Utilising prefabricated light gauge steel (LGS) framing made from TRUECORE steel helped the builder, Badge Constructions save time and reduce costs at the two-storey Insight Early Learning Centre project in Port Coogee, WA.

The project

Badge Constructions was engaged by RG Property in the early stages of the project (ECI phase) to make recommendations on the selection of building materials and methods that would reduce cost and speed up the construction program. The collaborative ECI phase ran for four weeks and concluded with Badge Constructions proposing the use of LGS framing.

Once these recommendations were submitted to RG Property, Badge Constructions was awarded the Design and Construct (D&C) contract, and they subsequently engaged architectural firm, MODE Design Corp to complete construction design detailing for the project.

Having worked together on the WA PPP Schools project, Badge Constructions once again engaged fabricator Steelscene during this 10-week design period to first design and then fabricate the LGS framing made from TRUECORE steel.

“They [Badge Constructions] were aware of our capabilities in relation to design and consulting advice,” said Brendan Luxford-Sweett, general manager at Steelscene. “They came to us early in the design stage so we could advise on cost and methodology for various steel frame elements in the building.”

The site for the childcare centre was narrow, with one wall adjoining a grocery store. The restrictive site posed challenges for material delivery scheduling. With one-point unloading in place, Steelscene needed to co-ordinate the prefabrication of framing to align with the installation at the site.

Precast panels, along with 21 concrete columns at the ground level, provided support for the first floor suspended concrete slab. Prefabricated framing made from TRUECORE steel was then used for the internal framing, three of the four external walls on both floors, and the roof trusses on the first floor.

The construction of the approximately three-metre eave overhang was another challenge that required out-of-the-box thinking by Steelscene. The roof trusses were designed with engineered precision, and then prefabricated to the required strength by combining different profiles rolled from TRUECORE steel of various gauges.

Following the 33-week construction period, Insight Early Learning Centre was completed at the end of 2019, and handed over 10 days ahead of the targeted completion date. The centre opened its doors in January 2020. Its unique design featuring a custom semi-translucent mesh screen spanning across the whole façade quickly attracted positive feedback from locals.

Key benefits delivered

Construction manager Brenton Rzepecki said Badge Constructions achieved the following benefits from the use of LGS framing made from TRUECORE steel:

Design Versatility:
- Frames made from TRUECORE steel have an impressive strength-to-weight ratio, which allowed for the three-metre-long roof eaves to be created.
Fast and Efficient Installation:
- Prefabricated and dimensionally accurate, the lightweight, yet strong frames made from TRUECORE steel were quick and efficient to unload and install.
Straight and True:
- Framing made with the inner strength of TRUECORE steel meant less onsite adjustment.
Cost and Time Savings:
- The framing, which was made from TRUECORE steel, was installed in six weeks. Based on prior experience, Badge Constructions estimated that framing in alternatives such as brick would have taken weeks longer to complete.

Key outcomes

Badge Constructions reflected positively on the use of framing made from TRUECORE steel for this project and was particularly happy with the positive feedback that they received from trades.

“Our site manager really likes the product because it’s quick. If you put the time in during the design phase, you definitely get the benefit of building quickly,” Rzepecki stated.

Steelscene has recently expanded its range to include 64, 75, 89, 150 and 250mm profiles, as well as rolling 25 and 40mm battens across various gauges to suit engineering requirements.

“Being able to offer this wide range of profiles, we aim to supply the commercial sector additional options. The prefabricated nature of the product will assist in accuracy, and reduce time on site,” Luxford-Sweett added.

Principal Steel Products:

Framing: Approximately 11,000 linear metres of TRUECORE steel
Roofing: COLORBOND steel in Stramit Monoclad profile, in the colour Surfmist

Sources:

Brenton Rzepecki, Construction Manager, Badge Constructions
Brendan Luxford-Sweett, General Manager, Steelscene

Architecture & Design Team

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BlueScope

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