The Art & Precision of Structural Engineering

In the world of structural engineering, precision and problem-solving go hand in hand. Whether designing for seismic forces, modeling complex structures, or ensuring that a crane carrying hundreds of tons operates safely, every detail matters. It’s a discipline that demands both technical expertise and a deep sense of responsibility.

For Paul, a principal engineer at Miller Consulting Engineers, that responsibility is at the core of his work. His career has been shaped by a dedication to solving intricate engineering challenges—whether analyzing how a crane runway will perform under dynamic loads or using finite element modeling to diagnose hidden stresses in a failing structure. He thrives in the details, ensuring that every connection, every load path, and every material choice is carefully considered.

In this edition of Building Bones, we explore how Paul’s expertise in cranes and structural modeling reflects the larger role of engineers as problem-solvers. From high-stakes nuclear projects to industrial facilities that rely on seamless material movement, his work highlights the unseen but essential contributions of structural engineers in keeping the built environment safe and functional.

Building Bones is a Miller Consulting Engineers (MCE) series of articles highlighting the fascinating work being done by a small, Oregon-grown structural engineering firm located in Portland, Oregon. We hope you enjoy meeting our team.

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MEET PAUL

HOW LONG HAVE YOU BEEN IN STRUCTURAL ENGINEERING?

36 years.

WHAT ASPECTS OF THE CAREER SPARKED YOUR INTEREST?

The problem solving. Puzzle solving.

HOW DID YOUR INTEREST IN ENGINEERING DEVELOP?

Like many engineers, my journey seemed to begin with Legos. As a kid, I was fascinated by how structures fit together and the forces that acted on them. My living room became a construction zone, where I built floor-to-ceiling towers just to see how high they could go before gravity had other plans.

I quickly learned that carpeting is a terrible foundation, making stability a constant challenge. But that only fueled my determination—stacking bricks higher and higher, climbing onto furniture to place one last piece. Could I make it touch the ceiling without toppling? Then, the sudden, unpredictable collapse was more than just thrilling—it was an early lesson in stability, load paths, and the forces that every structure must withstand.

DOES THE JOB MATCH YOUR ORIGINAL VISION OF STRUCTURAL ENGINEERING?

I didn’t realize how much teaching would be involved. Teaching clients, explaining how things work so they can make informed decisions. Teaching younger staff, helping them grasp the concepts at a deeper level to enable the growth and development of their practice. 

WHAT DO YOU THINK IS MISUNDERSTOOD ABOUT STRUCTURAL ENGINEERS?

Clients sometimes have a bit of a Star Trek mindset when it comes to the speed of engineering. You’ve seen it—an urgent call comes in: "Structural integrity is down 40%!" The engineer pushes a button, the shields reinforce, and suddenly, everything is back to 100%.

Of course, real engineering doesn’t work that way. It takes time. A thorough analysis isn’t just a formality—it’s essential. Good engineering isn’t about quick fixes; it’s about precision, details, and ensuring the structure is truly safe.

At the end of the day, I want to sleep well at night—knowing I’ve checked every detail and that the structure will stand the test of time.

WHAT’S YOUR NICHE?

It seems that engineers develop niche project areas that they lean into. Can you describe to me the types of projects you enjoy?

CRANES

One of my focus areas is cranes and crane runways. I really enjoy diving into the details of their structural design, and have had the opportunity to work on many different types of cranes. Most commonly, I work on fabricated bridge cranes and their runways, but have also done specialty fixed position cranes, jib cranes, and gantry cranes.

• Jib cranes are typically fixed at the base and rotate about a single point.
• Bridge cranes are mounted on a crane runway.

They all have unique design requirements. Frequently, I work with specialty crane fabricators or mechanical engineers who need help with the seismic design or other aspects of the crane's structural design.

