Author: fhurst

Thistle House, Steel Fabrication

This was a unique challenge that required special attention and consideration to detail. The floor plan was designed as a architectural dream around key points of interest to the customer. The structural steel fabrication required to accomplish this dream was by far NOT common to industrial standards. No standard steel fabrication shop wanted to be part of this creation. This required us to take it upon our selves to fabricate each component. Using AutoCAD Advance Steel, numerous phone calls and email, file sharing and links to 3D drawings (such as the one below), we were able to come to an agreement between the Architect and Structural Engineer to how this dream would come to life. All together 52,500 lbs. of steel would be required to create the structure.

Shear Wall

Shear Wall

During a remodeling project on a military base two existing joining building walls were removed.  This caused the building to shift.  We were contracted by the General Contractor (GC) to reinforce/replace sections of the wall with a new Hybrid Steel Frame / Ordinary reinforced concrete shear wall system.    GC on the project presented to us the military’s plans.  We reviewed the plans and offered changes to help accommodate with the projects current level of completion.  Not interfering with current work and to spend as little time and money on the modification.  Once all plans were agreed upon, our portion of the remodel only lasted 17 days.

North Shear Wall

North wall was formed between (2) bays with Steel Frame reinforcement consisting of channel iron to contain the ends of the concrete and a horizontal wide flange beam to create a window to accommodate for the existing overhead duct work.   The traditional method of wood form work, steal snap ties and reinforcing bars were used when placing the concrete.

South shear Wall

South wall was also formed between (2) bays with Steel Frame reinforcement consisting of channel iron and wide flange beam.  Additionally because of the limited space between the walls we used steel plate backing and coil rods with the traditional wood form work on the front.


Both walls were poured with a 4350 psi minimum concrete.  On site mixing, precise water control and vibrators placed along the wall form work during pumping insured that concrete flowed and distributed evenly.  Each wall was pumped on the weekend and was completed in less than 8 hours each.

Fabrication and delivery

Frac Sand Processing Fabrication Project

Scope of work
  • Fabrication, deliver and commission an existing charge hopper that is  on plant site
    • Add top side boards for additional capacity
    • Fabricate and install product discharge profile gate

Fabrication and deliveryFabrication and delivery


  • Fabrication, deliver 2 each 30”x 40’ 150 tph belt conveyors

Fabrication and delivery Fabrication and delivery

3D Simulation and Stress Analysis

Simulation bearing-table

Customer has asked us to add a table to their bearing beam.  The table must be functional but also offer support to lift the shafts when work on the bearing is needed.  To guaranty this, we modeled the exciting condition and added a table.  Then simulated the situation by adding a 30ton force to the table under the shaft as the point of contact when lifting.  The simulation results are below.  In conclusion the table will support the necessary load to lift the shaft and work on the bearings.


Displacement simulation

Displacement Simulation

Displacement shows that we can expect a max deflection of 0.0216 inches


Stress & Strain simulation

Simulation strain

Strain shows that we can expect a max of 0.445 ft-lbs

Simulation stress-solidsSimulation stress-beams

Stress shows that we can expect a max of 27kpsi which is below the yield strength of 36kpsi.

3D SolidWorks Drafting

We offer 3D Solidworks drafting

  • 3 Dimensional Modeling & Detailing
  • Stress Analysis
  • Simulation
  • Pipe Routing
  • Interference Detection
  • Clearance Verification
  • Hole Alignment

Do it right the first time, Solving details before fabrication begins.

3D SolidWorks Drafting


Retro-fitted Truss

The purpose of this truss is to provide a 60 foot wide opening to move stainless steel tubing from the forming bay to the finishing bay of the manufacturing plant.

The truss supports three columns of a building and crane way live loads.

Sam Vacek PE designed the construction of the truss and we designed the method of installation.

Sam envisioned in place welding as the primary method of installation.

We designed and built the truss as 100% bolt-up at ground level,  then lifted completed truss to installation height.

This is a typical example of our ability to provide solutions for improving the outcome of non-forgiving scopes of work.