How to Overcome Transportation Limits in Large Truss Projects

In large-span steel projects, the challenge isn’t always about strength or design — it’s about logistics. Transport regulations often cap dimensions at 12m length x 2.6m width, meaning oversized trusses designed in software can’t physically reach site in one piece.

At the Aspire Mickleham Childcare Centre project, I faced exactly this issue with trusses reaching 26.6m wide and 3.8m high. Without careful detailing, these trusses would have been impossible to transport.

Turning Constraints into Smart Detailing

1. Modular Splicing – Breaking It Down to Build It Up

We introduced splice points at logical structural positions, allowing the massive trusses to be split into transportable modules.

2. Preserving Load Path Integrity

Every splice was carefully designed so that the full structural load transferred seamlessly across the joints, ensuring strength was never compromised.

3. Transport-Friendly Design

By breaking trusses into modules, each unit fit within transport limits — making delivery simple and compliant.

4. Site Assembly Made Easy

Detailed erection drawings guided the crane lifting and reassembly process, ensuring safe and efficient on-site construction.

Client’s Initial Splice Proposal

Initially i have got input like below for client’s end for splicing the length trusses

Optimized Splicing for Seamless Load Transfer

My Detailing Approach for Smart Splicing for Stronger Load Transfer

Finalized Spliced Truss Frame Arrangement

Smart Truss Frame Arrangement for Transport & Strength

On-Site Erection — From Plan to Reality

From Drawing Board to Construction Site

The Outcome — Buildability First

This approach not only solved the transport issue but also ensured:

✔ Zero on-site rework
✔ Safe and efficient installation
✔ Perfect alignment between design, fabrication, and assembly

👉 Takeaway: Smart detailing bridges the gap between ambitious design and practical construction.

I always ensure that every project is not just strong on paper but buildable in the real world.

🚀 Every project has its own challenges — the key is finding practical detailing solutions that work on-site, not just on paper.

I’d love to hear your thoughts or experiences with large-span trusses.
📩 Connect with me, Priyan Gandhi | LGS Detailer, to discuss smarter detailing strategies.