Sheds / Custom Sheds

Registered Building Practitioner

Custom Sheds Melbourne: Designed to Your Exact Specifications

RHS structural steel frames. VBA-registered builder. Design, permits, fabrication, and installation managed in-house.

At a glance:

Custom-designed steel sheds built from a blank brief, not a modified standard template
Universal Beams (UBs) and Open Web Trusses (OWTs) available for large-span industrial and commercial structures
VBA-registered builder: Trusteel holds both Domestic and Commercial building licences
Building permits and planning permits managed directly by Trusteel's licensed directors
Clear spans to 40m and beyond, including aircraft hangars, arenas, and commercial warehouses
In-house fabrication at Mulgrave, serving Melbourne metro and regional Victoria
Operating since 1976, with over 50 years of steel shed design and construction experience

Custom Sheds Built to Your Exact Requirements

A custom built shed starts with your brief, not a catalogue. Trusteel Fabrications designs and builds bespoke steel structures from the ground up, sized and engineered for your specific site, load requirements, and purpose. No standard template is stretched or trimmed to fit.

Trusteel has held both Domestic and Commercial building licences since registering with the Victorian Building Authority (VBA). This means one contract covers your entire project. Design, fabrication, permits, concrete, and construction are all managed in-house. You do not need to coordinate a separate builder, engineer, or concretor.

Trusteel has been building custom steel structures across Victoria since 1976. Projects completed include aircraft hangars, CFA fire stations, school shelter covers, equestrian arenas, commercial workshops, and wineries. If the structure is steel and the build is in Victoria, the scope is within reach.

What We Build

Trusteel builds custom steel structures across residential, commercial, rural, and community applications.

Structure types:

Aircraft hangars, including clear-span layouts with full-width door openings
CFA and emergency services buildings
School shelter covers and Covered Outdoor Learning Areas (COLAs)
Equestrian arenas, horse stables, and barn structures
Commercial workshops, factory sheds, and industrial warehouses
Winery and agricultural processing buildings
Storage sheds, backyard garages, and residential custom builds
Mezzanine floors within existing or new shed structures
Shed offices and internal fit-out structures

Structural options on every build:

RHS column and rafter frames as the structural standard
Universal Beams (UBs) and Open Web Trusses (OWTs) for large-span industrial builds
Gable, skillion, and raised roof configurations
Open-sided, enclosed, and semi-enclosed layouts
Insulated and ventilated roof and wall cladding options
Roller doors, sliding doors, and bifold hangar door systems

For commercial sheds including warehouses and industrial builds, Trusteel manages structural engineering certification and all BCA compliance documentation. If you’re looking for equestrian applications, including arenas and stabling complexes, our equine structures page offers dedicated design and specification details.

Trusteel delivers custom shed construction across Melbourne metro and regional Victoria, including Geelong, Gippsland, the Mornington Peninsula, Ballarat, and Bendigo, within approximately 150km of the Mulgrave workshop.

Structural Steel Frames Versus C-Section Kits

Most standard shed suppliers build with C-section frames. C-section is a folded steel profile, lighter and cheaper to produce. It is adequate for basic light-duty storage. For custom builds that need to carry unusual spans, heavy loads, or perform reliably for 30 or more years, C-section is not the right choice.

Because a custom shed can mean anything from a backyard workshop to a 40-metre clear-span aircraft hangar, the frame type is matched to what you are building. Trusteel builds most custom sheds with Rectangular Hollow Section (RHS) structural steel, a closed-section profile that resists twisting and lateral buckling in a way C-section cannot. For larger commercial and industrial custom builds, where the span or roof load exceeds what RHS carries efficiently, Trusteel specifies Universal Beams (UBs) or Open Web Trusses (OWTs) instead.

RHS, UB, and OWT frames all cost more than C-section alternatives. Here is what that investment delivers for your build:

Greater clear-span capability without intermediate columns or internal posts
Higher resistance to wind and racking loads, including in BAL-rated zones
Longer structural service life with lower maintenance requirements
More design flexibility for openings, additions, and future modifications
A stronger base for large door systems, including hangar-width bifold openings
Consistent structural performance across agricultural, commercial, and industrial applications

For large-span industrial and commercial structures, Trusteel supplements RHS frames with Universal Beams (UBs) and Open Web Trusses (OWTs) where span and load calculations require additional depth.

The Build Process

Every custom shed build follows a structured six-step process. Your primary involvement is at the brief stage and the design approval stage. Trusteel manages everything in between.

Site Assessment. Trusteel visits your property to assess the site conditions, access, ground preparation requirements, and any planning overlays. This shapes the design brief before any drawings are committed.
Design and Engineering. Your brief is translated into a structural design. Drawings include frame layouts, cladding specifications, door positions, and floor plan options. Engineering certification is prepared at this stage for permit submission.
Permits and BCA Compliance. Trusteel prepares and submits all building permit applications. For planning permits, Trusteel’s directors liaise with the relevant council directly. You do not need to manage this process yourself.
Fabrication at Mulgrave. All steel fabrication is completed in-house at Trusteel’s Mulgrave workshop. Frames, purlins, girts, and cladding are cut and prepared to specification before leaving the workshop.
Concrete and Site Preparation. Trusteel manages concrete footings and slab work where required. This is coordinated as part of the build contract, not a separate engagement.
Construction and Handover. Trusteel’s own construction crews erect the structure on site. On completion, Trusteel provides the occupancy permit and all structural documentation required by your insurer or council.

