Modular Steel Advantages

Modular steel construction refers to a construction technique where prefabricated steel modules are fabricated off-site and transported to the construction site for assembly. This method of construction has several advantages over traditional building methods, including:

1. Speed of construction: Modular steel construction allows for quicker construction time as the steel modules are prefabricated off-site and can be assembled on site in a matter of days. This can save significant time compared to traditional construction methods, which can take months or even years.

2. Cost-effective: The use of modular steel construction can be more cost-effective than traditional construction methods due to the reduced labor and material costs associated with prefabrication.

3. Sustainability: Modular steel construction is considered a more sustainable method of construction as it produces less waste and reduces the carbon footprint associated with transportation and construction.

4. Durability: Steel is a strong and durable material that can withstand harsh weather conditions, seismic activity, and fire. This makes modular steel buildings highly resilient and long-lasting.

5. Design flexibility: Modular steel construction allows for a high degree of design flexibility, as modules can be designed to fit almost any shape or size. This flexibility allows for greater design creativity and can lead to more innovative building designs.

Overall, modular steel construction provides numerous advantages over traditional building methods, including speed of construction, cost-effectiveness, sustainability, durability, and design flexibility.

Steel Fabrication - Phase 2

We are currently finishing up Phase 2. We have begun to work on the shear wall components. Shear walls are composed of braced panels that are used to counter the effects of lateral loads on a structure. The most common loads braced wall lines counteract are wind and seismic loads. Our team is using our bandsaw to cut 4 x 7.25-pound channels. The team used the CNC plasma cutting machine to cut 10-gauge material to the appropriate size. The welders assembled the components. Things are moving along quickly, and we are on our way to completing Phase 3.

Steel Fabrication

In Phase 2 of our project, we are finishing the beams and posts. We have utilized our CNC plasma cutting machine to precisely cut the holes on each beam. The holes had to be cut in the beams for assembly. Our welders had to weld plates that were cut but our CNC plasma cutting machine. A welding process was used to join the plates to the beams at the points where they are connected.

Once all the beams and plates have been completed, we painted them for them to be ready for the job site.

Steel Fabrication

In our fabrication shop, we are currently working on one of our larger projects. Our client is remodeling an existing house. Instead of wood, the structural foundation will be made of steel beams and tubes. For this project, we have divided the project into 3 phases. We are currently in phase 1. In this phase, we will utilize our CNC plasma cutting machine to cut our steel sheets and steel beams, our Ironworker to punch holes, our bandsaw to cut steel beams and steel tubing, and our welders to put everything together. 

To begin, the steel beams and tubing were first cut to the right lengths with the bandsaw. This project uses a variety of tubing sizes, including 4"x4", 5"x5", 3"x3/8", 3.5"x3.5"x1/4" and 10"x4"x1/4". The beams range from 8" to 18" wide and weigh 21 to 86 pounds per foot on the project. We are working with beams that range from 2' to 24' in length.  

With the help of our CNC plasma cutting machine, we have made more than 200 plates of various sizes and shapes. Each plate has a specific place and size and is cut into various shapes and sizes. After all the plates have been cut, we will use the ironworker (steel punching machine) to punch holes into them, and then we will begin welding them onto the beams and tubing. 

Plasma-Punch Machine Services

ES Denver offers steel projects as part of its scope of services. ES Denver uses a large format CNC plasma machine to cut steel. The bed can accommodate steel up to 8' x 16'. With the punch, the holes will be perfectly round and in the correct place.

In manufacturing and construction, a plasma cutting table is an efficient and versatile tool for cutting heavyweight and thick materials. The machine is controlled by a computer and helps to get an accurate cut. We save both time and money using the machine. Having the ability to cut up to 200 inches per minute, this machine is efficient. We can ensure that material sheets are used efficiently and that unnecessary material waste is avoided.

Plates that have been cut by our plasma table

Using 3D Scanning to Assess Structural Damage

At ES Denver we use cutting edge technology in our engineering inspections to assess structural issues with a property. The Matterport 3D Scanner is one example of the tools we use to gather data during a site visit.

Often it can be difficult to see if the walls of a building remain square or if they have shifted as a result of foundation or other structural problems. The high resolution 3D point cloud obtained from a scan allows any movement of walls to be quickly and easily detected and measured. In addition to providing fast and easy quantitative measurements, 3D scan data sometimes also uncovers additional structural problems that require a repair.

In the example above, a residence was undergoing foundation repairs. A previous engineer had estimated a wall to be 15” out of plumb, and the building was going to be condemned. But the 3D scan showed that the south wall of the residence was actually only 9” out of plumb, and a repair was possible. Using this data, ES Denver was able to design a cost effective repair plan for the homeowner to stabilize the foundation from further movement, and a historic building was saved.

