Optimization of Steel Structures – How to Reduce Project Costs Without Compromising Safety

Date of last update: 09.10.2025

Each tonne of steel in a structure represents a significant material and installation cost. In a typical warehouse hall, the steel structure is a major line item in the investment budget. Professional structural optimization makes it possible to reduce the mass of steel elements while maintaining full safety and compliance with design standards. Deliberate design using advanced calculation tools eliminates excess material where it is not needed, translating into tangible construction cost savings.

Key information: Steel structure optimization is a process of intentional design using advanced calculations and BIM technology that minimizes material consumption while ensuring the required strength parameters. The greatest opportunities for optimization come from a well-considered choice of the structural grid, minimizing the number of profile types, and designing connections focused on ease of assembly. In its optimization process, METIB uses advanced software—IDEA StatiCa for connection analysis, Tekla Structures for modeling, and Robot Structural Analysis for structural calculations—which allows precise tailoring of the structure to actual loads.

Table of contents:

1. Basic Methods for Optimizing Steel Structures
2. Advanced Optimization Tools in BIM Design
3. Where Is the Boundary Between Savings and Risk?
4. Optimization vs. Speed and Quality of Erection
5. The Role of Design Experience in Optimization
6. Summary
7. Frequently Asked Questions About Optimizing Steel Structures

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Basic Methods for Optimizing Steel Structures

The first step in optimization is the correct selection of the structural grid—the spacing of columns and transverse frames. An optimal grid considers not only the architectural and functional requirements of the facility, but also optimal load distribution, available material lengths, and the erection method. Often, modifying element spacing can significantly reduce the number of columns while maintaining the required load-bearing capacity of the entire structure.

The second area is the selection of steel profiles adapted to the actual loads in individual zones of the structure. Advanced calculations make it possible to differentiate member cross-sections depending on their real stress levels—a member subjected to higher stresses requires a larger section, while a less loaded element can be lighter. This approach eliminates the overdesign of structural elements.

Optimization of nodes and connections often yields significant benefits not only in terms of material usage but, above all, in erection time and cost. Complex welded nodes that require detailed calculations, certified welders, and time-consuming assembly can often be replaced with bolted connections, which are quicker to execute and easier to quality-control. Simplifying the erection technology directly shortens construction time.Another technique is using actual loads instead of maximum catalogue values. Design standards provide loads for worst-case scenarios. Analyzing the facility’s real operating conditions, geographic location, and process specifics often allows the adoption of loads closer to reality which, while maintaining required safety factors, enables a reduction in member cross-sections.

Advanced Optimization Tools in BIM Design

Modern structural optimization goes beyond the designer’s experience and catalogue tables for profile selection. Advanced calculation software enables multiple calculation iterations, testing of various structural scenarios, and identification of the solution that is optimal in terms of material consumption while meeting all normative requirements.

METIB uses IDEA StatiCa for detailed analysis of steel connections. The software models the actual behavior of a node under load, accounting for deformations, bolt and weld interaction, and stress concentrations. This makes it possible to design the connection precisely to carry the forces involved—without excess material, yet with the required safety factors maintained.

Tekla Structures enables parametric modeling—modifying structural parameters automatically recalculates the entire model, generates new material take-offs, and detects potential clashes. The ability to quickly analyze different structural layout variants allows the optimal solution to be selected without repeatedly redrawing the design.Structural analysis software such as Robot Structural Analysis Professional or Dlubal RFEM performs advanced analyses of the structure, taking into account nonlinear material behavior, geometric imperfections, and member interaction. Precise structural analysis allows for a more accurate assessment of load-bearing capacity and optimal use of the strength properties of the steel profiles employed.

Where Is the Boundary Between Savings and Risk?

The fundamental criterion in the optimization process is compliance with structural design standards. Eurocodes and other national standards (BS EN for the United Kingdom, DIN for Germany) define the minimum requirements for load-bearing capacity, stiffness, and durability. A design that meets these requirements is safe, regardless of the degree of optimization applied.

Problems can arise when optimization leads to excessive slenderness of elements. A profile may meet load-bearing requirements in structural calculations yet be susceptible to vibrations, deflections, or deformations that affect user comfort. Standard requirements for serviceability limit states must be met alongside ultimate limit state requirements.

A second pitfall is excessive diversity of profiles within the structure. A theoretically optimal selection may result in a large number of different cross-sections, each perfectly matched to a specific location. In practice, however, such diversity increases the risk of errors, extends execution time, and complicates site logistics. Sensible optimization also accounts for the technological and organizational aspects of the construction process.A third aspect is allowance for future needs. A structure optimized strictly for current requirements may lack the ability to adapt to changed operating conditions in the future. Sound design leaves a certain reserve of capacity for potential future modifications or changes in building use, increasing the investment’s flexibility.

Optimization vs. Speed and Quality of Erection

True economic optimization considers not only the cost of material but also the costs across the entire project delivery cycle. A structure that is slightly lighter but requires significantly more erection time and specialized execution procedures may ultimately be more expensive to deliver. The optimization analysis should therefore include both material costs and labor and schedule impacts.

