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How to Estimate Steel Fabrication Cost

In the metal fabrication industry, knowing how to accurately estimate steel fabrication cost is critical to satisfying customers and protecting your profit margins. While it’s not too difficult to come up with an estimate for time and materials, they are only part of the equation.

Steel fabrication projects come with associated costs – the design, prototyping, finishing processes, etc. To get the most out of your project while keeping clients satisfied, you need to have a cost-saving plan. The following tips, which have been compiled by the experienced team at VeriForm Inc., will help you strengthen your job costing and maximize profits and resources.

Cost Estimation of Steel Products- Getting Started

In today’s competitive markets, it is important to have a clear understanding of cost structure before developing a pricing strategy. The sheet metal production cycle includes bending, forming, punching, welding, and many more phases, each with its own associated costs. 

To start, break down the production cycle into more straightforward processes, so you can focus on one process at a time. Then follow the steps below to get an accurate estimate of the costs involved.

Prepare a Raw Material Cost Calculation

You’ll need to estimate the number of raw materials needed to complete a single product associated with the project. Use the following steel fabrication cost calculator to estimate the material cost per product piece:

Raw material cost= volume x density of material x cost of material per kilo

If you’re purchasing steel with a density of 7.4kg/dm3 at $0.8 per kilo and the plate dimensions are 700x300mm with a 1mm thickness, you’re looking at a raw material cost of $1.29. See the calculations below:

(7 x 3 x 0.01) x 7.4 x 0.8 = 1.29

This process must be repeated for each raw material.

Calculate the Machining Cost

At this point, you must know the hourly cost, efficiency, and cycle time (productivity) of the machines being used. To calculate this information, use the formula below:

Machining cost= (hourly cost x cycle time for single piece) / efficiency

If the cycle time is 10 seconds with an 87% efficiency and hourly cost of $77.30, this formula will yield the following information: 

(77.30 x 10) / (0.87 x 3600)

Machining Cost = (78.4 x 12) / (0.855 x 3600), which yields a total of $0.24. 

To get the total production cost for a single fabricated piece, combine the cost of your raw material with the machining cost. Using the figures above, this would be:

$1.29 + 0.24 = $1.53

These calculations can give you a reasonable idea of your costs during this particular machining aspect of the production cycle.

Calculate Costs For The Different Phases of Production

Now that you have the production cost for one machine, you can apply the same cost calculator for other machines or phases. This way, you’ll get an accurate idea of your steel fabrication costs from the moment production begins until the product is ready for delivery.

Factors That Affect the Cost of Steel Fabrication

In this section, we’ll discuss some of the different factors that may influence the cost of metal fabrication for your project.

Raw Material Costs

Raw materials often fluctuate in price, causing steel fabrication costs to vary. Other factors related to raw material cost include:

• Transportation (the closer your facility is to the source, the lower this cost will be)
• Metal thickness
• Requirement for multiple materials
• Supply chain disruption

Plating and Welding Costs

When sheet metal arrives pre-plated, welding is risky because the coating can release zinc oxide when heated. If you go with uncoated steel, you’ll want to coat it after fabrication to make it more corrosion-resistant. This added step increases both cost and lead time.

Work Required

The amount of physical work required to complete the metal fabrication process will dictate the number of workers needed, which affects labour costs. Some applications, such as the use of CAD/CAM software, call for expert skills that typically cost more.

Metal Structure Qualities

The design complexity of the metal structure will affect the cost of fabrication. For example:

• A project with fewer bends, cuts, and welds will cost less.
• Intricate designs and tight tolerances often require longer manufacturing times and incur higher labour costs.

Tips for Reducing Steel Fabrication Costs

There are ways to reduce steel fabrication costs without impacting the integrity of your project.

