Custom Metal Fabrication

Cutting Edge Fabrication (CEF) specializes in custom metal fabrication. With over 30 years of experience in the industry, we have earned a reputation for providing high-quality metal fabrication services, meeting the needs of our clients spanning a wide range of industries. Custom metal fabrication involves creating unique metal products tailored to each client’s specifications. This process requires high skill, precision, and state-of-the-art equipment and technology. CEF has invested in the latest tools and techniques to deliver the best possible results.

In addition to our custom metal fabrication services, CEF offers repair and maintenance services, including welding, machining, and fabrication services that help clients keep their existing equipment in top working condition.

Cutting Edge Fabrication is a leader in the custom metal fabrication industry. With our state-of-the-art equipment, experienced team of certified welders, commitment to quality, and cost-effective sheet metal fabrication processes, we create unique and innovative metal products that meet or surpass the most demanding requirements. We produce quality products using aluminum, AR plate | abrasion resistant plate, armor plate, carbon steel, heavy steel plate, alloy steel, iron, manganese, nickel-based alloys, sheet metal, stainless steel, steel, and structural steel.

Concrete Surge Hopper Fabrication Project

The CEF team are expert at large custom metal fabrication. We recently constructed numerous concrete surge hoppers comprised of over 50 different ASTM A-572 grade 50 steel components with an assembled length of 25.5 feet and weighing 5,000 pounds. The massive project involved every area of the fabrication shop. CEF also fabricated the heavy-duty paddles that stir the concrete during travel and evacuate the hopper’s mixed material.

Fabrication Project Scope
Manufacture concrete surge hoppers and paddles that transport, agitate, and deliver concrete by railcar to construction sites.

Fabrication Operations Required
laser cutting, plasma cutting, production sawing, press brake forming, rolling, fitting, and welding

Cutting, Bending, and Bump Forming

Like most fabrication projects, we start by cutting metal plate, sheet metal, and channels to shape, angle, and size. We utilized the CNC laser, plasma cutters, and automated miter saws. Many of the parts possess a radius and conical feature. We apply a bump-forming process on our CNC press brakes to create these parts. Numerous bends are made at precise positions with variable brake pressures to form the parts to specification. Many custom fixtures, templates, jigs, brackets, and braces are made and used during fabrication.

Fabrication Cutting, Bending, and Bump Forming Stage
Fabrication Fitting, Tacking, and Assembly Stage

Fitting, Tacking, and Assembly

Hopper fabricating starts in an inverted position. Formed and rolled panels are wrapped around custom-engineered templates to create a massive shell. Pre-welded channels and other metal components are tacked into place as we assemble the 5,000-pound puzzle. Numerous turnbuckle brackets and braces position and hold parts during fitting and tacking.

MIG Welding

The tacked metal structure enters into the welding phase - a combination of stitch welds (intermittent) and seam welds (continuous) bond the fabrication. The hopper becomes stable during this process, with many braces and brackets removed, leaving the build table and rotating by crane for continued welding. Weld strength is critical, as well as the need for seal welding. Remember, the hopper transports concrete and must be tight against leakage.

Fabrication MIG Welding Stage
Fabrication Finishing and Final Inspection Stage

Finishing and Final Inspection

The hopper is finally in its upright position. We remove the bracing and clean the welds and seams during finishing. Quality checks took place at every fabricating phase; now, we enter into the final inspection to review every square inch of the structure again. The fabrication passes quality inspection, meets or surpasses all design specifications, and deserves customer delivery. This ingenuity, dedication, and quality make Cutting Edge Fabrication the preferred metal fabricator.

Contact Cutting Edge Fabrication today for more information on our metal fabrication services or to request a quote!