Steel Structure Galvanizing

Steel Structure Galvanizing

Galvanizing is the process of applying a protective zinc coating to prevent rusting.
The most common method is hot-dip galvanizing, where the steel parts are submerged in a bath of molten zinc.

Hot dip galvanization is a highly-specialized job therefore at Tekmetsan, galvanization works are subcontracted to the specialized subcontractors.

Although it is a more expensive type of coating compared to 2 layer organic paint coating, hot dip galvanization offers the below great advantages;

1. Durability

A galvanized coating is one of the most durable forms of corrosion protection on the market. An average coating thickness of 85 microns, the same thickness as a sheet of A4 paper, can protect a steel framed building for the better part of more than 50 years.

2. Sustainability

The long-term durability provided by galvanizing is achieved at relatively low environmental burden in terms of energy and other globally relevant impacts.

3. Reliability

Galvanizing is a relatively straightforward and closely controlled process. The coating formed is consistent, predictable and simply specified. Hot dip galvanizing is defined by a single standard – EN ISO 1461.

Unlike a paint coating, the metallurgical bond that is formed through galvanizing becomes part of the steel itself and is not merely a chemical or mechanical bond.

Due to the metallurgical bond that is formed when steel is dipped into molten zinc, a galvanized coating offers straightforward, secure protection from the get-go. Hot dip galvanizing requires rust-free, uncontaminated steel for the process to occur. Once the coating is present, it is impossible for it to fail from underneath. Other coatings can adhere to residual contaminants, this can undermine performance, lead to flaking and cause premature failure.

4. Predictability

A galvanized coating offers predictable corrosion protection that weathers in a linear fashion. Coating thicknesses are measurable and offer lifespans that can be easily forecast and relied upon.

Batch hot dip galvanizing is a standardized process which produces a quantifiable coating thickness. The coating is simply specified through European and international standards.

The coating thickness depends upon the gauge of the steel that is galvanized and is produced consistently across the component, both inside and out. This can be measured easily throughout its lifetime, using non-destructive methods.

5. Complete Coverage

There are multiple reasons why hot dip galvanizing outperforms other organic coatings. A crucial factor is the way the process achieves complete coverage of a component, both inside and out.

The dipping of steel into a tank of molten zinc via the hot dip galvanizing process means the zinc can access even the trickiest areas.

A further benefit of hot dip galvanizing is that hollow components are coated on internal surfaces too, meaning that a structure will not corrode from the inside out. In addition, the coating will also build up at vital corners and edges, unlike brushed or sprayed coatings, which traditionally thin out in these areas.

6. Abrasion Resistance

Galvanizing has an abrasion resistance up to ten times better than organic paint coatings. The hot dip process is unique, producing a coating which is bonded metallurgically to the steel.  As a result, galvanized steel has superior resistance to mechanical damage during handling, storage, transport and erection.

Conclusion

Along with paint coatings, Tekmetsan offers hot dip galvanization finish to its steel fabrications. It is essential to know whether products are going to be galvanised right in the beginning of the design phase in order to customise the part design for the hot dip galvanization.

BIM in Steel Structures

Building Information Modelling

The key idea behind BIM (Building Information Modelling) is to have all information related to a facility organized in one application-independent model. Ideally, this model is started at concept stage and expanded during each phase of construction and operation of the facility.

While BIM is centred on a 3D model, it is not limited to geometry. Other possibilities are costs, maintenance information, manufacturers, materials, names, dates and times, position and assembly numbers, phases, revisions, and so on.

In the preconstruction phase of steel structure, performing collision detection and design review using BIM can help to reduce the losses that occur in the construction phase by identifying the problems that can be solved beforehand at the design phase (e.g., design errors). Doing so improves the design quality by reducing design errors, design changes, and rework. In the fabrication phase, the procurement process of construction frame members through BIM-based prefabrication can be simplified, and the productivity of workflow between the designers and constructors can be improved. In addition, in terms of production productivity, the workers that are involved in the production of frame members can utilize the information inputted to BIM objects to support the manufacturing process.

