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  1. Benefits of Prefabricated Components

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    Prefabrication is the process of building a structure in a controlled facility for installation at a predetermined site. By manufacturing and assembling these components in a controlled environment, you can reduce onsite labor costs and increase overall productivity. Learn more about prefabricated structural components, product types offered by AGI Fabricators, and the benefits of choosing prefabricated components.

    What Are Prefabricated Components?

    Prefabricated structural components are any components, such as metal beams, columns, panels, and platforms, intended for a final project site. In contrast to building the entire structure on site, prefabricated structures are built in a fabrication facility and are mostly complete by the time they are delivered to the installation site. Once there, they are assembled and installed.

    Product Types

    AGI Fabricators offers pipe, structural steel, and equipment fabrication. As long-term industry leaders, we have experience in many disciplines, markets, and materials, which allows us to tailor our prefabricated structural components to meet a variety of industry requirements.

    Pipe Fabrication

    We fabricate steel pipes and components, including tees, elbows, reducers, and flanges, to allow for the transport of gases, liquids, and solids within modern infrastructure. Our capabilities include cutting, beveling, and welding in alignment with industry standards and specifications.

    Structural Components

    Our structural fabrication team includes structural engineers, certified shop and field welders, project managers, and an in-house certified weld inspector to verify that every weld meets industry and safety regulations. We have the most advanced tools and equipment to get the job done right, including systems like AutoCAD, Revit, and SolidWorks.

    Equipment Fabrication

    We are here for every stage of your project, including design, testing, and startup. Our large-scale equipment fabrication capabilities make sure controls and programming are properly completed, all components function as intended, and the system is easily installed in the field. We have years of experience working with a wide range of materials, including:

    • Aluminum
    • Carbon steel
    • Stainless steel
    • Duplex stainless
    • High-alloy steel
    • And more

    Benefits of Prefabricated Components

    While there is a time and place for on-site structural steel fabrication, prefabrication offers many benefits for specific applications.

    Cost Savings

    While the initial investment is higher, the long-term cost savings of prefabrication are significant, making it a great option for large-scale projects and high-volume prefabrication of stainless steel components. These cost savings come in the form of:

    • Reduced labor costs
    • Time savings
    • Material savings
    • Increased productivity
    • Transportation efficiency

    Custom Solutions

    You can take the time to design and test custom components off-site for specific applications. These parts are then easily duplicated through automated fabrication systems.

    Environmental Impact

    Off-site prefabrication is an environmentally-friendly choice that has far-reaching implications:

    • Reduced dust and pollution
    • Reduced noise pollution
    • Reduced material waste
    • A smaller job site footprint, which protects local plant and animal life

    Improved Safety

    Within a controlled environment, workmanship, comfort, and safety aren’t compromised by adverse weather conditions. In the facility, you can easily create a safety zone around the work area, whereas on a construction site, a welder may be forced to work next to gas lines, large equipment, material storage, or other people.

    Furthermore, a prefabricated component can be installed more quickly on-site, reducing time spent on the job site and reducing the number of people who may have to be involved. With less crowding and fewer materials in the way, the process is streamlined and creates fewer opportunities for mishaps and injuries.

    Pipe, Structural Steel, and Equipment Fabrication With AGI Fabricators

    Since 1893, AGI Fabricators has specialized in custom fabrication projects to serve commercial and industrial clients throughout North America. Our prefabrication solutions make it easier for construction companies to complete projects on time, within budget, and according to industry safety and quality standards.

    With certified welding capabilities, structural engineering services, short proposal turnarounds, minimal lead time, and a 100% satisfaction guarantee, we proudly serve clients in a range of industries:

    • Food processing
    • Chemical
    • Environmental
    • Material handling
    • Pharmaceutical
    • Pollution control
    • And more

    Contact us today to learn more about our structural metal fabrication capabilities, or request a quote for your prefabrication project.

  2. What is Structural Fabrication?

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    Creating large-scale metal structures is a massive undertaking. Everything from high-rise apartment buildings to military ships relies on structural fabrication to have long-lasting, sturdy frames and structural elements. At AGI Fabricators, we provide high-quality structural fabrication services starting from the scope and design stages through to on-site assembly and inspection. Learn more about structural fabrication, the multi-stage process of producing structural fabrications, and how we can manage your next project.

    What Is Structural Fabrication?

