What Are the Common Challenges in Steel Detailing for Large Infrastructure & SOE Projects?
The Saskarc Design & Detailing Differentiator in Support of Excavation - Chapter 3
TL;DR
Behind every success lies myriad challenges. And steel detailing isn’t any different. So, what are the common challenges in steel detailing for large infrastructure and SOE (Support Of Excavation) projects?
Here are a few
- Communication Gaps
- Changes & Scope Creep
- Site Conditions vs. Design Assumptions
- Heavy Member Sizes
- Tight Timelines
And one key criteria for succession steel detailing projects for large infrastructure projects?
Collaboration.
Table of Contents
- Introduction
- Common Challenges in Steel Detailing
- Communication Gaps
- Changes & Scope Creep
- Site Conditions vs. Design Assumptions
- Heavy Member Sizes
- Tight Timelines
- Success in Steel Detailing: The Role of Collaboration
- Saskarc’s Detailing Advantage
- Real-Life Impact: When Steel Detailing Fails
- The Last Word: Detailing as the Foundation of Project Success
- FAQs : Common challenges in steel detailing for excavation support
Table of Contents
Introduction
In large infrastructure and Support of Excavation (SOE) projects, steel detailing sits quietly behind the scenes, yet it’s the difference between a project that runs smoothly and one that grinds to a halt. It is the stage where design intent is translated into buildable, precise shop and erection drawings, the connective tissue between engineering vision and on-site reality.
As we have explored in our earlier articles, “What is Steel Detailing in Infrastructure Projects” and “Steel Detailing for Support of Excavation Projects,” the importance of steel detailing goes far beyond drawings. It drives constructability, safety, and cost certainty — especially in projects where timelines are tight, ground conditions are unpredictable, and every bolt and splice matters.
But even the most sophisticated designs face real-world friction. Communication gaps, evolving site conditions, heavy member logistics, and relentless schedule pressure can quickly turn a well-intentioned plan into a coordination maze. When detailers are left out of early conversations or forced to work through layers of RFIs, small misunderstandings can cascade into costly rework, delays, and site frustration.
This article explores those very challenges and how collaboration, proactive detailing, and Saskarc’s own Detailing Advantage help turn potential pain points into performance wins. We’ll also look at how history has shown what can go wrong when detailing fails to connect design with execution.
Read on to see why successful projects aren’t just built in the field – they are detailed for success long before the first piece of steel arrives on site.
Common Challenges in Steel Detailing
Communication Gaps
A key recurring challenge and one of the biggest issues in early works and temporary steel projects, in our experience, is communication gaps. Think about this. A strut and waler project has started, but the excavation reveals unexpected soil conditions. The design must adapt, the erector spots installation conflicts, and the engineer must recalculate forces. The steel detailer, working on their own, submits an RFI. And then they wait. Days turn to weeks as the request is interpreted differently by each party. Now consider the difference if the detailer gets included on calls with both the client and the EOR. Issues are shared in real time, screens are shared, and solutions are developed collaboratively. What could have taken weeks is solved in hours. When steel detailers lack direct access to the Engineer of Record (EOR) or the client (erector), all issues must go through RFIs. While well-crafted RFIs are critical, even small misprints or ambiguities can delay approvals and create frustration. The best option is direct collaboration. But when this isn’t possible, clear and proactive RFI’s are essential.
Communication Gaps
A key recurring challenge and one of the biggest issues in early works and temporary steel projects, in our experience, is communication gaps. Think about this. A strut and waler project has started, but the excavation reveals unexpected soil conditions. The design must adapt, the erector spots installation conflicts, and the engineer must recalculate forces. The steel detailer, working on their own, submits an RFI. And then they wait. Days turn to weeks as the request is interpreted differently by each party. Now consider the difference if the detailer gets included on calls with both the client and the EOR. Issues are shared in real time, screens are shared, and solutions are developed collaboratively. What could have taken weeks is solved in hours. When steel detailers lack direct access to the Engineer of Record (EOR) or the client (erector), all issues must go through RFIs. While well-crafted RFIs are critical, even small misprints or ambiguities can delay approvals and create frustration. The best option is direct collaboration. But when this isn’t possible, clear and proactive RFI’s are essential.
