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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.

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

13/02/2025 by enduroframe

Enduroframe at Sydney Build 2025

Join us at Sydney Build 2025

7 – 8 May 2025, ICC Sydney

Stand P30

We would love to invite you to visit Enduroframe’s Sydney Build display at the Sydney International Convention & Exhibition Centre, Stand P30.

Come along and learn more about the ENDUROFRAME® Building System, the ENDUROCADD® design software and ENDURO® rollforming solutions!

Sydney Build is Australia’s largest construction and design show and general access is free. Register here

We look forward to seeing you there!

13/02/2025 by enduroframe

Endurocademy: World-first Light Gauge Steel Online Training Portal

Endurocademy:
World-first Light Gauge Steel Online Training Portal

The quality of light gauge steel (LGS) frames is heavily dependent on 3 key factors:

The quality of the framing system being used. This includes the ease of rollforming, assembly and installation, as well as the range of accessories and connections that are included;
The quality of the software being used to design and manufacture the LGS frames. This can include the engineering calculations carried out and whether they are certified to comply with local construction codes, the software ease of use, and whether it can prepare all of the information required for smooth production and installation.
Whether users know how to proficiently use the various software applications.

Too often, the third point is overlooked. In our experience at Enduroframe, skilled users who are adept at using software to its full extent are important to ensure that detailing is done quickly, the end frames are easy to manufacture and install, and the frames are cost effective minimising the amount of steel, accessories and labour.

Unfortunately, there have not been any traditional education pathways for users to learn how to detail LGS frames. Each LGS framing system is different – they have different sections and connections which affects the frame strength, different methods to manufacture and install, some will require professional engineers to review designs while others don’t, to name a few.

To address this gap, we have launched the pioneering online training platform, Endurocademy. This platform aims to educate users on utilizing the diverse software tools developed by Enduroframe. You can explore the array of courses available on the Endurocademy course page.

Each course comprises multiple lessons, culminating in a quiz. Some courses mandate the submission of designs created in the ENDUROCADD® software to the Enduroframe expert team for review, ensuring students can apply the acquired skills. Upon successful completion of each course, students receive certificates as proof of understanding the subject matter. This certification is essential for students to qualify as Trained Software Users under the ABCB Protocol for Structural Software, eliminating the need for costly engineering sign-offs for buildings falling within the protocol’s scope.

Completion certificates are valuable for LGS business owners and managers, instilling confidence in the students’ ability to design certified buildings.

Endurocademy is accessible from anywhere with an internet connection, and can be completed when convenient for students to do.

Want to learn?

One of the best features of the Endurocademy program is that it is free! Simply contact us and request access to Endurocademy.

13/02/2025 by enduroframe

SteelPro Framing Specialists: Premier Light Gauge Steel Fabrication in Western Australia

SteelPro Framing Specialists:
Premier Light Gauge Steel Fabrication in Western Australia

Based in Canning Vale, WA, SteelPro Framing Specialists leverages over 50 years of combined construction and engineering expertise to deliver innovative steel fabrication solutions using the ENDUROFRAME® Building System.

The distinguished team comprises chartered structural engineers, building services engineers, and experienced detailers who collaborate to create cost-effective solutions that align with project budgets and timelines.

SteelPro FS excels in delivering complete solutions across:

Residential projects
Commercial developments
Infrastructure projects

SteelPro Framing Specialists’ comprehensive service package includes flooring systems, wall framing, and roof truss installations. From the outset, they have demonstrated their technical prowess by successfully tackling complex projects, including the sophisticated design and fabrication of frames featuring architectural arches for a childcare facility in Perth.

Their dedicated team of experienced site installers ensures seamless project execution, offering both supply and installation services for efficient project completion. The company’s partnership with a chartered structural engineer has enabled them to specialize in replacing traditional structural steel with light gauge alternatives, resulting in:

Cost savings
Reduced installation time
Simplified construction processes

SteelPro FS maintains its competitive edge through the implementation of the cutting-edge light gauge steel ENDUROFRAME® Building System which has been specifically tailored to meet Perth’s unique construction requirements while ensuring full compliance with National Construction Code (NCC) guidelines.

