As the construction industry continues to embrace faster, smarter, and more sustainable building practices, cleat steel systems—anchored by the use of steel cleats—are becoming essential tools in the structural engineer’s and fabricator’s toolkit. Once considered mere accessories for connecting beams to columns, steel cleats have evolved into strategic components that drive efficiency, precision, and modularization in modern projects.

This article explores the role of cleat steel in transforming how we build—from reducing on-site labor and improving safety, to enabling full off-site fabrication and simplifying assembly in modular construction.

What Are Steel Cleats?

Steel cleats are connection plates—usually right-angled or flat—that link steel structural members such as beams, girders, columns, or trusses. These cleats can be bolted or welded, and their primary job is to transfer load from one component to another safely and efficiently.

A cleat steel system refers to a structural assembly that utilizes cleats as a key method of joining multiple elements. These systems are prevalent in steel-framed buildings, warehouses, mezzanines, bridges, towers, and modular structures.

The Shift Toward Prefabrication

Prefabrication is reshaping construction globally. Under this model, most components are built off-site in controlled environments, then transported to the job site for assembly. Cleat steel systems are perfectly suited to this approach because:

• They standardize the connection process

• Enable easy alignment and fit-up of beams and columns

• Support repeatable, scalable designs for volume production

• Minimize the need for complex field welding or adjustments

Whether it’s a high-rise tower or a prefabricated school building, steel cleats reduce construction time and improve installation accuracy.

Advantages of Using Steel Cleats in Modular Construction

Let’s look at how cleat steel designs support modular building practices:

1. Speed of Assembly

Cleated components can be bolted together quickly with minimal skilled labor. Unlike welded joints, bolted cleat connections require no curing time, allowing for faster erection and sequencing.

2. Safety Enhancement

Reduced on-site welding and cutting means fewer risks from fire, heat exposure, and sharp edges. Prefabricated cleats arrive ready to install, improving workplace safety.

3. Improved Tolerances and Fit-Up

Cleats can be designed with slotted holes or tolerances that account for minor variations in structural member lengths or angles. This flexibility simplifies on-site adjustments and ensures proper alignment.

4. Reusability

Bolted cleat connections can be dismantled and reused. This makes them ideal for temporary structures, exhibition setups, or buildings designed for disassembly and relocation.

5. Scalability

In large projects with repeated bay layouts—like factories or warehouses—standardized cleat details allow for streamlined fabrication and bulk manufacturing.

Designing Cleats for Construction Efficiency

For cleat steel systems to be effective in prefab and modular contexts, the following design strategies should be employed:

• Standard Hole Patterns

Uniform bolt spacings across cleats make alignment easier and reduce errors in drilling and layout.

• Interchangeable Components

Designing cleats to connect with multiple beam sizes or orientations can simplify inventory and improve flexibility during installation.

• Clear Identification

Labeling cleats during fabrication helps match parts to locations during erection. This minimizes confusion and improves assembly speed.

• Lightweight Design

Where feasible, cleats should be optimized for weight without compromising structural integrity. Lighter cleats are easier to handle manually on site.

Case Studies: Modular Success with Cleat Steel

• Modular Hospital Units in Europe

During a rapid-build healthcare project, modular hospital rooms were manufactured off-site with cleated steel frames. Once delivered, the units were lifted into place and bolted together using pre-aligned cleats, cutting weeks from the schedule.

• Temporary Event Structures in the Middle East

For an international expo, several pavilions were built using steel cleats and SHS columns. These pavilions were designed to be dismantled and reused, with cleated joints allowing fast disassembly and minimal material waste.

• Affordable Housing Projects in Southeast Asia

Cleated steel frames were employed in modular housing developments where speed and affordability were critical. The standardized cleat system helped local builders complete homes with minimal specialized training.

Cleat Steel and Digital Construction

The effectiveness of cleat steel systems is amplified through the use of digital modeling and fabrication:

• BIM Integration: Cleat details are modeled in 3D alongside other structural elements, ensuring clash-free coordination and visual validation before fabrication.

• Automated Fabrication: CNC machines can cut, drill, and prep cleats with millimeter accuracy based on digital inputs.

• RFID Tagging and QR Codes: For large-scale projects, cleats can be tagged for traceability and matched to their corresponding locations in the model.

This digital integration enhances speed, reduces waste, and increases quality control throughout the project lifecycle.

Cleats in SHS Column Connections

SHS columns (Square Hollow Sections) are popular in modular construction due to their compact form and multidirectional connection potential. Cleats used with SHS columns must be specially designed:

• Flush-mounted cleats: Welded inside or on the face of the SHS column for a seamless connection.

• Wrap-around cleats: For heavier loads, cleats may extend around the corners of the SHS for added anchorage.

• Through-bolt cleats: Where welding isn’t possible, cleats may be bolted through the SHS with internal sleeves or stiffeners.

These solutions ensure that cleats can integrate cleanly into the modular grid layout without disrupting architectural lines.

Sustainability Benefits

In addition to efficiency and speed, cleated steel systems contribute to sustainable building practices:

• Reduced On-Site Waste: Prefabricated cleats reduce cutting, grinding, and material loss on-site.

• Energy Efficiency: Less welding means less power consumption during assembly.

• Design for Disassembly (DfD): Cleated connections allow for deconstruction and reuse, aligning with circular economy principles.

• Optimized Transportation: Modular, cleated systems pack more efficiently for shipping, reducing logistical emissions.

This makes steel cleats an attractive option for developers pursuing green building certifications like LEED or BREEAM.

Conclusion

In a construction world moving rapidly toward speed, sustainability, and standardization, steel cleats and cleat steel systems are proving to be more than just connectors—they are enablers of innovation. Their ability to simplify fabrication, streamline installation, and adapt to both permanent and temporary structures makes them indispensable in modern prefabricated and modular construction.

As the industry continues to embrace digital tools, smart fabrication, and flexible design, cleated connections will remain at the forefront—delivering strength, speed, and sustainability to every steel-framed structure.