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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.

28/11/2023 by enduroframe

Sustainability of House Frames Made From TRUECORE® steel

Sustainability of House Frames Made From TRUECORE® Steel

With sustainability being an important consideration when constructing a home its good to take a holistic view of the materials that go into the build. TRUECORE® steel makes an excellent choice. Whilst it can be carbon intensive in its manufacture, the manufacturing process is only part of the emissions profile of a material. TRUECORE® steel is strong, durable and versatile and a good choice for buildings designed for long life and that require flexibility to accommodate future reuse options without significant reinvestment.

The inherent properties of steel allow it to be reused, remanufactured or recycled into equivalent, or higher quality products, over and over again. As it is highly recyclable, steel is also less likely to end up in landfill.

Durable and resilient

TRUECORE® steel incorporates BlueScope’s industry-leading metallic coating incorporates Activate® technology, to provide enhanced corrosion resistance. Its long life can help conserve resources and energy that may otherwise be invested in products with a shorter life span.

Incorporates recycled materials

Across the range of steel products manufactured by BlueScope in Australia, including TRUECORE® steel products, the average recycled content in the steel is 17.4%¹, which includes pre- and post-consumer recycled materials. Materials reclaimed within the steelmaking operations represent an additional 6.8% average recovered content.

Recyclable

The steel in TRUECORE® steel is 100% recyclable without loss of quality.

Design for disassembly and reuse

Frames made from TRUECORE® steel are lightweight, durable and can be screw assembled – highly suitable for modular design, and can be designed for disassembly and reuse.

Reduced onsite waste

As frames made from TRUECORE® steel are fabricated off-site to exact specifications, minimal offcuts are generated during fabrication and minimal cutting is required onsite. This means that minimal waste is produced onsite, which results in greater material efficiency and potential waste removal cost savings.

Consistent quality

BlueScope’s Australian manufacturing facilities are accredited to the globally recognised standard ISO 14001 (Environmental Management Systems), demonstrating BlueScope’s commitment to continual improvement.

Produced by a responsible manufacturer, BlueScope

BlueScope is a founding member of ResponsibleSteel™, the industry’s first global multi-stakeholder standard and certification initiative supporting the responsible sourcing and production of steel. BlueScope achieved ResponsibleSteel™ site certification of Port Kembla Steelworks in February 2022.

For further information around the sustainability and the environmental impacts of using steel in your project please reach out to us.

1. Across the range of steel products manufactured by BlueScope in Australia, the average recycled content (according to recycled content categories defined in ISO 14021:2016) in the steel is 17.4%, which includes pre- and post-consumer recycled materials. Scrap and iron-bearing materials generated and reclaimed from BlueScope’s steelmaking, coating and painting operations represent an additional 6.8% recovered content, which is not reported as recycled content. Scrap from rollforming and fabrication processes are included as pre-consumer recycled content. The figures provided represent our best estimate at the time of publication. For current recycled content figures please contact BlueScope Steel Direct on 1800 800 789.

11/10/2023 by enduroframe

ENDUROCADD® Software update October 2023

ENDUROCADD® Software Update October 2023

We are excited to release the latest version of the ENDUROCADD® and ENDUROCADD® NX Software! Read on to learn about Hip Type 3, staggered noggings and more new features for detailing ENDUROFRAME® Building System light gauge steel frames.

Hip Type 3

The Hip Type 3 is the biggest building feature we have added to the ENDUROCADD®️ software in a few years with several benefits over alternative hip end options:

It is suitable for low pitched roofs less than 8 degrees.
It ensures that all the trusses in the hip end are properly designed and verified, and that all the tiedowns connecting them are adequate.
It features bent tab connections, tabs that can be folded to attach trusses to girder trusses, making installation easy and fast. The tabs have been extensively tested at a NATA-accredited laboratory to determine their strength and performance.
The Hip Type 3 can accommodate raised heel heights, which are ideal for situations where extra truss strength is needed.
It is the only hip option which allows box gutters to run around multiple roof faces.
It is the most similar to timber trusses, which makes it easier for installers to adapt to light gauge steel.
The hip girder truss is centred on the hip line which is preferred by many roof installers.

Find out more about Hip Type 3 at the introduction page here
ENDUROFRAME® Help Centre login required

Staggered noggings

Traditionally, studs in ENDUROWALL® panels are threaded through the web notches in continuous noggings. The benefit of continuous noggings is that they are rolled in a single part and require fewer screws to connect to studs.

Fabrication of wall panels may be sped up and automated if studs do not need to be slid through continuous noggings. By breaking noggings down into sections that can fit between studs they can potentially be installed last after the rest of the frame has been assembled (in a vertical axis) which removes a lot of the access issues screwing in the middle of the frame which can be difficult to reach.

Look for the new checkbox for Staggered noggings in Wall Detailing Options in the ENDUROCADD® Software.

