How a Champion of Construction Technology Aims to Lift the Entire Industry
Flawless Steel, an AISC-certified steel fabrication company in Denver, Colorado, has stood out as a technology innovator and leader in the construction industry. After opening its doors in 2011, Flawless Steel and its CEO, Victor Garcia, recognized the value of advanced technology and implemented it early on, evolving the company into a model of efficiency, accuracy, and scalability.
By integrating Trimble technologies into connected, digital workflows—combining Tekla Structures, Tekla PowerFab, and Trimble Connect—Flawless Steel was able to streamline its operations, reduce process errors, and position itself for continuous growth in a competitive environment.
Common challenges in steel fabrication
Before founding Flawless Steel, Garcia was well aware of the many challenges that often arise from manual, legacy steel fabrication and construction processes. Estimating, detailing, and production tracking were time-consuming, error-prone tasks that required significant human oversight and labor hours. Initially an erector by trade, Garcia recalls his early experience hunching over blueprints that barely fit on his table and using rulers and pens to perform estimates and takeoffs.
“We were small, and everything was done by hand,” Garcia said. “I would lay prints out in my living room, marking them up with a ruler. It was slow and tedious. That’s when I realized there had to be a better way.”
Recognizing the limitations of traditional workflows, Garcia wanted to do something different when starting Flawless Steel. As a result, he sought out solutions that would improve accuracy and efficiency—a technology commitment that led him to Trimble.
Implementing digital solutions in a pen-and-paper industry
When Garcia founded Flawless Steel in 2011, he wanted his new company to avoid the “bad habits” that plague many construction firms entrenched in traditional siloed workflows and processes. One of his earliest decisions was to adopt Trimble’s Tekla product line (Tekla Structures, Tekla PowerFab, and Trimble Connect) to support their estimating, detailing, and production control efforts.
“At first, we used a patchwork of tools like Bluebeam, FabSuite, and Steelbid Wizard. Eventually, we consolidated everything with Trimble products like Tekla Structures, Tekla PowerFab, and Trimble Connect,” Garcia said. “It allowed us to take our operations to the next level.”
By leveraging Tekla PowerFab for production control and Tekla Structures for BIM coordination, Flawless Steel shifted from paper-based processes to fully digital, connected workflows. The result? Garcia noticed an immediate improvement with enhanced team communication, fewer errors, and better client collaboration.
Implementing Trimble connected solutions in steel fabrication
Through a connected workflow with Tekla Structures, Tekla PowerFab, and Trimble Connect, the teams at Flawless Steel were able to plan their projects with greater precision before stepping on-site. Tekla PowerFab, for example, allowed them to track progress, identify potential issues early, and adjust their production schedules in real time.
“We’re always three steps ahead of everyone else because of the technology we use,” Garcia said. “With Trimble Connect, we can visualize the entire project before it starts. We track every piece of steel in real-time and stay ahead of any potential delays.”
For example, sharing IFC models across teams and partners improved the team’s ability to collaborate with other stakeholders. Whether general contractors, engineers, or field teams, all stakeholders and role players could work from the same data, ensuring accurate coordination across the project lifecycle.
This proactive approach enabled Flawless Steel to deliver projects faster and with greater accuracy, shaving weeks off typical project timelines. As an example, when bidding for a project for the Department of Energy in Golden, Flawless Steel had already modeled the entire structure in Tekla Structures before the project was awarded. This early preparation allowed the company to deliver anchor bolt submittals within two weeks, which significantly reduced lead time and helped it stand out from competitors in the project.
Overcoming technology resistance with a culture of innovation
Despite the benefits of digital, connected workflows in steel fabrication, many companies similar to Flawless Steel remain hesitant to adopt new technologies or ways of working. As a board member of the Steel Erectors Association of America, Garcia has witnessed firsthand the significant resistance to change that still persists today.
“Most guys in this industry are stuck in their ways,” he said. “They’ve been doing things the same way for 30 years, and they’re reluctant to change. But technology is the future, and if you don’t adapt, you’ll be left behind.”
Flawless Steel’s willingness to embrace technology early on allowed the company to scale efficiently, especially during the more challenging economic periods of the past 13 years. Due to this culture of innovation, Flawless Steel is now positioned as an industry leader and a technology champion in a field where many still rely on outdated methods.
This culture of innovation extends beyond leadership. The company has fostered an environment where employees are empowered to embrace new technologies and improve their skills. Younger workers, in particular, have adapted quickly to using iPads, digital models, and automated production processes.
“Our younger staff is tech-savvy, and they’ve really taken to the tools we provide them,” Garcia said. “It’s made our workflows more seamless and efficient.”
Looking to the future of steel fabrication
Looking ahead, Flawless Steel is well-poised for further growth. The company is beta-testing additional software solutions to enhance its already sophisticated workflows. By continuing to refine its processes and implement the latest technology, Flawless Steel plans to stay at the forefront of the industry.
“As more companies adopt these tools, we’ll still be ahead because we’ve already integrated them into our daily operations,” Mr. Garcia explained. “We’ve built a strong foundation, and now we’re ready to scale.”
Flawless Steel’s journey highlights the power of technology to revolutionize an industry that’s been slow to evolve, proving that innovation, technology adoption, and forward-thinking leadership are key to long-term success.