Our engineering department is fully engaged with the BIM software and all design & fabrication activities are carried out within the BIM framework of our clients.

Quick Facts about Steel Buildings

Quick Facts about Steel Buildings

Why do so many people choose metal for building? The pre-engineered steel building facts speak for themselves.

Almost all the industrial buildings and majority of the commercial structures are being constructed with steel frames.

1. Prefab Metal for Building is the deal

The return on investment is one of the major criteria in decision making and steel buildings offer lowest cost per square meter. Like any other business, building owners focus hard on the bottom line. 

Steel certainly could not hold such a lead in commercial and industrial construction if metal buildings were not affordable.

Using steel for building costs less over time, too.  For example:

• Heating and cooling is significantly cheap in a well-insulated steel building 

• Metal structures require very little maintenance

2: A Steel Frame Building Creates a Stronger Structure

Steel has the highest strength to section ratio which provides strongest structures with minimum material usage. Neither concrete, nor timber can provide this performance.

3: Span Farther When Using Steel for Building

Many commercial and industrial buildings require huge, open interiors.  Steel frames enable to build spans over 30 meters without any columns inside the building. Even for the spans less than 30 meters, steel frames offers the cost advantage compared to the concrete and timber frame structures. Steel is the ideal frame system for structures like these;

• Airplane and helicopter hangars
• Barns
• Workshops
• Metal Auto Repair Workshops
• Large restaurants
• Manufacturing plants
• Vehicle showrooms
• Warehouses and distribution centers
• Other large commercial and industrial projects

4: It is Simpler to Build Steel Frame Buildings

Prefabricated steel components make a prefab metal building kit very easy to erect. 

No steel work is left to the construction site, everything arrives cut, welded, shaped, drilled, painted, and marked. After the offside fabrication each part is clearly marked and delivered ready to assemble without further processing.

5: Fast Fabrication and Quick Delivery

Thanks to developments in machining technology, steel parts are all fabricated with state of the art CNC machines providing quick lead times and high quality control.

Tekmetsan optimizes its building design to provide fast and safe erection works, eliminating possible risks and threats beforehand.

6: Sustainable Buildings

Steel buildings also outperform other frame type building in terms of sustainability as well.

When you build steel frame structures, they last decades longer than other types of buildings. Steel framed buildings have longer lifetime, require less maintenance and have a value even when its lifetime is over. 

7: Green Buildings with steel

Steel is also an eco-friendly material, and its 100% recyclable.

No matter how many times steel is recycled, it remains just as strong as it was in its first time.

How to select the right paint for steel?

How to select the right paint for steel?

Selecting the correct paint system for protection against corrosion assures that the most economical and best technical solution is achieved.

A weak paint system might be cheaper at first but additional maintenance cost in the lifetime of the building might boost the overall cost. On the other hand an excess of paint for a very low corrosion environment will be a mismanagement of the project budget.

Identifying the corrosion category of the environment is the most important factor to consider before selecting a protective coating.

When selecting a paint system it is vitally important to define the conditions in which the structure, facility or installation is to operate. To establish the effect of environmental corrosivity, the following factors must be taken into account:

• humidity and temperature (service temperature and temperature gradients)
• the presence of UV radiation
• chemical exposure (e.g. specific exposure in industrial plants)
• mechanical damage (impact, abrasion etc)

The nature of the environment and the corrosive contributing conditions will have an effect on:

• the type of paint used for protection
• the total thickness of a paint system
• the surface preparation required
• minimum and maximum recoating intervals
Corrosion Categories

ISO 12944 distinguishes 6 basic atmospheric corrosion categories:

C1

Very Low

C2

Low

C3

Medium

C4

High

C5

Very High

C6

Extreme

The characteristics of the above categories are as follows;

For every steel structure project, we set the relevant corrosion category together with our clients and determine the paint system according this category.

