Author: Dhileepan

  • Balcony Step-Down & Splice Clash Resolved in Scarborough Residence

    Balcony Step-Down & Splice Clash Resolved in Scarborough Residence

    Project Background

    In a residential project nestled in the scenic suburb of Scarborough, Bundeena, a critical coordination issue surfaced during the construction of the first-floor balcony. Originally designed to sit 100mm lower than the internal first-floor level (with the balcony at RL+33.000 and the floor level inside the residence at RL+33.100), the structural drawings, however, did not reflect this intended step-down.

    ARCHITECTURAL PLAN
    STRUCTURAL PLAN

    Floor Depth Conflict

    Adding to the complexity, the vertical space between the first-floor Finished Floor Level (FFL) and the ground floor Ceiling Level (FCL) was only 300mm, while the structural floor members specified were 327mm deep. This created an unintended exposure of the first-floor framing—both below the ceiling and above the balcony floor.

    Level Adjustment Solution

    Upon identifying the discrepancy, Tek1 promptly flagged the issue to both the structural engineer and the architect. A collaborative resolution was achieved by adjusting the levels: the internal FFL was raised to RL+33.253 and the balcony FFL to RL+33.153, restoring the 100mm step-down while maintaining all ground floor steel members at their original elevations. The level variation was managed by introducing floor joists of different depths—an efficient solution that avoided reworking the base structure.

    Splice Connection Clash

    Another issue surfaced in the form of a splice connection detail provided in the structural drawings. The original design called for splice plates on both the top and bottom flanges of the beam. However, the bottom plate posed a risk of clashing with the ceiling board. Tek1 proactively suggested an alternative splice configuration that avoided interference with the ceiling. This revised detail was reviewed and subsequently approved by the structural engineer.

    DESIGN SPLICE
    PRPOPOSED SPLICE

    Conclusion

    This case serves as a strong example of how early-stage detection, open communication, and thoughtful coordination between teams can lead to efficient, buildable solutions—ensuring design intent is met without compromising on functionality or aesthetics.

  • A New Addition to Launceston Christian School, Tasmania

    A New Addition to Launceston Christian School, Tasmania

    Let’s dive into the exciting expansion at Launceston Christian School in Tasmania—a thoughtfully designed new building covering an area of 1,440 square meters. This structure adds essential facilities to the campus, including classrooms, an auditorium, a storage room, and a library.

    Challenges:

    A key engineering challenge in this project was related to the cast-in base plates. These base plates had to be finalized and fabricated before the slab pour could begin. This required us to release accurate base plate fabrication drawings and exact location details early in the project timeline.

    Since altering column positions later would not be feasible—especially if rafter alignments or other components demanded changes—we had to finalize all column locations at the earliest stage. This meant that the column modeling had to be both precise and quick.

    Once the column layout was locked in, the modeling of the beams and girts progressed smoothly without any complications.

    This project serves as a great example of how early coordination, clarity in design, and proactive decision-making contribute to successful structural outcomes.

  • Addressing Stair Landing Slopes with Steel Modifications

    Addressing Stair Landing Slopes with Steel Modifications

    In our previous blogs, we discussed common mistakes that can occur while detailing a stair landing with slopes. You can find the link to the previous blog here: https://www.tek1.com.au/australian-standards/designing-a-multi-level-staircase-common-mistakes-and-key-considerations/


    Now, the designers have replaced precast slabs with pavers. Since pavers cannot have varying thicknesses, we were instructed to do something with the steel structure to achieve the required falls.
    The stair landing system has steel frames, 10mm plates on their top & EA support members to bolt them. The 50mm pavers are placed on top of the 10mm plates.


    TEK1 played a key role in designing the modifications, adjusting the steel supports and slopes to achieve the necessary fall. If the required slope were unidirectional, achieving it would be straightforward. However, in this case, the stair turns 180°, and the mid-landing’s fall transitions in three directions.


    Handling Slope Transitions
    The landing below Flight-02 and the top of Flight-01 are in opposite 180° directions.
    A single rectangular plate cannot connect these two slopes seamlessly.
    To address this, we introduced two triangular plates in the middle to enable a smooth transition between the slope directions.


