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Mgi infra (LGSF) TECHNICAL DOCUMENT

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MGI India was incorporated in the year 2011 by a group of experienced professionals from the field of design and construction with a motive to provide green and fast track construction technology across India covering all types of building solutions.

MGI Infra Pvt. Ltd. specializes in the design and provision of complex fast – track modular buildings using light steel framing construction methods.

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Mgi infra (LGSF) TECHNICAL DOCUMENT

  1. 1. MGI CR MANUAL LIGHTER STRONGER FASTER 1 Cold Form Building – Technical Specification, Construction & Finishing Manual
  2. 2. MGI CR MANUAL LIGHTER STRONGER FASTER 2 INDEX CHAPTER 1 - INTRODUCTION – COLD FORM STEEL................................................3 CHAPTER 2 - MGI STRUCTURAL SYSTEM....................................................................5 CHAPTER 3 - STEEL ASSEMBLY PROCEDURE....................................................... 18 CHAPTER 4 - SERVICE INSTALLATION ...................................................................... 21 CHAPTER 5 - PAINTING PROCEDURE......................................................................... 25 CHAPTER 6 - DOOR AND WINDOW FRAMES INSTALLATION ............................. 26 CHAPTER 7 - OTHER CONNECTION ............................................................................ 29
  3. 3. MGI CR MANUAL LIGHTER STRONGER FASTER 3 Chapter 1 - Introduction – Cold form Steel 1.1 Evolutionof Cold form Steel Framing 1. Began around 1850. In North America, 1946. 2. Some of the countries using the system today: – USA, Canada, Western and Eastern Europe, China,Austria,NewZealand,India,Malaysia,Indonesia, SouthAfrica,Gulf countries,andAlgeria. 3. Made fromstructural qualitysheetsteel formedintoshape either through press‐braking blanks sheared from sheets or coils, or more commonly, by roll forming the steel through a series of dies. No heat is required to form the shapes (unlike hot‐rolled steel), and thus the name Cold Formed Steel. 4. Cold‐formed steel members and other products are thinner, lighter, easier to produce, and typically cost less than their hot-rolled counterparts. 5. A varietyof steel thicknessesare availabletomeetawide range of structural and non‐structural applications. 1.2 Description - Coldform Steel Framing The wall panels,roof trussesandfloorjoistsare all made upof roll-formedcoldrolledsteel sections of thicknessrangingfrom0.75mm to 1.6 mm, (Yieldstrength500MPa- 550MPa) thatcomplywith ASTMA1003 Structural Grade 33 (NS33). The Steel Structure isdesignedforaDesignLife of minimum50years.VariousCodes&Standards usedforDesignpurpose are:  IS 875: Part 1 to 5 – Loads onStructure  IS 800: 2007 – Designof Steel Structures  IS 801: 1975 & AISI S100 – Designof ColdFormedSteel Structures  IS 456: 2000 – Designof Concrete  IS 1893: 2002 – Earthquake ResistantDesign Fig.1 Cold Roll Coils
  4. 4. MGI CR MANUAL LIGHTER STRONGER FASTER 4 1.3 Corrosion Protection - Coldform Steel Framing The steel ishot-dippedgalvanizedwithaminimumZ220 coatingfor loadbearingapplicationsand non-loadbearingapplications.Alternatively,steelhot-dippedinAlum/Zinccoating(knownas Galvalume with55%Aluminium and45%Zinc) isalsoused.The applicable codesare ASTMA653 for galvanizedandASTMA792 for galvalume.The lightgauge cold-formedsteel structural membersare designedasperAS/NZS4600:2005 andAISIS100. The Resultsof variousTestsand Studiesconductedonthe material coatingsindifferentatmospheric conditionsstate thatthere isa lossof only1-2% of the coatingovera periodof 10years evenintest locationsasclose as 10m fromthe coast. Fig 2. Designed shape HEIGHT (mm) WIDTH (mm) LIP (mm) THICKNESS (mm) 150 41 11 0.75 150 41 11 0.95 150 41 11 1.15 89 41 11 0.75 89 41 11 0.95 89 41 11 1.15
  5. 5. MGI CR MANUAL LIGHTER STRONGER FASTER 5 Chapter 2 - MGI Structural System 2.1MGI Wall Panels MGI Wall Panelsare made up of ColdFormed Steel C-LippedSections.The typical membersthat comprise a Wall panel are listedinthe figure below: Fig 3. Cold rolled Frame wall Fig 4. Cold rolled Frame wall system
