Mgi infra (LGSF) TECHNICAL DOCUMENT

MGI CR MANUAL
LIGHTER STRONGER FASTER
1
Cold Form Building – Technical Specification,
Construction & Finishing Manual

MGI CR MANUAL
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

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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

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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

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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

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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.

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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

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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

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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.

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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

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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.

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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

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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.

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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

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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

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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

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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

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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

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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

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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

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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)

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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

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Fig 35. Water Closet Connection Detail -2
Fig 36. PVC Pipe Connection Detail-1

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Fig 37. PVC Pipe Connection Detail-2

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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

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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

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Fig 46. Door Jamb Section Detail
Fig 47. Timber Door Frame Detail

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Fig 48.Typical Aluminium extruded Jamb Profile detail
Fig 49.Shadowline door jamb detail

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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

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Fig 52.Steel Column covering detail

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Mgi infra (LGSF) TECHNICAL DOCUMENT