The Complete Solution

Sigmat 4 Step Process

Design, Manufacture, Assemble, Install

 A complete solution from initial design through to on-site installation of LGSF load-bearing and SFS non load-bearing panelised frames.

1 Design

Our in-house building Designers and Structural Engineers utilise Tekla BIM software to design the appropriate and most efficient building superstructures that are EC3 compliant. Each solution is rendered via Tekla into a 3D, BIM ready model.

55

Designers and Detailers

18

Structural Engineers

5

Regional Offices

1

Culture

We can take your design and virtually test if it really is the optimal solution or we can take a blank canvass and design the optimised solution for you. The earlier you engage with our structural design team when you have a project in mind, the greater the opportunity to enhance a rapid return on your investment.

See how we halved the time on site!

Read our case study

Good design is also cost effective. It considers the many ways money can be saved as well as the structural integrity. For instance, via our design expertise we have created many unique, patented sections and profiles which have a direct benefit to the build speed and finished frame quality of our onsite installation teams.

You can also be certain that early certification for statutory approvals is achieved as part of our process.

2 Manufacture

Once the design is approved, design specifications from Tekla are automatically transferred directly to our cold rollforming mills, ensuring absolute accuracy from design to manufacturing of every cold rolled component section and profile. Hot rolled fabricated panel strengthening components are manufactured in parallel ready for final assembly. Each component is barcoded and moves to the panel assembly area where it is assembled into finished panels.

Roll forming

Our roll forming mills manufacture our patented range of Light Gauge Steel Framing Systems. The mill is fitted with fully automated data control systems to receive the numerical manufacturing data direct from our 3-D CAD modelling software in pre-determined phases. A unique reference mark is clearly printed on each component we produce.

The tight corner radii ensure we achieve full contact end bearing for our studs, which are manufactured to exact lengths and piercing tolerances.

All SIGMAT components are roll-formed in our factory from galvanised steel coils which are pre-slit to the required profile girth. All Sigmat profile sections are manufactured using hot dipped galvanised steel to (BSEN 10143:2006) in grades from S280 and S450, as required. They have a Z275 coating and are supplied self-finished.

Panel Assembly

Following profile manufacture into individual panel bundles, the profiles and hot rolled elements are transferred to the assembly bays. They are then pre-assembled in jigs in our factory to form storey-height panels up to 7.5m in length.

All internal and external wall panels are assembled in a vertical orientation in jigs (including boarding/insulation to the external panels as required). These are placed on rolling conveyor lines, eliminating the need to handle the panels until they are complete and quality checked. At this point they are loaded on to our transport for delivery to site.

All panels are assembled using our unique recess boss and bolt system in close tolerance holes with locking nuts. Panels are assembled in accordance with the panel assembly drawings and are individually stamped with a unique bar code to allow tracking through the entire process, including installation on site.

All sheathing and insulation boards are pre-cut to a material list schedule provided from the 3-D CAD model. When hot rolled steel elements are required in the panel they are pre-fabricated for inclusion into the panel assembly process.

Fabrication Services

We fabricate a full range of additional structural steel elements to offer our clients the complete structural envelope from one reliable source.

We manufacture a variety of hot rolled steel elements, including steel stairs and balcony steel work. These are shot blasted to Sa2.5 standard and coated with primer paint or a hot dip galvanised finish where required.

When feasible, integral posts and lintels are included in our off-site panel assembly process. Beams and other major elements will be delivered to site with the wall panels for fitting on-site.

When a podium structure is required we offer a fully integrated design and construct package with beams positioned under all load bearing walls.

We maintain strict in-house quality control and co-ordinate the fabrication of light gauge and hot rolled elements to ensure that everything delivered to site is compatible and simple to install.

Scale and speed of supply

We provide a seamless process from plan and assembly drawings to site-ready panels. Our offsite capacity enables multiple components and frames to be manufactured and assembled simultaneously. This efficiency is aided by our in-house logistics services which plan ahead for delivery and on-site installation.

A complete solution

External panels are manufactured to include pre-formed door and window openings. They are normally boarded on the external face with a suitable sheathing board or foil-faced insulation and stainless steel brick tie channels, depending on the façade finish required. This helps to provide a dry envelope construction allowing rapid commencement of internal trades.

The unique Sigmat load bearing stud profiles use a double lip configuration, which together with a web stiffener rib, significantly increases the axial load capacity over that of a similar traditional 'C' section of a similar weight per metre.

Our unique single-piece ‘Top Hat’ Wall Head member has removed the need for a 2 or 3 member solution. It reduces component manufacture, panel assembly and on-site installation time. In addition, it provides improved temporary weathering during construction, allowing the earlier introduction of follow on trades.

Unlike many of our competitors Sigmat is developing and improving the whole structural frame solution by embracing buildability, increasing the speed of construction and interfacing with follow-on trades.

3 Assemble

Cold rolled components combine with fabricated HRS sections and are assembled in-house into storey height panels, typically 3m to 8m in size. External panels receive an A1 fire-rated 12mm Y-wall sheathing board to provide water and fire protection. Depending on client requirements, additional insultation and support channels are installed at this time. Each panel receives a unique panel assembly number ready for its timed slot in the on-site install process.

380000

m2 panel capacity annually

3

Production Lines

12000

m2 manufacturing facility

18200

Panels assembled annually

4 Install

Careful planning and coordination ensures that the Sigmat programme dovetails closely with the full project build. Our on-site teams have experience on more than 300 schemes and will work closely to ensure project prelim savings offer the greatest advantage in cost and build time.

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