At ES Denver we are committed to integrating the latest technology into our design process. Call us to day to discuss you project’s engineering needs.

Reframing the problem: A unique design for cantilever support

Recently, a client came to us with a difficult design problem. A building the client was constructing needed a cantilever beam to support the roof. Unfortunately, there was very little head clearance, and therefore not enough space to place a steel cantilever beam under the roof joists.

This required innovation.

The solution: A unique framing design that could provide adequate support while also providing enough head clearance. A traditional cantilever support consists of a beam that sits beneath the roof joists. In our design, the joists are made of 2 x 12 lumber which is notched to allow the steel beam to fit inside the joists, rather than sitting underneath them. This significantly increases the clearance of the beam.

This framing design allowed the client to proceed with the project.

As a client you may have design challenges that require a unique solution. At Engineering Studio Denver we are always up to the task. There is nothing we love more than a good engineering challenge! Call us today to discuss your project’s engineering needs.

Structural Integrity of Light Poles with Non-Invasive Testing

This month ES Denver was contacted to solve a unique problem for a customer. The customer’s property contained 18 light poles in a parking lot. One of these poles had fallen down due to rusting at the base of the pole. It appeared the pole had rusted from the inside due to water intruding and pooling inside the pole base. The customer wanted to know if any other light poles on the property had experienced internal rusting and needed to be repaired.

Detecting rusting and degradation of the steel inside the poles required a non-invasive testing method, as any invasive testing would damage the poles or allow water to intrude inside the pole base. ES Denver came up with a solution for the customer: use an ultrasonic metal thickness gauge to check the thickness of the steel in the remaining 17 light poles. The ultrasonic gauge is non-invasive and can detect the thickness of steel to the nearest 1/100th inch.

Using the ultrasonic thickness gauge to test the steel thickness of a light pole base.

The remaining poles were examined with the ultrasonic thickness gauge, with a minimum of 20 measurements taken around the base of each light pole. If the steel was measured at less than the required 1/8 inch thickness, this indicated likely deterioration of the steel from internal rusting.

Metal thickness data from each pole was plotted to determine how much of the base had experienced internal rusting.

An example of a pole which failed the structural integrity test and is showing deterioration of the steel in multiple sections around the base.

After carefully examining all 17 light poles, it was determined that 3 poles had experienced significant deterioration from internal rusting and were at risk of collapse. 2 other poles were found to be marginal. The other 12 light poles showed full thickness of metal around the entire base and were deemed to be structurally sound.

This analysis by ES Denver saved the customer money, as they can now proceed with repairing or replacing only those poles which showed internal rusting.

ES Denver is always looking for creative solutions to your unique engineering problems. Give us a call today so we can discuss your needs!

3D Engineering Observations

We are offering 3D scans for framing, rebar and as built observations. This allows us to document that the job was done properly. We can document your job beginning to end, document errors and fixes. Using this engineers can better communicate and improve turn around times for customers.

ESDenver adds Matterport's 3D Camera to Assist in Site Visits

Engineering Studio Denver has often gone to job sites and thought afterwards, “I wish I had got a picture of that” or something along the lines of “it would be nice to have this all documented to see progress of the project”. No matter how well we document a job, there is always one image in our mind that we may miss with our camera. That worry went out the door!

We have spent time recently trying to think of a different way to conduct site visits or how to re-walk a site without having to figure out the costs to us or the client for something minor. ES Denver’s founder, Dustin Randle, PE, came across Matterport’s 3D Camera that can be used indoors or outdoors allowing us to see mulitiple levels of a project whether a house/building is already constructed or to document from below ground to multiple stories high.

Less than a couple days into the purchase of this camera, we’ve been able to document some of the unique carnival rides we’ve done for Wisdom Rides, do a layout of Granada High School mechanical and structural layout to conduct site visits where we spend just as much time to document 20-50 images with just the Matterport’s 3D Camera giving us all those images and being able to re-walk the site.

ES Denver plans on using this camera for site visits, construction management and as an aid help train employees and help educate current and future clients what to expect from their project by showing our capabilities as if we are walking the site.

ES Denver looks forward to using this new tool to tell you more about the projects we have done and/or are doing going forward.

How To Apply For A Building Permit in Denver (and how ESD can help)

The thought of applying for a zoning or building permit can be daunting for anyone, especially when attempting to keep a project on-time and on-budget, arid a simple google search only adds to the confusion and frustration. To ease your frustrations and expedite the process, see our easy to follow guide below:

How do I apply for a permit?

