Metal Fabrication
Napa Valley, San Francisco North Bay, Ca. USA

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Fabrication, when used as an industrial term, applies to

 the building of machines , structures, process equipment for chemical, fertilizer sector by cutting, shaping and assembling components made from raw materials. Small businesses that specialize in metal are called fab shops.

Steel fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on the metal preparation, welding and assembly aspect while the machine shop is more concerned with the machining of parts.

Metal fabrication is a value added process that involves the construction of machines and structures from various raw materials. A fab shop will bid on a job, usually based on the engineering drawings, and if awarded the contract will build the product.

Fabrication shops are employed by contractors, OEM's and VAR's. Typical projects include; loose parts, structural frames for buildings and heavy equipment, and hand railings and stairs for buildings.

Planning

Once awarded the bid, the shop will begin planning the job. Purchasing agents will order materials and sub-contract out work to other shops if specialized fabrication equipment is needed.


Engineering

The fabricator may employ or contract out steel detailers to prepare shop drawings, if not provided by the customer, which the fabricating shop will use for manufacturing. Manufacturing engineers will program CNC machines as needed.


Raw materials

Standard raw materials used by metal fabricators are;

plate metal

formed and expanded metal
tube stock, CDSM
square stock
sectional metals (I beams, W beams, C-channel...)
welding wire
hardware
castings
fittings

Cutting and burning

The raw material has to be cut to size. This is done with a variety of tools;

Special band saws designed for cutting metal have hardened blades and a feed mechanism for even cutting. Abrasive cut-off saws, also known as chop saws, are similar to miter saws but with a steel cutting abrasive disk. Cutting torches can cut very large sections of steel with little effort.

 

 

 

 

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Alphabetical Listings

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Aalba Dent Inc
400 Watt Dr, Fairfield, CA 707 864-3335

A C Fence
615 Florida St, Vallejo, CA 707 738-4769

B & R Metal Specialties
50 StoneCreek Dr, American Canyon, CA 707 252-6323

Copper Iron Designs
849 Jackson St, Napa, CA 94559  707 252-1949


C C & M
1388 Copperhill Pkwy # B, Santa Rosa, CA 707 577-8283

Eclipse Design 

427 Corona Rd, Petaluma, CA 707 763-3104

Fabrique Metal
1175 El Centro Ave, Napa, CA 707 944-9393

Fun With Fusion
849 Jackson St, Napa, CA 707 252-6637

Gomez Metal
44 Commerce Pl, Vacaville, CA 707 446-0898

John Ostrat Co Inc
2361 Morrison Ln, Suisun City, CA 707 864-5600

JR Schneider Co Inc
 
849 Jackson St, Benicia, CA 707 745-0404

Lux Metals Inc
90 Ridgeway Ave, Santa Rosa, CA 707 546-1821

Metalformz
849 Jackson St, Napa, CA 94559  707 252-6637


Meuller Metals
16200 Watson Rd, Guerneville, CA 707 869-3745

Napa Valley Metal Designs
870 Sanitarium Rd, Deer Park, CA 707 963-8806

Rolf By Design
29211 Arnold Dr, Sonoma, CA 707 939-8168

Sonoma Forge
133 Copeland St # A, Petaluma, CA 707 789-9130

Steel Art
347 Cascade Dr, Fairfax, CA 415-454-5734

Steel Geisha Designs
19480 8th St E, Sonoma, CA 707 935-6210

Steinke Machinery Works
9100 Green Valley Rd, Sebastopol, CA 707 829-5741

Turner & Turner Metal Works
21 Pamaron Way # H, Novato, CA 415-883-8059

Vigil Mechanical
110 Kristina Ct, Vallejo, CA 707 649-2653

Will Built
146 Almonte Blvd, Mill Valley, CA 415-381-2246

WMS
1412 Sheridan Dr, Napa, CA 707 259-1822

 
 
 Burn tables are CNC cutting torches, usually natural gas powered. Plasma and Laser burn tables are also common. Plate steel is loaded on a table and the parts are cut out as programmed. The support table is made of a grid of bars that can be replaced. Some very expensive burn tables also include CNC punch capability, with a carousel of different punches and taps.


Forming

Hydraulic brakes with v-dies are the most common method of forming metal. The cut plate is placed in the press and a v-shaped die is pressed a predetermined distance to bend the plate to the desired angle. Wing brakes and hand powered brakes are sometimes used.

Tube bending machines have specially shaped dies and mandrels to bend tubular sections without kinking them.

Rolling machines are used to form plate steel into a round section.


Machining

Main article: machining
Fab shops will generally have a limited machining capability including; metal lathes, mills, magnetic based drills along with other portable metal working tools.


Welding

Welding is the main focus of steel fabrication. The formed and machined parts will be assembled and tack welded into place then re-checked for accuracy. A fixture may be used to locate parts for welding if multiple weldments have been ordered.

The welder then completes welding per the engineering drawings, if welding is detailed, or per his own judgment if no welding details are provided.

Special precautions may be needed to prevent warping of the weldment due to heat. These may include; welding in a staggered fashion, using a stout fixture, covering the weldment in sand during cooling, and straightening operations.

Straightening of warped steel weldments is done with an Oxy-acetylene torch and is somewhat of an art. Heat is selectively applied to the steel in a slow, linear sweep. The steel will have a net contraction, upon cooling, in the direction of the sweep. A highly skilled welder can remove significant warpage using this technique.

Steel weldments are occasionally annealed in a low temperature oven to relieve residual stresses.


Final assembly

After the weldment has cooled it is gener
 
 
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Also See:

Steel Distributors & Warehouses
Steel Mills
Metal Buildings

Welding Equipment & Supplies
Welder Training

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