Integrated Digital Workflow for Structural Design, Fabrication Documentation, and Quantity Estimation of an Industrial Steel Warehouse

Oct 23, 2026

Accurate fabrication documentation and material quantity estimation are critical for industrial steel building projects. Conventional 2D-based methods and manual calculations often underestimate secondary members, connection components, and fabrication accessories, creating gaps between design intent and construction needs. This study assesses an integrated digital workflow combining structural analysis, Tekla Structures-based detailing, and fabrication modeling, and compares generated reports with conventional manual quantity take-offs for improved consistency and completeness.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages15

Reading Time38 min

AccessFree to download

Abstract

Introduction

Materials and Methods

Results and Discussion

Conclusion

Cureus Journal of Engineering [https://doi.org/10.7759/s44388-026-00232-1](https://doi.org/10.7759/s44388-026-00232-1) Original Article Integrated Digital Workflow for Structural Design, Fabrication Documentation, and Quantity Estimation of an Industrial Steel Warehouse Brajendra Singh 1, , Vasudev Rodwal 2 , Priyanka Rajput 2 1. Department of Structural Engineering, Sage University, Indore, IND 2. Department of Civil Engineering, Sage University, Indore, IND Received: June 23, 2026 | Review began: June 30, 2026 | Review ended: July 09, 2026 | Published: August 20, 2026 © Copyright 2026 This is an open access article distributed under the terms of the Creative Commons Attribution License CC-BY 4 .0., which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited. | Abstract
Accurate fabrication documentation and material quantity estimation are critical for the successful execution of industrial steel building projects. Conventional quantity estimation methods based on two-dimensional drawings and manual calculations frequently underestimate secondary structural members, connection components, and fabrication accessories, resulting in discrepancies between design and actual construction requirements. This study evaluates an integrated digital engineering workflow for structural design, fabrication documentation, and quantity estimation of an industrial steel warehouse by integrating structural analysis with Tekla Structures-based detailing and fabrication modeling.
A pre-engineered industrial warehouse measuring 23.4 m × 9.4 m with an eave height of 5.5 m was selected as the case study. Structural analysis and member design were performed using STAAD. Pro CONNECT Edition under dead, live, wind, and seismic loading in accordance with IS 875 (Parts 1-3): 2015, IS 1893 (Part 1): 2016, and AISC 360-16 (Allowable Strength Design) . The finalized structural members were subsequently developed into a detailed three-dimensional fabrication model using Tekla Structures 2024, incorporating primary and secondary framing members, bracing systems, connection assemblies, bolts, and other fabrication components. Fabrication drawings, erection drawings, assembly drawings, and material quantity reports were generated directly from the coordinated BIM model and compared with conventional manual quantity estimation.
The integrated workflow produced a total estimated steel quantity of 12,960.92 kg, whereas conventional estimation yielded 11,930 kg. This represents an increase of 1,030.92 kg (8 .64%) compared with conventional manual estimation due to the inclusion of secondary framing members, connection plates, foundation bolts, fasteners, cladding accessories, and other components that are commonly omitted or simplified in manual quantity take-oﬀs. The integrated workflow also improved consistency between structural analysis, detailing, and fabrication documentation by reducing manual data transfer and minimizing coordination errors.
These findings demonstrate that the integration of structural analysis with Tekla Structures-based detailing provides more comprehensive quantity estimation, enhances fabrication documentation, and improves coordination throughout the design-to-fabrication process. Although the investigation is based on a single industrial warehouse case study, the proposed workflow provides a practical and reproducible framework for improving documentation quality and material estimation in industrial steel construction projects. | | --- | | Categories: Structural Engineering | How to cite this article: Singh B, Rodwal V, Rajput P (August 20, 2026) Integrated Digital Workflow for Structural Design, Fabrication Documentation, and Quantity Estimation of an Industrial Steel Warehouse. Cureus J Eng 3 : es44388-026-00232-1 . DOI [https://doi.org/10.7759/s44388-026-00232-1](https://doi.org/10.7759/s44388-026-00232-1) Page 1 of 15

FAQs

What problem does the integrated workflow address in industrial steel projects?

It targets inaccurate fabrication documentation and quantity estimation caused by relying on 2D drawings and manual calculations, which often omit secondary members and connection/fabrication accessories.

How was structural analysis and member design performed in the case study?

Structural analysis and member design were carried out using STAAD Pro CONNECT Edition under dead, live, wind, and seismic loading in line with IS 875, IS 1893, and AISC 360-16.

What impact did the workflow have on estimated steel quantity compared with conventional methods?

The workflow estimated 12,960.92 kg of steel versus 11,930 kg conventionally, an increase of 1,030.92 kg (8.64%) due to additional components captured by the BIM-to-detailing process.

Oct 23, 2026

Upload by Valentina