• Using Standard Metal Sizes and Gauges: Standard sheet sizes are often less expensive than special-length sheets. Selecting material grades based on present market conditions can help minimize costs associated with variable gauges.
• Strategic Material Selection: Raw materials affect sheet metal fabrication costs. Use stock sizes whenever possible and choose less expensive materials for prototypes. You can also reduce costs by buying mill-direct.
• Lower-Cost Finishing Options: A special finish may require cost estimators to obtain external quotes, adding to the price and lead time. Some standard finishes are less expensive and faster to obtain. Finishes such as chrome plating and powder coating are readily available at a minimal cost.
• Contact a Professional Steel Fabricator: A fabrication company capable of handling most of the process on its own can speed up production and deliver products of the highest quality while helping to save costs in the long run. By connecting with a reputable steel fabricator, you can get the products you need at a competitive rate.

VeriForm Inc.: Your Steel Fabricating Experts

One of the factors to consider when designing sheet metal parts is fabrication costs. If you follow the tips discussed above, you can effectively control and even reduce the cost of steel fabrication.

VeriForm Inc. provides customers with cost-effective steel fabrication services calculated to deliver maximum cost savings. Our unique combination of an expert team, quality materials, and efficient machining processes results in superior results at a competitive rate. Learn more or get a quote for your next project by visiting our website, calling 519-653-6000 or contacting us online. 

What is Structural Steel Fabrication?

Structural steel fabrication is the process of cutting, bending, and shaping steel components for later use in steel structures like buildings, towers, and bridges. The various steps involved, which include the use of complex fabrication technologies, often call for equal measures of experience, skill, and artistry. 

Structural steel fabricating is a specialty skill that requires experience in converting raw materials into products that meet applicable codes and standards. It is widely used in the following industries:

• Aerospace
• Automotive
• Construction
• Energy
• Manufacturing
• Mining
• Shipbuilding

At VeriForm Inc, our structural steel fabrication services are provided by highly skilled tradespeople and state-of-the-art equipment. In this article, we’ll explain what structural steel fabrication is, what it’s used for, and how a top-rated Ontario metal fabrication company can help you get quality results. 

What is the Most Commonly Used Structural Steel?

Steel’s chemical composition and the treatments it undergoes can affect its hardness and ductility, making different types of steel suitable for specific applications. We’ll discuss the three main types of structural steel below.

Carbon Steel

For structural applications, carbon steel is a popular choice. As a matter of fact, it is the most commonly produced steel in North America. Carbon steel is both strong and ductile (it can bend into any shape without breaking), and it is also relatively easy to manufacture. 

This structural steel is an alloy, which means that it’s mixed with other metals or non-metallic materials. The main constituents of carbon steel are iron and carbon, with a few other elements alloyed in very small amounts. It is made in a blast furnace by mixing iron with coke (an industrial fuel made from coal or oil). The steel is cast into a mold after undergoing additional processes such as deoxidation. After that, it can be rolled, cold-formed, or heated to create the exact steel you require.

Since carbon steel is so common, it can be used for a wide variety of purposes, from bridges and buildings to bolts and fasteners. Nonetheless, other forms of steel are also suitable for specific applications.

Tool Steel

Steel alloys become stronger and harder when they are quenched and tempered. The first step is to quench alloy steel. In other words, it is heated up to a critical temperature and then cooled down immediately. (To prevent brittle edges on the steel, this process must be tightly controlled.) Following quenching for extra toughness, the alloy will be tempered. In tempering, the metal is heated once more, but below its critical point. It is then air-cooled. 

Alloy steel that has been quenched and tempered can be used for many things, including building bridges and skyscrapers. It is also used for making tools, which is why it is called tool steel.

HSLA Steel

The term HSLA refers to high-strength low-alloy steel. Elements like manganese, copper, nickel, zirconium, or more are added to steel to make it harder. Steel was originally designed for pipelines, but now you can find it in cars, cranes, and even roller coasters. Since HSLA has a good strength-to-weight ratio and can withstand a lot of stress, it is an ideal building material.

This steel also tends to be more corrosion-resistant than other kinds due to the particular elements alloyed into it. It is, however, more difficult to manufacture than carbon steel.

What Happens During Structural Steel Fabrication?

Structural steel fabrication is a multi-step process that starts with cutting and bending and usually progresses to welding and assembly.