Changes & Scope Creep
Another major challenge is the handling of scope changes and scope creep. Frequently, early works projects see design adjustments as the excavation progresses. Or in some cases, practical installation challenges that are identified by the erector. Adapting quickly, detailers need to work with engineers and clients to resolve conflicts without delaying the schedule. This is where early engagement on detailing allows issues like these to be addressed before they become critical path blockers. Also preventing rushed decisions that could compromise safety or quality.
Changes & Scope Creep
Another major challenge is the handling of scope changes and scope creep. Frequently, early works projects see design adjustments as the excavation progresses. Or in some cases, practical installation challenges that are identified by the erector. Adapting quickly, detailers need to work with engineers and clients to resolve conflicts without delaying the schedule. This is where early engagement on detailing allows issues like these to be addressed before they become critical path blockers. Also preventing rushed decisions that could compromise safety or quality.
Site Conditions Vs. Design Assumptions
Practical considerations often necessitate design assumptions. However, actual site conditions often throw off the most planned designs. Unexpected field conditions or variations in excavation often require changes in member sizes, connection design, or reinforcement. This necessitates rapid updates to models and drawings by the detailer.
Site Conditions Vs. Design Assumptions
Practical considerations often necessitate design assumptions. However, actual site conditions often throw off the most planned designs. Unexpected field conditions or variations in excavation often require changes in member sizes, connection design, or reinforcement. This necessitates rapid updates to models and drawings by the detailer.
Heavy Member Sizes
A single waler can weigh so much that a site crane may not be sized to handle it. Without careful planning and splice design, installation grinds to a halt.
Heavy Member Sizes
A single waler can weigh so much that a site crane may not be sized to handle it. Without careful planning and splice design, installation comes to a halt.
Tight Timelines
Finally, tight timelines force detailers to prioritize speed over perfection. Late awards mean drawings are sometimes released while still under review, necessitating rework and multiple rounds of approvals. Investing in experienced steel detailers who follow strict standards, such as the Saskarc Detailing Standard, CISC ( Canadian Institute of Steel Construction) and AISC (American Institute of Steel Construction) practices, is essential to mitigate these risks and maintain project flow. Experienced detailers following proven standards prevent errors from slipping through and ensure that site, fabrication, and erection teams can work efficiently. At Saskarc, we fight these challenges by being proactive: pulling in the right voices early, pushing for direct conversations, and owning our role as problem-solvers. With clear and consistent communication, pro-active problem solving, adherence to detailing standards, SOE projects move smoothly. And the key metric to determine its success are the minimal (query) calls from the site.
Tight Timelines
Finally, tight timelines force detailers to prioritize speed over perfection. Late awards mean drawings are sometimes released while still under review, necessitating rework and multiple rounds of approvals. Investing in experienced steel detailers who follow strict standards, such as the Saskarc Detailing Standard and AISC practices, is essential to mitigate these risks and maintain project flow. Experienced detailers following proven standards prevent errors from slipping through and ensure that site, fabrication, and erection teams can work efficiently. At Saskarc, we fight these challenges by being proactive: pulling in the right voices early, pushing for direct conversations, and owning our role as problem-solvers. With clear and consistent communication, pro-active problem solving, adherence to detailing standards, SOE projects move smoothly. And the key metric to determine its success are the minimal (query) calls from the site.
“Late starts, design changes, and tight timelines don’t stop problems — but expert detailers make them manageable.”
Success in Steel Detailing: The Role of Collaboration
Imagine this: a strut and waler project is progressing, but the erector keeps hitting roadblocks. Connections aren’t fitting as expected, and everyone’s frustrated. Traditionally, detailers would submit RFIs and wait — days turn into weeks. Miscommunications pile up, and site crews start calling to troubleshoot problems.