Improved NC-Data Errors & Warnings

We’ve revised the way NC-Data Errors and Warnings are communicated after feedback from both ENDUROCADD® Software detailing frames and ENDUROHUB® Portal users who generate cutting lists for ENDURO® Rollformers.

NC-Data Errors must be fixed by detailers before a job is released to manufacture. If Errors are not resolved there may be delays in production because ENDUROHUB® will not allow cutting lists to be generated in order to avoid rollformer damage or jamming of parts in the rollformer.

If the Error is caused by ENDUROCADD® Software rather than a detailing decision, please report the issue. Especially if the error cannot be resolved by editing parts in the wall/panel editor or truss editor.

Jobs with NC-Data Warnings are allowed to be rolled. The intent of Warnings is to flag to detailers that they should probably fix them to avoid minor assembly issues.

A modified message box now appears highlighting any errors to the detailer to show what must be fixed before a job is submitted to manufacture. This message box can also be brought up in the Options menu even after a job has been detailed.

Ancillary list with product codes for ERP systems

An often-overlooked aspect of detailing is creating comprehensive lists of ancillary parts which need to be delivered to site. This is often an additional process to work out what ancillary parts are required, adding them into an ERP system, and generating lists that can be provided to a storeman to pick from. ENDUROCADD®️ makes this process much simpler with much of the process automated.

Using the Order Parts feature, it is possible to use formulas to calculate the quantities of ancillaries. This release of ENDUROCADD®️ has fixed a number of issues so that user-defined part codes that may be used in an ERP system can be selected in the partdatauser.xlsx file and added against all parts in the Materials Usage Markup Report.

We have added standard Ancillary lists into ENDUROHUB®️ so checklists of parts can be generated and printed out to enable parts to be selected for delivery.

Show/hide user loads in Truss Editor

In the Truss Editor, you can now easily check loads that have been applied to the truss by typing Ctrl+L or go through the Show Menu.

User loads are shown in a table with numbers on the truss corresponding to each row.

How to install ENDUROCADD® Software updates

Click through to the ENDUROCADD® Software release notes for further information on new features and instructions on how to install the updates:

ENDUROFRAME® Help Centre login required

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03/10/2023 by enduroframe

ENDUROHUB update Oct 2023

ENDUROHUB Portal update October 2023, R3-17

We’re very excited to share all of the new features available in ENDUROHUB® in October 2023. We believe this is one of the biggest releases of ENDUROHUB® since its introduction and you can see how it is taking shape to play a central role to manage your business, and have some really cool features that are only available in the ENDUROFRAME® Building System for Light Gauge Steel Frames.

Click on the link below to find out more information on this ENDUROHUB® Portal Update and detailed instructions on how to use the new features. ENDUROFRAME® Help System login is required for access.

High Accuracy Printing is here!

Over the last couple of months we’ve been doing testing on how ENDURO® Rollformers can accurately mark the locations of trusses on top plates. A huge thanks to Steer Manufacturing, Stoddarts and Centurion for the use of their rollformers for testing.

With this ENDUROHUB® Portal update the correct NC data can now be applied to locate trusses and rafters on top plates that can be accurately printed by ENDURO® rollformers.

This is a great example of the ENDUROCADD® Software, the ENDUROHUB® Portal, ENDURO® Rollformer HMI software, the PLC and Markem Imaje printers all working together to make it easier to install frames on-site. This has taken extensive research and development over several years to get all aspects of this process working. We believe this to be a world-first for steel framing system.

Rollforming data sent from HMIMk5 v6.0.7.0 to ENDUROHUB

In the most recent update to the ENDURO® Rollformers HMI software, HmiMk5 version 6.0.7.0, one of the big changes was to allow cutting list progress to be sent from the HMI to ENDUROHUB®. This ENDUROHUB® update is the second half of that work, to see the information from the HMI in ENDUROHUB®.

Assembly Tracking, Fabrication Records

While rollforming data is sent from the ENDURO® Rollformer HMI and reported in ENDUROHUB®, the new assembly tracking features in ENDUROHUB® allows data assembling walls, trusses and other ENDUROFRAME® Building System components to be collected and easily viewed.

The specification for Assembly Tracking features in ENDUROHUB®, including background information on assembly and fabrication metrics, and why it is important to your business is documented here, ENDUROHUB Assembly Tracker (ENDUROFRAME Help Center login required).

Step-by-step instructions on how to record assembly work in ENDUROHUB® is documented on this page, How to use the ENDUROHUB® Assembly Tracker. (ENDUROFRAME Help Center login required)

Make sure you attend the webinar!

Rollforming and Fabrication progress reporting

After the ENDURO® Rollformer operation software update, HMIMk5 v6.0.7.0, Rollforming progress reporting in the ENDUROHUB® Orders list is improved and more stable. Parts are highlighted green in Cutting Lists when they are completed.

When you upload assembly work information to Fabrication Records, this information is used for Fabrication progress.

Dashboard

With this ENDUROHUB® update, ENDUROHUB® managers will be able to view new Dashboard features which uses data sent from ENDURO® Rollformers, as well as data from the new Fabrication Records.