    Structural steel fabrication is a manufacturing process that can create a wide variety of different structural products from hard materials, such as carbon and stainless steel. Structural fabricators use different cutting, forming, bending, and assembly techniques to create structures either from a single structural piece or a complex assembly of multiple pieces. Manufacturers and their clients can use structural metal fabrication processes to create goods and installations like:

    • Steel Construction and Construction Components
    • Industrial Equipment
    • Heavy Duty Tools
    • Consumer Goods

    Structural Fabrication Process

    While countless different types of components can be structurally fabricated, the process of creating unique products follows the same broad steps, regardless of industry or scale. At AGI Fabricators, we follow this multi-step process to define the project, design and refine the products, and fabricate them.

    Planning Stage

    The planning stage is the initial step before designing or metalwork can begin. It’s comprised of these two phases:

    Establishing and Presenting the Initial Scope

    Structural steel fabrication is a project, and it needs a robust project plan with a clear scope before work can begin. Outlining the scope involves identifying the following:

    • Materials
    • Costs
    • Any Environmental Concerns Affecting the Project
    • Location Parameters

    By the end of this stage, the planning and design team will present an overview of the finished project to the fabrication team for in-depth parts selection.

    Estimating Rough Order of Magnitude

    In this phase, decision-makers look more closely at the cost, labor, and effort the project will require. This information, along with the material costs, will make up the budget estimate. Once this information is prepared, the project can be approved and transitioned to the design stage.

    Estimating Rough Order of Magnitude

    The design stage encompasses all the steps to create the detailed fabrication plan. It involves these three phases:

    Creating and Sending Conceptual Design for Approval

    Here, designers and fabricators will work together to specify the right materials and components for the design, i.e., which parts are standardized and which must be custom-made.

    Performing Structural Engineering

    The engineering team will survey the project to ensure the optimal outcome. Our professionals will consider factors such as:

    • Identifying the Key Objectives
    • Finalizing Material Selection: Especially in regard to environmental conditions like indoor or outdoor use

    By the end of this phase, the engineering team will complete a step-by-step breakdown of the tasks for the project, including a timeline.

    Developing Shop Fabrication Drawings

    Next, designers will create shop drawings and product or structure blueprints. Today, these design plans are typically made through state-of-the-art industry software, which can help virtually control design parameters, industrial or building code requirements, and other factors. Once the designs are complete, virtually tested (as needed), and approved, the project will move to the fabrication stage.

    Fabrication Stage

    Now, the fabrication team will create the entire structure from start to finish. Using powerful CNC machinery and other tools, fabricators will create each of the steel components using techniques such as the following:

    • Cutting, Including Laser, Plasma or Waterjet Cutting
    • Bending, Shaping, and Rolling with Specialized Press Brakes or Rolling Machines
    • Drilling
    • Fastening, Including Welding and Holes for Bolts and Rivets

    Manufacturers operate within extremely tight tolerances to ensure every piece has the right dimensions and has holes or other features added at precisely the right location. Fabricators will follow every detail of the blueprints and product designs.

    Testing and Finishing Stage

    Once the fabrication is complete, trained technicians will assemble it. Each individual component of the assembly will have a part number etched or engraved into the metal for precise on-site assembly, and fittings, fixtures, or other pieces will be used to complete the installation. In some cases, the fabricated materials will be test-assembled in the shop.

    Next, it will be disassembled, and the pieces will be finished with shop primer or multi-layer paint. The pieces can even be coated with fireproofing or rust-proofing materials.

    At the final stage, the parts will be inspected, shipped, and assembled at the final location. Inspectors can assess the structure annually as needed to create inspection reports.

    Industry Applications of Structural Fabrication

    Structural fabrication is suitable for a wide range of applications, especially for building large-scale structures and vessels. At AGI Fabricators, we provide structural fabrication services for these and other applications:

    • Bridges
    • Building Construction (Commercial and Industrial)
    • Mining
    • Shipbuilding
    • Commercial Construction
    • Industrial Structural Applications

    Choose Complete Structural Fabrication Services From AGI Fabricators

    Creating high-quality structural fabrications is an in-depth process that requires multiple teams with the expertise to design, refine, engineer, and build the structures. At AGI Fabricators, we provide comprehensive in-house services and project management to complete your next build from start to finish. Reach out today to request a quote or learn more about our services.