Case Study
Steel Deck Installation at an Urban Jobsite
Myles McNickle, detailing supervisor, New Millennium
Here’s a truth: Urban jobsite pose many challenges. Space is often limited. Weather, as always, is unpredictable. Wind can become a real concern at higher elevations.
Here’s another truth: Steel deck is strong. Steel deck is versatile. Steel deck is always a great choice for a building material.
We spoke with Myles McNickles, a detailing supervisor at Steel Deck Institute member New Millenium, about overcoming the challenges of urban jobsites so you can still get all the benefits of steel deck for your project.
Below are excerpts from that conversation.
What are some unique challenges of installing steel deck in an urban environment compared to sub urban or rural job sites?
One of the biggest challenges is tighter job sites. There’s no lay down room to deliver full trucks, so we need to deliver only what is needed. That means more frequent and smaller deliveries. Sometimes we’ll need to use lighter trucks and have the deliveries be timed to mitigate traffic congestion. Deliveries also need to be there first thing in the morning or they can’t take them.
If we know we are going to struggle meeting delivery requirements because of accelerated timelines or daily deliveries, we will sometimes ship the material to either the fabricator’s yard or a marshaling yard. We ship full trucks to the marshaling yard, and then, daily, other trucks will take exactly what’s needed to the job site.
Another major thing is when they’re going vertical, we need to be aware of changes in elevation to make sure that deck is bundled separately for separate elevations. If temporary shoring is required, we need to make sure that everyone’s coordinating and to know that all of that is in place before the deck direction starts.
What types of steel deck profiles are most suitable for urban construction projects and why?
Any profile can be used. I’ve worked for specialty deck companies and commodity deck companies, and depending on the building and application they need, any deck profile can be used for high-rise buildings. That means you’re going to want to focus on the typical aspects of deck selection for your project—like composite decking vs. non-composite, span and load capacity, thickness, fire and acoustic ratings, and coatings and finishes.
How can project teams minimize disruptions to surrounding businesses and residents during the installation process?
A lot of this is up to the general contractor, but in the relationship with a deck supplier, meeting delivery windows will cut down on traffic hangups. And as we are seeing other issues on the site, we should be communicating those upstream as we’re seeing them. That’s from the time of sale all the way to delivery so everyone is coordinating correctly.
Do typical timelines for steel deck installation projects differ?
For a smaller project, the lead times and timelines of erection are not that different from a typical project. Bigger projects that are more vertical, like large high-rise structures, tend to take a bit longer to get going. That’s especially true if they’re retrofits. But once started, the erection can go pretty quickly.
Generally, coordinating a retrofit project will take longer—up to a year or two on a large high-rise building or something similar. As for smaller projects,timelines are measured in months from sale to delivery to erection.
What innovations or technologies are currently being used to streamline the installation process for urban projects?
The introduction of BIM (Building Information Modeling) has completely changed the game for urban construction projects. Using 3D modeling, teams can spot and fix potential issues before construction even starts. This not only avoids costly mistakes but also keeps the installation process smooth and on schedule.
How does weather affect installation of steel decking at an urban jobsite?
When you’re going vertical, you can’t lift material up with cranes or even move it around on the building. It becomes really dangerous. So, weather, in that respect, can cause a lot of delays. You have to be careful and take precautions to make sure those dangerous occurrences don’t happen.
However, building with steel does mitigate some of the weather-related challenges that come with using steel and concrete. Steel is lightweight compared to concrete, making it easier and faster to lift and position. And unlike wood, steel is also less affected by moisture, reducing the risk of warping or swelling during wet weather.
What are some common mistakes to avoid during the installation process on urban job sites?
One thing we try to do is mitigate waste in the field. It’s dangerous to cut material and then bring it back off the building. So, creating waste material needs to be avoided when possible, and it’s easy to do with steel deck since it’s generally manufactured to size which reduces the waste left on job sites.
SDI has published the third edition of its Manual of Construction that offers guidelines for the unloading, storage, and handling of decking and deck bundles once they arrive on the job site. You can find the manual under the Publications tab on our site in the Construction Manuals section.
Can you share some examples of how installation processes differ between new builds and retrofits in urban settings?
In a new structure, everything should be on plan. There’s no need to field verify dimensions since we have all the needed information from the outset, and we can provide the deck at the correct length with no waste. It’s coming to the site ready to be installed. That’s the biggest difference.
While retrofits require more coordination due to the number of moving parts, this ensures the final result aligns perfectly with the existing structure. After demolition, field dimensions are carefully verified to supply the right materials, often right when the deck is needed. Retrofits may involve more on-site cutting than new builds, but this flexibility allows teams to adapt seamlessly to the specific needs of the project, delivering tailored solutions that fit like a glove.
Are there any unique site preparation steps required before steel deck installation begins in an urban setting?
The staging of material is the biggest thing. If we’re delivering the right amount of material at the right times, things shouldn’t be too difficult. Coordinating with the crane lifts is also an impactful site prep activity.
Again, SDI’s Manual of Construction goes in depth on topics like site preparation and is available under the publications tab on the website.
As a material, steel decking’s flexibility and reliability make it a go-to choice for urban construction projects. Its adaptability simplifies coordination, perfect on tight urban job sites with limited space. It can be customized to project specifications, reducing waste and ensuring materials are ready for installation. Its lightweight design compared to concrete alone and resistance to weather-related issues like warping makes it a dependable solution across varying conditions. Whether it’s new builds with straightforward plans or retrofits requiring field adjustments, steel decking remains consistent in delivering high performance, meeting the diverse needs of urban construction projects.