Tekmetsan offers mainly 4 types of paint coating
1.Alkyd Coatings

Alkyd paints are the modern descendant of oil paints. Instead of pigment suspended in oil, alkyd paints are typically formed by an alkyd resin dissolved in a thinner. These one-component primers are easy to apply and economical but offer limited

protection against rust in the long run. For low corrosive environments, these paints can be used for budget purposes.

2. Epoxy Coatings

Epoxy coatings are typically comprised of an epoxy base and a curing agent. A wide variety of coating properties can be achieved by manipulating either of these components: 

Epoxy polyamide coatings offer great moisture resistance, epoxy mastic coatings offer exceptional film thickness and phenolic epoxy coatings offer good chemical resistance. 

And due to this versatility, you’ll find epoxies used as a primer, intermediate coat or even a topcoat depending on the needs of the application.

Advantages
• Abrasion resistant
• Chemical resistant
• Good performance when submerged
• Can easily build film thickness for enhanced abrasion resistance
• Can be formulated to exhibit a wide variety of favorable coating properties


Disadvantages
• Chalks when exposed to UV light
• Low flexibility

3. Polyurethane Coatings

Polyurethane coatings are widely used —often as a topcoat— in applications where durability and abrasion resistance are key considerations. 

Most often, polyurethanes are chosen as the topcoat of a total protective coating system. For example, polyurethane might be applied as a topcoat above a zinc-rich primer and epoxy intermediate coat. 

Polyurethanes are versatile enough to be formulated to handle a wide variety of service environments.

Advantages
• Abrasion resistant
• High gloss and color retention
• Aliphatic polyurethanes perform well against weathering and UV light
• Aromatics perform well when submerged
• Low VOC formulations available

Disadvantages
• Contains isocyanate (-NCO) ,a harmful carcinogen
• Skilled workers and protective equipment are necessary for application
• Higher priced than epoxies
4. Zinc rich Coatings

As a generic coating type, zinc-rich coatings refer to organic or inorganic coatings with high loadings of zinc dust. 

The zinc provides galvanic protection of the steel surface, meaning that it will corrode instead of the steel beneath it. 

As the zinc-rich coating corrodes it forms a barrier between the steel and its environment

Zinc-rich primers will often be applied as part of a two-coat (zinc-rich primer, polysiloxane topcoat) or three-coat (zinc-rich primer, epoxy intermediate coat, polyurethane topcoat) system. 

Advantages
•     Provides both galvanic and barrier protection to steel
•     Abrasion resistant
•     High level of durability

Disadvantages
•     Must be top coated in many applications
•     Both inorganic and organic variations
have low resistance to acid and alkali
Conclusion

The prevailing service environment —along with factors such as cost, accessibility of the asset, expected labour costs and desired service life of the coating system— will define which coating system is best-suited for your application.

Coating selection happens on a case by case basis, and we can evaluate the specific needs of your application, offering several systems that could work based on our decades of experience in the industry.

Contact our team to get more information about the coating options of your metal building project.

Time saving benefits of working with Tekmetsan

Time saving benefits of working with Tekmetsan 

Time saving is essential for commercial builders. Every additional hour of construction raises their total project costs.

Tekmetsan optimizes the steel design for a quick, easy and safe erection process.

Metal Building Experts

Tekmetsan’s specialists bring years of hands-on metal building construction experience to the table. They can offer you valuable advice on streamlining and improving your construction project. Their expertise helps bring your project in on time and budget.

Lightning Fast Design/Engineering System

State-of-the-art steel engineering software dramatically shrinks design time for Tekmetsan’s prefab metal structures.
In addition, our three-dimensional structural analysis programs ensure the integrity of your steel building design. And as an added time saver, today’s computer-aided-design software quickly generates detailed fabrication drawings. These drawings dramatically increase the speed and accuracy of manufacturing your building.

Quicker Delivery
All our steel structure orders ship directly from our factory in Turkey to your job site. Our factory is located very close to the container port which will save time and slash your freight costs, too.