I have worked on many different types of cranes, including some that are used for general material handling and others that are specific to industrial processes, such as lifting plastic ingots for plastic material manufacturing. Each crane and its design is tailored to the particular needs of the industry, which makes it a fascinating area of engineering.  Industrial cranes can range from 3 tons to over 500 tons. Understanding how the steel framing, seismic systems, and connections come together is truly exciting. Over the years, I’ve developed my expertise in crane details and continue to find new challenges and solutions. 

STRUCTURAL MODELING

Another focus area is structural modeling, specifically finite element modeling. It’s a specialized field that involves breaking a structure down into tiny pieces, allowing us to assess the stresses at each point. The goal is to understand how forces interact with various elements and identify the pressures on areas of interest. For structures with complicated geometry, finite element modeling is invaluable when conventional analysis can’t provide the answers. Even though the computer does the work, a solid understanding of the fundamental structural behavior is essential.

One example of its application was a project involving the base of a power transmission column that was cracking. The client needed to understand why these cracks were forming, which led us to model the complex geometry of the base connection. Without finite element analysis, it would have been nearly impossible to predict the stresses involved. Another example would be septic tanks, which can have strange, irregular shapes that are difficult to analyze without computer modeling.

How did you get into finite element modeling?

I first got into modeling through projects that required the level of detail only computer modeling could provide. At the time, I didn’t have exposure to this in school, so I basically learned on the job. Early on, computer processing power was limited, so to run a structural model, we’d start on Monday, chain the models to run consecutively, and leave them for 40-50 hours to see the results. Often, we’d have to run the model 5-6 times to complete the analysis, and if there was an issue, we'd have to start over. Tools to generate the finite element mesh were limited, tedious, and time consuming. You had to think very carefully as to what areas you were most concerned about and how you were going to develop your mesh.

These days, we can typically complete a model in minutes, thanks to advances in software and technology. It’s been amazing to see the evolution of this tool and how much more efficient we’ve become.

FORENSIC ENGINEERING - A Structural Puzzle

Another part of the job that I find interesting is forensic engineering. It’s all about solving the puzzle and figuring out what went wrong with a structure.

Early in my career there was a large church building in southeast Washington that was being constructed. After the roof was completed, cracks in the walls were observed, along with a noticeable drop in the trusses. Thinking fast, the contractor was able to call in some favors and get a 300-ton crane out to the site and in place within 12 hours. This held the roof in place, stabilizing the building. Upon investigating the failure, we found the truss suppliers' design team changed the design of the bottom chord connections in an attempt to value engineer the system for a more efficient design. There was a lot of pressure to get a solution and identify the cause quickly. Working through the details of the connection and identifying the cause was a valuable learning experience. Details do matter.

WHAT MAKES A DAY OF ENGINEERING SUCCESSFUL?

A successful day is simple for me: it’s when I’ve been able to solve a meaningful problem for a client—giving them answers they can actually use.

For me, a satisfying day also involves digging into a project and resolving an issue. It’s rewarding to uncover the root cause of a problem, define it clearly, and then determine the best solution. Ideally, this helps the client reduce costs or fabrication expenses.

MENTORSHIP & INFLUENCE

Is there someone who has had a big impact on your professional growth?

I was hired by the firm’s founder, Ray Miller, and he had a significant impact on my growth. He had a talent for explaining complex concepts clearly, making them easy to understand. Beyond that, he was willing to give me opportunities that shaped my career. I am deeply grateful to Ray for giving me a chance, and for teaching me valuable lessons in engineering and life.

It’s much harder than you’d think to hand over a client to another engineer. Developing strong client relationships and trust takes time and effort, and it’s a challenge to trust someone else with that responsibility. But Ray was willing to do that. He’d tell me, “Go for it!” and send me off to serve his clients. By placing his trust in me, he not only demonstrated his confidence in my abilities, but also encouraged me to meet his expectations and grow in my craft.

Many times we would come to Ray and say, 'this will never work.' And, he'd show us, with grace, that it did actually work. I always appreciated how Ray could do a complicated structural analysis by hand for an entire building in two or three pages.