    Structural Adjustments
    The main steel structural members remain consistent throughout the mid-landing.
    We adjusted the RL (Reduced Level) and slopes of the EA support members to match the required slope of the 10mm plates that support the pavers.


    By implementing these changes, we successfully accommodated the required falls while ensuring structural integrity and proper drainage. This approach maintains a practical and efficient solution when using pavers instead of precast slabs in stair landings.

  • Melbourne Airport Gantry

    Melbourne Airport Gantry

    At Melbourne Airport, a gantry supporting a signboard spans 26 meters between laced columns without intermediate supports. The box gantry alone weighs 8 tonne. Since the gantry would bend because of to its self weight, pre-camber of 170mm was provided at the middle.


    For accurate representation, two models were created: one with pre-camber for assembly drawings and another without for general arrangement (GA) drawings. This approach ensures clarity in fabrication and erection, maintaining structural integrity while achieving the desired final alignment.

  • Designing a Multi-Level Staircase: Common Mistakes and Key Considerations

    Designing a Multi-Level Staircase: Common Mistakes and Key Considerations

    When designing a staircase, one of the most overlooked aspects is the correct distribution of risers, especially when integrating a mid-landing with a falling finish.

    Understanding the Mid-Landing Design:

    In this case, the staircase consists of two flights turning 180° with a mid-landing. The purpose of this stair is not only to provide access between Ground Floor (GF) and Level-01 but also to facilitate movement to the mezzanine level from the mid-landing. The design for the mid-landing incorporates a 10mm plate with a 50mm paver on top. However, an important requirement was added: allowing for a fall in the paver to prevent water stagnation.
    We received an instruction to keep the landing RL 20mm lower than the door near the mezzanine level to incorporate falls in the paver.


    Common Mistake in Flight-02 Design    :


    For a steel detailer, just paver RL which is 20 mm below the door level & 50mm paver thickness is enough to place the steel below. The sloping surface in the paver will be taken by some other parties. But the key thing to notice here is, the slope continues to the bottom of flight-02 as well.
    At the end of Flight-01, the paver thickness remains 50mm.
    Near the mezzanine door, the thickness increases to 70mm (50mm + 20mm fall).
    A frequent error occurs when designing Flight-02. Many assume the risers should be evenly divided between Level-01 FFL (Finished Floor Level) and the RL of the mid-landing, neglecting the impact of the paver thickness variation.


    To achieve the correct stair profile:

    The mid-landing RL should be set based on the increased paver thickness near the flight-02.
    Flight-02 risers should be distributed between Level-01 FFL and the actual top surface of the paver (which is 70mm at the bottom of Flight-02, not 50mm).
    Else, the first riser in the flight-02 will be comparatively smaller than the rest of the risers.

    Key Takeaways for Stair Detailing:

    Account for varying thickness: Do not assume uniform paver thickness; adjust accordingly at different points.


    Correct riser distribution: Ensure the risers of the second flight are calculated based on the actual mid-landing RL, factoring in paver thickness variations.


    Clarify detailing instructions: Steel detailers do not need to model the paver exactly but must ensure the mid-landing RL is accurately set.

    By paying close attention to these details, staircases can be designed more efficiently, reducing costly rework and ensuring a smooth construction process. Proper coordination between architectural and structural teams is essential to avoid misalignment and achieve a seamless build.

  • Transforming 3D CAD Models into 2D Fabrication Drawings: The Orange Rope Project

    Transforming 3D CAD Models into 2D Fabrication Drawings: The Orange Rope Project

    Imagine trying to build a complex 3D structure using only flat, 2D puzzle pieces—every cut, weld, and alignment must be perfect. That’s exactly the challenge we faced with the Orange Rope project, where 3D CAD models had to be transformed into precise 2D fabrication drawings. How did we tackle this engineering puzzle? Let’s dive in!

    The “Orange Rope” is a series of rolled pipes placed between the piers in a bridge. This project involves a total of 11 ropes, with the following images showcasing a sample of a rope.

