Custom Engineered Steel Structures

In custom work, cost is controlled by how many unique pieces, weld volumes and fabrication steps the design requires. We rationalize curved and faceted geometry into repeatable panels, convert complex castings or nodes into fabricated plate assemblies where appropriate, and choose weld details that reduce distortion and inspection effort. Splitting large components at practical splice points also improves transport and erection, saving schedule on site.

Typical work includes heavy plate girders, box and multi-plate nodes, curved and twisted members, transfer structures and components in special grades such as weathering or high-strength steel. Welding procedures are qualified for the specific grades, thicknesses and joint geometries, with preheat and heat input controls where required.

Fabrication is driven directly from the 3D model, and trial assemblies verify fit and alignment of complex components before shipment. Pieces carry detailed match-marks, orientation references and survey targets so that site teams can assemble components in the same configuration verified in the shop, with minimal adjustment at the work front.

Custom components receive an inspection and test plan developed for their specific risks, with full traceability of plates and sections through mill certificates and, where specified, through-thickness or impact properties. NDT is extended for heavy or highly restrained welds, typically ultrasonic testing combined with magnetic particle testing. 3D dimensional surveys compare fabricated geometry with the model. All records are compiled into a QC dossier per the EN 1090 execution class or AWS D1.1 requirements specified.

Protection is selected for both environment and function. We specify ISO 12944 systems from C3 through CX, hot-dip galvanizing where component size and geometry allow, and duplex systems for long design lives. Architecturally exposed custom steel receives finish coats and surface preparation matched to its visual requirements, and intumescent fire protection is coordinated where needed. Weathering steel components are detailed to drain and avoid moisture traps.

Custom components are often oversized or heavy, so we plan transport during design. Large elements travel as break-bulk or project cargo with engineered saddles, lifting lugs and sea fastening, while smaller parts and connection kits ship in containers. Each item carries match-marks and packing references, and we prepare the export documentation, packing lists and shipping drawings required for oversized cargo.

We provide erection drawings, lifting and rigging information for heavy or irregular components, and input to method statements covering temporary supports and survey control. Sequence planning ensures components arrive in the order needed for assembly. When agreed, our engineers deliver technical supervision or advisory support during critical installation stages, while the appointed erection contractor carries out lifting and assembly.