WHAT VALUE OR PRINCIPLE DO YOU HOLD DEAR?

Trust is something I hold deeply, both professionally and personally. I am purposeful about building relationships based on trust—whether with clients, colleagues, or anyone I work with. I take pride in being someone who says what they mean and means what they say, so others can rely on me.

Honoring commitments is a big part of that. Whether I’m personally working on a project or a member of my team is, I’m responsible for ensuring that we all uphold our commitments. It’s not always easy, but it’s what keeps me motivated. I value transparency and truth, and I want to be known for speaking honestly without hidden agendas. Above all, I value my reputation and strive to ensure that everything I tell my clients is true to the best of my ability.

ANY PROJECTS THAT STAND OUT AS PARTICULARLY REWARDING?

In the last few years, I've been helping a mechanical engineering client with multiple large cranes related to the nuclear industry. Imagine the challenge of refurbishing a nuclear plant—originally built in the 1970s with the highest technology of its time. Now, we need to strengthen it to meet today’s demands.

The design is particularly rewarding because we’re working with extremely high seismic loads. A crane that handles nuclear material must remain secure, even during a major earthquake. The stakes are high, and ensuring that these cranes can withstand the worst seismic events is both a significant responsibility and an incredibly rewarding challenge.

HOBBIES & INTERESTS

What do you enjoy doing outside of work?

I’ve always been interested in technology—It has always been a puzzle, a fascination to me; learning, building, and creating things. I even built a 3D printer from a kit. It’s fun to experiment and see what I can create. When my kids were small, we used to sit down and I'd show them what a moment was and what a shear was. We'd work out mechanics problems for fun. Now two out of three of our children are engineers.

Outside of that, I like staying active. I play pickleball, take walks with my dog, and spend time with my family. I also love learning. When I retire, I’d like to go back to school and study subjects I didn’t have time for during my degree—things like anthropology, history, and the humanities. There’s always something new to explore.

Typically working behind the scenes on projects, structural engineers are the innovators and problem solvers that move the artist's vision into real, workable plans that contractors can use to actually build the structures. Stay tuned for more interviews behind the screens, with the folks whose passion it is to make our structures possible and safe. You can learn more about our team at miller-se.com.

Jane Mayfaire, Business Development | Miller Consulting Engineers | 11/2024 BB15

Series Index

Article 1 | "A Glimpse of the Magic Behind the Screens" 11-2023 | Kevin McCormick, PE, SE, Managing Principal

Article 2 | "Structural Sleuths" 12-2023 | Lane Jobe, PE, SE, Principal

Article 3 | "It's About the People" 01-2024 | Sherri Mansur, Controller

Article 4 | "Tree Forts & Geodesic Shapes 02-2024 | CJ Marquardt, PE

Article 5 | "A Heart for Math & Mentorship" 03-2024 | Michelle Juarez, PE

Article 6 | "Engineering for Joy & Inclusivity" 04-2024 | Ben Steer, PE

Article 7 | "The Haiku Project" 05-2024 | Jordan Toews, PE

Article 8 | "Peru to Portland" 06-2024 | Jennylin Lopez, Structural Designer

Article 9 | "Numbers Tell a Story" 07-2024 | Kylean , PE

Article 10 | "Life + Work = Balance" 08-2024 | Evan Altorfer, PE

Article 11 | "Value People. Foster Relationships." 09-2024 | Andrew Leichty, PE, SE, Principal

Article 12 | "Cultivating Leaders" 10-2024 | Eric Watson, PE, SE, Principal

Article 13 | "All the Other Hats" 11-2024 | Jenn Adamy, Office Manager

Article 14 | "Intern Spotlight" 12-2024 | Emma Mason, Structural Design Intern

Article 15 | "Design in Action" 01-2025 | Barry Maslen, PE, SE

Article 16 | "The Art & Precision of Structural Engineering" 02-2025 | Paul Albertine, PE, SE, Principal