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10/08/2021 by enduroframe

How sophisticated testing leads to cost-effective steel trusses

How sophisticated testing and engineering leads to cost-effective light gauge steel trusses

A common misconception is that all light gauge steel roof trusses spanning the same distance and with the same loads use the same amount of steel. This is not true. Smart research and development in trusses and sophisticated software can provide reductions in steel usage of up to 50% compared to less efficient light gauge steel trusses.

The ENDUROCADD® design software has been developed over 20 years as a design tool for the ENDUROTRUSS® system, a key component of the ENDUROFRAME® building system. Over this period the system has responded to changes in building construction, design standards and regulatory requirements.

The foundation of this success is a commitment to extensive testing of truss connections and entire roof truss assemblies at our state-of-the-art NATA-accredited laboratory in western Sydney. All truss connections are tested in compliance with AS4600: Cold formed steel structures. Once the results have been verified the data is fed into our ENDUROCADD® software to provide efficient steel truss designs.

Putting our testing to the test

We are so confident in our testing that a decade ago we put forward the ENDUROCADD® software to be used as a test case for the drafting of the ABCB Protocol for Structural Software. This was a huge deal for our customers because under this Protocol, trained software users of compliant software applications are permitted to design and sign-off buildings that fall within the Protocol scope. Compliance with the ABCB Protocol for Structural Software means expensive and time-consuming engineering approvals can be avoided

The ABCB Protocol for Structural Software requires independent verification from a third party to ensure that software calculations comply with the Building Code of Australia (BCA) and Australian design standards. Swinburne University provides independently checks that the ENDUROCADD® software complies with the Protocol.

Working with the benefits of extensive testing

When you use the ENDUROCADD® software, you are presented with intuitive truss design functions that test every load case defined in the loading standards. The ENDUROCADD® software runs design and analysis for all members and connections which, in a typical truss, will be 112 load cases. This ensures that all required load conditions are considered and provides confidence that trusses are structurally sound.

When your job is complete, you can view detailed connection drawings that show required screw types and their installation locations. Even better, when truss components are produced the number of screws required at each chord-to-web and chord-to-chord connection is inkjet marked on the parts. This avoids any confusion during assembly.

There are many connection options which include multiples of screws and different types of gusset plates to vary the connection capacity. As there are about 2000 different connections, a summary sheet of the connections required for a specific job are generated for easy truss assembly.

We believe the number of truss connections is the most of any light gauge steel framing system. This reduces the chance that connections are the determining factor in the truss strength and performance. In turn, this increases the cost effectiveness of the truss system. It is always cheaper to increase the capacity of a connection with a few screws than it is to increase the gauge of steel used in the entire roof truss.

Boxing Saving Costs

Boxing is another way the ENDUROCADD® software helps you reinforce truss chords and webs just where additional strength is required without increasing the overall truss gauge. Boxing is inserted on the reverse side of the truss to the webs and is precisely positioned where required to resist loads. In the diagram above, the darker section demonstrates the sections of truss chords that are boxed. In many cases chord boxing does not need to extend along the entire length of the chord. The boxing part is manufactured together with the truss and, unlike in-plane trusses, the boxing can extend across multiple sections of chords and webs. Pre-punched holes assist with the location of boxing on truss chords.

We’ve created a set of posters showing the assembly details for roof trusses. Sticking these up in your factory is a great way to keep everyone on the same page. See ENDUROTRUSS® fabrication posters.

Find out more about how the ENDUROFRAME® system reduces truss costs here.

For drawings and photographs that clarify truss construction, please read the ENDUROTRUSS® installation manual. See ENDUROTRUSS® Roofing System Installation manual.

10/08/2021 by enduroframe Leave a Comment

Looking To Reduce Your Steel Truss Costs? Here’s How.

Five ways to check whether your steel truss system is costing you too much

Light gauge steel trusses can be created using a wide variety of proprietary systems and a common assumption is that all the trusses created using these systems cost the same. This is rarely the case. In fact, trusses designed with less-efficient systems can cost up to twice the amount of trusses designed with more efficient systems.

The cost of a truss is determined by the following variables:

steel cost (including the amount of steel and the unit cost of the steel)
cost of the connections used in the truss
labour costs to design, manufacture, assemble and install the trusses.