Find out more

For further details, click through to the SteelPro Framing Specialists webiste or call the team directly on on 08 8244 6821

SteelPro FS website

13/02/2025 by enduroframe

Safe and Cost-Effective Wall Panel Lifting Solutions

Enduroframe is always looking at smart, innovative ways to save fabricators money when making light gauge steel frames by solving common manufacturing, installation and logistics issues.

Enduroframe delivers cost-effective solutions through several innovative approaches: advanced testing methodologies that optimize steel usage, enhanced framing systems that streamline assembly and installation processes, and sophisticated software implementations that automate various design elements.

Traditional lifting methods

Traditional wall panel lifting methods using slings can cause significant damage to wall frames at the bottom of packs due to the weight of frames above. While steel lifting lugs with pre-punched holes and eyelets have been an effective solution, they present challenges: high manufacturing costs, poor return rates from construction sites, and expensive collection and retrieval processes. It is not uncommon that the cost of a truck returning expensive lifting lugs is worth as much or more than the lifting lugs themselves!

Enduroframe solution

Enduroframe has engineered an innovative and economical alternative. Combining the ENDUROFRAME® building system’s unique lipped and unlipped sections to make a robust lifting lug provides:

an engineered solution
easy screw-on installation
a cost-effective manufacturing process, and
a recyclable solution which eliminates costly return logistics.

The lifting lugs offer versatile post-use applications such as repurposing as house frame components, converting into various brackets, or even re-using the brackets in subsequent deliveries.

This solution not only addresses the practical challenges of wall panel lifting but also provides a sustainable, cost-efficient alternative to traditional methods.

Manufacturing instructions and an engineered report provided by a structural engineer are included as part of the licensing of the ENDUROFRAME® building system.

Find out more

Contact us to find out more about the many ways that Enduroframe helps you to make cost-competitive light gauge steel frames.

Contact Enduroframe today Find a supplier

01/10/2024 by enduroframe

ENDUROCADD NX Software version 2.0

ENDUROCADD® NX software version 2.0

Enduroframe is proud to unveil ENDUROCADD® NX Version 2.0, the latest and greatest iteration of the ENDUROCADD® software!

This version boasts a sleek, completely revamped design and a user experience that’s faster and more intuitive than ever before. ENDUROCADD® NX empowers users to tackle sophisticated modeling and engineering of complex buildings using light gauge steel with ease.

This version provides comprehensive 3D modelling and views of roof shapes and roof trusses to make it even easier to design complex roofs with complex ceilings.

Fully BIM-compatible, this release introduces a host of new features that seamlessly integrate structural steel with light gauge steel frames. It’s a game-changer for anyone looking to model intricate roof shapes, build roof trusses, and rafters. And the best part? More features from the legacy application will be continuously added to the ENDUROCADD® NX software, making it even more powerful over time.

Screenshot of ENDUROCADD® NX software version 2.0

Find out more

Find out more about the powerful ENDUROCADD® NX software and how it provides cutting edge designs that use up to 40% less steel than alternative software design packages.

About the ENDUROCADD® software

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

Putting our testing to the test

Working with the benefits of extensive testing

Boxing Saving Costs

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

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

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

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

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

Example of roof with saddle trusses

Example of roof with trusses that follow the roof line

Number 5: Is truss pre-cambering supported?

Automated ICJs and Binders

A Smarter Way to Design Light Gauge Steel Roof Structures

What Are ICJs and Binders?

ENDUROCADD® Automation

Key Features & Benefits

Why It Matters

Find out how to start making frames

Join us at Sydney Build 2025

Endurocademy:
World-first Light Gauge Steel Online Training Portal

Want to learn?

SteelPro Framing Specialists:
Premier Light Gauge Steel Fabrication in Western Australia

Find out more

Safe and Cost-Effective Wall Panel Lifting Solutions

Traditional lifting methods

Enduroframe solution

Find out more

ENDUROCADD® NX software version 2.0

Find out more

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