Influence of Web-Perforated Cold-Formed Steel Studs on the Heat Transfer Properties of LSF External Walls

Thermal bridging through cold-formed steel (CFS) studs significantly reduces the thermal performance of light gauge steel frame (LSF) wall systems, particularly in climates demanding higher thermal resistance (R-value). While thermal breaks are commonly used, they increase material costs and construction complexity. According to NCC 2022, the minimum total R-value requirement for external walls ranges between 2.8 and 3.8 m2·K/W depending on the climate zone and building class. This study therefore evaluated web-perforated steel studs as a passive strategy to enhance thermal resistance of LSF walls, analysing 120 configurations with validated 3D finite element models in Abaqus and benchmarking in THERM. The results showed that web perforations consistently improved R-values by 14 to 20%, as isotherm contours and heat flux vectors demonstrated disruption of direct heat flow through the stud, thereby mitigating thermal bridging. Although the axial compression capacity of web-perforated CFS studs decreased by 29.5%, the use of 4 mm hole-edge stiffeners restored 96.8% of the original capacity. The modified NZS 4214:2006 and ASHRAE Modified Zone methods, incorporating steel area reduction and heat flux redistribution, closely matched Abaqus predictions, with coefficients of variation (COV) below 0.009, corresponding to less than 1% relative deviation between analytical and numerical R-values. Furthermore, application of web-perforated CFS studs in five external wall systems demonstrated improved thermal resistance, ensuring compliance with NCC 2022 R-value requirements across all Australian climate zones. Overall, the findings establish web-perforated studs as an effective solution for improving the energy performance of LSF building envelopes.