Structural Steel Cutting

Fabricators cut structural steel using a variety of methods that include:

• Oxygen-Acetylene Flame Cutting: This technique is commonly used for general cutting or edge preparation, such as beveling, coping, or notching.
• Plasma Cutting: This mechanically-guided process is often used to cut steel plates up to one inch thick.
• Laser Cutting: Like plasma cutting, this process is useful for cutting steel plates.
• Water Jet Cutting: This manufacturing process uses high-pressure water jets to cut and shape various types of materials.
• Shearing: Performed with mechanical presses, shearing is generally useful for cutting plates and angles.

Structural Steel Bending or Rolling

The next step is to bend or roll the alloy. The process of rolling or bending structural steel involves curving it to a specified radius and arc length. The term bending generally refers to creating a bend with a tighter radius, while rolling describes a bend with a larger radius. Bent and rolled steel are often used in environments that require a curved aesthetic, such as domes, arenas, canopies, and roof trusses.

A steel fabricator can hammer steel manually or with a machine. Whether you should do one or the other depends on how much repetitive bending your project requires. Fabricators are more likely to use machinery if bending structural steel is highly repetitive.

Structural Steel Assembly

Combining the various steel parts is the next step in creating steel structures. Although some structures call for the pieces of steel to be joined using rivets, welding is the most commonly used option. This is because welding can make the steel stronger, preparing it for high-pressure applications like I-beams or columns. Compared to riveting, welding gives structures greater strength and durability.

Cleaning and Painting

The last step of the process is to clean the structure surface of any debris. The surface is prepared for painting by using a variety of cleaning methods, such as surface rusting, blasting, etc. Generally, steel structures are painted with two layers of normal paint and one layer of anti-rust paint, which protects against corrosion caused by environmental factors.

VeriForm Inc.: Your Structural Steel Fabricating Experts

Whether you work in the construction industry or the manufacturing industry, a quality structural steel fabrication process is essential for the best results. VeriForm Inc. provides expert welding services on all your fabrication projects, with any oversized or complex parts being welded on Demmeler Bluco fabrication tables for extra accuracy. If you need help with an upcoming structural steel fabrication project, we’ll be pleased to offer a competitive quote. Learn more by visiting our website, calling 519-653-6000 or contacting us online. 

Applications of TIG Welding: Analysis of Advantages & Disadvantages

Tungsten Inert Gas (TIG) welding, also known as Gas Tungsten Arc Welding (GTAW) is a form of arc welding that uses a non-consumable tungsten electrode to create the weld. Due to their high performance, strength, and reliability, GTAW welds are commonly used in aerospace and nuclear energy.

In the 1940s, TIG welding skyrocketed in popularity after successfully joining magnesium and aluminum. Today, it’s an appealing replacement for gas and manual metal arc welding because it uses an inert gas shield instead of slag to protect the weld pool. 

At VeriForm Inc, TIG welding is one of our core processes due to its corrosion and crack-resistant welds and compatibility with a wide range of metals and fillers. In this article, we look at how TIG welding works and analyze both its advantages and disadvantages in terms of application, operator skill, and efficiency.

TIG Welding: the Process

During TIG welding, a pointed tungsten electrode and the workpiece are joined by an arc in an inert environment of helium or argon. Small intense arcs created by these pointed electrodes are ideal for precision and high-quality welding. Since the electrode is not consumed, welders don’t need to balance the heat input from the arc. Filler metal must be added separately to the weld pool when it is needed.

Advantages of TIG Welding

Make Clean, High-Quality Welds

When appearances matter, you can create clean welds with TIG due to its superior arc and weld puddle control. TIG welding allows you to control the weld puddle’s temperature with a foot pedal, similar to driving a car, giving you precise control over the weld bead. Therefore, TIG welding is ideal for cosmetic welds such as automotive and metal sculpting.

In addition:

• With TIG welding, no smoke or fumes are produced, unless the metal being welded contains oil, grease, paint, lead, or zinc. Welding should begin with a clean base metal.
• The welding puddle only contains the necessary amount of filler metal, so there is no spatter or sparks when you work with clean metal.
• No flux needs to be applied or used because the Argon gas protects the weld puddle from contamination. There is also no slag to obstruct your view of the weld puddle and the finished weld won’t have any slag that needs to be removed between passes.