However, since truss systems use different truss profiles and connections (which may be screws, bolts, rivets, or sometimes even proprietary methods), it can be difficult to determine whether the trusses designed using your system are costing too much. Here are five things to check for to see if your truss system is costing you too much.

Number 1: Do the steel trusses have a high web density?

Web density is the number of webs that need to be put into a truss to make it structurally sound. Weaker truss systems require more webs to strengthen the truss, and more webs means more steel, more connections and more labour to assemble the trusses. The web density can be affected by the strength of the sections used in the truss webs and chords, whether the chords are used in their strong or weak axis and the strength of the connections used in the truss. Depending on the truss span, a truss that has twice the web density as another truss in a 22.5 degree roof will require approximately 30% more steel.

Number 2: Do the steel trusses use a thick gauge of steel?

Standard gauges of steel used in trusses are 0.55 mm, 0.75 mm, 1.0 mm or even thicker. There are many factors that can drive the gauge of steel used in trusses. A thicker gauge of steel may be required either because a section of the truss or even a single connection fails.

As intermediate gauges of steel are not readily available, an increase from 0.75mm to 1.0mm means 33% more steel is required when keeping the same web patterns.

The factors mentioned above that drive web density can also determine the gauge of steel required. Even using one gauge of steel in the chords and another in the webs can make a large difference.

Number 3: Do the steel trusses support multiple connection options?

Different light gauge steel truss systems use different types of connections. Connections can be screws, bolts or even specialist rivets, and may also include stiffening gusset plates. It is important to easily and cost-effectively scale connections with loads. The truss system should have cheap connection methods for connections with small loads, but also options for much stronger connections where the the load is higher.

You can find out more about how testing reduces truss costs here.

Having only one type of connection (e.g. two screws or a bolt per connection) can be problematic. If the load is very light, an over-designed connection can increase the cost of the truss. Conversely, not having higher capacity connection options can mean trusses fail due to single connections that are just not strong enough. This scenario may mean that thicker gauge chords and/or webs are required to get the truss to pass.

In this example, you can see multiple engineered connections being used on this truss.

Number 4: Can saddle trusses on girders be easily replaced with trusses following the roof shape?

Where roofs are not rectangular and valleys are required, there are two main ways to construct the roof:

a girder truss with a second layer of saddle trusses sitting on top of the girder truss (it may also include a layer or rafters to support the saddle)
roof trusses that follow the shape of the roof.

Using saddle trusses on girder trusses doubles-up the amount of material (in the main trusses and the saddle trusses and any additional rafters). This also increases installation time because installers need to lay out both the main trusses and the saddle trusses.

Trusses that follow the roof shape have a more complex shape, but they use much less material. Additionally, installation time is lower because only the main roof trusses need to be laid out. Unlike timber trusses, which may require extensive jig setups to achieve complex truss shapes, light gauge steel trusses are self-jigging through the alignment of chords and webs with pre-punched locating holes.

Example of roof with saddle trusses

ENDUROCADD Basics – Saddle trusses by enduroframe on Sketchfab

Example of roof with trusses that follow the roof line

Modified peak trusses by enduroframe on Sketchfab

Number 5: Is truss pre-cambering supported?

Roof trusses need to withstand a variety of loads. One of the largest loads that a roof truss needs to withstand are loads from the roofing (in particular, tile roofing) and other equipment that may be incorporated in the roof. These loads do not vary over time and are referred to as ‘dead’ loads. When dead loads are applied to trusses they cause the truss to deflect. This means the truss must be designed to be stiff enough to not only deflect within allowable limits for dead loads, but also other loads as well.

Truss A below shows what a standard A truss looks like deflecting under dead load.

Pre-cambering roof trusses is done by calculating the amount the truss deflects under dead loads and then shortening the truss webs so the bottom chord is cambered upwards – ‘pre-cambered’ – when it is manufactured. Truss B shows what a pre-cambered standard A truss looks like before any loads are applied. Truss C shows what a pre-cambered truss looks like after dead loads have been applied.

While it can be complicated to calculate, pre-cambering trusses is a relatively simple and cost-effective feature to incorporate into light gauge steel trusses which self-jig the truss shape.

