Where the Buck Stops with Metal Buildings

by Paul Deffenbaugh | 1 February 2022 12:00 am

In this debut column, I look at the deepest pitfall of them all: not having a single person or firm responsible for the overall performance of the building framed with MBS. Any structure beyond a simple storage shed bearing on rock will likely have custom-designed foundations, exterior and interior finishes, mechanical systems, doors, windows and insulation. These and many other building components are typically not included in the MBS. So, who, exactly, is in charge of coordinating and overseeing the design and construction of the entire building? Is it the general contractor? The metal building manufacturer? The erector? The owner? The insurance broker? Things tend to be done in one of two ways.

Who, exactly, is in charge of coordinating and overseeing the design and construction of the entire building? Is it the general contractor? The metal building manufacturer? The erector? The owner? The insurance broker?

The Right Way to Do It

As in conventional construction, the owner commissions the architect, who in turn engages a team of other design professionals including a structural engineer. The design team is responsible for specifying both the MBS and any building components not provided by the MBS manufacturer.

The team produces the construction documents that depict every aspect of the building with the design of the superstructure (the part of the structure located above grade) delegated to the metal building manufacturer. The design criteria for the MBS are included in the construction documents. The structural engineer on the design team serves as the structural engineer of record (SER), who seals the permit documents submitted to the local building department.

The SER specifies the structural criteria for the building, such as the design loading, column layout, whether the column bases are fixed or pinned, the deflection and stiffness criteria, purlin bracing, the type of the lateral-load resisting system, anticorrosive finishes, etc. The SER typically reviews the submittals (and design calculations, if specified) provided by the MBS manufacturer for conformance with the design intent. In my experience, there could be a number of iterations until the shop drawings are finally approved. The SER also typically designs the building foundations and anchor bolts.

The general contractor is then responsible for the execution of the project and for coordination among the subcontractors. Alternatively, there could be a design-build or some other arrangement that still has clear lines of responsibility.

Procuring the MBS without Involving a Design Team

Here, the owner of the proposed building goes directly to a builder, who then procures the MBS structure from a manufacturer. In many cases, there are also middlemen known as the building brokers. This procurement method opens up a huge pitfall for everyone involved because nobody might be in charge of specifying the items listed above. If an inexperienced owner believes that all metal buildings are the same and vary only by price, why not save the architect’s fee?

Yet the level of MBS performance varies quite a bit, even among the buildings certified as conforming to the building code. (See some examples below.) To illustrate, do you go to a car dealer and ask for just a car? Or would you have some specific requirements in mind? You’d be disappointed if you buy the cheapest subcompact, but you really need to tow a heavy trailer.

It’s easy to understand the builders who go along with such owner’s fantasies. If the project walks through the door, would you be calling for some other cooks to help with the broth?

As with that car, when nobody specifies the level of MBS performance and serviceability in advance, the common result is that the manufacturer provides the cheapest structure possible. It conforms to code, but might prove unsatisfactory for the owner’s needs. Some of the issues are discussed in detail in my book, “Metal Building Systems: Design and Specifications.”

Even worse, an inexperienced owner might think that the metal structure provided by the builder is the entire building, and all other construction work is secondary. Getting the lowest price on the MBS becomes the goal. In reality, the MBS structure is just an empty shell, not the whole building. From my experience, the cost of an MBS as a percentage of the entire project’s cost is about the same as that of the superstructure in other types of construction—perhaps on the order of 12% to 15%. On some projects, the site work, concrete work, mechanical systems and electrical systems could each cost more than the MBS. The owner still has to procure the foundations, interior finishes, HVAC systems, sprinklers, etc., but without the benefit of a single firm coordinating the design of all these items with the design of the MBS.

It’s easy to understand the builders who go along with such owners’ fantasies. If the project walks through the door, would you be calling for some other cooks to help with the broth? Also, even some builders might think that the MBS manufacturer would serve as the SER. After all, the manufacturer produces a set of stamped erection shop drawings. However, a close look at those drawings would probably reveal a stamp clearly stating the opposite—that the manufacturer is responsible only for the metal superstructure and is not the SER for the entire project.

Why Is It So Important?

When a building component not included in the MBS is improperly specified or falls through the cracks, claims or litigation could follow. Without a single point of responsibility, at least on structural issues, almost everyone involved would be swept into a litigation dragnet. This might include the steel erector, the MBS manufacturer, the builder and its subs. Here are some examples from my experience when no SER or even an architect, were involved:

• The prospective building owner procured the MBS by contracting directly with a builder, who purchased the building from a manufacturer through the intermediaries. The building was located in a mountainous area, where the design snow load was not included in the building code’s maps. The MBS manufacturer contacted the local building official, who provided incorrect snow-loading data. The building later collapsed under a moderate amount of snow accumulation. While the building codes generally shield the building officials from liability in performance of their duties, the claims among the other parties dragged on for years. An experienced local structural engineer could have helped the owner avoid this problem.
• The owner of a tennis court framed with an MBS used the same direct procurement method. When one of the players got hurt by a sharp metal piece in the building, lengthy litigation ensued. Many efforts (and thus much money) were expended arguing whether the builder, manufacturer, steel erector or others were negligent. An architect would have specified the proper interior finishes, protecting the players.
• A church experienced extensive snow damage. The roof purlins got deformed, the ceiling tiles displaced and widespread roof leakage occurred. The MBS manufacturer was not aware of the plan to install a ceiling in the future. Again, litigation followed. An SER would specify not only the strength level, but also the deflection criteria for the purlins and help everyone sidestep this pitfall.

I will discuss some specific pitfalls in the upcoming columns, but I hope it’s already clear that having no design overseer of the project is a recipe for trouble. When a prospective owner directly approaches the builder to procure the metal building, the builder would be wise to insist that an experienced design team, or at least a structural engineer, be a part of the project.

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Alexander Newman, PE, is a Boston-based forensic structural consultant with more than 40 years of design and forensic experience. He specializes in controversies, claims and litigation involving metal building systems, and is the author of “Metal Building Systems: Design and Specifications,” third edition. (McGraw-Hill, 2015) and two other authoritative reference books. Contact him at newmanauthor.com[1].

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