tight enclosure in less than 18 days after mobilization. In order to make this approach work, assumptions in the design are to be carried out, and communication between all three teams must be constant and documented.

Early Contractor Involvement and Digital Coordination Tools

Including the steel contractor during the schematic design phase—and not waiting until after the permits are issued—can drastically reduce the project timeline. They can determine the appropriate design elements based on the availability of materials and the local building code to identify issues before finalization. Digital coordination, especially using clash detection in 3D BIM models, helps to avoid construction issues digitally before they occur in the field. This software, part of Autodesk Revit or Tekla Structures, allows teams to find issues such as MEP systems penetrating a purlin or bracing, and causes the least disruption to the construction schedule. Digital coordination tools drive the production schedule while avoiding mark ups to the schedule. When executed with a fixed contract and a defined scope, this approach shifts the contractor’s role from a vendor to a partner, with a reduction in the total project design and construction schedule of as much as 25%.

FAQs

1. How long does it take to complete a light steel structure workshop?

Timelines for the design, fabrication, and assembly spans can occur in as short of a window as 6 weeks, but can take as long as 12 weeks, depending on size and complexity.

2. What factors can delay a light steel structure project?

Delays can occur from the complexity of design, site readiness, weather, staffing, logistics, and permits.

3. Do the light steel structure projects benefit from the use of standard kits?

Prefabricated ‘kit’ systems are modular, and due to their nature, are easily permitted. They can reduce the project timeline, on average, by 2 to 3 weeks.

4. What is the best way to shorten the project timeline?

The best way to achieve the shortest project timelines is through the use of parallel workflows, early contractor involvement, and digital coordination tools through the use of 3D BIM.

5. How does light steel construction benefit from offsite fabrication?

Offsite fabrication promotes increased accuracy, significantly reduces issues caused by weather-related delays, and speeds up the construction process. This is made possible by pre-assembled components that are ready to erect.