Find out more about building the ENDUROTRUSS® system at https://enduroframe.com/building/. You can find out how to minimise the cost of roof trusses at this link.

26/06/2025 by enduroframe

True Steel Frames, Victor Harbour Medical Center

A Case Study in Innovative Construction Solutions

Victor Harbour Medical Centre by True Steel Frames wins high commendation in the ASI steel awards

The project was to provide light gauge steel frames for the upper story of the Victor Harbour Medical Centre. Covering almost 2300 square meters, this represents the largest single building constructed by True Steel Frames. Meticulous detailing resulted in an exceptionally efficient final structure, achieved through the minimization of structural steel, maximising cold formed steel, and thinking ahead the logistical challenges.

Challenges of scale

The Victor Harbour Medical Centre presented some interesting considerations that had to be resolved in order for Adelaide-based True Steel Frames to initially win the project and then to deliver on these promises.

This large building covered almost 2300m2 and was the largest single building True Steel Frames had supplied in their history.

Cost reduction

Initially, the building was designed with an all-structural steel framework, complemented by lightweight non-structural LGS for walling.

True Steel Frame’s approach to value engineering focused on minimizing the use of structural steel throughout the build. This was achieved by strategically eliminating various structural steel elements through thoughtful planning and maximizing the use of cold-formed sections whenever feasible.

The design brief specified that window head heights should align with ceilings to achieve a seamless appearance. By thinking innovatively, they crafted the windows in a way that allowed the ceilings to merge into the openings, serving as the reveal. This innovative approach provided a finish which greatly pleased the architect.

Engineering with LGS

One of the significant challenges involved was providing support for the mechanical equipment on the roof without using structural steel. Collaborating with an engineer, True Steel Frames devised a light gauge steel solution using the ENDUROFRAME® building system to uphold the substantial plant platform and eliminate the need for structural steel entirely which was a significant achievement. Roof trusses were up to 17m long with voids incorporated into the truss for ducts, beams, and gutters.

Additionally all the tricky cantilever canopies were able to work without the need for anything other than light gauge steel trusses designed using the ENDUROCADD® software.

Efficient construction

The construction project involved meticulous planning to address various challenges. This included careful consideration of building size, on-site logistics, and design aspects such as truss and wall dimensions to comply with transport regulations. Efficient scheduling of manufacturing and panel stacking was crucial to minimize double handling on-site and optimize load capacity. Due to the school’s location on a busy road, traffic control measures were implemented for each delivery. Deliveries were strategically divided into 6 stages to ensure a steady supply without overcrowding the work site. Coordination with a large commercial crane was also essential to facilitate the installation of frames and trusses on the upper floor.

Frame erection was completed in 28 days, a remarkably swift timeline considering the scale of the project. This expedited progress was facilitated by the minimal need for structural steel and consequently reduced dependency on cranes.

Meticulous staging of the frame erection proved effective as the installer could effortlessly stand walls and trusses in one section before seamlessly transitioning to the next stage without any obstacles. This approach differs from the industry norm, where typically all wall frames are first installed before proceeding to truss installation, potentially impeding access for the installer. One significant advantage of using LGS frames in this project was their lightweight nature, which facilitated the easy handling required during the construction.

Builder satisfaction

Upon completion, the builder, Bella Build and Design, expressed great satisfaction with the frames, highlighting that the construction process was significantly faster than if they had completed with timber frames. Additionally, they emphasized the cleanliness of the site. Very importantly, the builder was thrilled by the substantial cost savings achieved on the project, largely due to the reduction of structural steel.

True Steel Frame’s coordinatation with the builder ensured all parties were on the same page and no surprises arose that could have caused delays.

This project is a great example of how a large building with careful thinking, collaboration with a LGS centric engineer and a strong desire to not compromise on quality over price can still result in an extremely cost effective and timely build.

Would the builder use True Steel Frames again? Absolutely!

True Steel Frames

Want to learn more?

