Behind the Scenes: How Major Industrial Shed Manufacturers Create Spaceframe Structures Using Metalkarma Spaceframes

When it comes to constructing large-scale industrial sheds, spaceframe technology has become a game changer. The ability to create massive, open, and flexible spaces with reduced material use and faster construction times has revolutionized the industry. But how do major industrial shed manufacturers actually create these high-performance spaceframe structures?

In this blog, we’re taking you behind the scenes to explore the intricate process of designing, engineering, and constructing spaceframe structures using Metalkarma spaceframes, a leader in this field. From initial design concepts to final installation, the journey of creating a spaceframe-based industrial shed is both an art and a science.

1. Understanding the Fundamentals of Spaceframe Technology

Before we dive into the specifics of the manufacturing process, it’s important to understand the fundamental concept behind spaceframe technology.

A spaceframe is a three-dimensional structural system made up of interconnected triangular or tetrahedral units. These units distribute loads evenly across the entire framework, creating a strong yet lightweight structure. By connecting multiple smaller elements into larger modular systems, spaceframes can span large areas without the need for intermediate columns or supports.

Metalkarma spaceframes utilize this technology to create industrial sheds that are not only structurally sound but also efficient, cost-effective, and adaptable to a variety of operational needs.

2. Design and Planning: Tailoring Spaceframes to Client Needs

Every industrial shed has unique requirements based on its purpose, location, and client specifications. The first step in creating a Metalkarma spaceframe structure is the design phase. This is where the collaboration between the client, architects, and Metalkarma engineers begins.

Custom Design Solutions

The design process starts with understanding the client’s needs—whether it’s for a large warehouse, manufacturing facility, or logistics center. Factors such as the required floor space, load-bearing capacity, ceiling height, and climate conditions (e.g., wind, snow loads) all play a role in determining the ideal design.

For example, in the case of a manufacturing facility, the design might prioritize wide, open spans to accommodate large machinery or heavy equipment. For a warehouse, maximizing vertical storage and optimizing interior layout might be the primary focus.

Metalkarma uses advanced Building Information Modeling (BIM) technology to create detailed digital models of the spaceframe structure. BIM allows engineers to visualize the entire building, optimize load distribution, and detect potential design issues before construction begins. This ensures that the final design is both efficient and cost-effective.

Optimizing Material Usage

One of the key advantages of spaceframe technology is its material efficiency. Unlike traditional steel frames that require large beams and columns, spaceframes use a lighter, yet stronger framework. In the design phase, engineers work to optimize material usage, ensuring the structure is as lean and sustainable as possible without sacrificing safety or durability.

3. Engineering: Creating the Blueprint for Success

Once the design is finalized, the spaceframe structure undergoes detailed engineering calculations. This step ensures that all components meet safety standards, structural integrity requirements, and local building codes.

Load Analysis

Spaceframe structures distribute loads in a way that minimizes stress on any single element. Metalkarma engineers perform finite element analysis (FEA), a computational technique used to simulate how each part of the spaceframe will react to various forces (e.g., wind, snow, seismic activity). This ensures that the structure will perform as expected under real-world conditions, especially for large industrial sheds that need to withstand heavy loads and environmental stresses.

Pre-Fabrication and Modular Components

Once the engineering calculations are completed, the next step is to create the individual spaceframe components. Metalkarma’s spaceframe structures are made up of pre-fabricated modules that are assembled on-site. These modules include trusses, joints, and nodes that interconnect to form a large, stable structure.

Pre-fabrication is one of the most efficient aspects of the spaceframe manufacturing process. By producing the individual components in a controlled factory environment, Metalkarma ensures high quality and precision while minimizing errors. This process also allows for faster construction, as all the parts arrive on-site ready to be assembled.

4. Manufacturing and Production: From Steel to Spaceframe Components

The next step in the creation of a Metalkarma spaceframe is the actual manufacturing of the structural elements. This involves sourcing high-quality materials—primarily steel or aluminum—and processing them into the required shapes and sizes.