How to save money on a steel building?

How to save money on a steel building?

Buying a cheaply manufactured metal building will save you a few dollars in the beginning but you might regret when you see what you received at the end

A well-made steel building not only provides decades of useful service but also enhances the market value of your property.

However, even with a good product from a reputable vendor, there are some ways to reduce your metal building construction cost.

1. Identify what you are looking for

It is essential to know what you are looking for prior to placing your order.

You should be sure about the dimensions and features of your building. Adding costly features or going for a bigger space than you need will drive up your construction budget.

Keep unnecessary features to a minimum. It saves money, time.

Asking for changes in your building after the order may cause delays and probably additional cost. 

2. Choose Options for Pre-engineered Metal Buildings Wisely

TEKMETSAN Steel Building Systems offers great options to customize and accessorize your prefab metal building.

TEKMETSAN steel building options and upgrades include:

• Gutters
• Sandwich panels
• Partitions and walls
• Mezzanine systems
• Overhangs, eave extensions, and canopies.
• Crane Runways
• Door openings
• Skylights and wall lights

Determine which options you really need— and which ones you do not. Eliminating unnecessary features moderates your metal building costs.

Evaluate which options you need and you won’t. You can always consult our team in prioritizing your needs whilst staying in you budget.

3. Planning for future expansion

Plan your future expansion today and reap the benefits tomorrow.

Prefab metal buildings are simple and easy to expand. Let us know in what direction you might expand your building and we will customize your building according to your future needs.

Locate your building in your plot considering your future expansion plans.

If you are tight on building space you can always consider increasing building height and accommodating mezzanine floors inside your building. Majority of our clients locate their offices in mezzanines in order to increase the usable space on the ground floor. 

4. Construction Team Management

Construction is a multi-party business which includes architects, local building officials, ground working contractor, foundation contractor, building fabricator, erection team, mechanical contractor and so on. 

If you are not planning to hand over all the responsible to a general contractor, it is your task to manage and check the proper communication and interaction between these parties. If you are working with a general contractor still you should be setting clear objectives for your general contractor.

5. Time management and planning

Like other type of building constructions, metal building construction consists of consecutive works of different disciplines and requires adequate planning and time management skills. 

For example scheduling rental equipment too soon or too late may incur additional burden into your budget. Moreover, if you rent a crane that is too big or too small for your building, you waste both time and money.

6. Skilled Crew

If you are using a professional erection team, they will arrange their tools and crew, however, if plan to erect your building by yourself, you need to find skilled workforce who have a general understanding of metal building assembly preferable some prior experience.

All the building materials provided by TEKMETSAN are clearly marked with part codes and you will receive assembly drawings showing the place of all parts on the building.

You can always consult TEKMETSAN specialist for suggestions on how big a crew you will need for your specific project.

Conclusion:

Check the details and consult Tekmetsan in order to stay in your budget.

Steel Frame Members

Steel Frame Members

In a steel framed building system, load-bearing and load distribution functions are ensured by installing a main frame consisting of beams and columns.

Columns

The main purpose of the columns is to transfer the vertical loads to the foundations. However a part of the horizontal actions (wind action) is also transferred through the columns.
In multi-storey buildings, the columns are heavily compressed and they are designed for buckling

Variable profile sections can deliver a certain architectural dynamism to the design of these columns.
Formed from standard sections or plates, these columns have as their main characteristic variable lengthwise dimensions which can optimize their structural function.

Beams

Beams spread the vertical loads and are mainly subject to bending. The beam section must therefore present sufficient stiffness and strength in the vertical plane.

There are many different types of beam, as shown in the below table. Amongst these, composite beams are particularly well suited to multi-storey buildings. 

When combined with steel, the concrete works in compression and the steel (mainly) in tension: the outcome is a system that offers good mechanical performance, both in terms of resistance and stiffness.

