Our revolution in steel beam design and
complete building envelopes powered by automated processes, have changed the way large-scale structures take shape.

The Formsteel Process

Get in Touch

Tell us what you're building. Whether you have a detailed brief or just a concept, our team engages early to understand your site, your goals, and what success looks like. If we can help, we will. If we can't, we'll tell you that too.

Meet Your Project Manager

Early in the process, a dedicated Formsteel project manager is assigned to your project. They get to know your site, your expectations, and your goals — and they stay with you through to handover. One point of contact. Full accountability. No gaps.

Concept + Design

Using StructuralIQ™, we rapidly model, optimise, and engineer your structure. Site conditions, planning requirements, and your architectural vision are all factored in from the start. Forget traditional timelines. What used to take weeks, we deliver in days.

Engineering + Pricing

StructuralIQ™ produces detailed structural calculations, fabrication drawings, and upfront fixed pricing — all in one package. Options are refined collaboratively until the solution is compliant, efficient, and cost-effective. No surprises. No scope creep.

Consents + Compliance

Our design and compliance team coordinates the consent process on your behalf — working with councils, structural consultants, and local authorities to keep your project moving. Less friction. Fewer delays. More certainty.

Fabrication

Your structure enters precision manufacturing. Every component is produced to exact specification — and carries a unique QR code so your on-site team knows exactly what each piece is and where it goes. Fast. Accurate. No guesswork.

Project Management + Delivery

Our project managers coordinate every phase — site logistics, sequencing, subcontractors, and supply chain — operating to tight programmes so your build stays on time and on budget. Clear communication throughout. No handover surprises.

Handover

Built in weeks. Designed to last decades. When your project is complete, it's more than a building — it's proof that there's a better way to build

Structural.IQ™

10 weeks of specification + design work done in 1 day.

Structural.IQ Produces;

  • Design and Drafting
  • Full Engineering Calculations
  • Producer Statement (PS1)
  • Council-ready documentation
  • Seamless integration with Revit/CAD
  • Manufacturing documents sent direct to production machines
  • Fully automated process to reduce human error

Benefits of Structural.IQ™

Specify with Confidence

Structural.IQ™ automates and accelerates the entire process, from quote to manufacture — allowing you to prepare, draft, and produce documentation with complete accuracy and ease. No guesswork. No gaps.

Project Acceleration

Speeds up the design, engineering, and consenting process, cutting unnecessary red tape and removing room for error. Less time in approvals. More time building.

Simple to 
Integrate

Full integration gives you full control. Structural.IQ™ exports directly to Revit, allowing you to add your own design flair while saving countless hours from not having to recreate models. Work in your preferred platform, without limitations.

Slash your workload

Our focus on automation dramatically reduces the time it takes to draft, calculate, and create council-ready documentation. What used to take your team weeks now takes a single day.

Precision Guaranteed

Automation means accuracy. No human error, no time-consuming re-works, no project delays. Every document produced by Structural.IQ™ is built to be right the first time.

Our Advanced Building System allows architects and designers full creative opportunity and works in with other product seamlessly so you never have to compromise on aesthetics.

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Project Gallery

SuperSpan™

SuperSpan™ is a patented structural beam system — three times stronger than conventional structural steel, yet significantly lighter. Up to 60m clear spans, 47% lower embodied carbon, and a 50-year structural guarantee. Less steel. Less cost. No compromise on integrity.

013x Stronger

SuperSpan
9.2
Universal Beam
2.9

Compared with universal beam weight-to-weight.
Strength/weight ratio (kNm/kg). Portal purlins spaced at 2m.
Comparison based on a 60m clearspan, 3,000sqm building.

0247% Less Carbon

SuperSpan
123.95 kg
Universal Beam
233.1 kg

Compared to equivalent universal beam to achieve 60m clear span.
Carbon (CO2e)pm based on 1.85 tonnes of CO2e per tonne of steel.

033x Less Crane Lifting

SuperSpan
20 T
Universal Beam
60 T

For a 60m clearspan based on weight.
Measured in Crane Tonnes

043x Less Transport

SuperSpan
3
Universal Beam
9

For a 60m clearspan, 3,000m2 building.
Approximate truck loads based on 1 tonne per truck.

05Span + Scale

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Our patented beams with stiffening technology are stronger yet lighter than traditional steel beams, allowing you to create a structure that spans further than any other - while still using less steel.

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Our unique plate connection has 100% success rate and zero failures. It all starts with accurate component manufacture 
for easy & precise installation on site.

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    Designed to withstand a category 5 cyclone with 300km/hr winds

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    Significant seismic strength through lower mass and high tensile properties.

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    Designed to withstand heavy snow loads and monsoon level rain

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    3 x stronger than structural steel, with 1 tonne of shear strength per TEK screw.

AlloyCoat™

The smarter alternative to standard galvanised steel.

AlloyCoat™ is Formsteel's premium corrosion-resistant steel coating. A high-durability Zn-Al-Mg alloy system that outperforms standard galvanised steel in every condition that matters. It protects your build, extends its service life, and keeps maintenance costs low, for the life of the structure.

Designed to impress. Built to last.

Superior Corrosion Resistance

AlloyCoat™ outperforms standard galvanised steel by up to 5–10x in salt spray testing. The magnesium component forms a protective barrier at exposed edges and cross-sections, arresting red rust and dramatically extending structural service life in coastal, industrial, and high-exposure environments.

Self-Healing Protection

AlloyCoat™ uses a magnesium-enriched alloy that reacts with moisture to seal scratches and cut edges, restoring protection where damage occurs. It's a coating system that keeps working, even after installation.

Excellent Cut-Edge Defence

Active corrosion protection minimises red rust formation at exposed edges, one of the most vulnerable points in any steel building envelope. AlloyCoat™ keeps those points protected for the long term.

Built for Coastal NZ

The magnesium addition provides substantially greater resilience in severe marine and high-humidity conditions, making AlloyCoat™ the specification of choice for coastal and exposed environments across New Zealand.

Lighter. Longer-Lasting.

With higher durability at lower coating weights, AlloyCoat™ enables leaner structural design without compromising lifespan. Less steel, lower embodied carbon, and easier handling on site, without any sacrifice on performance.

Reduced Lifecycle Maintenance

Improved durability and barrier performance lower long-term repair and replacement costs. Specify AlloyCoat™ and you're not just choosing better protection today, you're reducing the cost of ownership over the life of the building.

Environmentally Safer

AlloyCoat™ is available with a chromate-free post-treatment, meeting modern environmental and safety expectations without compromising on corrosion performance. Better for the environment. No compromise on quality.

Looking for more detail?

Technical Resources