  6. 6. MGI CR MANUAL LIGHTER STRONGER FASTER 6 2.2MGI Load Bearing Wall Panels A loadbearingwall isone whichcarriesvertical loadsfromthe constructionabove andlateral loads resultingfromthe windaswell asseismicforces.These loadsmayact separatelyorincombination. Both internal andexternal wallsmaybe loadbearing.The resultantimpactisfarbetterascompared withanyconventional structure. MGI LSF Systemrecommends the following for the load bearing walls:  All loadbearingstudsshall be minimumG550 coldformedsteel of 0.75mm thickC 89 section. The thicknessof sectionwill varyfrom0.75 to 1.6mm thickdependsonthe loadingrequirement.  A structural top track isusedto carry truss loadsfromthe roof to the studs,where the studsare not locateddirectlyunderthe trussloadpoints.Toptrackshall be G550 coldformedsection.The top track shall be secured transverselybyincomingtrussesorrafterswithapprovedwall support brackets.  The bottomtrack must be fullysupportedundereveryload-bearingstud.Thisiscritical with studsbeside openings,orstudscarryingmajorloadsforthe roof,ceilingorupperfloor construction.The supportcan be providedbya floorjoist,blockingpiece locateddirectlyunder the stud.  Lintelsare neededforopeningsgreaterthan1200mm of loadbearingwalls.Lintelsundersheet metal roofsare principallydesignedforupliftfromwindloadingonthe roof structure while lintelsundertileroofsare designedprincipallytosupportdownwardloadsfromthe roof trusses.  Noggingsinthe formof a notchedplate maybe usedinload bearingwallstoprovide lateral restrainttothe wall studs.  Bracing isneededincertainwallstoprovide rackingresistance againstwindload.Itcouldbe in the form of bracing strapsor bracing sheetsdependingonthe requirement.  The studs,joistsandtrussesmustbe properlyalignedinordertotransferthe loadsto the memberbelow. 2.3MGI - Non-Load bearing Wall panel Internal wallswhichdonotsupporttrussloadsare considerednon-loadbearing. MGI systemrecommends the following for non-loadbearing walls:  Studsfor internal non-loadbearingwallsshall be minimumLightgauge steel G550 C89, 0.75mm thickcold formedsection.  Top plate shall be fixedtotrussestoprovide lateral stabilityforthe wall.The connectionshall not transmitvertical loadstothe wall.  The bottom track shall be minimumG550 cold formedsection  Angle lintelsare notrequiredforopeningsinnon-loadbearingwall frames.  Noggingsisgenerallynotneededforinternal non-loadbearingwalls unlessnotedotherwise.
  7. 7. MGI CR MANUAL LIGHTER STRONGER FASTER 7 2.4MGI – Wall ConnectionDetails MGI LSF system uses Steel bolts, nuts and washers complying with AS 1112:2000 or ISO 4759- 1:2000. Self-drilling screws (SDS) complying with AS 3566.1 and AS 3566.2 are used. 1) MGI Connectors The MGI Connectorsare usedto connectthe differentCRmember.The application ismentioned below Fig 7. MGI Connector MGI-CM1 Used to connect the steel sections with concrete foundation, and also for steel to steel connections MGI-CM2 Used to connect the steel sections with concrete foundation,andalso for Light gauge steel walls connections at floor levels MGI-CM3 Used to connect the Non load bearing walls with concrete foundation, and also for steel to steel connections
  8. 8. MGI CR MANUAL LIGHTER STRONGER FASTER 8 2) Mechanical Anchor Bolt Highperformingrange of steel mechanical expansionandscrew anchorslike heavydutyanchors, heavymediumdutyanchorsetc.are usedtoanchor LSF Frame structure to the foundation. The requiredembedmentdepthiscalculatedduringthe structural design. Fig 8. Mechanical Anchor bolt 1) Wall To Wall ConnectionDetails: L-holddownsare usedto connectLSF frame wallsatnogginlevels. andS.D.S.Phil Modi Truss Type BSD # 3PT of length19mm are usedto connectthe all lightgauge steel memberslike wallstuds, joists,trussmembers. Fig 9. S.D.S. Phil Modi Truss Type BSD # 3PT Special ScrewsnamelyS.D.SPhil ThinWafer8Nibstype BSD#2PT, Size #8X32 are usedto connect cementboards,Gypsumboardsto wall frames Fig 10. S.D.S Phil Thin Wafer 8 Nibs type BSD #2PT