 

Bracings

A bracing system is a secondary but essential part of a steel structure. A bracing system serves to stabilize the main girders during construction, to contribute to the distribution of load effects and to provide restraint to compression flanges or chords where they would otherwise be free to buckle laterally.

In order to avoid bracing between the beams, it is possible to design rigid-jointed continuous frames. Multi-storey buildings with a load-bearing structure formed of rigid frames
often require an increase in the column section and sometimes in the beam
section.
Since ensuring stability by frame action is less economical than by bracing, a
combination of the two systems can provide an efficient and balanced solution.
It is possible to have frames in one direction and to use bracing for stability in
the perpendicular direction.

Custom Metal Frame Building for your specifications

Custom Metal Frame Building for your specifications

Tekmetsan custom metal buildings are affordable, simple to erect, cost-effective to operate, strong, reliable, and very versatile.

Tekmetsan’s Custom Metal Buildings Offer Amazingly Flexible Designs

With today’s advanced structural steel computer programs, a Tekmetsan frame building is quick and economical to design. You just order the building size that best fits your needs and budget and then let us take care of the rest.

In a Tekmetsan portal frame steel building, columns are typically spaced 6 meters apart.

Our clear span buildings range from 4 meters to 50 meters in width. Adding a single centre column in each frame allows structures as wide as 300 meters.

Figure 1 Clear Span Buildings

Only steel is strong enough to handle the loads for such massive dimensions.
Our pre-engineered metal buildings have no length constraints.  And all our structural steel buildings extend easily for later expansion.
A Tekmetsan metal framed structure can also be up to 12 meters or more in height.
Also, all Tekmetsan metal frame buildings work on any foundation system, including perimeter footing, pier-and beam, and concrete slab.

 

Custom Metal Buildings with Remarkably Precise Fabrication

Every Tekmetsan prefab steel frame building is cut, welded, and drilled precisely to exacting industry standards.  Tolerances are tight.

When completed, fabricators mark each part for easy identification on the job site.

A Tekmetsan Steel Frame Building Provides Adaptable Floor Plans

Since the Tekmetsan steel framing is completely self-supporting, you will enjoy complete freedom for your interior layout.
Our prefab metal buildings also make remodelling a snap. Change wall locations and remodel as you need, without worrying about load-bearing walls.

Exterior Options with Your Tekmetsan Metal Framed Building

Today’s metal buildings do not look like the old tin barns of past.  In fact, there are no limits to the exterior looks available with a Tekmetsan steel building system.

Complete your Tekmetsan metal framed structure with brick, colourful steel panels, decorative block, aluminium panel, glass, stone, wood— or in any combination of these materials.

In addition, you may customize your metal frame building with gutters, energy-saving insulation, canopies and mezzanines, overhangs, parapets, skylights, vents, wall lights, and sturdy entry and overhead doors.

 

The Countless Uses for Tekmetsan Prefab Metal Buildings

You will find there is a Tekmetsan metal building solution for almost any application. In fact, buyers find that Tekmetsan’s steel building systems adapt perfectly for every use imaginable. For example:
• Helicopter hangars and shade structures
• Automotive, mechanic, and welding shops
• Barns, livestock shades, stables, sheds
• Commercial structures
• Distribution centres and warehouses
• Equestrian riding arenas
• Gymnasiums, sports and recreational centres
• Industrial and manufacturing operations
• Office buildings
• Outdoor pavilions
• Residential storage, RVs and boat garages, multi-purpose garages, and workshops
• Restaurants
• Self-storage operations
• Stores and other retail businesses
• Vehicle dealerships and showrooms
Conclusion
Tekmetsan offers the most versatile metal buildings in the industry today.

Steel Warehouses

Steel Warehouses (Halls)

In the last decades, steel frames became the predominant structural frame for the new warehouse projects all around the world.

The main reasons why warehouses are made of steel structure.