Cutting and Shaping

Steel or aluminum components are cut, shaped, and welded into the specific parts required for the spaceframe system. Advanced CNC (Computer Numerical Control) machines ensure that each component is precisely manufactured to the specifications outlined in the design.

Coating and Finishing

Once the components are fabricated, they are treated with corrosion-resistant coatings. Depending on the location and environmental conditions of the industrial shed, these coatings may include galvanization, powder coating, or other protective finishes. This step extends the lifespan of the spaceframe structure, ensuring it can withstand harsh weather conditions, high humidity, or chemical exposure.

Quality Control

Metalkarma’s manufacturing facilities adhere to stringent quality control processes. Each component undergoes rigorous inspections to ensure that it meets both the design specifications and international standards. This process helps to prevent defects and ensures that the final structure will perform reliably over its lifespan.

5. Assembly: Putting It All Together

With all the components manufactured and pre-fabricated, the next step is the assembly and installation of the spaceframe structure on-site. This process is a collaborative effort involving skilled engineers, workers, and construction crews.

On-Site Assembly

Unlike traditional steel frame buildings that require complex on-site welding and fabrication, spaceframe structures are designed for quick and efficient assembly. The pre-fabricated modules are transported to the construction site and assembled with minimal disruption. Workers use cranes to lift the components into place, and the pieces are connected using bolts, welding, or interlocking joints.

The spaceframe’s modular design means that large sections of the shed can be assembled simultaneously, reducing overall construction time. The lack of internal columns and the efficiency of the structure allow for quick installation and immediate utilization of space.

Roofing and Cladding

Once the spaceframe structure is in place, the next step is to install the roof and exterior cladding. Depending on the client’s needs, Metalkarma can customize the roof type (e.g., flat, pitched) and use a variety of cladding materials, such as corrugated steel, insulated panels, or glass. The roof is often designed to be durable and energy-efficient, with proper insulation to regulate temperature and reduce energy consumption.

6. Final Inspections and Handover

Before the industrial shed is handed over to the client, it undergoes a series of final inspections to ensure it meets all safety and operational standards. Engineers check the structural integrity, insulation, electrical systems, and more. The final step is a quality check to ensure that all components fit together seamlessly and that the structure will function as intended.

Once everything passes inspection, the industrial shed is ready for occupancy, and the client can begin using the space for storage, production, or other operational needs.

7. Key Benefits of Building with Metalkarma Spaceframes

• Speed and Efficiency: The pre-fabricated, modular nature of spaceframe technology speeds up construction and minimizes on-site disruption, saving both time and labor costs.
• Cost-Effectiveness: With optimized material usage, reduced labor costs, and faster construction, Metalkarma spaceframes offer a more economical alternative to traditional steel frame buildings.
• Design Flexibility: Spaceframes allow for large, open spans with minimal internal columns, maximizing the usable space within the shed and offering flexibility for future expansions.
• Durability: The strength of spaceframe structures ensures they can handle heavy loads, extreme weather conditions, and wear and tear over the long term.
• Sustainability: The material efficiency and modular nature of spaceframe technology reduce waste and support more sustainable construction practices.

8. Conclusion: A Smarter Way to Build Industrial Sheds

Building massive industrial sheds with Metalkarma spaceframes is an intricate yet highly efficient process that combines advanced engineering, precision manufacturing, and innovative design. By optimizing material use, reducing construction time, and providing unmatched flexibility, Metalkarma spaceframes are transforming the way we build large-scale industrial structures.

Whether you’re constructing a warehouse, manufacturing facility, or distribution center, Metalkarma’s spaceframe technology offers the durability, cost-effectiveness, and speed that today’s businesses need to stay competitive.

Want to learn more about how Metalkarma spaceframes can revolutionize your next industrial shed project? Contact us today to discuss your needs and discover the future of industrial construction.