  9. 9. MGI CR MANUAL LIGHTER STRONGER FASTER 9 3) Exterior Cladding – Building Wrap BuildingWrapfunctionsasa weather-resistantbarrier,preventingrainfromgettingintothe wall assembly whileallowingwatervaportopass to the exterior.If moisturefromeitherdirectionis allowedtobuildupwithinstudorcavitywalls,moldandrotcan setinand fiberglass orcellulose insulation will loseits R-valuedue toheat-conductingmoisture. BuildingWrap isinstalledoverthe sheathingandbehindthe exteriorsiding.Inall cases,the Building Wrap is the last line of defence in stopping incoming water or exterior water condensation from getting into the stud wall. 4) Exterior Cladding – Fibre Cement Board MGI uses6mm Fibre CementBoardforexternal cladding. Description: Fibre cementisa composite material made of sand, cement and cellulose fibres. The raw materials usedto manufacture fibre cementare low in toxicitywoodpulp,cement,sand and water meaning a reduced environmental impact. Application: Fibre cementboardisa buildingmaterial usedtocoverthe exteriorof abuildingandforflooringin bothcommercial anddomesticapplications. Exterior wall cladding is done with 6mm thick Regular fibre cement board with 24mm polystyrene for finishingandwaterproofing. The cement boards are fixed with countersunk self drilling screws with the joints duly filled and finished with putty and plain surface achieved. It is used not only as cladding but is also commonly used as a soffit / eave lining and as a tile underlay on decks and in bathrooms. Benefits: Weather Resistant Fibercementisdurable ininclementweathersuchasfreezingconditions,strongwinds,blistering heat,humidityandsaltwaterexposure. Low Maintenance Fibercementwill notrot,warp,mildeworgrow mold.It is also termite and bug resistant and offers non-combustibility with fire and flame retardant properties. Versatility A number of designs, textures and colors are available in fiber cement such as horizontal and vertical siding with stucco, wood, smooth and cedar shingle appearances. Trim boards, soffits and fascia boards are additional siding products that can be found in fiber cement.
  10. 10. MGI CR MANUAL LIGHTER STRONGER FASTER 10 SoundInsulation Air borne sound reduction varies between 30 and 37 dB for the frequency range 100- 3150 HZ according to thickness of Panel. When used in stud partitioning, a reduction of over 60 dB can be achieved with suitable construction. Thickness (mm) 6 8 10 12 16 20 30 40 Reduction (dB) 30 31 32 33 34 35 36 37 Technical Data Thickness 6 mm Fire Resistance properties Non-combustible andqualifyfor EarlyFire Hazard indices as per AS-1530 part 3 and Resistance to Fire as per BS-476, Part 4, 5, 6, 7 & 8 Standard Weight 15.2 kg/m2 for 9 mm Compressive strength 15MPa Bending Strength 9MPa Moisture Content Moisture resistant and are tested as per IS - 14862 Nail Holding Power 205kg Lamina Bond Strength 2.1 MPa Impact Strength 12.0 Kj/m2 for 9 mm Thermal Conductivity 0.21 W/m/K at 500C Density 1650 kg/m3 average Durability Tested for durability as per IS - 14862 Modulus of Rupture 16 MPa in wet condition
  11. 11. MGI CR MANUAL LIGHTER STRONGER FASTER 11 5) Exterior Cladding – EIFS MGI uses24mm ExtrudedPolystyrene forExternal Cladding. Description: The MGI EIFS systemconsistsof Polystyrene (24mm),fibre glassmeshandalayerof weatherproof basecoaton top. Polystyrene isatype of insulationmaterial withfine,closedcells,containinga mixture of airand refrigerantgas. Ithas a highthermal resistance value,goodmoisture resistance, and highstructural strengthcomparedtootherrigidinsulationmaterials.Extrudedpolystyrene is usedextensivelyasthermal insulationinindustrial,commercial,andresidentialconstruction. Fig 11. EIFS System Application: The EIFS systemisusedas an external wall insulationandrendermaterialandprovidesareadyto paintsurface. Benefits: AcousticPerformance: Polystyrene is a good Sound absorbent and has a high Noise Reducing Coefficient (NRC). Fire Performance: Polystyrenehasexceptionalfire performance characteristics. The thermal conductivity of extruded polystyrene is 0.027 W/K.m Resistance to Moisture: The moisture absorption from the atmosphere is less than 1% by volume at 95% relative humidity.
