From pixel to portal: How to rapid build a 1,000m2 structure with X-CALIBR™
In our earlier project story, we looked at how this 1000 m² portal structure was erected in Tokoroa in just four hours using our X-CALIBR™ Roll-formed Structural System.
In this follow-up article, we trace the full end-to-end process from digital design to completed construction, and show how smart planning, roll‑formed precision, and a lean site crew came together to make that four‑hour lift possible.
The requirement
To help Tokoroa grow one local developer had big dreams for the town, literally: a large portal structure over 1000 m², built cost-effectively and designed tough to meet the test of time. The only question was how fast could it be done?
That is where Central Steel Framing (CSF) and the X-CALIBR™ Roll-formed Structural System made all the difference.
The details
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Building dimensions: 44m long x 25m wide
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Knee height: 5.4m
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Portal installation time: Just over 4 hours
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Products used: X-CALIBR™ rafters, columns, purlins, girts
How Central Steel Framing delivered
This project demonstrates perfectly what can be achieved when digital planning, precise prefabrication, and clean installation all come together.
Design
To start the process, the CSF design team collaborated with the client to build the structure in a digital environment using 3D CAD software.
Building digital first gave the client full control over their project. They could explore every detail to the last bolt and iterate at pace while factoring costs at every point.
Thanks to the precise nature of light gauge steel and the seamless integration with the X-CALIBR™ technology, the efficiencies of this digital design only accelerated from there.
Manufacturing
With final designs loaded into CSF’s roll-forming machines, all the necessary rafters, columns, purlins, and girts were manufactured in just six days.
X-CALIBR™ is a streamlined roll-forming process that reduces steel handling in production by 66% compared with hot-rolling. First, steel members are precisely manufactured with 0.5mm accuracy and holes pre-drilled. These are securely connected using CSF’s IP rivet system to form the structurally strong, made-to-measure steel sections needed for wide-span portal construction.
Compared with the 21 different steps involved in manufacturing structural steel the traditional way, the X-CALIBR™ system involves just six steps. No sandblasting, painting or welding.
Installation
With its exceptional strength-to-weight ratio, transportation is easy and minimal heavy lifting equipment is required. The roll-formed sections are simply positioned, prepared, and lifted into place using a crane and access platform, allowing a small crew to align and secure them into position.
The outcome? A structurally sound, made-to-last portal construction, with rafters, columns, purlins and girts erected in just 4 hours; without the unnecessary costs, extra labour, inconvenience and onsite waste of hot-rolled construction.
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