Dashboard: Rollformer Charts, Production Overview summary

The Production Overview Summary chart is now on the Rollformer Charts tab. This chart uses information from the HMI and reports on the rollformer run time.

Dashboard: CutParts Charts, Meters Run

The Meters Run charts has been moved to the new CutParts charts tab. This chart uses information from the HMI and reports on the lineal meters rollformed over time. You can show different Product Codes e.g. C7575ra.

Dashboard: Fabrication charts

Various summary charts of assembly data across all jobs are available on the Dashboard’s Fabrication Charts tab:

Number of Screws Inserted Per Work Man Hour
Total Screws assembled
Lineal m of product assembled per man hour
Total lineal m of product assembled
Meters of assembly per man hour (Wall length and Truss/Floor joist span)
Total meters of assembly (Wall length and Truss/Floor joist span)
Total hours worked
Number of fabricators
Break types

These charts use information added to an order’s Fabrication Records.

23/08/2023 by Kelly Watts

ENDURO® Rollformer operation software update: HMIMk5 Version 6.0.7.0

We are pleased to announce the release of the eagerly awaited update for HMIMk5, the software used to operate ENDURO® Rollformers which occurred on Monday, September 4th, 2023.

Logging of Coil Information is now possible!

There are several new features included in this release which will improve the operation of your factory. Coil information can now be recorded directly into the HMI including the coil number and the coil weight or length. In turn, this enables the following to be done:

Reduce the amount of scrap at the end of coils by loading the exact length of parts to be made
By connecting the HMI with ENDUROHUB®, measure the amount and type of scrap that is generated on each coil
Get a warning when the coil is down to a user-defined length so that the next coil can be prepared
Ensure that the machine setting is compatible with the thickness of coil that is being loaded
Provides a check that parts that are thinner than have been detailed are not accidentally rollformed (contact the Enduroframe team if you want this check turned off)

Information from the HMI is now able to be automatically read by ENDUROHUB®!

Tick the 3 boxes below in the Setup menu to have information from the HMI automatically and seamlessly uploaded to ENDUROHUB®.

This uploads a wide range of data which can be used by ENDUROHUB® including dashboard on productivity, rollformer uptime and downtime, the status of manufacturing orders, as well as scrap records. This is our first step towards making ENDUROHUB® your factory management tool so you can track productivity and costs.

Click on the link below to watch a 2 minute overview of these features.

Click on the link below to find out more details on what is included in this release and detailed instructions on how to use these new features.

What do you need to do?

Before the update, follow these steps:

Read the release notes at HmiMk5 version v6.0.7.0 highlights – Manufacturing Help – Confluence (atlassian.net).
Make a backup of the database file at c:/HMIMk5/data.db before September 1st.
In the Help Menu, click on the Updates tab and ensure the Updates Channel is set to “Prod” and the Automatically Update box is ticked.

06/07/2023 by Warren Tharle

Highlight on Light Gauge Steel in Cyclonic areas with Steeline GRP Darwin

Darwin is well known for its tough cyclonic conditions with all construction needing to meet exacting levels of engineering.

The Engineering behind the ENDUROCADD® Software complies to the ABCB protocol meaning a trained software user can sign off on projects that meet these requirements, right up to C4. The toughest in Australia.

Steeline GRP proudly manufactures the ENDUROFRAME® Building System and has been supplying steel frames all over the Northern Territory for the past 7 years.

Their friendly and knowledgeable team will work with you to provide a cost-effective solution for your next commercial or residential project.

Please contact the team at STEELINE GRP for more information

Steeline GRP
84 Pruen Road, Berrimah Northern Territory 0828
Phone (08) 8935 3900

www.steeline.com.au

09/05/2023 by enduroframe

Case Study: Bonnie Doon project by Border Steel Framing

Case Study:
Bonnie Doon project by Border Steel Framing

When building in a visually pleasing setting, the design should complement the location. The client excelled here, incorporating cathedral ceilings running in two directions, with large window and door openings to capitalise on the views.

Accurate detailing was the key here to ensure a perfect and fast fit on site. The team at Border Steel Framing in Cobram, Victoria, took this in their stride using the efficient ENDUROCADD® software to make the model then fabricating the frames and delivering on time. Erection was straight forward, assisted by the accompanying comprehensive site installation documentation.

Pricing needed to be competitive with other framing systems and materials, which is a given as the ENDUROFRAME® Building System uses a lot of tested engineering values which are more accurate than systems relying on calculation, reducing the amount of steel that goes into the job.

The project is now finished providing peace of mind that the steel frame is highly durable with the added bonus that termites cannot eat the frame and the frames will not burn.

For further enquiries on this project or to find out how Border Steel Framing can help you with yours, please contact Wendy on (03) 5871 2122, Option 3 for the steel department, or visit the website at https://oasishomes.com.au/border-steel-framing/

Border Steel Framing
Phone: (03) 5871 2122, Option 3
Email: [email protected]