At 3.47 PM on a Tuesday, structural engineer Mike discovered a nightmare hiding in cell R23 of his beam calculation spreadsheet,

The number looked right. The formula seemed correct. But something felt off about the deflection values, that engineer’s “spidey sense” that comes from years of experience. 

After two hours of cell-by-cell detective work, he found it: a unit conversion error that had been silently multiplying through his entire calculation. Pounds become kilograms somewhere around row 15, and nobody caught it. 

If this scenario makes your stomach drop, you’re not alone. 

Every structural engineer has a story like Mike’s. Maybe it’s a misplaced decimal point. A forgotten load factor. A reference to the wrong building code section. These aren’t just embarrassing mistakes. They’re project delays, budget overruns, and sleepless nights wondering if you missed something critical. 

That’s exactly why Calcs.com obsess over quality in ways that would make other software companies think we’re crazy. Because when you’re designing structures that people live and work in, “good enough” isn’t good enough. 

At Calcs.com, we strive to eliminate calculation anxiety with two solutions: Calcs Library and Calcs Builder.

Calcs Library provides secure, standards-based templates that simplify construction and engineering calculations. By adhering to global building codes, these prebuilt calculators enable engineers to confidently design and analyse structural members while focusing on the critical aspects of their projects.

But where do these calculators come from? That’s where Calcs Builder plays a pivotal role. This no-code platform is the backbone of every calculator in the library, empowering our engineering team to create fully customisable tools tailored to specific needs. 

With features like computed inputs, custom diagrams, and automated unit checking, Calcs Builder eliminates spreadsheet complexities and ensures each calculator is both reliable and practical. 

The best part? Our engineers don’t need to write a single line of code to develop calculators, allowing them to focus entirely on solving engineering challenges.

This article takes you behind the scenes of how our engineering team uses the Calcs Builder to develop the calculators in the library. From initial research to rigorous testing and validation, every step is designed to deliver tools engineers can trust. 

As Laurent Gérin, our Head of Engineering Content, explains: “Quality is how we make sure... we can sleep at night and be confident that people are safe.”

1. Research and understanding build the foundation

Our process begins with an in-depth research phase. Before diving into the specifics of a calculator, we ensure we fully understand the needs and expectations of our users. 

Whether our end users are structural engineers or building materials manufacturers, we focus on how calculations are performed in real-world contexts and the challenges engineers face.

What this involves: 

Client collaboration

‍We engage directly with engineers and manufacturers to understand workflows and typical calculations. This ensures our tools reflect real-world practices.

Leveraging field expertise

‍Many of our engineers have prior experience working in engineering firms, bringing specialised knowledge in areas such as cold-formed steel, aluminium, concrete, and formwork. This deep domain expertise ensures the calculators we develop are practical, effective, and aligned with real-world engineering demands.

Developing intuition

‍During this phase, we aim to build a sense of what makes calculations both accurate and practical. 

As Laurent explains:

“We seek to understand... trying to get a feel for the intuition here as well, of what's reasonable, what's not reasonable.”

This "spidey sense" helps identify potential red flags early and ensures the calculators align with user expectations and industry standards.

2. Planning and scoping lay out the blueprint

Once we’ve established a thorough understanding of the problem, we begin the planning and scoping phase. This step ensures the project is well-defined and risks are identified before development begins.

Collaborative reviews

‍An initial plan is drafted by one engineer and reviewed by at least two others to identify risks and unknowns. 

“Nothing gets started without having test cases that we can compare against,” Laurent says.

Understanding test cases

‍A test case is a predefined scenario used to validate the accuracy of a calculator. 

It includes specific input parameters and expected results derived from verified hand calculations, industry examples, or code provisions. For instance, in our validation examples for the wood beam calculator, we test standardised scenarios to ensure the calculator handles varying loading conditions and code requirements correctly.

Test cases act as a safety net, catching discrepancies during development or updates and ensuring our calculators are reliable for users.

‍3. Implementation embeds safeguards in every step

During implementation, our engineers use Calcs Builder to bring the blueprint to life. 