Effective collaboration between detailers, engineers, fabricators, and erectors is critical in early works and temporary steel projects. Direct access to the Engineer of Record (EOR) can significantly expedite problem-solving. Historically, detailers submit issues via RFIs, which require careful wording to avoid rejection or confusion. Even small misprints can trigger follow-up RFIs, resulting in delays and frustration.
At Saskarc, we handle this differently. We have found that including detailers and connection engineers in calls with the EOR and clients drastically reduces response times. In one memorable project, a live screen-share meeting clarified a conflict that might have taken months to resolve. Suddenly, the team could see the model, understand the engineer’s intent, and agree on a solution. The detailer could then submit an RFI that everyone understood, moving the project forward immediately.
Collaboration on site also matters. On a recent strut and waler project, bringing our detailer directly into calls with the client and EOR revealed the intent behind certain restrictions. With that knowledge, the team quickly developed solutions, and the installation proceeded smoothly without on-site interruptions.
The result? Smooth installation, no surprises on site, and a satisfied client. When the erector later commented that the struts and walers went up flawlessly, it was clear that early collaboration, combined with proactive, experienced detailing made all the difference.
Early and open collaboration ensures issues are addressed proactively, reducing costly delays and last-minute “fire drills.”
“Cut corners on detailing, and you’ll pay for it twice — once in dollars, and again in delays.”
Saskarc’s Detailing Advantage
We believe that steel detailing is much more than a drafting exercise. At Saskarc, we consider it a critical step that combines smart thinking with practical experience to make projects run smoother. That’s why designs and the detailers’ model is reviewed proactively by our team to simplify, strengthen , and streamline connections. Often these small improvements create major savings for the client in time and money by eliminating potential problems before they reach the site.
What makes our process work is collaboration. From day one, our engineers, detailers, and project managers all bring their expertise to the table. Their feedback strengthens the Saskarc Detailing Standard, which is our proprietary framework that we have built and refined with years of project experience. This standard, now in its 10th revision, keeps evolving with lessons learnt. It is our blueprint for accuracy, ensuring drawings are consistent, fabrication integrates smoothly, and costly errors are avoided before they reach the shop or field.
This framework helps us catch details that others might miss. For example, mislabelled parts, incorrect specifications, sequencing errors, or even shop compatibility challenges. And we don’t stop there. Using our battle tested infraMOD methodology, we optimize every connection for buildability and field performance. We do it because it directly translates to safer, faster installations, minimal rework and significant project cost savings.
And the outcome?
Fewer surprises, faster installs, and complete confidence that every piece of steel will fit exactly as planned.
“Investing in precision detailing upfront is the best insurance for a safe, efficient, and cost-effective project.”
Real Life Impact
Errors in steel detailing have led to some spectacular and unfortunate catastrophes that have led to significant loss of life.
The Case of the Hyatt Regency Walkway Collapse
The Hyatt Regency walkway collapse in Kansas City, Missouri in 1981, where two suspended walkways collapsed, killed 114 people and injured over 200 others. Changes in the walkway supports design that were not accurately reflected in the steel detailing drawings was widely attributed as the cause of the collapse.
Source: Wikipedia
The Case of the I-35W Mississippi River Bridge
After 39 years in service, it experienced a catastrophic failure during the evening rush hour on August 1, 2007, killing 13 people and injuring 145. The National Transportation Safety Board (NTSB) cited a design flaw as the likely cause of the collapse, noting that an excessively thin gusset plate ripped along a line of rivets.
Source: Wikipedia
Last word(s)
Every temporary / early works (support of excavation) project tells a story.
Successful early works projects depend on more than engineering and fabrication — they rely on detailing that anticipates challenges, integrates design intent with site realities, and delivers constructible solutions. At Saskarc, we recognize that steel detailing is not just a step in the process; it is the backbone of the project’s success.
