Episode 128 - Casting the Impossible: Rethinking Steel Connections
The Structural Engineering Podcast
Release Date: 10/07/2026
Episode 129 - Restarting the World’s Tallest Building
The Structural Engineering Podcast
In this episode, we go inside the engineering and restart of Jeddah Tower, the megaproject designed to become the world’s tallest building. We explore the structural systems behind the tower, what it takes for an engineer to step into a project of this scale, and the challenges of continuing a design that began years earlier. We also discuss what happens when construction on a megaproject stops for years and then starts again. From evaluating the partially completed structure and reviewing original design assumptions to considering changes in codes, technology, and construction practices, we...
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Episode 128 - Casting the Impossible: Rethinking Steel Connections
The Structural Engineering Podcast
In this episode, we explore how cast steel is changing what’s possible in structural connection design. We discuss the origins of CAST CONNEX, why traditional fabrication methods can struggle with complex connection geometries, and how casting can provide new opportunities for structural performance, constructability, and architectural expression. We also break down how cast steel connections are designed and manufactured, the differences between casting and forging, and where technologies like machining and 3D printing fit into the process. Finally, we go inside the engineering of the...
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Episode 127 - What If Wood Could Flow?
The Structural Engineering Podcast
What if structural timber could be shaped to put material exactly where it’s needed? In this episode, we sit down with the team from Strong by Form to explore Woodflow, a new approach to engineered timber that combines material efficiency, structural performance, and advanced manufacturing. We break down how Woodflow is formed, how strand length and wood grade influence its behavior, and how it compares with established mass timber products. We also get into the engineering: strength and stiffness, weight, failure modes, durability, connections, field modifications, and the testing...
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Episode 126 - Your Design Works… But Can It Be Built?
The Structural Engineering Podcast
In this episode, we step outside the design office to explore what structural engineers often get wrong about construction. We discuss the disconnect between design intent and what actually happens in the field from constructability and tolerances to sequencing, temporary conditions, and coordination. We also look at the details engineers tend to overcomplicate, the information contractors wish they had on structural drawings, and what makes an RFI response actually useful. Through real-world lessons from the field, we explore how understanding construction can help structural engineers design...
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Episode 125 - The Building Doesn’t Match the Drawings
The Structural Engineering Podcast
In this episode, we explore the unique challenges of structural engineering in existing buildings, where the drawings don’t always match what’s actually in the field. We discuss how engineers navigate unknown conditions, undocumented modifications, aging materials, and the constraints that can make seemingly simple projects incredibly complex. We also dive into creative problem solving how to avoid getting stuck on the first workable solution, think beyond conventional approaches, and find better ways to work within an existing structure. From deformation compatibility and load...
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Episode 124 - Your Concrete Numbers Are Wrong. Does It Matter?
The Structural Engineering Podcast
In this episode, we take a closer look at the concrete mixture requirements structural engineers encounter in ACI 318. We explore where the familiar values for water-to-cementitious-material ratio, air content, aggregate size, cement type, and durability requirements come from—and what they mean for the concrete we specify on our projects. We discuss how ACI durability exposure classes influence mixture requirements, including maximum water-to-cementitious-material ratios, minimum specified strength, air entrainment, and other material requirements. Guest Profile: Tyler Ley is a...
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Episode 123 - What’s Next for Structural Steel?
The Structural Engineering Podcast
In this episode, we explore what’s next for the American Institute of Steel Construction (AISC) and the future of structural steel. We discuss how AISC’s role extends beyond the Steel Manual, how research makes its way into the codes and standards engineers use every day, and the trends shaping the steel industry over the next decade. We also dive into AISC’s 2033 Initiative and what it could mean for engineers, fabricators, and the broader steel industry. Finally, we look at the next generation of structural engineers where new graduates are excelling, where they need more...
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Episode 122 - The Role of Structural Engineers in Resilience
The Structural Engineering Podcast
In Episode 122, we explore a question that goes beyond how we design buildings: how do we make our communities more resilient before disaster strikes? We discuss the growing challenges of natural disasters, infrastructure risk, insurance, and the economic consequences of rebuilding after the fact — and why simply designing for the minimum code requirements may not be enough. We also dive into what it means to “future proof” America, and how engineers can play a role in connecting technical solutions with government, finance, insurance, technology, and community investment. From disaster...
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Episode 121 - Are Structural Engineers Too Dependent on Codes?
The Structural Engineering Podcast
In this episode, we explore the future of structural engineering and what it will take to continue pushing the profession forward. We discuss why innovation can be difficult in a risk-averse industry, how performance-based design is changing the way engineers approach complex structures, and whether our reliance on codes and software is beginning to replace first-principles thinking. We also dive into the growing role of AI in structural engineering—where it could accelerate design and innovation, where it could create new risks, and what should always remain the responsibility of the...
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Episode 120 – How Glass & Grid Shells Make the Impossible Possible
The Structural Engineering Podcast
In this episode, we sit down with Joshua Schultz, Ph.D., P.E., to explore the engineering behind grid shells and structural glass. We discuss how grid shells achieve remarkable long spans through efficient geometry, the role of form-finding and computational design, and the challenges of analysis, connections, and construction. We also dive into structural glass, covering its behavior as a structural material, connection design, redundancy, code development, and the projects pushing the boundaries of transparent architecture. Guest Profile: Joshua Schultz, Ph.D., P.E., LEED AP, is a structural...
info_outlineIn this episode, we explore how cast steel is changing what’s possible in structural connection design. We discuss the origins of CAST CONNEX, why traditional fabrication methods can struggle with complex connection geometries, and how casting can provide new opportunities for structural performance, constructability, and architectural expression.
We also break down how cast steel connections are designed and manufactured, the differences between casting and forging, and where technologies like machining and 3D printing fit into the process. Finally, we go inside the engineering of the Sphere in Las Vegas to explore how cast steel helped solve some of the project’s most complex structural connection challenges.
Guest Profile:
Carlos de Oliveira, M.A.Sc., P.Eng., is the co-founder and CEO of CAST CONNEX and a recognized expert in the design and use of steel castings in building construction. The company grew out of Carlos’s graduate research at the University of Toronto, where he explored using cast steel to improve structural connections, particularly for seismic applications. Today, CAST CONNEX provides standardized and custom cast steel connections for complex structures around the world, including the Sphere in Las Vegas. Carlos has received numerous awards for engineering innovation and entrepreneurship throughout his career.
Michael Gray, Ph.D., P.Eng., is the co-founder and Executive Vice President of CAST CONNEX. He earned both his bachelor’s degree and Ph.D. in structural engineering from the University of Toronto, where his doctoral research focused on cast steel yielding elements for high-ductility structural systems. Michael specializes in nonlinear finite element analysis, seismic design, steel behavior, and complex connection design, and has helped advance the use of cast steel components on major projects around the world, including the Sphere in Las Vegas.
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