Direct Answer
All-in fabricated structural steel costs (material + labor + overhead, excluding erection) typically range from $2,500–$5,500/ton for standard commercial work in current market conditions. Light, repetitive work (industrial platforms, standard office buildings) falls at the low end. Complex work — seismic moment frames, industrial with heavy connections, architectural steel, or structures with significant miscellaneous steel — falls toward $5,000–$8,000/ton or higher.
Full Explanation
Cost components at $3,500/ton example: (1) Steel material: $1,100–$1,500/ton (market-dependent). (2) Connection material (plates, bolts, weld wire): $300–$600/ton. (3) Shop labor (layout, CNC, welding, inspection): $800–$1,400/ton at $65–$90/hour burdened rate, assuming 10–18 hours/ton. (4) Overhead (equipment, facility, management): 25–35% of labor. (5) Detailing (if included): $200–$600/ton. (6) Primer and blasting: $100–$200/ton. (7) Profit markup: 8–15%. All-in ranges are highly sensitive to steel market pricing, wage rates by region, and project complexity.
What This Means for Your Shop
When you're asked to 'ball-park' a project before drawings are available, use $/ton as your estimating proxy — but be explicit about the assumptions (complexity level, seismic yes/no, coating system, detailing included or excluded). A ball-park without stated assumptions becomes an expectation.
Common Mistakes
Using the same $/ton factor for all project types. A $3,000/ton factor for a simple industrial project will grossly underbid a seismic moment frame project that should be $6,000+/ton.
Recommended Process
Develop $/ton ranges for each of your shop's typical project types based on historical cost data: standard office buildings, seismic moment frames, industrial platforms, multi-story residential, etc. Use these as your ballpark basis and refine with a detailed cost build-up for any project above $500K.