How Thick Should a Metal Stud Be?

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About the author: Adam Toth

Adam Toth owns Tag Frames, a Queensland-based firm that crafts steel house frames. Holding a QBCC licence, he is acknowledged for his specialisation in steel framing for homes, with a track record of numerous successful steel frame projects.

How Thick Should a Metal Stud Be?

Reading Time: 10 minutes and 5 seconds

steel house frames, steel wall frames, steel stud wall, metal stud wall, steel wall framing Queensland

I could never forget one of the first projects I took on.  We were building a small commercial office, and I was eager to keep costs low for the client. When it came time to choose the metal studs, I decided to go with the thinner option, figuring it would save us some money. That decision turned out to be a huge mistake, and boy did it cost us! 

Just months after we finished the project, the client reported that cracks started forming in the walls, and doors weren’t closing properly. The root of the problem? The metal studs weren’t thick enough to handle the load. I had to explain to the client what went wrong and it was a tough conversation (and an embarrassing one, too!). That mistake made me realise that choosing the right metal stud thickness is crucial for every project, big or small. Since then, I’ve approached every new build with one key lesson in mind: the right stud thickness can make or break the structure.

That was a costly lesson I learned the hard way. Let me tell you what I have learned so that you don’t have to experience what I have! 

 

Table of Contents

What happens when you choose the wrong metal stud thickness?

Here’s another lesson I learned the hard way. A few years ago, I was working on a large commercial project—a sleek, modern building designed to stand out in the city skyline. We made the same rookie mistake of opting for thinner metal studs for steel wall frames to save on costs. Everything looked great when we finished the build, but after the first storm season, the issues started creeping up. 

  • Structural issues: The thinner studs couldn’t handle the wind loads, causing sections of the wall to bow and shift.
  • Increased maintenance costs: We had to send teams back multiple times to repair the walls, costing us far more in labour and materials than we saved by choosing thinner studs.
  • Loss of client trust: The client wasn’t happy, and it impacted our relationship moving forward.

After that experience, I realised that every project, no matter how well-planned, comes with its own set of challenges. The key is learning from those mistakes and making sure you don’t repeat them. Metal stud thickness is not a detail to be taken lightly.

What are the standard thicknesses, and how do they apply to different projects?

Over the years, I’ve worked with a wide range of stud thicknesses, each suited to specific types of projects. Plus, according to the National Construction Code, here’s what I’ve found works best:

ThicknessProject TypeKey Insights
0.42mmResidential RoofingIdeal for lightweight roofing solutions in residential builds. Provides good protection, but ensure proper underlays are used for added durability.
0.55mmLight Commercial WallsBest for interior, non-structural walls in light commercial projects. Easy to work with, but doesn’t provide much load-bearing capacity.
0.9mmIndustrial ShedsA strong option for industrial sheds, offering both durability and support for larger spans without too much extra weight.

You know, I’ve figured out over the years that you can’t just copy-paste solutions from one job to the next. Every project’s got its own personality, if you will. What worked like a charm on one site might be a disaster waiting to happen on another. These days, I take a good hard look at the whole picture – where the building’s going up, what kind of weight it’ll need to hold, and even how they’ll keep it in shape down the track. All that stuff comes into play when I’m picking out the right thickness for those studs.

When should you choose thicker metal studs?

A particularly challenging project I undertook involved building a beachfront property constantly exposed to high winds and the corrosive effects of salt air. Initially, we considered using thinner studs to maintain budget flexibility. However, after carefully evaluating the environmental conditions—and a few sleepless nights spent reconsidering our approach—we opted for thicker, galvanised studs.

And I’m glad we did. That structure is still standing strong today, years later, with no signs of corrosion or damage. What this experience taught me is that in high-wind areas, thinner studs can easily bend or warp, putting the entire building at risk. Coastal properties, in particular, need stronger, galvanised studs to withstand the moisture and salt in the air. Taking the time to assess the environment before making decisions like this can really save you from major headaches down the line.

What should you consider in selecting metal studs?

  • Thinner studs are vulnerable to warping in high-wind regions, compromising structural integrity.
  • Coastal environments require thicker, galvanised studs for enhanced resistance to salt and moisture.
  • Proper environmental assessments are critical to ensuring long-term durability.

How do I know which metal stud size I need?

When it comes to choosing the right metal stud size for your project, it’s all about understanding the specific needs of your build. Here’s how I usually guide my clients through the process:

Understand the Project Requirements

First, figure out whether your wall is load-bearing or non-load-bearing. Load-bearing walls need thicker, stronger studs to support the weight. Also, make sure to check local building codes to ensure you’re meeting all regulations—these codes usually dictate the minimum stud size you’ll need.

Consider the Gauge and Thickness

The gauge of a stud refers to how thick the metal is. A lower gauge means a thicker stud. For most home projects, you’re looking at gauges between 25 and 20. If it’s a commercial building, you might need to go even thicker, like a 16-gauge stud.

Think About the Stud Dimensions

Metal studs come in various widths—1 5/8″, 2 1/2″, 3 5/8″, 4″, and 6″. The width you choose depends on what the wall will be used for and how much space you have. Also, consider the depth, which will determine how thick your wall will be and how much room there is for insulation and utilities.

Think About the Environment

If your project is in an area prone to moisture, I always recommend galvanised or coated steel studs to prevent corrosion. And since steel is non-combustible, it’s a great choice for fire-resistant construction.

Plan for Utilities

Don’t forget to plan for what’s inside the walls! Make sure the studs are wide enough to allow space for plumbing, wiring, and insulation. This will help improve both thermal and sound insulation.

