Have you ever wondered how metal buildings in League City are put together or manufactured? The process is both complicated and precise. The manufacture of a metal building is an awesome combination of engineering, draftsmanship, ingenuity, teamwork, know-how and metal building manufacturing expertise. Each building receives the utmost care and attention throughout the manufacturing process, manufactured by experienced craftsmen and watched over by a dedicated staff of professionals from start to finish. Precision engineering, machinery and components plus exceptional quality control yield a precision high quality manufactured product.
Once a customer has purchased a pre-engineered metal building or metal building system, their sales person, who performs multiple functions of building consultant, building designer, technician and estimator, forwards the purchaser’s order to the steel building factory. In the top metal building factories, the factory itself fabricates all required building components in house. That way, all components are compatible and go together easily on the job site with no surprises and no waiting for components to arrive from different suppliers.
At the steel building factory, the order entry department oversees the order from start to finish, from the time the order is received until the steel building is shipped. Steel building factory staff verifies all design codes, snow and wind loads and seismic information to make sure that everything complies with the purchaser’s contract and enters the order into scheduling software to ensure that the buildings manufacture is efficiently managed.
How does one elect the best metal building to use in League City based on all the factors to consider?
Have you ever wondered how steel buildings are manufactured? The process is both complicated and precise. The manufacture of a steel building is an awesome combination of engineering, draftsmanship, ingenuity, teamwork, know-how and metal building manufacturing expertise. Each building receives the utmost care and attention throughout the manufacturing process, manufactured by experienced craftsmen and watched over by a dedicated staff of professionals from start to finish. Precision engineering, machinery and components plus exceptional quality control yield a precision high quality manufactured product.
Once a customer has purchased a pre-engineered steel building or metal building system, their sales person, who performs multiple functions of building consultant, building designer, technician and estimator, forwards the purchaser's order to the steel building factory. In the top metal building factories, the factory itself fabricates all required building components in house. That way, all components are compatible and go together easily on the job site with no surprises and no waiting for components to arrive from different suppliers.
At the steel building factory, the order entry department oversees the order from start to finish, from the time the order is received until the steel building is shipped. Steel building factory staff verifies all design codes, snow and wind loads and seismic information to make sure that everything complies with the purchaser's contract and enters the order into scheduling software to ensure that the buildings manufacture is efficiently managed.
Pre-engineered steel buildings engineers are responsible for optimization of the steel building, each engineer certified by the state where the building will be constructed. Building details including snow and wind loads and seismic information is input into an advanced metal building software program that generates engineered shop drawings for the framing of the building as well as other drawings needed for the buildings manufacture and construction.
The metal building factory's pre-engineered steel building engineers review the building drawings and check the purchase order again for accuracy. Permit drawings are generated that can be used to help secure permits to erect the building.
Actual building production begins with the input of building specifications into CNC (Computer Numerical Control) machinery, a process that involves the use of computers to control machines programmed with CNC machining language (G-code). The CNC machinery controls all machine features including feeds and speeds.
Components of steel buildings, such as I-beams, gutters and downspouts, sidewalls and end wall panels, and even standing seam roofs are systematically manufactured in designated areas called "lines" throughout the metal building factory. Each manufacturing line completes a specific function, automated by use of conveyors that move the steel sheeting, I-beams and fabricated metal components from station to station. Since each steel building is manufactured to order, building components are produced as required to fulfill each steel buildings exact specifications.
The manufacture of steel buildings rafters and columns begins with the Plasma Table. The Plasma Table cuts the web, the center of the rafter or column (like the center of the letter "H"). The web moves to a holding station waiting to move by automated conveyor to the station where the web will be tack-welded to the flange.
The flange machine cuts flanges into specified lengths determined by the pre-engineered buildings specifications from steel bar stock. After cutting, the flanges move to a holding station waiting to move by automated conveyor to the station where the flanges will be tack-welded to the web prior to going through the automatic welding machine.
Certified welders tack-weld flanges and webs in place to form rafters and columns. The tacked rafters and columns move by conveyor to the PHI machine. At the PHI machine, an automatic welding process fuses the web and flange materials, permanently welding the flanges to the web. A Welding Inspector checks all welds to ensure that strict AISC standards are met.
Roof and sidewall panels are fabricated from steel sheeting. Large coils of metal sheeting are placed in a machine called an "uncoiler" which passes the sheeting through another machine called a "straightener" that straightens the sheet. The straightened sheet is die cut and passes through a roll former to give the straightened sheet the shape of roof or sidewall sheeting. As with all machinery in the steel building factory, computers are feeding information to the metal corrugation machine giving it the exact specifications for each building.
Sophisticated machinery on the Trim Line automates the process by which custom trim is formed and ensures exact bends and perfect angles. Starting with a coil of steel mounted on an uncoiler, the steel passes through a straightener to a series of ten roll formers that form the shape of each trim and make all trim components: rake trim, corner trim, jamb trim, head trim, base trim, eave trim, rake angle, base angle, gutter straps, downspouts and gutters.
Out in the yard the Staging Department gathers all the steel building components and carefully loads them onto trucks to deliver the building to the job site. Special attention is given to the Bill of Materials ensuring that every order is complete and accurate. The Traffic Office handles the shipment of each building, scheduling trucks and coordinating buildings to arrive at the job site on time where the erection crew is waiting for delivery..