  12. 12. MGI CR MANUAL LIGHTER STRONGER FASTER 12 6) Internal Cladding – GypsumBoard Description: Fibre cementisa composite material made of sand, cement and cellulose fibres. The raw materials usedto manufacture fibre cementare low intoxicitywoodpulp,cement,sand and water meaning a reduced environmental impact. Application: Gypsumboard is a buildingmaterial usedtocoverthe interiorof abuildingandforceiling cladding inboth commercial anddomesticapplications. The wall cladding is done with 12.5 mm thick Gypsum. The Gypsum boards are fixed with countersunkself drillingscrewswiththe joints duly filled and finished with putty and plain surface achieved. Benefits: Weather Resistant Gypsumboard isdurable ininclementweathersuch as freezing conditions, strong winds, blistering heat, humidity and salt water exposure. Low Maintenance Gypsum boards will not rot, warp, mildew or grow mold. It is also termite and bug resistant and offers non-combustibility with fire and flame retardant properties. Versatility A number of designs, textures and colors are available in Gypsum boards Technical Data Thickness 12.5 mm Fire Resistance properties Non-combustible andqualifyfor EarlyFire Hazard indices as per AS-1530 part 3 and Resistance to Fire as per BS- 476, Part 4, 5, 6, 7 & 8 Standard Weight 9.5 kg/m2 for 12.5 mm Compressive strength 8.1 MPa Moisture Content Below1% and are tested as per IS – 14862 Nail Holding Power 200N Thermal Resistance 0.069 K. M2/ W Density 680-750 kg/m3 Durability Testedfor durabilityas per IS – 14862
  13. 13. MGI CR MANUAL LIGHTER STRONGER FASTER 13 7) Wall Insulation – Rock Wool MGI uses75mm (Density48kg/m3 ) Rockwool slabsasWall Insulation. Description: Rock wool,are fibresmade fromnatural or syntheticmineralsormetal oxides.The rockwool being usedcompliedwiththe IS8183-1993. Theirabilitytopartitionairmakesthemexcellentheat insulatorsandsoundabsorbers.The fire resistance,of rockwool makesitcommonbuilding materialswhere fire resistanceisrequired. Fig 12. Rockwool Application: External wall insulationsystemsgenerallycompriseaninsulationlayertoachieve the requisite standardsof thermal performance. Rock wool isusedas insulatorforbothexternal aswell asinternal walls. Benefits: AcousticPerformance: Rock wool is good Sound absorbent. The Noise Reducing Coefficient, (NRC) for Rock wool of 48 kg/cumec density and 100mm thickness is 1.0 Fire Performance: Rock wool has exceptional fire performance characteristics. The limitingtemperature of rockwool is 1000 C,and the continuous service temperature limited to 800 C. Resistance to Moisture: The moisture absorption from the atmosphere is less than 0.02% by volume at 95% relative humidity.The fibre constructionandlayingpatternallowsnatural dryingof rockwool inthe event of local ingress of water Biological: Rock wool fibresdonotpromote the growthof fungi,moulds or bacteria and sustain vermin attack. Rock wool is completely rot proof.