Only One Shielding Gas is Needed 

The versatility of Argon allows you to TIG weld all metals and thicknesses, so you only need one gas in your shop. This simplifies the welding process since you don’t have to work with a variety of gas types.

More Versatile Welding

You can make TIG welds in any position – flat, horizontal, vertical or overhead. This versatility makes it an ideal option for shops that produce items like roll cages or need to carry out welding work in tight or confined locations.

Furthermore, TIG welding can weld a greater variety of metals and alloys than any other method available. You can use this process to weld steel, nickel alloys, bronze, copper, magnesium and even gold. In the case of thin sheet metal, there is no better arc welding process: TIG prevents warping, discolouration, and burn-through by using multiple arc and heat control methods.

Greater Operational Control

TIG welding uses tungsten electrodes to create the electrical arc, which improves control. Unlike stick or MIG welding, where a consumable electrode melts into the weld area, tungsten electrodes heat and melt the filler material that is fed into the weld area by the operator. The level of control can make a difference in the quality of the results.

In addition:

• Foot pedals control amperage to the electrode, which is not the case with other welding methods, such as MIG (gas metal arc welding), in which the arc voltage is set at a preset value. A TIG welding setup has variable amperage, which is one of the main differences between it and processes like MIG welding.
• TIG welding’s filler material application helps to achieve control. As we mentioned before, TIG welding electrodes are non-consumable, so the operator can better control the amount of filler rod used by separating the filler metal application from the heating step. MIG welding, on the other hand, uses the gun as both an electrode and a filler material.

Disadvantages of TIG Welding

TIG Welding Can Be Difficult

Although TIG welding equipment and materials are relatively affordable, skilled and experienced technicians are needed to perform the process, which can result in higher labour costs. (Even the most experienced welders gradually switch over to TIG welding.) 

Welders without experience have a hard time handling heat with the pedal, as an accidental jerk will create small welding craters on the metal surface. Improperly performed inclusions, contaminations, and unbalanced heating can result in warped or defective products, as well as wasted materials.

TIG Takes Longer

TIG welding takes a lot of time. The kind of precision it’s known for is extremely time-consuming compared to other technologies like stick welding. The machines themselves also need to be thoroughly cleaned after each use: since any contamination will corrode the surface being welded, there is no room for error.

Overheating is a Risk

As the temperature is controlled by a pedal, distractions or operational errors can cause overheating. Upon overheating, the metal surface will discolour instantly, making the joint brittle and prone to breaking. You won’t be able to reduce the amperage smoothly if you haven’t developed the pulsing ability. Overheating will result in every time.

VeriForm Inc.: Your Welding and Fabrication Experts

TIG welding is one of many state-of-the-art technologies that have a place in modern metal fabrication shops. At VeriForm Inc, our CWB CSA W47.1 and W59 certified welders deliver expert and outstanding results on your fabrication projects, and all oversized or complex parts are welded on our Demmeler Bluco fabrication tables for extra precision. If you have a routine or complex welding project, we’re here to help. Learn more by visiting our website, calling 519-653-6000 or contacting us online. 

Welding Best Practices

Welding is a process that consists of different technologies and an equally diverse range of materials. The process you use and the metal being worked on will largely dictate the tools and steps involved.

Having said that, there is a set of ‘golden rules’ that can be safely applied to all welding applications. In this article, the experienced fabricators at VeriForm Inc. go over welding best practices that will maintain both efficiency and the quality of your output.

Common Welding Challenges in Fabrication Environments

Although materials with a carbon steel base are often used in welding applications, they aren’t the only ones. Stainless steel, aluminum, and even bronze and titanium are becoming more common in manufacturing and fabricating environments. When you run an enterprise that welds different materials, you’re often looking at investing in more welding equipment as well as adjusting the schedule to accommodate equipment changeover between applications.

Do’s and Don’ts of Welding

Welding solutions designed for different types of materials can help you gain flexibility and efficiency while making high-quality welds. These best practices can help ensure you always have the right equipment on hand and use it to its best advantage.