    Challenges and Solutions

    1. Converting 3D Models to 2D Fabrication Drawings

    The initial input received was in the form of 3D CAD drawings, while the required output consisted of 2D drawings for fabrication. To achieve this, the 3D ropes were broken down into a series of 2D pipe members, which were then welded together to recreate the 3D structure. Each rope was divided into 4 to 5 assemblies, each containing multiple 2D pipes that, when assembled, would form the final 3D shape.

    2. Welding and Alignment

    Welding each 2D pipe in the correct position to form the 3D structure presented a significant challenge. With intricate dimensions, aligning each pipe manually would be nearly impossible. To tackle this issue, a splice system was introduced. This system involved a welded plate with a nut affixed at the bottom of one pipe and a corresponding hole in the adjacent pipe. By bolting the pipes together through these holes, proper alignment was ensured before welding. Once the pipes were secured and welded, the bolts were removed, and the holes were plug-welded for a seamless finish.

    3. Asymmetrical Cuts for Base Plate Fixing

    Another major challenge was the presence of asymmetrical cuts in the pipes for fixing them onto the base plates. To ensure precise cuts, unwrapped views of the pipes were provided. These unwrapped views were printed on paper at a 1:1 scale and then wrapped around the pipe. This method allowed for accurate cutting directly from the template, ensuring proper fitment and alignment during installation.

  • Can You Spot the Mistake in This Stair Design?

    Can You Spot the Mistake in This Stair Design?

    Imagine you’re reviewing a staircase drawing, and you see this note:

    “8 THK CONTINUOUS FOLDED PLATE TREADS AND RISERS.”

    Sounds fine, right? But here’s the catch—is it actually possible to fold a single plate continuously for an entire stair flight? 🤔

    The Hidden Problem

    A plate cannot be folded continuously to form multiple stair treads and risers because:

    • Fabrication limitations – Bending steel plate repeatedly at stair angles is nearly impossible.
    • Structural concerns – Excessive bending weakens the material and creates stress points.
    • Installation challenges – A long, folded plate is difficult to transport and position correctly.

    The Right Approach

    Instead of one continuous folded plate, each tread and riser should be a separate, single-folded plate. These individual elements can then be welded or bolted together to form a strong and practical staircase.

    So next time you see a similar detail, take a closer look—is it actually buildable?

  • Staff Memo – Webmail Login

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  • Fabrication drawing requirements : Modelling for Non-Structural Plates: A Guide

    Fabrication drawing requirements : Modelling for Non-Structural Plates: A Guide

    When working with elements like cladding plates, balustrade infills, decorative panels, and chequer plates, the approach to modelling them differs significantly from that used for standard structural plates. Ensuring accuracy in these cases hinges on a thorough understanding of working points and the rotation property, which are essential for ensuring the correct orientation of the visible side when generating drawings or DXF files.

    Understanding the Critical Role of Working Points

    It might seem simple to assume that these sheets can be flipped or rotated as needed after they are cut. However, this is a common misconception that can lead to significant errors during fabrication. The key to avoiding such issues lies in setting up the working points correctly, particularly when dealing with intricate designs or surface finishes.

    The Importance of Proper Rotation

    Take a stair panel, for example. If the panel features any patterns or surface differences, the working point must run in the direction from left to right when facing the stair panel. Additionally, the rotation must be set to either “top” or “front”—never “bottom” or “back.” This ensures that the visible side of the panel is correctly positioned.

    Symmetry Doesn’t Eliminate the Need for Attention

    Even in cases where the pattern is symmetrical or there appears to be no pattern at all, the orientation of the face of the sheet is crucial. It’s easy to think that since the machine will cut the plate according to the DXF file, it doesn’t matter how the drawing is flipped or rotated. However, this is where problems can arise.

    Avoiding Aesthetic Imperfections

    During the cutting process, the machine can leave minor marks on the material. These marks are typically left on the non-visible side of the sheet. Therefore, it’s critical to feed the sheet into the machine with the correct side facing outwards. If not, the marks could end up on the visible side, compromising the aesthetics of the final product.

    Conclusion: Precision is Key to Quality

    Proper modelling and careful consideration of working points and rotation properties are essential when dealing with cladding plates, balustrade infills, decorative panels, and chequer plates. By ensuring the visible side is correctly oriented from the start, you can avoid costly mistakes and ensure a high-quality finish.