There are two options to apply for a permit:

1)    By Email (PlanReview@denvergov.org)

2)    In-Person

Both can be complicated processes with many intricacies depending upon your scope of work so read carefully. Below is an overview of the steps, note that the Denver Department of Development Services provides thorough guidelines on their website.

There are two main types of Building Permits: Residential and Commercial.

RESIDENTIAL BUILDING PERMITS

Residential building permits are for single-family and duplex project. This applies to new residential construction, additions, attic conversions and other projects that include structural or excavation work such as structural remodeling, as well as zoning only reviews. Interior remodels, windows, doors, decks, detached storage, and other non-structural repairs which  are considered "Home Project” do not require a building permit.

Here are the minimum requirements needed to submit your permit*:

• Legal Address

• Permit Application

• Statement of Valuation Form

• Plans:

  • Cover Sheet

  • Site Plan

  • Floor Plan

  • Building Elevations/Section

*Additional documentation might be required for certain projects including an Asbestos Inspection Form and/or Approvals from Landmark Preservation of Board or adjustments.

Pro Tip: If submitting by email, save all files as PDFs and make sure all email attachments use the following naming convention:

<DocumentName>:_<Address>_ <Date>

COMMERCIAL BUILDING PERMITS

All documents and plans prepared by an architect, engineer, or surveyor must be signed and sealed by that individual.

Hard copies submitted at the permit counter can have a printed seal but must have an original signature.

• Emailed documents must have a valid electronic signature and a printed seal.

• Download a step-by-step guide for creating electronic signatures if this is not something you have done before.

There are 10 Steps to getting a Commercial Building Permit:

PRIOR TO SUBMISSION

1. Use DevelopDENVER to look up your proposed development site.

2. Determine if you need to submit a Site Development Plan (SOP). SDPs are required for all new commercial construction, new residential construction of three or more units, and major additions or remodels.

   • To see if this applies to your project, contact the project coordinator listed for your site on the DevelopDENVER map in step 1.

3. Determine if you will need reviews or approvals from other disciplines.

   • Landmark

   • Zoning

   • Public Works

   • Right-of-Way

   • Address Assignment

   • Forestry

4. Ensure that your project will follow all local, state, and federal regulations. This may include having the site inspected for asbestos and lead based paint before applying for building permits, and finding a certified contractor to do abatement or remediation work as needed.

SUBMITTING PLANS FOR REVIEW

5. Assemble the items listed on either the New Buildings, Additions, and Change of Occupancy or Tenant Finish and Remodel forms (whichever form applies to your project) contained in this guide.

6. Determine whether you will need to log in your plan review or if you will be able to obtain a permit at the commercial/multifamily walk-through counter.

BUILDING FEES

7. Fees are based on customer-provided valuations for the scope of the project, including materials, labor, overhead and profit. These valuations are checked against construction costs prepared by the International Code Council or similar resources, and additional fees may be assessed if the customer-provided valuation is found to be below current construction costs. Once your project has been logged in, you will receive a log number and instructions for how to pay plan review fees. The review will not begin until review fees are paid.

DURING PLAN REVIEW

8. Your project will be assigned a log number. Depending on your project scope, plan review may include multiple disciplines, such as electrical, plumbing, architectural/structural, mechanical, fire, transportation, environmental health, and wastewater.

9. Use your log number or site address to check your application status online.

10.  Before your plan review is complete, provide staff with the name and license number of the contractor who will be associated with the building permit for your project. This will allow you to receive the building permit by email once all reviews are complete and final permit fees are paid.

Help! I need a permit immediately.

There are two scenarios in which you may be able to receive a Commercial Same-day Permit:

• Quick permits for simple projects like re-roofs, minor electrical work, and like-for-like mechanical or plumbing replacement

• Commercial/multifamily walk-through for projects valued under $500,000 that do not require structural work, change of occupancy, or a review by disciplines other than electrical, mechanical/plumbing, architectural/structural/access control or fire

How do I get my permit? 

Plans can be brought in by anyone, but permits will only be issued to a contractor licensed for that work in Denver.

Make sure the person picking up the permit can demonstrate the validity of the contractors' license on the permit application by bringing an original contractor license card (no copies or faxes accepted), company check, or company credit card. 

While the process of applying for a building permit can be daunting, breaking it down into smaller, more manageable pieces and following the checklist provided by Denver Development Services will ensure you are well prepared with what to expect and can anticipate potential road blocks. 

Engineering Studio Denver can help provide all engineering documentation and support for residential and commercial structural changes. Contact us with any questions regarding what you may or may not need to move your project forward.