The platform incorporates numerous safeguards that prevent common errors and streamline the development process. 

Automated unit checking

“Units are absurdly commonly the source of errors in engineering,” Laurent explains. Our builder ensures unit consistency, eliminating simple mistakes like missing a conversion factor.

Live testing

‍Engineers can test calculations in real-time, catching errors early and avoiding costly late-stage revisions.

Visual equation rendering

‍The Calcs Builder displays fully rendered equations, making it easier to verify complex formulas. “Seeing the formulas helps catch issues like misplaced brackets or mislabeled variables,” Laurent adds.

Adhering to codes or innovating through research

Beyond these safeguards, our engineers either align calculators with established codes or conduct detailed research to ensure accuracy and reliability.

“For something like the timber beam calculator, virtually every line can be tied to a specific equation or clause in the standard,” Brooks Smith, our Head of Engineering R&D, explains.

This alignment ensures engineers can trust the accuracy of the results and reference the exact source when needed.

However, not all design codes provide clear guidance. For example, retaining wall design codes in Australia and the US are often vague, requiring engineers to rely on first-principles engineering and modern research. Calcs.com addressed this by conducting an in-depth comparison of methodologies.

“We validated our approach by comparing modern methodologies with older ones, which revealed where outdated methods fell short,” Brooks notes

This detailed research ensures our calculators reflect the most reliable methods, giving customers tools that prioritise safety and compliance over minimal design sizes. As Brooks emphasizes: 

“We’re not looking for the method that’s going to give the smallest, cheapest design. We’re looking for the method that’s going to give the most trustworthy and reliable design.”

4. Rigorous reviews and testing aim for perfection

Every calculator undergoes a thorough peer review and testing process before moving forward. This step is critical for identifying edge cases, logical errors, and potential bugs.

Automated testing

‍A suite of tests checks if outputs have changed compared to established test cases. “Any change whatsoever in those results… will throw a big red X, and we have to investigate,” Laurent says.

5. Beta testing and validation refine every detail

Before full release, calculators are deployed in a beta phase for testing by select customers and professional engineers. This iterative process ensures our tools meet the highest standards.

‍Customer and expert input

‍Feedback from beta testers helps refine functionality and catch any usability issues. “As our user base has grown, this feedback loop has become even more efficient,” Laurent notes.

External review

‍Every calculator is independently validated by professional engineers outside Calcs.com, ensuring an objective assessment of its reliability. As Brooks explains: “Somebody outside of Calcs.com has to verify the calculator’s accuracy. It’s a vital part of maintaining trust with our users.”

6. Launch and ongoing monitoring sustain reliability

Once a calculator is ready for release, our commitment doesn’t end there. We continue to monitor its performance and remain transparent about any issues that arise.

While our rigorous testing process catches most issues early, occasional bugs are inevitable in any software. As Brooks notes: “The more carefully you do the initial development, the less likely you are to have bugs. But you can never be 100% certain, so customer feedback becomes an essential safety net.”

One of the things that sets Calcs.com apart is our proactive error notifications, ensuring customers are never left in the dark about potential issues. When errors are identified, we don’t just fix them—we notify affected users directly, providing clear instructions on how to update their calculations and explaining the issue in full.

“We’re the only ones… that are going to tell you when there’s a mistake and when you actually need to check it,” Laurent emphasises.

This level of transparency is unmatched in the engineering software industry. Instead of vague changelogs or leaving users to guess if past calculations were affected, Calcs.com actively works to maintain trust with engineers by providing immediate, actionable insights.

‍Conclusion

At Calcs.com, our development process is driven by an unwavering commitment to quality and trust. From the foundational research phase to continuous post-launch monitoring, every step is designed to ensure our calculators meet the highest standards of safety and reliability.

As Laurent reflects: “We’ve gotten better… especially when you think we’re producing a lot more with fewer bugs.”

Ready to streamline your workflows and design custom solutions tailored to your team’s needs? Explore how Calcs Builder can help your engineering team optimize processes, eliminate spreadsheet headaches, and deliver high-quality results.

Learn more about Calcs Builder.

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