Discover how ENDUROFRAME® can transform your next project by contacting us today

Contact Enduroframe

26/06/2025 by enduroframe

Border Steel Framing, Stoneway Constructions

Built Like Home

Border Truss & Frame and Stoneway Constructions deliver quality without compromise

At Stoneway Constructions, no house is too big or too small. Every project receives the same exceptional level of attention to detail because Wayne builds each home as if he were going to live in it himself.

Whether you’re dreaming of a sleek, modern skillion roof home or a timeless pitched roof design, Stoneway is ready to bring your vision to life. With over 10 years of experience building custom homes across Northern Victoria, Stoneway understands that their clients demand more than just a house. They want a home built to the highest standards.

That’s why they partner with Border Truss & Frame, a name synonymous with strength and efficiency. Their use of the ENDUROFRAME® building system ensures that every steel frame is strong, lightweight, and cost-effective. With patented, builder-friendly features, these frames are designed for faster, easier on-site assembly—helping Stoneway deliver dream homes with precision and care.

If quality craftsmanship and a personal touch are what you’re after, contact Stoneway Constructions today to discuss your next home.

Stoneway Constructions, Tocumwal NSW on Facebook

Border Truss & Frame

Want to learn more?

Discover how ENDUROFRAME® can transform your next project by contacting us today

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26/06/2025 by enduroframe

Ultimate Steel Framing: Kool Beanz Child Care

Building a Legacy

Gold Coast Suns and Ultimate Steel Framing Team Up for Kool Beanz Child Care

The Gold Coast Suns have aimed to be more than just an AFL team right from the start. Their mission extends beyond the football field into the heart of the community by investing in the next generation of Gold Coast children.

One of their most impactful initiatives to date is the Kool Beanz child care facility, a project that demanded precision, reliability, and excellence at every stage. Given the scale and prestige of this development, partnering with a trusted and experienced frame manufacturer was non-negotiable.

Enter Ultimate Steel Framing!

Precision Engineering Meets Community Vision

Ultimate Steel Framing took the lead in manufacturing all light gauge and structural steel for the project, while also overseeing the erection process. Leveraging the power of ENDUROCADD® software, their team expertly detailed the structure, significantly reducing the need for hot-rolled sections and keeping costs in check.

Over a focused three-month construction period, 26 tonnes of TRUECORE® steel were installed seamlessly. Thanks to meticulous planning and expert detailing, the framing posed no issues for follow-on trades such as electrical, plumbing, and HVAC installations.

A Model of Efficiency and Collaboration

This project stands as a testament to what can be achieved when community vision meets engineering excellence. The Kool Beanz facility is more than just a building. It’s a foundation for future generations to grow, learn, and thrive.

Learn more about the Kool Beanz childcare facility here.

Ultimate Steel Framing website

Want to learn more?

Discover how ENDUROFRAME® can transform your next project by contacting us today

Contact Enduroframe

26/06/2025 by enduroframe

Opening header solutions

ENDUROFRAME® opening header solutions for any sized door or window

The ENDUROFRAME® system offers a variety of options designed to support loads above door and window openings, covering a broad spectrum of truss loads and opening widths. This extensive range of options ensures that there is design flexibility, structural integrity, and cost effectiveness.

Trussed header

The most cost-effective and straightforward opening system is a trussed header, which can accommodate openings of up to 2700mm. These headers can be constructed using standard sections produced by the ENDURO® rollformer.

Angle lintel

High tensile steel angle lintels are available in two sizes: 200 x 35 x 1.0mm and 200 x 35 x 1.5mm.

Opening widths given in the Tables are nominal and cover 1000-4900mm. These are rollformed from high tensile G450 steel and can be purchased cut to exact length, or in longer stock lengths to be cut to size in the factory.

C purlin

C purlin can be the strongest header option as the available sizes can range from 100mm to 300mm. Purlins are easily available in most locations and can be purchased cut to exact length, or in longer stock lengths to be cut to size in the factory as required.

Beam headers can be made from ENDUROFRAME® sections cut to length off the rollformer. Beam headers can be selected by detailers when inserting a door or window opening, and also using the auto-opening feature, which makes beam selection simple. The advantage of this method is no stock needs to be ordered or kept as the parts are rollformed only when required. They are most suited for smaller openings.

