Table of Contents

• Introduction

• Understanding the Challenge

• Turning Field Data into Digital Detailing

• Crafting Complex Structural Connections

• Collaboration Beyond the Model

• From Complexity to Clarity

• Watch the Project Video

• Conclusion

Introduction

Every expansion project begins with an existing story — one that demands precision, adaptability, and collaboration.
At Nexont Engineering, our mission is to transform complex structural environments into seamless detailing solutions.

Our recent Federal Medical Building Expansion demonstrates how steel detailing, field coordination, and data-driven modelling can merge to achieve remarkable construction accuracy. This project reflects our commitment to delivering precision in every connection while optimising fabrication and on-site installation.
If you’ve explored our earlier blog — From Concept to Construction: Building a Multistorey Industrial Stair Tower from Scratch — you’ll recognize a similar commitment to precision and process.

But this time, the challenge wasn’t creating something from scratch — it was building on what already exists.

Understanding the Challenge

Unlike new construction, expansion projects introduce an additional layer of complexity — working around existing concrete and utilities.

This Federal Medical Building expansion required integrating new structural steel framing into an active facility.
The challenges included:

• Pre-existing reinforcement bars (rebars) within concrete beams and columns

• Underground utility lines and embedded conduits

• Extremely tight connection tolerances between steel and concrete

Before modelling began, the Nexont team performed high-resolution field rebar scanning.
This data was imported into SDS/2, allowing detailers to plan anchor locations, beam placements, and base plates with millimetre-level accuracy — eliminating rework and ensuring absolute alignment on-site.

The workflow mirrored our detailing discipline showcased in From 2D Sketches to 3D Precision: Nexont’s Commercial Building Project, where every line on screen translated into field-ready precision.

Turning Field Data into Digital Detailing

The transition from field data to digital modelling formed the backbone of this expansion.

Every new member had to integrate perfectly with existing structures, requiring built-up beams, CJP welds, and precisely anchored connections.

Key actions included:

• Mapping rebar scan data into the SDS/2 environment

• Designing custom anchors and stiffeners aligned with actual field conditions

• Verifying elevations and geometry against site-measured benchmarks

By grounding digital design in real-world data, Nexont ensured that fabrication drawings were error-free and field-ready, minimizing site interruptions and material waste.

Crafting Complex Structural Connections

The upper levels of the expansion featured multi-story framing connected to existing concrete columns.
Some members demanded internal welds within HSS columns, a task known for its fabrication difficulty.

To address this, Nexont’s detailing team:

• Modelled access holes for internal welding

• Designed loose cover plates to close openings post-weld

• Added comprehensive weld symbols and notching details in 2D shop drawings

This approach enhanced fabrication efficiency, improved safety, and ensured long-term connection durability — key outcomes that highlight Nexont’s detailing precision.

Collaboration Beyond the Model

Behind every beam and anchor lies a conversation.
Our project's success came from continuous coordination between field engineers, structural detailers, and fabrication partners.

Regular review sessions ensured that design intent matched constructability, while data sharing between field and modelling teams maintained consistency throughout the project lifecycle.

The result was not just a 3D model — it was a communication ecosystem built around clarity and precision.

From Complexity to Clarity

The completed detailing package included:

• A fully clash-free 3D SDS/2 model

• Shop-ready 2D fabrication drawings with precise weld and notch details

• Field-verified anchor layouts and connection designs aligned with existing conditions

This expansion proves that Nexont Engineering doesn’t just produce drawings — we deliver constructible precision.
Our process bridges the gap between design, data, and on-site reality, ensuring every connection is accurate, safe, and ready to build.

Precision is not the result — it’s the foundation of every connection.

Watch the Project Video

See the complete detailing journey of this Federal Medical Building Expansion — from rebar scanning to final fabrication — on our official YouTube channel.
👉 (YouTube Link)

Discover how Nexont transforms field complexity into digital clarity.

Conclusion

Expansion projects challenge every layer of engineering — from scanning to modelling to fabrication.
This project demonstrates Nexont’s ability to integrate field data, structural detailing software (SDS/2), and technical expertise to deliver reliable, high-precision results.

At Nexont Engineering, we continue to innovate in steel detailing and construction design by redefining how precision connects existing structures with future possibilities.