  14. 14. MGI CR MANUAL LIGHTER STRONGER FASTER 14 Technical Data Thickness 40, 50, 75, 100 mm Fire Resistance properties Non-combustible Non-combustible and tested as per IS 3144,3346. Density 48,64,96,144 kg/m3 Thermal Resistance 11.8 for 75 mm thick, 48kg/m3 density Moisture Content Below 1% and are tested as per IS - 14862 Thermal Conductivity 0.068 W/K. m at 200 o C
  15. 15. MGI CR MANUAL LIGHTER STRONGER FASTER 15 2.5 MGI WebbedFloor Joist MGI WebbedFloorJoistsare made upof ColdFormedSteel C-LippedSections.The bottomandtop cord lipout where the websare coming.The webshave the swage atthe endto putinside the top and bottomcord. Fig 13 Floor Webbed Joist
  16. 16. MGI CR MANUAL LIGHTER STRONGER FASTER 16 2.6MGI ROOF TRUSSES Whatever the roof, it is generally designed to give you, and the inside of the property, the best protection possible from the weather. Roof design is quite a complex field and involves many calculations regarding the strength of the materials used. A roof has to withstand very high wind speedsand snow loading and each roof is designed to carry the covering, eg tiles, that is put on it. Light-gauge steel trussesoffermanyadvantagesovertraditional roof framing components. Because of steel’s incredible strength, light-gauge trusses can be designed for larger clear spans. They can eliminate intermediate bearing walls and create large open spaces. Steel trusses not only span farther,theypermitwider on-center spacing that results in additional labour and material savings. The roof of light gauge steel frame structure is of two types: 1) Flat Roof System 2) Inclined Roof System 1) Flat Roof System: The flat roof of light gauge steel frame structure is made up of with Joists. The heavy duty cement board or metal sheet screwed to the joists on which Foam concrete poured over and finally roof finishing will be done with the tiles. 2) Inclined Roof system: Differenttypesof Trusses: A roof truss isa frame,typicallymade outof Lightgauge steel members.The frame iscomposedof a seriesof connectedtrianglesasthatparticularshape has greatstructural stability. Roof trussesserve a pairof critical functionsforabuilding.There are manydifferenttypesof roof trusses.Whichtrussdesigntouse depends ona numberof factors andthat decisionisbestlefttoa professionalengineer. Fig 14. Various roof trusses
  17. 17. MGI CR MANUAL LIGHTER STRONGER FASTER 17 2.7MGI Roof ConnectionDetails The roof structure isgenerallyasteel trusssystemwhichcanbe designedfor metal sheetsortiles. Thisis a roof truss systemwhichtypicallyconsistsof C89 andC150 sectionsasthe chord and web membersof the truss. Triple grips(MGI-CM5) are usedto connectthe roof trusseswiththe wall frame. Steel roof sheetingortile andwouldbe screweddirectlyontopurlin. Connection Details of Triple Grips S.D.S. Phil Modi Truss Type BSD # 3PT of length 19mm are used to connect the all light gauge steel members like studs, joists, truss members. Fig 15. Roof Connection Detail MGI-CM5 Usedto connect the floor Joists and roof trussesto the wall
  18. 18. MGI CR MANUAL LIGHTER STRONGER FASTER 18 Chapter 3 - Steel Assembly Procedure 3.1Wall Assembly 1. All the pre-cut,pre-marked,pre-punchedmembersarrive atsite inbundles. 2. Openthe bundles markedwiththe same wall numberandalignthe steel membersasper the wall assemblydrawing. 3. Jointhe membersusingScrewsatpre-punchedholelocations. Fig 16. Wall Assembly drawing sample
  19. 19. MGI CR MANUAL LIGHTER STRONGER FASTER 19 3.2Joist Assembly 1 All the pre-cut,pre-marked, pre-punchedmembersarrive atsite inbundles. 2 Openthe bundlesmarkedwiththe same Joistnumberandalignthe steel membersasperthe Joistassemblydrawing. Fig 17. Typical Joist Fabrication detail 3 Jointhe membersusingScrewsatpre-punchedholelocations. Fig 18. Typical Joist Assembly
