Steel Detailing | Precast Detailing | Estimation

Author: Ganesh Kumar

  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 5

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 5

    We hope you found our previous blogs on the Sydney Metro project insightful. If you missed them, check them out.

    In this blog, I’d like to share an important lesson about concrete encasement for conduits that every steel detailer should keep in mind.Normally, conduit encasement falls under electrical scope, so detailers don’t focus much on it. However, the encasement’s location and size can directly affect the steel layout — as we discovered in one of our projects.

    We detailed the steel as per design drawings, but on-site, the encasement dimensions varied. Some conduits were larger, others smaller, which caused clashes between the steel and the encasement, and in some areas, created unwanted gaps. This required on-site modifications to our steel.

    When detailing steel near conduit encasements, always verify the actual encasement size and location before releasing fabrication drawings. Small checks early in the process can prevent major issues and rework on-site.

  • Mezzanine floor & stair handrails

    Mezzanine floor & stair handrails

    TEK1 recently completed a Mezzanine steel & stair for a prominent organization in Australia. The goal was to provide detailed support steelwork for mezzanine floor & stair including handrails.

  • Do not stick your neck out

    Do not stick your neck out

    While detailing a project for a leading organization in Australia, the client asked us to calculate material quantities for production and procurement.

    However, this involves high risk.As detailers, we don’t control the nesting process — which depends on factors like sheet size, scrap management, and fabrication methods. Each fabricator uses different nesting techniques. If we provide material calculations without knowing their exact process, the numbers could be inaccurate.Any miscalculation could lead to over- or under-procurement, and the blame may fall on the detailer.

    Even if the client is willing to pay for it, detailers should avoid taking on such high-risk tasks. Stick to your scope and let the fabricator handle material estimation based on their own nesting and production methods.

  • Media wall

    Media wall

    TEK1 recently completed a media wall support project for a prominent organization in Australia. The goal was to provide detailed support steelwork for a large media wall screen — with a unique challenge.

    Unlike most projects, we didn’t receive any structural design drawings. Instead, we were given only a concept design, leaving it to TEK1 to determine suitable steel profiles and connection details.

    Our team carefully studied the concept and nominated appropriate profiles for each connection based on feasibility, strength, and ease of fabrication. Once the detailing was complete, we submitted it to the structural engineer for review.

    The engineer approved our detailing with minimal changes, which helped speed up the process and made things easier for the client. The use of different profile types also optimized the design for practicality and efficiency.

  • Project – Bridge – 25

    Project – Bridge – 25


    Tek1 recently completed a cladding project for a prominent organization in Australia. The project involved detailing cladding and its support system around a footbridge with unique challenges.


    The footbridge featured curved ends, but these were not simple linear curves, making the design and detailing process particularly intricate.


    Tek1 conducted numerous meetings with the client and engineers to finalize the cladding’s shape and ensure it met both aesthetic and structural requirements. This collaborative approach ensured the project’s success.


    Stay tuned for more projects from Tek1!

  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 4

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 4

    We hope you found our previous blogs on the Sydney Metro project insightful. If you missed them, check them out.

    In this blog, I’d like to share another connection detail we proposed to the structural engineer on the Sydney Metro project

    Since this is a metro project, fireproofing sheets are required on steel members as per the structural engineer’s specifications. However, the original connection details provided by the engineer were not feasible interms of installation of fireproofing sheets — they would make installing the fireproofing sheets difficult and time-consuming.

    Please see the connection details below. These are the standard connection details typically used for the steel members.

    However, applying these as-is may create difficulties during the installation of the fireproofing sheets.

    We identified this issue early in the detailing stage and proposed alternate connection details that would allow easier installation of the fireproofing sheets without compromising the structural requirement.

    The engineer reviewed our proposal, suggested a few adjustments like thickness changes, and then approved our updated connection details.

    Catching these issues early during detailing avoids major headaches later for installers and saves valuable time on-site

    Stay with TEK1 for more updates on this sydney metro project

  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 3

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 3

    We hope you found our previous two blogs on the Sydney Metro project insightful. If you missed them, check them out using the link below!

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 1
    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 2

    In this blog, we’ll share about a connection detail that we proposed to the engineer.

    As per the design, a PFC beam needed to be supported by an I-beam above. However, in one location, the PFC beam was offset from the I-beam — and no connection detail was provided for this condition in the design drawings.

    To address this, TEK1 proposed adding tab plates to connect the offset PFC beam securely. This solution maintained structural intent while resolving the missing detail.

    The structural engineer reviewed our proposal and accepted it.See the below response from the engineer ‘Option shown in snap-03 accepted to maintain 2 bolts at each connection. Additional tab plate to be 80×10 FPBW to PFC. Bolt spacing to follow 140 gauge line of flange of SB14.‘

    We go beyond drawings to ensure constructibility, reduce rework, and keep projects moving forward.Stay with TEK1 for more updates on steel detailing challenges and solutions in our upcoming blogs.

  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 2

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 2

    In the last blog in Sydney metro project , we discussed about the design issue regarding angle weld. https://www.tek1.com.au/steel-detailing/tek1s-steel-detailing-for-sydney-metro-resolving-design-challenges-1/

    Here we are going to discuss about the member placement issue.

    The design specified two PFCs on both sides of a column.Column was surrounded by fireproofing sheets. However, the PFC flanges clashed with the fireproofing sheets, making installation difficult. Additionally, the bolts connecting the PFCs would interfere with the fireproofing.

    To resolve this, TEK1 planned a simple yet effective adjustment—changing the orientation of the PFCs. This allowed for seamless fireproofing installation without compromising the structural integrity.

    If we have followed the design , then the erection team will have difficulties to provide the fireproofing sheets.By identifying and addressing potential clashes early in the detailing process, TEK1 saved significant time and costs for the client, ensuring a smooth execution on-site.

    Stay with TEK1 for more updates on steel detailing challenges and solutions in our upcoming blogs.

  • TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 1

    TEK1’s Steel Detailing for Sydney Metro – Resolving Design Challenges – 1

    TEK1 is currently engaged in steel detailing for the Sydney Metro project, working with a reputed organization in Australia. During the detailing process, we have encountered several design challenges. Here, we will share one such issue and how we resolved it.

    The Issue

    A design required two unequal angles welded to a small hanger with 10mm packer plates. This left insufficient weld space, making fabrication tough.

    Recognizing this issue early, we raised a query with the concerned team. Our initial proposal was to cut both angles to create the required weld space.

    After reviewing our concern, the team suggested an alternative solution that involved reducing the packer plate thickness from 10mm to 4mm. This adjustment allowed for a 6mm weld clearance on both sides without significantly affecting the design.

    If this issue had gone unnoticed and we had followed the original design, it would have caused complications for both the fabricator and the designer. By identifying the problem early and addressing it proactively, we saved time and costs for the client.

    Stay Tuned for More Insights

    This is just one example of how TEK1 ensures seamless steel detailing by resolving design issues efficiently. Stay with TEK1 for more updates on steel detailing challenges and solutions in our upcoming blogs.