AGI added a dual purpose to our 2,000SF stainless steel room this summer by incorporating a bleeding edge welding technology to our tool kit. The industry’s newest welding technology is called “laser welding” and uses a fiber optic light to generate precise heat and control to fuse base metal and filler wire in typical welding applications. This is a process that can take the place of MIG/TIG at nearly 4x and 10x the typical welding speed respectively.
Where Is Laser Welding Used?
AGI has successfully applied this technology in stainless steel food grade applications, aluminum and galvanized ductwork, and will be utilizing it for our Winkler Blast Gate division. We are seeing an immediate increase in productivity (decrease in welding time) and improved quality across numerous projects. This tool is incredibly easy to use and learn, often easier to learn with the less conventional welding experience you have.
Our next steps with this technology are to qualify some AWS (American Welding Society) certifications. We would like to qualify procedures that are consistent with industrial fabricated ductwork from stainless steel and carbon steel. Our in-house CWI is generating Qualified Welding Procedures in AWS D9.1 specifications to help us further integrate this laser welding technology in our operation. AGI continues to implement technology to enhance our industrial welded ductwork and blast gate fabrication talents.
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 catalog 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.
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 Catalog Fabrication Drawings
Next, designers will create catalog 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 catalog.
Next, it will be disassembled, and the pieces will be finished with catalog 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.