The Many Advantages of Commercial Steel Structures
I’m dying. This isn’t news I received from a doctor, it’s just the truth. I hate to break it to you, but you’re dying too. In fact, we can be fairly certain that almost anyone reading this will have taken their last breath by the end of this century. Believe it or not, the same holds true for our buildings.
I’m not stating this out of some obsession with death. I don’t have a fatalist sense that life will pass me by without a chance to leave a strong legacy for the generations that follow. Rather, I’m concerned that the places we are building won’t do the same.
A large percentage of our built environment has a surprisingly high “mortality” rate. In fact, the lifespan of a building — made of concrete, steel, wood — is shorter than that of a flesh-and-blood human. According to the U.S. Department of Energy, the average office building lifespan in 2008 was 73 years. In contrast, human life expectancy in the U.S. was 78 years. Given their similar life expectancy, one would assume we spend a comparable amount of money on a person’s shelter as we do on other essential aspects of their life, right?
The Bureau of Labor Statistics estimated in 2008 the average cost of living on food, shelter, transportation, and healthcare to be around $35,000 per year — or more than $2.7 million during a 78-year lifetime. We spend that on ourselves simply to survive. And what about the office environment where, for 45 of those 78 years, we will devote more than 50% of our waking hours? We currently spend around $200 per square foot for a conventional office building, with each worker needing roughly 200 square feet to do their job (direct work, collaboration, breaks, storage, etc.). That’s a total cost of $40,000 per person for every new building built. Additionally, according to the Building Owners and Managers Association, the average annual operating costs are about $8/sf (or $1,600/sf per person each year), which over a 45-year career yields a total operating cost per person of $72,000. In total, we’re allocating about $112,000 per person on buildings during an individual’s career.
The quick math? We spend 24x less on the facilities shaping our daily experience and health than we do on the bodies that inhabit them. Yet I’ll wager most people expect buildings to outlive them many times over.
This seems like a misalignment worth exploring, especially as we aspire to improve the health of both our cities and their citizens. Are we expecting too much from our buildings, or are we not spending enough money on them? Either way, here are two approaches that may help us start the uncomfortable conversation on the merits of “architectural euthanasia.”
Long Live the Short-Lived
As humans we’re predestined, eventually, to return to earth, ashes, and dust. Based on their similar lifespan, should buildings have the same fate? When buildings cease to change, when they cease to give back, when they cease to learn, they die. Yet we have a tendency to put them on life support, often for long periods of time. Instead of investing in “permanent” materials that, ironically, will be deconstructed in less than a century, let’s instead focus on lightweight, rapidly constructible and dismantle-able solutions as part of a flexible, component-driven system.
For instance, lightweight tensile structures are deployed throughout the globe to house sports, social venues and even laboratories, and can more broadly be considered for day-lit envelopes or inflatable facilities that disappear when not in use. Or imagine the beauty — both literal and figural — of exterior walls where reusable felt panels become both insulation and rain screen. Explorations in paper materials such as cardboard have become more prevalent, while 3-D printing affords us the opportunity to experiment with soluble materials that simply wash away after serving their purpose.
Materials for short-term buildings don’t necessarily have to be less durable, but they likely need to perform more than one function. A single material serving as structure, enclosure and window is faster and simpler to assemble — and therefore more likely to encourage a project to go up or come down. Perhaps we can learn a thing or two from millennia of nomadic lifestyles.
We started designing for human health centuries ago, and the outcome on the built environment has been noticeable. The term euthenics — the study of the improvement of human functioning and well-being by the improvement of living conditions — was coined in the 1890s when society began to stress the importance of natural light, fresh air and open space in the buildings that shape everyone’s daily life. Cast-iron façades and long-span timber elements were effective approaches to freeing up both the exterior and the floor plan. Not by coincidence, the buildings that succeeded in doing this best a hundred years ago are some of today’s most sought-after real estate investments.
Some of our biggest challenges with structures derive from our failure to foresee the continual changes that occur in how we live and work. Architecture that uses an exoskeleton — or structural elements on the exterior — is a strong first step towards accommodating such change, eliminating internal columns and walls that often constrain the uses around them. Moment connections at columns can do the same while enabling future flexibility for the placement of elevator cores and floor openings. Taller floor-to-floor heights invite daylight deeper into a space — making it more comfortable and usable — while providing a greater range of opportunities for evolving programmatic needs, from offices, to residences, to loft-like workspaces or even labs or industrial use.
Interestingly, it’s not the materials in long-term buildings that need to be more durable, but rather the forward-thinking ideas about how space will be used. Perhaps this conceptual trajectory might force us to rethink our criteria for sustainable features, so that conversion and adaptive reuse would trump bicycle storage and recycled materials.
We can spend less on shelter and, like buying furniture at Ikea, know we will get something that is decently crafted but will last only a few years. Or we can spend more on design, materials, mechanical systems, exterior walls, floor-to-floor heights, and so on and guarantee that our buildings will outlive us and the generations to follow.
Think of it like the sell-by on a grocery item. Perishable foods must be used up quickly, while shelf-stable foods are labeled for the longer term, packaged as nutritional insurance for the future. Perhaps it’s time we establish the same expectations for our buildings, designing with the knowledge that they, too, have an expiration date.