  20. 20. MGI CR MANUAL LIGHTER STRONGER FASTER 20 3.3 Truss Assembly 1 All the pre-cut,pre-marked,pre-punchedmembersarrive atsite inbundles. 2 Openthe bundlesmarkedwiththe same Trussnumberandalignthe steel membersasper the Truss assemblydrawing. 3 Jointhe membersusingScrewsatpre-punchedholelocationsonly. Fig 19. Typical Truss Fabrication detail
  21. 21. MGI CR MANUAL LIGHTER STRONGER FASTER 21 Chapter 4 - Service Installation 1.1 Electrical andPlumbing Conduits 1. Electrical & Plumbingconduitsare runthroughthe service holesalreadyprovided inthe CFS members(referfiguresbelow). Fig 32. Grommet fixing Detail 2. Where the pre-punchedholesare notsufficient,customholescanbe cut usinga hole cutter and reinforcedusingBridgingChannels(referfigurebelow).Itmustbe ensuredthatthe hole be locatednearthe middle of the webandisnot greaterthan50mm diameter(holesgreater than 50mm diametershouldbe engineered) Fig 33. Hole Detail 3. The wire must be protected from contact with the edges of holes by use of a grommet. A Standoff shouldbe placedwithin305 mm (12 in) of the electrical box and at 1500 mm(60 in) centre to centre along the stud. (See Figures below)
  22. 22. MGI CR MANUAL LIGHTER STRONGER FASTER 22 Fig 34. Grommet Detail 4. Electrical boxes must be fastened to the web of studs. It is important that the box have adequate support and be attached to a stud or metal backing. 5. At locationswhere items(like Split AC, Tube lights, Ceiling Fans, Water Closets, etc.) are to be hung onwall/wall mountedadditionalmetal studsorSteel Plates(Backing) are provided. 6. For fixing water closets with concealed cisterns, additional studs are provided to fix the cistern assembly inside the wall cavity. (Refer figure below) Fig 35. Water Closet Connection Detail -1 Extra Stud Extra Stud Cistern Support for Wall Mounted WC
  23. 23. MGI CR MANUAL LIGHTER STRONGER FASTER 23 Fig 35. Water Closet Connection Detail -2 Fig 36. PVC Pipe Connection Detail-1
  24. 24. MGI CR MANUAL LIGHTER STRONGER FASTER 24 Fig 37. PVC Pipe Connection Detail-2
  25. 25. MGI CR MANUAL LIGHTER STRONGER FASTER 25 Chapter 5 - Painting Procedure 1.1 External Painting 1. Single Coatof primerisappliedoverthe base coat(Finishedexternal wall surface). 2. Single Coatof Weatherproof Paintisappliedoverthe primer. 1.2 Internal Painting Fig 46. Typical Painting Detail 1. GypsumBoard 2. Edge of board (ChamferedEdge) 3. Fibre Tape (Self Adhesive) 4. Jointbetweenboards 5. Two Coatsof Primer 6. Single Coatof AcrylicEmulsionPaint 3 4 5 6
  26. 26. MGI CR MANUAL LIGHTER STRONGER FASTER 26 Chapter 6 - Door and Window Frames Installation 1. Verifythe rough openingissquare byaccuratelymeasuring andcheckingthatthe diagonals are equal. 2. Make sure that the windowopeningisclearfromdebrisandobstructions. 3. Prepare door/windowopeningsbyfixingfibre cementboardonthe sill,jambstudand head usingself drillingscrews(asshowninfigure below). If Stone fixingisrequiredatthe Sill level, fix the Stone onthe Window SillusingReadyMix Adhesive (SuppliedbyWeber). Fig 44. Typical door fixing Detail 4. The door & windowframesmay now be fastenedthroughthe jambintothe studswith “countersunkhead”self-drillingscrews. 5. Install the door/windowshutter. 6. Apply sealantbetweenthe door/window frame andthe roughopening. Fig 45. Door Head Section Detail Fibre Cement Board SDS WaferHead Screw SDS WaferHead Screw SDS WaferHead Screw JAMB STUD SILL
  27. 27. MGI CR MANUAL LIGHTER STRONGER FASTER 27 Fig 46. Door Jamb Section Detail Fig 47. Timber Door Frame Detail
  28. 28. MGI CR MANUAL LIGHTER STRONGER FASTER 28 Fig 48.Typical Aluminium extruded Jamb Profile detail Fig 49.Shadowline door jamb detail
  29. 29. MGI CR MANUAL LIGHTER STRONGER FASTER 29 Chapter 7 - Other Connection 1) Some accessoriestoconnectto the cfs wall asshownbelow Fig 50.Hook Connection Detail Fig 51.Medium Weight fixtures detail (Eg., Cupboard and Shelves) Fig 52.Fixing to steel hollow section
  30. 30. MGI CR MANUAL LIGHTER STRONGER FASTER 30 Fig 52.Steel Column covering detail

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