• Clear Span: Most logistics centres, distribution centres, and warehouse buildings require uninterrupted space to store the wares. Steel frame enables to go up to 50 meters without any interior columns which makes it ideal for the contractors. Also the space between the consecutive columns can go up to 12 meters.

• Wide Structures: TEKMETSAN prefab steel buildings do not have a width limit with additional columns.

• Limitless Length: Our buildings do not have any length limitation

• Flexible Space: With clear span designs, the building’s interior easily adapts to sectioning as inventory changes.

• Building Height: TEKMETSAN offers standard steel buildings up to 8 meters height. We offer bespoke solutions for buildings more than 8 meters and multi-floor buildings. Whatever height is required, steel offers great flexibility and cost advantage compared to concrete and timber structures.

• Low Material Costs:  Prefab warehouses have low cost per square meter compared to other forms of construction making it the ideal choice for the builders.

• Fast Construction: Steel’s extraordinary strength means it is possible to construct a highly stable structure with few pieces.  Every piece of the framing is factory-built to exact specifications under strict quality control procedures.  Parts arrive at the site clearly marked and ready to assemble with special connection details. The ready fabricated parts are very easy to be bolted to form the structure in a very short time. 

• Minimal Maintenance: A steel warehouse building needs little upkeep.

• Easy Modification: Steel buildings are incredibly versatile— inside and out. Any extension and modification to the building is very easy compared to the concrete or timber buildings. A selection of wide options are available for the exterior finishing such as insulated panels, aluminium panels, composite panels, glass, brick, stone or etc.

• Durability: TEKMETSAN steel buildings retain their beauty and value year after year. A well painted steel system will last long without any corrosion or rust.

• Environment Friendly: Steel is high recyclable material with very low carbon footprint.

Conclusion

TEKMETSAN not only produces steel warehouses but also offers free consultancy services to configure the ideal building for your budget.

Steel Price Fluctuations

Steel Price Fluctuations

It’s no secret that construction costs are on the rise, with the upswing in the global economy, an increase in the number of building projects, and an ever increasing global market, there is a direct correlation between the above mentioned factors and supply vs. demand. 

Globally, there has been a decrease in the availability of raw materials due to not only demand, but also the decreased output capabilities of some major suppliers.

How does all this affect your building project?

• In the past, price increases were most often forecast with ample time for owners to make smart decisions in advance on when and how to move forward with their projects, as of lately the volatile market is experiencing literally overnight price updates that makes it complicated for decision makers to anticipate this as the new normal and be ready to act in order to protect their budget. 

A 10% increase in raw steel prices on a $100,000.00 project is and additional $10,000.00 immediate cost. As your steel supplier, we do everything in our power to assess the markets and communicate closely with our factories to stay ahead of the pricing curve, and we always work with our clients to minimize the risk to your bottom line with timely information.

• The size and design of your project is obviously another key factor affected by price increases. A project that initially uses 150 tons of steel may be a candidate for redesign with critical thinking (value engineering) that allows for a deduction in overall steel while maintaining the desired footprint and structural integrity. Every one of our structures goes through rigorous design process that allows for maximum efficiency that translates into cost savings for our clients.

• Price increases on steel can have a dramatic effect on funding, especially for pending projects about to begin. Most lending institutions insist on the upfront costs to be identified, and it is often an additional negotiation with the financing institution when the planned budget increases, another reason to make sure order of your project is placed with a fixed price right after funding and deposits are secured.

• The price fluctuations of steel also affects the price of the cladding & roofing materials and the accessories of the metal buildings. Roofing and cladding sheets and insulated panels are also made of steel, therefore, the price increase in the steel primarily affects the cladding material costs.

Conclusion

Price fluctuations are the “new normal” in today’s economic times, at least for the foreseeable future. With that said, building with steel is, and will always be the best choice for commercial construction in both time and money. With a proper planning, a good understanding the markets, along with an experienced supplier like Tekmetsan, you can manage all the risks and deliver a success story.

We work hard for our clients to achieve success in every project we are a part of.