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Rondo conducted a 15-month investigation into imported steel wall and ceiling products. This involved six rounds of independent laboratory testing on steel products sourced from over five Australian suppliers importing from China.

Our investigation revealed several issues with these tested products, including non-compliance with Australian Standards and other requirements, poor quality, incorrect markings, and inadequate coating protection. These problems can compromise the safety, workmanship, and durability of buildings, especially in critical applications like ceilings and fire-rated walls.

Since steel systems are often concealed by plasterboard, it can be challenging to identify the specific steel products used. This report highlights the need to assess and verify the compliance, quality, and durability of steel components prior to construction.

KEY FINDINGS OF TESTED IMPORTED STEEL WALL & CEILING PRODUCTS:

Over the coming weeks we will be releasing findings from our investigation. These findings relate to the more than five suppliers that we investigated covering the following products: Steel Stud, Wall Track, Deflection Head Track, Furring Channel, Top Hat, and angles.

1.

 

Base Metal Thickness
  • Non-Compliance with AS/NZS 4600 Light Gauge Steel Design Standard
  • Incorrect Base Metal Thickness Markings

2.

SERIES 2 TBA

COMING SOON

3.

SERIES 3 TBA

 COMING SOON

4.

SERIES 4 TBA

 COMING SOON

 

1. BASE METAL THICKNESS

Our first findings release focuses on the steel product’s Base Metal Thickness (BMT) which refers to the thickness of the steel material before any coatings or treatments are applied. This measurement determines the strength, structural adequacy and suitability of the steel for specific applications.

 

Non-Compliance with AS/NZS 4600 Light Gauge Steel Design Standard

Non-Compliance with AS/NZS 4600 Light Gauge Steel Design Standard

Some imported wall and ceiling products that we investigated failed to meet AS/NZS 4600 standards, which require cold-formed steel to be at least 95% of the designed base metal thickness. Our testing and an importer’s own published test data revealed some imported steel wall and ceiling components ranged between 85% to 94% of their specified Base Metal Thickness (BMT).

Incorrect Base Metal Thickness Markings

Incorrect Base Metal Thickness Markings

Some imported steel products were labelled as 0.50 BMT, but our testing showed that the stud and track components were actually 0.46-0.47 BMT and the furring channels were 0.45-0.46 BMT. Additionally, one importer publishes a product catalogue which lists a base metal thickness for steel stud as 0.50 BMT and track as 0.55 BMT, however, the same importer's own test data reveals the true BMT to be 0.468 BMT and 0.484 BMT, respectively.

 

Non-Compliance with to AS/NZS 4600 Light Gauge Steel Design Standard

To comply with AS/NZS 4600, designers of cold-formed steel structures must adhere to the specifications outlined in clause 1.5.1.5 ‘Acceptance of Steels’ of the AS/NZS 4600, which requires that the uncoated minimum steel thickness at any point in the cold-formed product, as delivered to the job site, be at least 95% of the thickness used in its design.

Our investigation revealed a concerning issue with some of the tested imported steel products that were marked as 0.50 BMT but the steel studs had actual measurements ranging between 0.46- 0.47 BMT and furring channels 0.45-0.46 BMT—meaning the BMT was 92-94% and 90-92% respectively of the specified thickness. Furthermore, some steel tracks marked 0.55 BMT showed test results of only 0.47-0.48 BMT, with only 85-87% of the specified BMT.

Consequently, these components would be non-compliant if designers use 0.50 BMT or 0.55 BMT to calculate the load capacities of wall or ceiling systems. This is particularly troubling when it comes to safety-critical fire-rated walls, external walls and ceiling systems.

Test results of some of the wall and ceiling components we tested:

 

                            Product

 

Importer’s Specified BMT

 

Tested imported steel product BMT

 

AS/NZS 4600 requirement

 

Test result

  64mm Stud

0.50

0.46

95%

94%

  64mm Stud

0.55

0.47

95%

85%

  64mm Track

0.50

0.47

95%

94%

  64mm Track

0.55

0.47

95%

85%

  64mm Deflection Head Track

0.50

0.46

95%

92%

  64mm Deflection Head Track

0.55

0.51

95%

93%

  28mm Furring Channel

0.50

0.45

 95%

90%

 28mm Furring Channel 

0.50

0.46

95%

92%

 

Furthermore, a contractor received a Rondo Installation Guide from an importer’s reseller for installing some of the tested imported steel products. Rondo's technical literature is designed exclusively for use with Rondo products, as our engineers' calculations are based on detailed testing, tolerances, and performance specific to Rondo steel products, which significantly differ from those of the tested imported steel products. This situation highlights how using our technical data with non-Rondo products can lead to non-compliant design and installation outcomes as our wall heights and load tables have been developed using our specified BMT.

Base Metal Thickness Markings:

During our investigations, some of the imported steel products were marked as 0.50 BMT, yet our testing revealed that some stud and track components were instead 0.46-0.47 BMT and the furring channels were all 0.45-0.46 BMT.

Our investigation also found one importer’s product catalogue advertising steel stud as 0.50 BMT and track as 0.55 BMT, yet their own publicly available test data indicates the actual base metal thickness to be 0.468 BMT and 0.484 BMT, respectively. Customers might base their purchasing decisions on the advertised BMT figures, assuming they are getting stronger and more durable wall and ceiling components than they are.

Possible implications of reduced Base Metal Thickness (BMT):

Structural Integrity

Structural Integrity

Given the structural calculations are based on the labelled BMT, where the BMT is lower than specified this may impact the structural calculations causing them to be inaccurate. This discrepancy may jeopardize the safety and stability of walls and ceilings within the home.

number-2

Non-compliant Installation

As noted earlier in this report, installations using a product with less than 95% of the designed BMT do not comply with AS/NZS 4600 standards. This non-compliance may lead to legal and/or safety issues.

number-3

Incorrect Cost Comparisons:

Customers expect to pay for a certain quality and thickness of material. If the actual BMT is less than advertised and NCC tolerance (95% of specified thickness), customers are paying for a standard of product below their expectations, which may drive a misrepresented cost comparison.

number-4

Trust and Reputation

Discrepancies between the specified and actual BMT may erode trust among stakeholders. Failing to meet project specifications may have reputational damage of the involved companies and can impact future business opportunities.

Please note: The information presented in the Cutting Corners Campaign is based on Rondo’s investigation of imported steel products and is current as of 21st October 2024. This investigation involved six rounds of testing conducted at an independent laboratory on steel wall and ceiling products sourced from over five Australian suppliers importing from China. While Rondo has sought to ensure it investigated a broad sample size for the purposes of this campaign, the data and information in this article is not representative of every imported product in the Australian market. We encourage readers to conduct their own evaluation of steel products, including performance and code compliance, and not to rely on the information provided in this campaign when making purchasing decisions. If you have any questions, please contact us at rondo@rondo.com.au.

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