Accurate detailing lies at the very heart of good fabrication and construction, taking designs from concept to precise, constructible instructions. Even with the best steel detailers, errors can still occur. Uncaught errors inevitably lead to costly rework, site delays, and frustration. As a fabricator, knowing what to look for will save you problems later and keep your projects on schedule. Here’s a breakdown of the most common steel detailing errors, real-world examples, and actionable insights to protect your time and budget.
1. Missed Field Installation Dimensions
Getting field installation dimensions right is crucial to ensure components fit perfectly on-site. A common problem happens when beams or supports are detailed without accounting for real-world conditions and tolerances, leading to misalignment during installation.
Example:
Imagine a beam designed to connect to a column. It looks okay on paper, but the detailed beam assembly allows no room for minor variations in field measurements. On-site, this misalignment results in delays as crews adjust or shim the components to fit together and thus slows down the project
How We Catch These Errors at ESD Solutions:
- Detailed 3D Models
We use advanced tools to create highly accurate models, making sure every beam and connection is positioned exactly as it should be.
- Field Checks
We double-check erection drawings against field measurements to ensure everything will fit well on-site. We also analyze the “structure logic” to spot missing field information or conditions that may affect the steel.
- Team Coordination
We work closely with fabricators and field teams to confirm critical dimensions and ensure everything aligns as expected.
2. Connection Detailing Errors
Some connection parts, like gusset plates or shear tabs, are hard to miss because they directly attach other members and they are “embedded” into the detailing software logic. However, others, such as web stiffeners, are commonly forgotten because they appear to serve independently. Oversight of these details may lead to inadequate connections, reduced member strength, and costly reworks.
Example:
A beam-to-column connection is detailed, but columns web stiffeners are missing from the model and the shop drawings. Without them, the connection might not handle the expected loads, leading to potential problems with safety.
How We Catch These Errors at ESD Solutions:
- Model-to-design checks
We recheck the 3D model and erection drawings against the design and all incoming information before every release. This ensures that every connection detail meets the project’s overall requirements.
- Single-part Inspection
We inspect each part before issuing construction drawings to ensure it meets the design with respect to size, location, and attachment methods, including welds or bolting.
- Cross-Verification
Our procedure is to check each model element and its respective detail in the shop drawings, and there is no scope for overlooking certain things.
3. Incomplete or Vague Shop Drawings
Missing dimensions, illegible notes, or lack of annotation about special finishes can indeed confuse your shop crew and create delays or errors in fabrication.
Example:
A stair stringer detail may not include critical dimensions such as carrier angle rake or nosing dimensions. The shop can’t fabricate without this information, therefore resulting in delays. Since lost time on the shop floor has to be paid for, the fabricator loses money waiting for the detailer to revise the missing dimension.
How We Catch These Errors at ESD Solutions:
- Complete Assembly Checks
We carefully analyze each assembly drawing for completeness, including all necessary connections and dimensions, so that every part is correctly positioned to be “fabrication-ready.”
- Two-Tier Review Process
The released drawings go through a two-step review by different team members before release. This process minimizes the risk of oversights, like missing dimensions or wrong member size, ensuring the highest level of accuracy.
4. Clashes with Other Trades
One of the most common steel detailing errors in projects involving several trades is the conflict steel components with the MEP ducts or piping. Poor coordination will result in on-site conflict and expensive fixes.
Example
On a rooftop project, the HVAC team lowered a duct without informing anyone. This caused a collision with a roof framing beam. The issue wasn’t spotted until installation, which meant redesigning both systems mid-project—a costly and time-consuming delay.
How We Catch These Errors at ESD Solutions:
- Clash Detection Tools
Utilize clash detection software in BIM to find potential conflicts. We can use Navisworks, Glue, Revizto or any other similar tool for clash detection/coordination.
- Proactive Coordination
Coordinate regularly with the other trades during the detailing phase. Even if we are not provided with MEP 3D models, we always ask for their “latest and greatest” shops to ensure everything works together.
5. Ignoring Constructability
Some designs look good on paper, but when the time for fabrication or installation comes, they are impracticable. Inexperienced detailers often replicate the design of more experienced professionals without considering real-world constraints, which lead to problems that hold up projects and inflate costs.
Example:
A detailer places a shear tab inside a W8 column, making it nearly impossible to bolt due to the tight conditions. On-site crews would struggle to access the connection, creating delays or forcing last-minute modifications.
How We Catch These Errors at ESD Solutions:
- Comprehensive Erectability Check
We carefully analyze the model for buildability – that is, to ensure the structure can be fabricated effectively in the shop and can be assembled easily in the field. Every connection and joint is analyzed to avoid any possible site problems.
- Feasibility Testing Advanced Tools
We use software tools that can simulate real conditions on-screen, such as verifying the accessibility and usability of TC guns and impact wrenches for tightening bolts. This will ensure that connections are not only designed but also practical to install under tight conditions.
6. Overlooking Field Conditions
Field conditions often differ from theoretical drawings. A detailer that overlooks or can’t envision such realities risks coming up with components that may not fit as required, necessitating modifications at the site or complete re-fabrication of steel member.
Example
Steel beams are fabricated based on theoretical wall-to-wall dimensions. However, if the actual site conditions differ—such as slight variations in wall alignment—the beam could end up being too short or too long. When that happens, a beam may have to be trimmed at the site or even re-fabricated, thus taking more time and money.
The same steel detailing errors may occur if one assumes the same dimensions throughout the building without measuring it section by section.
How We Catch These Errors at ESD Solutions:
- Field Verification for Critical Structures:
We ensure that field measurements are provided for all components sensitive to site conditions. This eliminates any chances of errors occurring from depending solely on theoretical dimensions.
- Requesting Field Photos:
To go beyond the numbers, we request field photos for review for any potential surprises that may exist, such as existing structures, pipes, or MEP systems. This visual check will enable us to identify and resolve challenges in advance of fabrication, ensuring that the design will fit perfectly in the real world.
How Fabricators Can Proactively Avoid Steel Detailing Errors
- Hold Your Detailers Accountable
Ensure your detailers thoroughly review every drawing before submission. Meticulous checking eliminates the need for fabricators to double-check, saving time and avoiding errors. Reliable detailers mean build-ready drawings from the start.
- Leverage Technology
Utilize 3D modeling and BIM to find clashes or out-of-alignment problems at the front end of the process.
- Establish Clear Standards
Create a comprehensive set of standards and expectations for your detailers. Specify connection types, submittal package format, and QA/QC procedures.
- Communicate Regularly
Communicating frequently with your steel detailer will catch the mistake at an early stage, which limits the potential project delay. Share your fabrication people’s knowledge to get practical designs.
- Invest in Training
Detailers who have fabrication or field experience will better produce practical designs with minimal errors.
Steel detailing is a team sport. By behaving proactively, by leveraging technology, and by fostering clear communications, you can significantly reduce costly rework.
What steel detailing errors have you come across in your projects? Share your experiences in the comments below, and let’s discuss how we can all work smarter to build better.
