Brookbanks Podcast #24: Light Gauge Steel Design
As the construction industry continues to look for efficient, adaptable and sustainable building solutions, light gauge steel is becoming an increasingly valuable option across a wide range of projects. From vertical extensions and low-rise structural frames to internal partitions, risers and specialist fire barrier systems, its versatility makes it a material worth considering early in the design process.
In the latest episode of the Brookbanks Podcast, Ewan Wise, Structural Engineering Director at Brookbanks, sat down with James Arber, Project Engineer, to discuss what light gauge steel is, where it can be used, and how Brookbanks can support clients and project teams from early concept through to detailed design and coordination.
What is light gauge steel?
Light gauge steel, often referred to as LGS, is a cold formed steel product made from thin structural metal sections shaped at room temperature. These sections are commonly formed into C-sections, tracks or angles, with typical thicknesses ranging from around 0.9 mm to 3 mm. This makes the material far thinner and lighter than conventional hot rolled steelwork, while still offering significant structural capability in the right applications.
Throughout the discussion, James explains how this difference in material form changes the way engineers approach design. Because light gauge steel sections are thin, local buckling of webs and flanges becomes an important consideration. Rather than relying on the same published properties associated with hot rolled steel sections, engineers work with effective section properties in line with cold formed and thin-walled steel design guidance.
Where can LGS be used?
Light gauge steel can be used across a wide range of building elements, from infill and non-structural partitions to loadbearing walls, floors, roof structures and trussed systems. In certain circumstances, it can also form the main structural frame for low-rise buildings, particularly where projects benefit from repetition, shorter spans and regular loadbearing wall layouts.
One of the key messages from the podcast is that light gauge steel is highly adaptable, but it is not a one-size-fits-all solution. James explains around four storeys is a sensible upper range for purely light gauge steel construction, with taller or more heavily loaded structures often requiring traditional materials in selected areas or at lower levels.
Why choose light gauge steel?
Ewan and James discuss how light gauge steel can offer real advantages when weight, speed and coordination are key project drivers. Compared with timber, it provides greater structural capacity for many comparable applications while avoiding issues such as warping, twisting or shrinkage. Compared with hot rolled steel, it can offer a much lighter solution, which is particularly valuable for vertical extensions to existing buildings.
The ability to fabricate panels offsite also brings benefits for quality control, logistics and programme. On constrained sites, pre-fabricated wall panels can be easier to transport and lift into position than long sections of hot rolled steel. With less cutting and adjustment required on site, light gauge steel can also help reduce waste and support a more controlled construction process.
What are the challenges?
As with any construction method, successful use of light gauge steel relies on choosing the right application and coordinating the detail early. Because many systems are fabricated offsite, dimensions and interfaces need to be highly accurate. Installation also requires specialist contractors, tools and fixings, rather than the flexibility associated with more traditional site-based construction methods.
Projects also need to account for how light gauge steel connects with other materials, including concrete, hot rolled steel and traditional ground-floor construction. Brookbanks’ experience as both lead structural engineer and specialist designer helps project teams understand these interfaces, transmit loads effectively and coordinate the wider building design.
Project examples and specialist applications
During the podcast, James shares examples of how light gauge steel can be used in practice. These include vertical extensions, bespoke trussed portal frame solutions and fire barrier systems within risers and service zones. These examples demonstrate how LGS can perform not only as a primary structural system in suitable buildings, but also as a secondary system designed to resist actions such as self-weight, wind loading, roof loading or accidental loads.
When should light gauge steel be considered?
The earlier light gauge steel is considered, the greater the opportunity to assess whether it is the right solution. Early involvement allows the design team to compare materials, understand cost and programme implications, coordinate specialist fabricators and installers, and shape the building design around the strengths of the system.
For clients and design teams exploring lightweight, efficient and sustainable methods of construction, light gauge steel offers a flexible option with a wide range of potential applications. With the right expertise involved from the outset, it can provide a practical and coordinated route from concept to construction.
Listen to the Podcast
Listen to the full episode of the Brookbanks Podcast to hear Ewan and James explore the practical applications, benefits and design considerations of light gauge steel in more detail, and discover how early specialist input can help unlock the right structural solution for your next project.