Use Sizing Tables and Tools

We provide detailed sizing tables to help you choose the right stud size based on your wall’s height and load requirements. Our team is also available to assist you in making the best decisions tailored to your specific project needs, ensuring that you have the right materials and support every step of the way.

Consult With the Experts

For those bigger, more complex projects, it’s always a smart move to check in with an engineer or architect. They can help make sure you’re choosing the right steel stud size for the specific structural and safety needs of your build. A little expert advice upfront can save a lot of headaches down the road and ensure your project is rock-solid from the get go!

How can I upgrade to thicker metal studs without affecting the overall build quality?

I’ll be the first to admit that early in my career, I sometimes rushed through installations to meet tight deadlines. On one particular project, I didn’t take the time to properly install the thicker metal studs. We ended up tearing down a large section of the frame and redoing it. The time and money wasted could have been easily avoided with a little more care and attention to detail.

Ever since then, I’ve learned that taking my time and focusing on the small details really does pay off in the long run. Now, whenever I’m working with thicker metal studs, I make sure to do things the right way from the start.

Here are some tips that help me get it right:

  • Measure Twice, Cut Once: It sounds simple, but trust me—when you’re dealing with thicker studs, precision is everything. Double-check those measurements before making any cuts.
  • Invest in Quality Tools: Don’t try to cut corners with cheap tools. Heavy-duty saws and fasteners will save you headaches (and money) in the long run.
  • Proper Measurement and Cutting: Getting a clean, accurate cut is half the battle. Use a good metal-cutting saw, and you’ll set yourself up for a smooth installation.
  • Secure Tracks with Care: Make sure the top and bottom tracks are securely fastened with the right screws or anchors, and always use a level to keep everything straight.
  • Vertical Placement Matters: Line those studs up perfectly straight and make sure they’re secured tightly. A loose connection can cause major problems down the line.
  • Don’t Skip the Bracing: Consistent spacing and bracing keep everything solid. If your studs start twisting or buckling, you’re in for trouble.

That one project was a real eye-opener, but it changed how I work for the better. By being more methodical, I can ensure that every installation is built to last, saving time and money in the long run.

Is investing in thicker studs worth it in the long run?

When it comes to building something that lasts, the choice of materials can be the difference between peace of mind and constant repairs. Thicker studs may cost more upfront, but they bring durability that’s worth every penny, especially when the elements put your structure to the test.

Take one of my clients, for example. They were unsure about using thicker studs due to the cost, but after some convincing, they opted for 1.2mm studs. Fast forward a few years, a severe storm hit their area. While many other buildings needed extensive repairs, their building held up beautifully. They called to thank me, relieved they had made the right choice.

This is exactly why I always recommend investing in thicker studs. Here’s why they make all the difference:

Why Thicker Studs Are a Wise Choice

  • Tough as Nails: Thicker studs give your building that extra strength it needs to handle whatever comes its way. They won’t bend or buckle like thinner ones can, so your structure stays solid for the long haul.
  • Extra Fire Protection: Steel is fire-resistant, and with thicker studs, you’re adding even more protection. It’s one more way to keep your building—and everyone inside—safe.
  • No Pests Allowed: Termites love wood, but they won’t touch steel. With thicker steel studs, you’re not just building a stronger structure—you’re keeping it pest-free for years to come.
  • Earth-Friendly: Steel studs are often made from recycled materials, and when the time comes, they can be recycled again. So, not only are you building strong, but you’re also building green.
  • Saving You Money in the Long Run: I get it—thicker studs are a bigger investment upfront. But trust me, they save you money over time by cutting down on repairs and extending the life of your building.
  • More Design Freedom: If you’re looking to do something creative with your build, thicker studs can handle the bigger, bolder designs without sacrificing strength.

In the end, thicker studs are about more than just durability—they’re about protecting your investment and building something that stands the test of time.

 

Build Stronger and Smarter With Thicker Steel Studs

The lesson is clear: when it comes to building projects, cutting corners on the thickness of metal studs can lead to costly repairs, compromised safety, and a weakened structure. My experience has taught me that while thicker studs may seem like a bigger upfront investment, they provide the strength, fire protection, and long-term savings that make them worth every dollar.

At Tag Steel House Frames, we specialise in providing top-quality steel frames that are designed to last. Don’t settle for less when you can build with confidence. Contact us today to discuss how our thicker, high-grade steel frames can be tailored to meet your specific project needs and ensure your structure is built to withstand the test of time.

Metal Studs FAQ

Both thick and thin steel studs won’t catch fire because steel doesn’t burn. Thicker studs can slow down heat from spreading through the wall a little more because they have more mass. However, the fire resistance of a wall mostly depends on everything put together—like the drywall, insulation, and studs as a whole. Fire ratings are based on how the entire wall performs, not just the studs. So, while thicker studs can help, it’s important to focus on the overall design and follow fire safety rules.

Even though steel studs might cost more at first, their strength, low upkeep, and ability to speed up construction can save you money in the long run. The best choice really depends on what your project needs and how much you want to spend.

Yes, there are building codes and regulations in Australia that specify metal stud thickness. The National Construction Code (NCC) outlines safety and structural requirements that influence the right thickness for your studs. Standards like AS/NZS 4600 and AS 4100 provide more detailed guidelines to make sure your steel framing is up to code. The Australian Steel Institute (ASI) also offers helpful resources for proper steel frame installation. If you’re unsure, it’s a good idea to check with a structural engineer to ensure your project meets all the necessary regulations.

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