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 explore the engineering required to get Jeddah Tower rising again—and what engineers can learn from one of the most ambitious structural projects in the world.

Guest Profile:

John Stark, EIT, M.Eng., is a structural engineer with Thornton Tomasetti in Chicago, where he works on complex tall-building design and construction. He earned his master's degree in structural engineering from MIT, with a focus on tall buildings, structural dynamics, and computational design. John is currently part of the structural engineering team working on Jeddah Tower, contributing to ongoing design updates and construction-phase engineering as the project continues toward becoming the world's first kilometer-tall building.

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structurEd (our free PE/SE study tool): TheEngineeringPodcast.com/structurEd

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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 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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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 required to bring a new structural system to market. From current applications and code approval to manufacturing scale, embodied carbon, cost, and future research, this conversation looks at what it takes to move an emerging timber technology from the lab into real structures.

Guest Profile:

Jorge Christie is the co-founder and Chief Product Officer of Strong by Form, where he leads the development of Woodflow, a biomimetic engineered-wood technology that combines computational design, material optimization, and advanced manufacturing. An architect with advanced degrees in computational design and digital fabrication from the University of Stuttgart and ETH Zurich, Jorge's work focuses on translating the structural efficiency found in nature into high-performance timber products for construction and other industries.

Links & Resources:

structurEd (our free PE/SE study tool): TheEngineeringPodcast.com/structurEd

https://strongbyform.com/

https://strongbyform.com/woodflow-core

https://www.youtube.com/watch?v=casNqN2u

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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 better, communicate more effectively, and ultimately deliver more successful projects.

Guest Profile:

Sergio Ortiz is a Senior Project Manager at Fransen Pittman Construction with extensive experience managing complex construction projects throughout Colorado and beyond. His portfolio includes schools, healthcare facilities, fire stations, commercial developments, historic renovations, and major additions to existing buildings. Sergio brings a field-focused perspective on constructability, coordination, sequencing, and the challenges that arise when structural designs move from drawings to reality.

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structurEd (our free PE/SE study tool): TheEngineeringPodcast.com/structurEd

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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 redistribution to constructability and historic building practices, this episode explores what existing buildings can teach us about becoming better structural engineers.

Guest Profile:

Dan Sloat, S.E., is an Associate Principal with Degenkolb Engineers in Seattle, where his work focuses on structural engineering, seismic evaluation, and the challenges of existing buildings. He earned his B.S. in Structural Engineering from Rice University and his M.S. in Structural Engineering from the University of Washington. Dan is passionate about creative problem solving and finding practical solutions within the constraints of existing structures topics he recently presented on at NASCC: The Steel Conference.

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structurEd (our free PE/SE study tool): TheEngineeringPodcast.com/structurEd

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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 professor and concrete researcher whose work focuses on concrete materials, mixture proportioning, durability, cement chemistry, air entrainment, curing, and field performance. Through his research and educational work, Tyler has become known for making complex concrete concepts accessible to practicing engineers and for emphasizing the connection between concrete mixture design and real-world performance.

Links & Resources:

Tyler Ley on YouTube: YouTube.com/@TylerLey

Tarantula Curve resources: ConcretePavements.org

structurEd (our free PE/SE study tool): TheEngineeringPodcast.com/structurEd

And as promised ~7 videos I really liked to help me learn about concrete mixes:

• Introduction to Concrete Mix Design
• How to Make Concrete Last 100 Years
• Aggregate in Concrete Mix Design
• Compressive Strength and Water-to-Cement Ratio
• Why Do We NEED Air Bubbles in Concrete?
• Intro to Curing Concrete
• Tarantula Curve

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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 development, and what young engineers should learn to become better steel designers.

Guest Profile:

Dr. Christopher Raebel, P.E., S.E., Ph.D., is Vice President of Engineering and Research at AISC, where he oversees technical activities including standards, research programs, and technical publications. Before joining AISC, Chris spent 12 years in structural engineering practice and later served as a professor, department chair, and director of the Architectural Engineering Program at the Milwaukee School of Engineering. His expertise includes structural steel design, connections, structural robustness, floor vibrations, and engineering education.

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structurEd (our free PE/SE study tool): TheEngineeringPodcast.com/structurEd

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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 mitigation and resilience standards to finding new ways to fund projects before a disaster occurs, this episode challenges us to think about structural engineering as part of a much larger system of risk and resilience.

If you like learning about this side of Engineering check out the Disasters Expo conference in mid-October.

Guest Profile:

Richard S. Seline is the Chief Executive and Development Officer of ROAR Partners and Executive Director of the Future Proofing America Collaborative. With more than 40 years of experience connecting government, industry, academia, investment, and communities, Richard has worked on hundreds of projects focused on resilience, economic development, and disaster risk mitigation. His work with ROAR and Future Proofing America focuses on shifting the conversation from recovering from disasters to investing in communities before disasters happen — and developing the standards, resources, and financial mechanisms to make that possible.

Sponsor:

This episode is sponsored by The Resilient Architecture and Structural Engineering Expo.

Links & Resources:

Richard Seline on YouTube: youtube.com/@rseline

Future Proofing America: futureproofingamerica.org — The initiative Richard leads, focused on building a more resilient and future-ready America.

Resilience Community Navigator: resiliencecommunitynavigator.org — Resources for navigating community resilience and disaster mitigation.

ROAR Partners: roarpartners.co/about — The "think tank-do tank" collaboration behind much of this work.

FEMA BRIC Program: FEMA Building Resilient Infrastructure and Communities — Federal funding for projects designed to reduce disaster risk and increase community resilience.

FEMA Hazard Mitigation Assistance: FEMA HMA Programs — Overview of federal hazard mitigation funding programs.

Fitch Ratings — Climate Vulnerability in Infrastructure Project Finance: Fitch Ratings — Proposed criteria for incorporating climate vulnerability into infrastructure project finance ratings.

Stimson Center — Climate-Responsive Resilient Building Codes: Stimson Center — Research on incorporating climate risk and resilience into building codes and standards.

World Bank Climate & Disaster Risk Screening Tools: climatescreeningtools.worldbank.org — Tools for assessing climate and disaster risk during project planning.

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