From IFC to BBS: Where Most Rebar Errors Happen

IFC drawings communicate design intent. They establish structural logic, load paths, member sizes, and compliance with codes. What they do not do is resolve how steel will actually be fabricated, sequenced, delivered, and installed on site.

Yet on many fast-track projects, IFC drawings are treated as sufficiently “final” to begin procurement and fabrication planning. This assumption creates a dangerous gap between what is designed and what is buildable.

That gap is where most rebar problems begin.

Where Errors Are Introduced in the Transition to Execution

1. Rushing From IFC Directly to BBS

One of the most common and costly mistakes is generating a BBS before Shop Drawings are fully coordinated and stabilised.

When this happens:

• Bar clashes are discovered late

• Congestion at columns, walls, and raft junctions goes unresolved

• Bar lengths and shapes require revision after fabrication has begun

• Scrap increases dramatically

• Fabrication slots are blocked while drawings are reworked

Once steel is cut incorrectly, recovery is slow and disruptive — especially in a market where cut & bend capacity is already constrained.

2. Treating Shop Drawings as a Drafting Exercise

Shop Drawings are where design intent is translated into buildable reinforcement layouts. This requires judgement, sequencing logic, and an understanding of site realities.

Problems arise when:

• Shop Drawings are produced without sufficient engineering oversight

• Resources lack experience in dense UAE structural systems

• Constructability and installation sequencing are not considered

• Coordination with embeds, sleeves, and MEP penetrations is weak

The result is drawings that look correct on screen but fail on site — leading to rework, RFIs, and installation delays.

3. Disconnect Between Engineering and Fabrication

Even well-prepared Shop Drawings can fail if they are not aligned with fabrication realities.

Common disconnects include:

• Bar shapes that exceed machine capabilities

• Diameters or bending radii not supported by available equipment

• Bundling and tagging logic that does not match delivery sequencing

• Lack of visibility on cut & bend capacity at the time of issue

When engineering, detailing, and fabrication operate in silos, errors are inevitable — and costly.

Why This Matters More in the UAE Than Ever Before

The UAE construction market is entering a phase defined by:

• Larger, denser, and more complex projects

• Severe pressure on cut & bend capacity

• Shorter mobilisation windows

• Less tolerance for error or delay

In this environment, late or poorly coordinated Shop Drawings and BBS do not just cause localised issues — they disrupt entire project programmes.

A delayed or incorrect BBS can:

• Block fabrication slots

• Delay structural pours

• Cascade into MEP and finishing delays

• Increase financing and overhead costs

This is why professional Shop Drawings and BBS delivery have moved from being support functions to critical-path activities.

The Hidden Cost of Getting It Wrong

When IFC-to-BBS transitions are poorly managed, the costs are often hidden until it’s too late:

• Excessive steel wastage

• Emergency re-fabrication

• Manual on-site cutting

• Increased labour hours

• Lost credibility with consultants and clients

By the time these costs surface, recovery options are limited.

Where Ferrum Steel Solutions Adds Value

Ferrum Steel Solutions operates precisely at this high-risk interface — where design intent becomes physical execution.

Our role is to:

• Bridge IFC drawings with practical, coordinated Shop Drawings

• Engineer BBS that reflect real fabrication and site constraints

• Align detailing with available cut & bend capacity

• Reduce scrap, rework, and sequencing conflicts

• Protect project timelines through disciplined planning

By integrating engineering, detailing, and supply-chain visibility, Ferrum ensures that steel moves from drawings to site without friction or surprises.

The Bottom Line

Most rebar errors do not originate in mills or fabrication yards. They originate in the gap between IFC drawings, Shop Drawings, and BBS.

Projects that invest early in professional coordination at this stage:

• Fabricate faster

• Waste less steel

• Reduce RFIs

• Maintain programme certainty

Those that don’t pay the price later — when corrections are slow, expensive, and disruptive.

In today’s UAE construction market, nothing moves efficiently unless the transition from IFC to BBS is managed with discipline, experience, and real-world execution knowledge.