The Chalets at Double Tree by Hilton in Nathia Gali, a commercial light-gauge steel project, demonstrates how advanced roll forming and steel framing systems can successfully deliver a high-performance mid-rise steel-framed building using light-gauge steel under extreme wind design, snow design, and seismic design conditions. Located in Nathia Gali, KPK Province, Pakistan, the project consists of ten four- and five-story chalets constructed for DoubleTree by Hilton. The chalets were designed and built by MSA Pvt. Ltd., a long-standing specialist in light-gauge steel framing with more than 15 years of experience using Scottsdale’s roll forming technology.
Situated at approximately 8,000 feet above sea level, the project required a commercial light-gauge steel solution capable of meeting demanding wind design, snow design, and seismic design criteria while maintaining fast construction timelines. The resulting mid-rise steel-framed building system stands as a milestone for steel framing in Pakistan and a benchmark for commercial light-gauge steel construction in extreme environments.
The Project Challenges:
Wind Design, Snow Design, and Seismic Design Constraints
From the outset, this commercial light-gauge steel project faced a unique convergence of challenges. The site is located in a mountainous Seismic Zone 3 with a peak ground acceleration of 0.33g, placing significant emphasis on seismic design. In addition, the chalets were required to withstand 140 mph design wind speeds and snow loads reaching up to five feet, making wind design and snow design equally critical.
Logistics further complicated the project. Narrow, steep, and winding access roads prevented the delivery of large, prefabricated assemblies, while limited on-site space restricted material storage and traditional construction methods. Winter weather, including heavy snowfall and sub-zero temperatures, posed additional risks to schedule and safety.
Project Challenges in a Snapshot:
- Elevation: approximately 8,000 ft above sea level
- Seismic Zone: Zone 3
- Peak Ground Acceleration: 0.33g
- Design Wind Speed: 140 mph
- Snow Load: Up to 5 ft
Phase I of the development had been delivered using conventional concrete construction, which resulted in significant schedule delays and additional costs due to extended curing times, weather exposure, and the logistical challenges of transporting and batching materials in a mountainous environment. Those lessons directly influenced the strategy for Phase II. By the time the chalet expansion began, the first phase of the hotel was fully operational, meaning construction activities had to proceed with minimal disruption to guests and ongoing operations.
The Solution Package:
Integration of Roll Forming Technology & Light-Gauge Steel Framing Design
Recognizing the limitations experienced with concrete, the owners made a strategic decision to move away from conventional methods and instead adopt steel framing solutions using integrated roll forming technology. This approach eliminated many of the risks associated with wet trades, reduced on-site congestion, and enabled faster, more controlled assembly, making it far better suited for delivering a mid-rise steel-framed building in a remote, high-altitude location while the hotel remained open and operating.
Structural design and detailing were completed using advanced digital workflows, enabling precise coordination of wind design, snow design, and seismic design requirements all within the ScotSteel software package. All cold-formed steel wall panels and trusses were fabricated using Scotpanel 7090 and Scotpanel 5140 roll forming machines, ensuring consistent accuracy across the entire commercial light-gauge steel project.
Because transporting large assemblies was not feasible, roll forming allowed individual light-gauge steel components to be manufactured and assembled on-site concurrently with foundation work. This approach maintained quality while adapting to the site’s logistical limitations. The inherent strength-to-weight advantages of light-gauge steel reduced seismic forces, while steel framing provided clear load paths essential for wind design and snow design compliance.
Project Solutions in a Snapshot:
- Roll Forming Machines: Scotpanel 7090 and Scotpanel 5140 roll forming machines
- Design Software: ScotSteel
- Fabricator: MSA Pvt. Ltd.
- Fabrication and Erection Time: 70 days
- Cladding Completion: 30 days
For lateral resistance, the mid-rise steel-framed building utilized strap bracing in the north–south direction, complemented by moment frames and chevron-braced frames in the east–west direction. This steel framing configuration was driven by architectural requirements for large window openings designed to maximize panoramic valley views, which limited the use of shear walls. The solution highlights how commercial light-gauge steel systems can be engineered to satisfy extreme environmental and seismic demands while meeting architectural design requirements.
The Results:
A Proven Commercial Light-Gauge Steel Project Delivered at Speed
Despite the harsh climate and complex logistics, the four- and five-story chalet structures were erected in just 70 days, with exterior cladding completed within an additional month. This level of performance underscores the efficiency of roll forming and steel framing when applied to a mid-rise steel-framed building.
No assembly or installation issues were encountered, a direct result of precise detailing, accurate roll forming, and disciplined steel framing design and practices. The light-gauge steel system performed exactly as designed under wind design, snow design, and seismic design criteria, validating the structural approach.
By avoiding wet trades and reducing on-site congestion, the commercial light-gauge steel project minimized disruption to surrounding hotel operations and mitigated weather-related risks. The speed, accuracy, and reliability achieved demonstrate how roll forming enables predictable outcomes even in severe mountain environments.
Steel Framing: Low-Carbon Performance with Maximum Economy
Steel framing is a low-carbon building solution that supports sustainable construction from fabrication through occupancy. Because light-gauge steel components are precision-manufactured through roll forming, there is virtually no fabrication waste, and any offcuts are fully recyclable. On this project, MSA Pvt. Ltd. leveraged advanced steel framing systems to achieve exceptional productivity, delivering approximately 5,000 square feet per shift and installing one full floor per week on this project. This level of efficiency highlights how steel framing maximizes economy while maintaining structural durability and consistent quality.
Beyond speed, steel framing provides long-term performance advantages. Its high strength-to-weight ratio enhances durability while optimized assemblies contribute to high-energy efficiency, outstanding thermal insulation, and strong acoustic performance. Compared to concrete, steel framing delivers a lower life-cycle cost due to reduced maintenance, improved resilience, and predictable long-term performance. The result is a sustainable, durable, and economically efficient building solution that meets modern demands.
Setting a New Standard for Mid-Rise Steel-Framed Buildings
The Chalets at Double Tree by Hilton in Nathia Gali illustrate how commercial light-gauge steel projects can successfully deliver complex mid-rise steel-framed buildings in regions governed by extreme wind design, snow design, and seismic design requirements. Through the strategic use of advanced roll forming steel framing technology, the chalets at Nathia Gali establish a repeatable model for resilient, high-performance mid-rise construction.
The integration of digital design, precision roll forming, and efficient on-site assembly proves that light-gauge steel is not limited to low-rise applications. Instead, steel framing can support demanding commercial light-gauge steel projects in some of the most challenging conditions in the world.
Additional Scottsdale Roll Forming Solutions and Resources
- Blog – How to Choose the Right Roll Forming Machine
- Blog – Building Steel Framing Success with the Best Roll Forming Technology
- Blog – Informative Guide to Corrosion Resistance of Steel Framing
- Blog – Complete Guide to Steel Framing Design in High Wind Zones
- Blog – Cold-Formed Steel Framing in High-Seismic Regions: All You Need to Know
- Blog – Best Steel Framing Results with Advanced Roll Forming Technology: ScotSteel
- Video – The Ultimate Home of the World’s Best Roll Forming Technology
- Financial Services
To learn more about Scottsdale’s roll forming solutions and steel framing ecosystem, visit us at www.scottsdalesteelframes.com, call us at +1 (888) 406-2080, or email us at rollformers@scottsdalesteelframes.info.