PFC

For wide openings, or in highly loaded situations, hot rolled sections such as parallel flange channels (PFC) can also be used. Great information around the spanning of these sections can be found at Spanman.

Want to learn more?

Discover how ENDUROFRAME® can transform your next project by contacting us today

Contact Enduroframe

26/06/2025 by enduroframe

Steel Framing Demand Surges at SydneyBuild 2025

Attending the recent SydneyBuild 2025 exhibition confirmed what we’ve been seeing across the industry – the appetite for steel framing is growing rapidly. It was fantastic to have builders and homeowners approach us with a simple but powerful question: “Where can we buy steel framing?”

This growing interest reflects a broader awareness of the many benefits steel brings to modern homes. While non-combustibility and pest resistance were once the primary drivers, today’s builders and homeowners are recognising a much wider range of advantages:

Sustainability
Perfect straightness
No shrinking or warping
Lightweight and easy to handle

These features are not just theoretical – they’re making a real difference on-site, especially for installers who appreciate the ease, lightness, and precision of working with steel.

Why ENDUROFRAME®?

The ENDUROFRAME® building system encapsulates all these benefits and more. Our advanced steel framing solution is not only high-performing but also cost-effective, thanks to our focus on efficiency at every stage:

Optimized detailing and machine run time
Fast, easy assembly
Intelligent on-site erection
Comprehensive layouts, 3D imagery, and full connection details

We’ve engineered the ENDUROFRAME® building system to streamline the entire process from design to installation, making it a smart choice for builders looking to stay ahead.

Want to learn more?

Discover how ENDUROFRAME® can transform your next project by contacting us today

Contact Enduroframe

13/02/2025 by enduroframe

Automated ICJs Intermediate Ceiling Joists and Binders

Automated ICJs and Binders

A Smarter Way to Design Light Gauge Steel Roof Structures

At Enduroframe, we’re always looking for ways to make roof design more efficient, precise, and user-friendly. That’s why we’re excited to highlight a powerful enhancement in our software: Automated Intermediate Ceiling Joists (ICJs) and Binders. This feature streamlines ICJ insertion, making it easier than ever to reinforce ceilings while reducing manual effort.

What Are ICJs and Binders?

ICJs are structural members that run parallel between trusses, at the same height as truss bottom chords. They provide key support for plasterboard ceilings and eliminate the need for ceiling battens or running trusses at closer spacings. In cases where trusses are spaced at 1200mm, ICJs help can provide a working platform when working at height.

Binders, on the other hand, run perpendicular to trusses and ICJs, sitting above roof truss bottom chords. They support the ICJs, ensuring a stable and well-distributed load. Binders can also be used as lateral restraints for truss bottom chords.

ENDUROCADD® Automation

Previously, adding ICJs and binders was a very manual process, requiring detailers to add members one-by-one as beams. Now our automated ICJ and binder insertion takes the guesswork out of the process. The ENDUROCADD® software follows built-in design rules to automatically place ICJs and binders where needed, ensuring optimal structural integrity. Users can also fine-tune settings for complete customization.

Key Features & Benefits

✅ Automatic ICJ Placement – ICJs are intelligently inserted at the midpoint between roof trusses, ensuring proper support and reducing manual input.

✅ Flexible User Configurations – Choose the section type, truss spacing, maximum ICJ length before splicing, and whether to add ICJs across the entire roof or block by block.

✅ Smart Binder Integration – Binders are placed at user-defined spacing, supporting ICJs seamlessly. Users can define overlap lengths and choose whether binders are boxed.

✅ Precision Manufacturing Data – ICJs and binders are now included in the BOM (Bill of Materials) and NC data for seamless manufacturing and job tracking in ENDUROCADD NX and ENDUROHUB.

Why It Matters

Eliminating repetitive tasks makes life easier for detailers. Automating ICJs and Binder insertion in ENDUROCADD® software is just one example of our ongoing commitment to innovation and continuous improvement of the ENDUROFRAME® building system.

For installers, it can mean less trusses and/or ceiling battens to install while providing a safe work platform, making a cost-effective roof solution!

Find out how to start making frames

With automated ICJs and binders, we’re making Light Gauge Steel roof detailing more efficient, accurate, and customizable than ever.

Contact Enduroframe