How You Can Save Up to 20% on Commercial Steel Fabrication Costs

Steel fabrication is a major investment in any commercial construction project—but that doesn’t mean it has to break the budget. With the right planning, partnerships, and design strategies, it’s possible to cut costs by up to 20% without compromising quality or performance. Whether you're building new structures or upgrading existing ones, small decisions made early in the process can lead to big savings down the road. In this post, we’ll break down where the hidden costs often creep in—and how smart choices in materials, fabrication methods, and local vendors can help you stay ahead, stay lean, and build smarter.

1. Start with Clear, Finalized Design Plans

The most common budget drain in commercial steel fabrication in Denver comes from changes after fabrication has started. These change orders can add up quickly — in time, labor, and material waste.

Before you send a project out for fabrication:

• Finalize your architectural or engineering drawings.

• Ensure your specs are precise, including material types, thicknesses, coatings, and finishes.

• Consult with your fabricator early. A reputable shop will help spot red flags or suggest cost-saving changes that still meet your intent.

Denver Railings & Metal Art works closely with architects, GCs, and business owners in the planning phase to avoid last-minute design changes. This collaborative approach often translates to fewer revisions, faster production, and tighter cost control.

2. Standardize Where You Can

Customization is great when needed — but if you can standardize components across your project (stair treads, brackets, guardrails, etc.), you’ll benefit from:

• Reduced setup and tooling time

• Lower material handling costs

• Faster fabrication and fewer mistakes

Ask your fabricator if certain elements of your design could be batch-produced or simplified. A slight design tweak can shave off hours of labor or avoid complex welds — both of which reduce your bottom line.

3. Bundle Fabrication Services In-House

A major hidden cost in commercial projects comes from shipping components back and forth between vendors. If your steel fabricator can also handle media blasting, welding, and powder coating on-site, you avoid:

• Transportation delays

• Rework from third-party miscommunication

• Additional handling and coordination fees

Denver Railings & Metal Art operates from a 27-acre facility in Strasburg, CO, where all fabrication, blasting, powder coating, and laser cutting are done under one roof. This integration not only improves quality control but also compresses project timelines — saving clients money without the usual outsourcing markup.

4. Use Materials Strategically

Material selection is a huge factor in total fabrication cost. While stainless steel or high-strength alloys are sometimes required, many projects can use more cost-effective alternatives like mild steel or aluminum without impacting performance.

Tips to reduce material cost:

• Avoid over-specifying thickness. Let your engineer determine the minimum needed.

• Choose locally available materials to reduce shipping costs.

• If aesthetics aren’t a concern (e.g., hidden structural supports), opt for more affordable finishes.

At Denver Railings & Metal Art, the team regularly helps commercial clients identify material alternatives that cut costs while meeting specs. These small changes — like substituting a hot-rolled steel for cold-rolled in a non-exposed application — can add up fast, especially across multiple units or large components.

5. Consolidate Projects When Possible

If your project includes multiple metalwork items — stairs, railings, platforms, safety barriers — bundling them with a single fabricator can significantly reduce overall costs. Here's why:

• You avoid minimum charges on small items

• Shared materials reduce waste

• Freight is combined

• There’s better coordination between components

This bundled approach also ensures a consistent finish and faster installation on-site. It’s one of the lesser-known ways smart builders maximize their steel budget without compromising execution.

6. Leverage CNC and Laser Cutting Technology

Manual cutting, fitting, and grinding are labor-intensive and prone to human error — both of which cost time and money. Today’s commercial fabricators use CNC machines and precision laser cutters to produce faster, more consistent results.

These machines:

• Reduce labor hours

• Minimize mistakes

• Cut complex shapes quickly

• Improve repeatability

Denver Railings & Metal Art uses state-of-the-art CNC fiber laser equipment to deliver high-precision steel components for commercial projects. Whether you're producing 10 brackets or 1,000 stair treads, automation is a big reason projects stay on budget and schedule.

7. Plan for Long-Term Durability

The cheapest option upfront is not always the best value in the long run. If you're cutting corners on corrosion protection, coatings, or weld quality, you'll likely pay for it down the line in repairs, replacements, or liability.

Instead, look for value in durability:

• Use powder coating instead of paint for longer wear

• Ensure welds are clean and load-tested

• Request sandblasting and rust inhibitors for outdoor components

A project that lasts 20 years with minimal upkeep is ultimately more cost-effective than one that needs to be touched up every 3–5 years. This is especially true in Denver’s climate, where snow, sun, and freeze-thaw cycles can take a toll on untreated metal.

8. Work with a Local Fabricator

Using a fabricator based in the Denver area eliminates freight costs, reduces lead times, and gives you better project oversight. It also means easier site visits, direct communication, and fewer misunderstandings.

Denver Railings & Metal Art has been serving the Front Range since 2009, providing commercial steel fabrication services in Denver for a wide range of industries. Their local presence means fast response times, on-site measurements when needed, and strong relationships with Denver-based contractors and developers.

Final Thoughts

Commercial steel fabrication in Denver is a serious investment — but it's also an area where smart decisions can lead to substantial savings. By planning carefully, working with the right partner, and leveraging in-house capabilities, it’s possible to cut up to 20% off total project costs without compromising on quality.

Whether you're building out a commercial space, retrofitting a facility, or adding functional steel elements to your property, working with an experienced, full-service local shop like Denver Railings & Metal Art can make all the difference — in your budget, your timeline, and the final product.