DO Wear Appropriate Clothing and Safety Gear

Maintaining compliance with safety regulations and personal protective equipment (PPE) requirements is essential. This includes wearing the following during welding operations:

• A welding helmet to protect the worker’s face from sparks and the ultraviolet and infrared rays that the arc emits
• Clothing that doesn’t have pockets or cuffs that could potentially catch sparks
• Respiratory protection to keep the welding fumes at bay

DO Clean the Metal Surface

It’s important to properly prepare the metal before you weld it. This includes removing surface contaminants like dirt, paint, and rust and sanding away any cracks or uneven surfaces. In most cases, a simple going-over with a powered wire brush is sufficient, but be prepared to go further if needed.

Should it be impossible to clean an area before repairing it, don’t use an MIG welder on it. Instead, use a stick welder with a 6011 rod and go slowly so gas bubbles escape from molten welds before these impurities can be trapped.

DON’T Stick to Basic Feeders

Don’t limit yourself to basic options when selecting wire feeders. In welding operations where materials are frequently changed, wire feeders with more advanced technologies can save time and increase productivity.

Dual feeder systems eliminate the need for separate welding cells for different materials. Integrated systems that include the power source and feeder on a single MIG runner cart can save time during setup and make it easy to move the equipment from one cell to the next. Advanced wire feeders also allow welders to save different weld programs, making it easy to retrieve the correct parameters for specific applications. 

DO Integrate Pulsed MIG Welding

Welders can produce high-quality welds and reduce rework by choosing a feeder and power source with pulsed MIG capabilities. Compared to CV MIG welding, pulsed welding is much better for aluminum because it provides lower heat input and greater arc control, reducing problems like burning, distortion, and spatter. 

There are also advanced pulsed welding processes that help you produce a better-looking weld and bead profile: some versions even compensate for welder inexperience by supporting accurate travel speeds and correct distances between the contact tip and workpiece.

DO Incorporate User-Friendly Welding Technology

With materials like aluminum and stainless steel, it can be more difficult to set the correct welding parameters to support the desired bead profile and penetration. Consider welding technologies that make these parameters easier to attain. For example:

• There are welding power sources that assist welders in setting proper parameters. When the welder enters the material type, thickness, and wire size, the machine will establish the parameters necessary to create a quality weld.
• When welding aluminum, a power source with a crater and hot start provides better arc starting and stopping capabilities. 

DO Choose the Right Filler Materials

It is critical to select the right filler metal for the application and base material. As aluminum and stainless steel come in many types, make sure the filler metal matches the base metal’s mechanical and chemical properties.

DON’T Use the Same Liner and Consumables for Different Materials

Welding steel should not be done with the same liner and consumables that weld aluminum. Cross-contamination or wire feeding issues can result. The liner for carbon steel is usually steel, while the liner for aluminum is plastic or Teflon with tighter tolerances. For the base material, you also need to use the correct feed guides and drive rolls.

DO Use the Appropriate Angle, Arc Spacing, and Speed

The correct angle will depend on the technology you are using. When wire welding, tilt the gun 10° to 15° in the direction you are pushing the weld. Maintain a 20° to 30° lead angle when stick welding.

When it comes to arc spacing, you’ll want to adjust your travel speed so that the arc remains within the leading third of the weld pool. With wire welding, maintain a distance of ⅜ to ½ inch. Stick welding requires a distance of 1/8” between the rod tip and the workpiece.

With travel speed, you’ll know that you’re going too slow when you’re producing convex, wide beads that have shallow penetration while depositing too much metal. If the travel speed is too high, the weld will produce a narrow, highly crowned bead. For most joints, the travel speed is well below 40” per minute.

VeriForm Inc.: Your Welding and Fabrication Experts

When you’re required to weld different materials, how well you adopt welding best practices can make a difference in your success rate. Pulsed MIG and advanced wire feeders allow operators to save time in setup and to produce high-quality welds, so investing in these additional capabilities can have a significant impact on the bottom line.

At VeriForm Inc., our CWB CSA W47.1 and W59 certified welders continually use welding best practices to ensure that we always meet your project specifications. We believe that in order to complete superior-quality welding, we need to use the best equipment and recommended technologies. To learn more about our metal fabrication services, please visit our website, call 519-653-6000 or contact us online.