Have you ever wondered what goes into constructing those large metal buildings you see around industrial parks and farms? Custom steel buildings require extensive planning, design, and construction to bring them to life. From concept to completion, metal buildings are complex projects that demand precision and expertise.
In this blog post, we’ll walk through the overall process of building custom steel structures from start to finish. We’ll look at key steps like initial design, permitting, materials and fabrication, and final construction. Understanding the full workflow will help you appreciate the care and effort that quality metal building contractors devote to these specialized structures. Whether you’re curious about the construction process or looking to build your own steel building, read on for an insider’s overview!
An Overview of Custom Steel Structures
Before jumping into the construction process, let’s briefly overview some basics about custom steel buildings. Metal structures can serve many purposes, from barns and workshops to warehouses and commercial spaces. The “custom” designation simply means they are built to suit the client’s unique needs rather than mass-produced.
Custom Omaha Steel Buildings provide almost endless design flexibility compared to traditional construction. You can truly customize the structure’s size, layout, materials, and components. The primary framework consists of structural steel columns, beams, and cross-bracing engineered to required specifications. Various exterior wall and roofing materials attach securely to the interior steel skeleton.
Metal construction offers advantages like durability, energy-efficiency, low cost, and rapid construction. The modular design also allows for future expansion if needed. Custom steel buildings require specialized expertise to construct but make up for it by providing versatility and performance.
Explain The Process of Building Custom Steel Structures
Now, let’s walk through the key phases of bringing a custom steel building to life:
Initial Design and Approvals
- Client consultation to define requirements and budget
- Initial site evaluation and recommendations
- Preliminary building design including layouts and drawings
- Submittal to zoning for permits and code approvals
This first step is all about collaborating with the client to create a building design that meets their functional needs and preferences while complying with zoning limitations. The contractor’s experts can suggest ideas to maximize usable space, efficiency, and aesthetics within the budget. It’s an iterative process that concludes with the necessary jurisdiction approvals to break ground.
Fabrication and Delivery
- Finalization of build plans for fabrication shop
- Material procurement for frames, exterior, accessories, etc.
- Detailed fabrication offsite at shop facility
- Organization and delivery of all components to project site
With approvals in place, the next phase shifts to fabricating the many steel and metal components that will comprise the new structure. The contractor directs the fabrication shop which follows the approved engineering plans. Materials are carefully ordered including the steel framing along with sheathing, accessories, doors and windows, insulation, and all nuts and bolts.
The shop pre-cuts and pre-drills materials for streamlined assembly. Fabricated pieces are then organized and delivered in proper construction sequence to the awaited job site.
Foundation and Shell Construction
- Excavation and concrete work to build foundation
- Erection of structural steel frame with columns and rafters
- Connection of frame with bolts and welds
- Installation of exterior wall and roof sheathing
The hands-on building process begins by using the site plans to dig and pour a concrete foundation engineered to specifications. The trucked-in steel frame pieces then get bolted into place upon the cured slab. Following connection plans, the columns and rafters get aligned and welded with extreme care and precision.
The building “shell” takes shape as the exterior wall sheathing and roof panels get fastened to the skeleton to seal the structure. At this exciting point, an empty steel box stands fully enclosed and ready for interior finish work.
Interior Finishes and Accessories
- Finish floor installation
- Electrical and HVAC mechanicals
- Insulation and drywall attachment
- Doors/windows, final paint, accessories
While the structure now has its skin, the interior remains an empty canvas to transform into the intended space. Tradespeople collaborate to outfit the box with functionality and comforts. The flooring goes in first before the electricians and HVAC contractors run wiring, lighting, and climate control systems.
Insulation batts and drywall panels get layered over the steel walls and ceilings. The finishing touches come from adding doors/windows, final paint, and whatever specific accessories or equipment the building calls for. The contractor coordinates this choreography of various subcontractors to execute the interiors efficiently.
Inspection, Certification, and Turnover
- Final quality control walkthrough
- Building commission testing and approvals
- Obtain certificate of occupancy
- Formal client acceptance and owner turnove
Before the client takes ownership, the nearly complete structure undergoes careful inspection and testing. The contractor checks that all construction matches the specifications without visible flaws or deviations. Building systems then get formally commissioned to verify proper function and safety. With passed examinations and gateway approvals, the jurisdiction issues the essential certificate of occupancy.
The structure now enters the owner’s control to furnish and operate as intended! The contractor delivers all manuals, warranties, and documents for the client’s records. They walk through the finished product to highlight essential maintenance and emergency information before handing over the (metaphorical) keys.
The Advantages of Custom Steel Buildings
This multi-step workflow illustrates the care and effort behind building custom Omaha steel buildings. While certainly more complex than buying a storage shed at a home improvement store, commercial metal buildings offer many performance advantages:
1. Durability - Steel withstands exposure and wear much longer than wood or other materials before needing replacement. Proper maintenance preserves the structure for decades of use.
2. Adaptability - The interior space within the steel shell can transform to accommodate changing business purposes over time.
3. Energy Efficiency - Modern construction techniques like spray foam insulation allow metal buildings to achieve favorable thermal ratings for lower heating and cooling costs.
4. Cost Savings - The modular design, factory-based fabrication, and rapid on-site assembly lead to notable per-square-foot savings over other building methods.
5. Weather Resistance - Steel exteriors stand up well to wind, rain, snow, and storms - an advantage for structures in climates prone to extreme weather.
6. Customization - Steel construction bends easily to custom layouts, openings, and finishes to suit specialized applications compared to off-the-shelf models.
While steel buildings require careful planning and construction, they offer advantages that make the diligence worthwhile for many commercial and agricultural applications. The technical skills of an experienced metal contractor pay dividends when it comes to translating unique needs into durable and high-performing structures built to last.
Bottom Line
Constructing custom steel buildings involves a process that involves many moving parts. Engineering considerations and zoning limitations shape the early design phases. Offsite component fabrication must align closely with onsite assembly plans and sequences. Finishing the interior provides endless ways to customize the open space.
The entire workflow relies intimately on the contractor’s technical expertise across structural engineering, site development, and finishes/accessories. While complex buildings come with challenges, a quality steel contractor like Lacey Construction Inc. helps navigate the process efficiently by leveraging years of experience.
With some fundamentals under your belt, you can better understand the site prep, equipment, and labor needed to build metal structures tailored exactly to an owner’s specifications and operational requirements. The solutions and performance are possible with steel make it a go-to choice for aircraft hangars, barns, warehouses, distribution centres, repair garages, and more.
The next time you drive by an imposing commercial steel building, you’ll have a deeper appreciation for the strategic design and step-by-step construction underlying the framework that encloses and protects the activities happening within.