Trusteel delivers complete design, fabrication, and installation across Melbourne and regional Victoria.

Permits for Custom Sheds in Victoria

In Victoria, a building permit is required for any new shed or custom structure that exceeds the exempt thresholds under the Building Regulations 2018. Most custom builds, including commercial workshops, equestrian arenas, aircraft hangars, and school shelters, require a building permit as a baseline. Many also require a planning permit, depending on the zone and any overlays on your property.

Managing this independently means engaging a registered building surveyor, preparing engineering documentation, and submitting applications to both the relevant building surveyor and your local council. For properties in Bushfire Attack Level (BAL) zones or heritage overlays, additional assessments are required before a permit can issue.

Trusteel’s directors hold both Domestic and Commercial building licences issued by the VBA. This means Trusteel prepares and submits your permit applications directly, without requiring you to engage a third-party registered builder or building consultant. The permit process is managed as part of your project contract. You receive a fully permitted and compliant structure at handover.

Custom Shed Costs

Custom shed pricing in Victoria depends on structure size, frame type, cladding specification, site conditions, and permit requirements. Indicative cost ranges for common custom build types are set out below.

Residential custom shed or backyard garage (up to 100m²): from approximately $50,000, depending on height, cladding, and concrete requirements
Rural or equine structure (100m² to 500m²), including stables and barn sheds: from approximately $180,000, depending on design complexity and site access
Commercial or industrial custom shed (500m² and above), including warehouses and aircraft hangars: from approximately $250,000 upward, depending on clear span, structural engineering requirements, and fit-out specification

These are indicative figures only. Final cost depends on your site conditions, council requirements, frame specification, and the full scope of work. A new shed in a BAL zone, on a challenging gradient, or requiring a planning permit will carry different costs to a standard flat-site build.

To get a cost estimate based on your actual requirements, use the free Shed Designer to build your structure online, or request a scope assessment and Trusteel will provide a site-based quote.

Trusted by Victorian Businesses and Organisations

Trusteel has completed custom steel structures for a wide range of Victorian clients and organisations. Named projects on the Trusteel portfolio include:

CFA fire stations across rural Victoria, requiring compliant emergency services buildings with specific access and structural standards
School shelter covers and COLAs for Victorian schools, built to BCA and DET specifications
Aircraft hangars for private and commercial operators, including wide clear-span layouts with full-width bifold door systems
Equestrian arenas and stable complexes for horse properties across Victoria
Commercial workshops and storage sheds for Melbourne-based businesses, including Cadbury Schweppes and Lane Toyota
Winery and agricultural processing buildings for rural producers

These are not standard catalogue builds. Each required bespoke structural design, engineering certification, and full permit management. They represent the range of custom work Trusteel has delivered since 1976.

Why Work with Trusteel

Established in 1976, with over 50 years of steel shed fabrication and construction in Victoria
VBA-registered builder: holds both Domestic and Commercial building licences
RHS structural steel frames as standard on every build, not C-section
Full in-house capability: design, engineering, fabrication, permits, concrete, and construction under one contract
In-house fabrication at the Mulgrave workshop, with no outsourced steel or third-party framing supply
Building permits and planning permits prepared and submitted by Trusteel’s licensed directors
Five-year structural warranty across all Trusteel shed builds
Registered HIA member, with demonstrated compliance history across residential and commercial projects
Clear-span capability to 40m and beyond for aircraft hangars, arenas, and commercial warehouses

Frequently Asked Questions

Can you build a custom shed to any size or specification?

Trusteel builds to your brief, not to a standard size range. Clear spans to 40m and beyond are achievable using RHS frames supplemented by Universal Beams and Open Web Trusses where structural calculations require it. If your project has unusual dimensions, site constraints, or specific functional requirements, the design process starts with those requirements.

How much does a custom built shed cost in Melbourne?

Custom shed costs in Melbourne start from approximately $50,000 for a smaller residential or backyard structure and extend well above $180,000 for large commercial or industrial builds. The final figure depends on size, frame specification, cladding, concrete requirements, and permit complexity. A site-based assessment gives you an accurate figure before any commitment.

Do I need a permit for a custom shed in Victoria?

Most custom shed builds in Victoria require a building permit, and many also require a planning permit depending on your zone and property overlays. Trusteel manages both applications directly as part of your project. You do not need to engage a separate building surveyor or building consultant.

What is the difference between RHS, UB, or OWT frames and a C-section frame?

RHS, universal beams, and Open Web Trusses are all closed or structural steel profiles that resist twisting and lateral buckling far more effectively than C-section. C-section is lighter and cheaper, and suits basic storage only. Trusteel uses RHS as standard and moves to UB or OWT for larger commercial and industrial custom builds where the span exceeds what RHS carries efficiently.

Can Trusteel build custom commercial or industrial sheds?

Trusteel holds a Commercial building licence issued by the VBA and has completed commercial and industrial custom builds including warehouses, factory sheds, aircraft hangars, and emergency services buildings. All structural engineering certification, BCA compliance documentation, and permit applications are managed in-house. There is no need to engage a separate commercial builder or project manager.