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

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.