Standardization of elements and solution repeatability are key to efficient erection. When most connections in a structure follow the same scheme, the erection crew achieves high productivity and minimizes the risk of errors. In addition, a steel fabricator produces series of similar elements more efficiently than one-off bespoke details, which affects manufacturing costs.

Simplicity of structural solutions translates directly into execution quality. Simple bolted connections are easier to execute correctly than complex welded nodes that require high welder qualifications and detailed quality control. The simpler the structural solution, the lower the execution risk and labor intensity.Connection optimization for erection also includes accessibility to all elements that must be joined. The design should ensure that all connections can be executed correctly using standard tools and erection equipment. Hard-to-access nodes prolong installation time and increase the risk of improper execution.

The Role of Design Experience in Optimization

Optimizing steel structures requires not only knowledge of advanced calculation tools but, above all, engineering experience. Understanding the real behavior of structures under load, awareness of the technological constraints of fabrication and erection, and familiarity with practical execution aspects are essential for effective optimization.

A thorough knowledge of design standards in different countries allows optimization of structures in line with local requirements. METIB has experience designing to Eurocodes used in Poland and EU countries, BS EN standards in the United Kingdom, and DIN standards in Germany. Each normative system has its specifics that influence the optimization process.

Cooperation with contractors is a vital element of successful optimization. A designer who is in touch with construction realities understands which solutions are easy to execute and which cause problems on site. Feedback from erection crews and steel fabricators enables the design of solutions that are not only optimal in calculations but also practical to deliver.Experience with a wide range of project types—from industrial halls, through building structures, to complex public buildings—allows proven optimization solutions to be adapted to the specifics of a given project. Each building type has its own characteristics and requires an individual approach to structural optimization.

Summary

Optimizing steel structures is a process that requires experienced designers, advanced calculation tools, and a holistic view of the investment. A professional approach to optimization reduces structural mass while maintaining full safety, compliance with design standards, and consideration of the practical aspects of project delivery.For over 15 years, METIB has been designing steel and reinforced concrete structures for investors in Poland and across Europe. A team of over 30 specialists leverages BIM technology and advanced software to create designs that are optimal in material usage, ease of execution, and erection efficiency. Each project is analyzed individually, with structural solutions tailored to the facility’s specifics and the investor’s requirements. Contact us to learn more.

Frequently Asked Questions About Optimizing Steel Structures

How much can be saved by optimizing a steel structure?

The savings potential depends on many factors—the size and type of the facility, the project’s initial assumptions, and the optimization methods applied. The greatest opportunities arise in long-span structures, multi-storey frames, and buildings with unusual functional requirements. A precise estimate requires analysis of the specific project. Remember that optimization covers not only reducing structural mass but also simplifying erection and shortening delivery time.

Does optimization extend the design schedule?

Using advanced BIM tools and analysis software enables efficient optimization within a standard design timeline. Automation of many calculations and the ability to quickly test various structural variants offset the extra time devoted to optimization analyses. Timelines may extend only when optimization requires nonstandard solutions that demand detailed approvals or additional specialist studies.

Is structural optimization safe?

Yes—provided it is performed by an experienced design office in full compliance with applicable standards. Optimization does not mean reducing safety factors below code limits; it means eliminating excess material where it is unnecessary while ensuring the required capacity and stiffness. Every project must comply with the relevant standards (Eurocodes, BS EN, DIN) with all safety factors specified therein.

Which structural elements offer the greatest optimization potential?

The overall structural layout and column grid, long-span members (roof beams, primary girders), and connection detailing offer the most potential. Optimizing the structural layout can significantly impact total structural mass. Members with varying loads across different zones of the building also offer high potential through differentiated cross-sections. Simplifying connections primarily affects erection cost and duration.

Does optimization require special materials or technologies?

No. Optimization relies on standard steel profiles and typical methods of joining structural members. The foundation of optimization is proper profile selection, a rational structural layout, and well-designed nodes—not the use of exotic materials or experimental technologies. Common profiles such as HEA, HEB, IPE, RHS are used, ensuring competitive material prices and standard fabrication processes at steel shops.

How can the quality of optimization in a delivered design be verified?

Check several aspects: whether the calculations demonstrate rational utilization ratios for individual members; whether the number of profile types is reasonable (too much variety complicates erection); and whether node solutions are feasible using standard methods. Pay attention to the clarity of the documentation and the logic of the adopted structural solutions. A well-optimized design is also characterized by ease of erection, which translates into a shorter construction schedule.Can an existing design be optimized before execution?
Yes—an optimization audit of an existing design is possible and commonly performed. A design office can review the documentation and identify areas with optimization potential. This requires time for analyses, any additional calculations, and preparation of revised documentation. The optimal moment for such an audit is before procurement/tender procedures, when project modifications can be introduced without affecting the investment schedule.