It is important to note though that when detailing is left too late, that story usually involves rushed drawings, endless RFIs, rework in the shop, and headaches on site. But when Saskarc is brought in early, the story changes.
By awarding steel detailing early on infrastructure & support of excavation projects, clients give us the ability to optimize connections, resolve design issues before they become problems, and ensure the entire project runs smoother.
Our people, knowledge, and processes — the product of years of experience and continuous refinement — acts like a blueprint for success, ensuring consistency and reliability across projects. That is why our detailers catch design challenges before they reach the field. Our team optimizes connections and splices so fabrication is efficient, and installation is smooth. Ultimately, the true value of good detailing is measured in fewer RFIs, less rework, smoother site installation, on time schedules, and reduced project risk.
The result?
Fewer surprises, fewer delays, and fewer costs eating away at the budget. Instead of phone calls from the site with problems, our clients call us after the project with gratitude. The difference is simple: when detailing is done right the first time, everyone wins.
“Detailing isn’t just drawings — it’s the difference between a project that struggles and one that succeeds.”
The most common challenges in steel detailing for large infrastructure and SOE projects include
- communication gaps between teams,
- frequent design changes,
- mismatched site conditions,
- handling heavy member sizes, and
- tight timelines.
These issues often stem from late involvement of detailers and lack of direct coordination between engineers, fabricators, and erectors.
When detailers don’t have direct access to the Engineer of Record (EOR) or erectors in large infrastructure projects or Support of Excavation (SOE) projects, all questions must pass through RFIs (Requests for Information). This indirect process slows approvals, causes misunderstandings, and increases the risk of rework. Collaboration in real-time between detailers, engineers, and clients gets rid of most of these delays.
Early collaboration in large infrastructure projects allows the detailing team to identify design conflicts, optimize connections, and adapt to changing site conditions before fabrication begins. Including detailers in design and coordination meetings can cut problem-resolution time from weeks to hours.
Scope creep happens when project requirements evolve during execution. For example, due to new excavation data or design revisions. Each change demands updates to models and drawings, which can disrupt schedules if not managed proactively through early engagement and clear communication.
Variations in soil, excavation depth, or actual field dimensions often differ from original design assumptions. These differences require quick adjustments to member sizes and connection details. Experienced detailers anticipate such changes and design for flexibility to avoid costly delays.
In Support Of Excavation projects, the weight of walers and struts can be over tens of tonnes. If the steel detailing does not account for crane capacities or splice design, installation can stall on site. Thoughtful and practical detailing ensures large members are modular, safe to lift, and easy to assemble within existing site constraints.
Late project awards often compress detailing schedules, forcing drawings to be released mid-review. This leads to rework and potential errors. The solution lies in early detailing engagement and adherence to proven standards like CISC and the Saskarc Detailing Standard.
Saskarc’s Detailing Advantage combines engineering insight, proactive collaboration, and a standardized detailing process developed over years of experience. This leads to fewer RFIs, smoother fabrication, faster installation, and reduced project risk, even under tight timelines.
History shows that inaccurate or incomplete detailing can lead to catastrophic failures, such as the Hyatt Regency walkway collapse (1981) and the I-35W bridge failure (2007). Both cases underline the life-safety importance of precision and accountability in steel detailing.
Engaging the detailing team early enables better design coordination, constructability reviews, and connection optimization. It reduces the risk of rework, saves costs, and ensures the project progresses safely and on schedule.
Large civil infrastructure projects: such as subways, bridges, tunnels, and support of excavation works, experience the highest detailing complexity. These projects involve heavy loads, deep excavations, and rapidly changing site conditions that demand detailed, flexible, and coordinated designs.
- Bring detailers and connection engineers into early planning meetings.
- Maintain open communication with the Engineer of Record.
- Follow recognized standards and consistent detailing protocols.
- Prioritize collaboration over transactional coordination.
