When delivering heavy‑duty lifting solutions, precision engineering and expert installation are essential. This project — completed with AMS Constructions at Wendy’s Bayswater — showcases how Light Gauge Steel (LGS) systems can be engineered to handle extreme loads while maintaining accuracy, safety, and efficiency on site.

High‑Strength Light Gauge Steel Design: Engineered for an 8‑Tonne Load

Both lift modules were designed using Light Gauge Steel trusses engineered to support an 8‑tonne design load. Early structural planning allowed our team to develop four purpose‑built lifting trusses capable of distributing weight safely and maintaining stability throughout the lift.

To achieve this performance, the LGS trusses incorporated:

• Additional scabs for reinforced strength
• Increased screw connections to manage high‑stress zones
• Detailed engineering to meet lifting and structural compliance standards

These enhancements ensure each light gauge steel truss performs reliably during lifting, positioning, and final installation.

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Scab Reinforcement: Critical Strengthening for Light Gauge Steel Trusses

A key feature of the design is the use of scab reinforcement — added steel plates that strengthen high‑stress regions of the truss. In Light Gauge Steel construction, scabs increase local stiffness and thickness, allowing the structure to:

• Distribute forces more evenly
• Reduce deformation and connection failure
• Support additional screw fixings for improved load transfer

This reinforcement ensures each LGS truss maintains structural integrity throughout the lift and installation process.

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Module 1: Heavy, Irregular, and Complex to Install

The first module weighed nearly 6 tonnes and featured an irregular geometry, making the installation particularly challenging. Precision was essential during the lowering and alignment phase.

Successful installation required:

• Rigorous lift planning
• Specialised rigging adjustments
• Close coordination between engineers, crane operators, and installation crews

Detailing Insights: Coordinating Light Gauge Steel Design

Throughout the design phase, our detailing team worked closely with engineers and consultants to manage design changes, maintain buildable geometry, and ensure accurate load paths.

Key detailing considerations included:

• Aligning the LGS frame with architectural and mechanical requirements
• Refining lift methodology to reduce rigging complexity
• Ensuring constructability across all stages of the project

Originally, the drive‑thru beams were planned to be lifted with the trusses, but the method was optimised to lift only the trusses — improving control and reducing risk.

Design Improvements for Efficient Fabrication & Installation

To streamline both fabrication and on‑site installation, several optimisations were introduced:

• Modularising long LGS lifting trusses into 200 kg sections for easier handling
• Optimising truss profiles to reduce weight (targeting 80 kg per truss)
• Standardising truss heights on irregular modules to simplify alignment

These refinements improved efficiency without compromising structural performance.

Engineering Challenges: Cranked Beams & Canopy Integration

The oversized drive‑through canopy required cranked beams, adding complexity to the detailing process. Determining whether these components should be lifted with the trusses required careful coordination to avoid clashes and ensure safe, buildable outcomes.

Coordination Across All Project Stages

Design Stage

• Close collaboration with project managers and consultants
• Ensuring the LGS frame aligned with architectural intent
• Managing critical mechanical interfaces

Installation Stage

• Rapid response to site queries
• Providing immediate solutions to maintain installation momentum
• Capturing feedback for continuous improvement

“This project was a great learning experience — the first of its kind I’ve detailed. The lessons gained will strengthen how I approach coordination, constructability, and standardisation on future modules.” — Su, Detailer

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Delivering Safe, Reliable Light Gauge Steel Lifting Solutions

From reinforced truss design to precise installation planning, this project demonstrates our commitment to delivering high‑performance Light Gauge Steel structures backed by engineering excellence and safe work practices.

For Light Gauge Steel framing, truss design, or modular lifting solutions, our team is ready to support your next project.