Quality Control in Metal Fabrication

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The metal fabrication process is complex and intricate, involving multiple production steps. From cutting and shaping to welding and finishing, each stage requires close attention to detail and precision. Quality control is essential throughout the metal fabrication process to ensure the final product meets the required specifications.

This article discusses quality control in metal fabrication, including what it is, why it’s important, how to achieve it and how it benefits both manufacturers and customers.

What Is Quality Control in Fabrication?

Quality control in fabrication refers to the measures, procedures and techniques manufacturers use to ensure their products meet required specifications and are of consistent quality. Quality control involves checking and verifying that the product is made according to the design requirements, materials and manufacturing processes established for it.

Quality control in fabrication typically involves various methods, such as the following:

Implementing quality control measures is the key to consistency and ensuring fabricators and customers understand the expectations of the finished product. Quality control is instrumental in establishing credibility as a trusted metal fabricator. The ultimate goal of quality control in fabrication is to ensure the final product is consistent, reliable and meets the customer’s requirements.

Why Is Metal Fabrication Quality Control Important?

Quality control in metal fabrication is important for many reasons. Most critically, quality control ensures the final product meets the required specifications. This is crucial in industries that use metal parts for applications such as automotive, aerospace and medical devices. Any deviation from the specifications needed in these applications could have dire consequences, including safety hazards and product failure. With quality control measures in place, manufacturers can minimize safety risks and ensure the end product is reliable and consistent.

Additionally, quality control measures help manufacturers identify and address production issues early on, ultimately saving time and money. By detecting problems early in production, manufacturers can make adjustments and corrections before the product is complete, avoiding costly rework. This saves money and shortens the time required to complete the project, allowing manufacturers to meet deadlines and deliver products more efficiently.

How to Achieve Quality Control in Fabrication

You can use several methods to achieve quality control in metal fabrication. Here are three common ways:

Benefits of Quality Control in Metal Fabrication

Implementing quality control measures in metal fabrication provides several benefits to both manufacturers and customers. For manufacturers, quality control can improve efficiency and reduce costs. Catching issues early helps manufacturers avoid reworking parts, ultimately reducing production costs. Quality control also helps manufacturers pinpoint areas for improvement, allowing them to refine their processes and become more competitive in the market.

Quality control also promotes the safety of metal fabrication employees. Metal fabrication involves heavy-duty machinery and equipment that can be dangerous if operators aren’t properly trained. Metal fabrication companies must ensure their employees’ safety and well-being, and quality control measures can help them do so by training workers to use machines and equipment appropriately.

For customers, quality control provides peace of mind that the product they receive is dependable, safe and high quality. Manufacturers build trust with their customers and ultimately improve their reputation in the industry when they fabricate and deliver high-quality metal products.

5 Essentials of Quality Control

Consider the following quality control essentials as you develop your own metal fabrication quality control checklist.

  1. Establishing standards: Establishing clear and concise standards for your products is the first essential of quality control. This step is critical because your standards will drive the rest of your quality control measures. Base these standards on your clients’ requirements and expectations, as well as industry standards and regulations. Once you’ve established standards, communicate them clearly to all employees involved in the production process.
  2. Documenting procedures: The second essential of quality control is to document the procedures you use to manufacture products. Documentation should include instructions for each step of the production process and any required testing or inspection procedures. Documenting procedures ensures a consistent production process all employees can follow.
  3. Training employees: Training employees on the established standards and procedures is the third essential of quality control. The training aims for all employees to understand the importance of quality control and how to follow the established procedures. Proper training promotes safety and helps prevent errors and inconsistencies in the production process.
  4. Monitoring and measuring performance: The fourth essential of quality control is to monitor and measure the performance of the production process. You can do so through various methods like visual inspections, dimensional checks and statistical process control. Monitoring and measuring performance can warn you of potential problems early in production, allowing you to take corrective actions at the best time.
  5. Continual improvement: The fifth essential of quality control is continually improving the production process. Continual improvement involves analyzing the data gathered during monitoring and measuring performance and identifying areas for improvement. Improving the production process leads to higher-quality products and reduced costs.

Superior Manufacturing Company Is Dedicated to Quality Control

Superior Manufacturing is a leader in precision metal fabrication with more than 75 years of industry experience, and businesses turn to us for optimally-engineered metal components.

When you need bulk orders of fabricated metal parts, you can trust Superior Manufacturing to deliver reliable, consistent goods verified by our quality control program. You’ll benefit from the fact that we’re a single-source supplier — we do everything in-house, which gives us complete control over the quality of your products.

Contact Superior Manufacturing today and experience the advantages that make us superior:

We look forward to hearing from you!

Heavy equipment operators already work in a dangerous environment, and a leaking operator cab doesn’t do them any favors. For businesses, leaks can also mean violating workplace standards and subsequent fines. Manufacturers must test cabs carefully after production, and users must continue periodic testing during use to ensure operators stay safe while using the equipment.

Still, that job can be complex. Leak tests can come in many forms, and different industries may have different standards or tolerances to meet. Knowing how to leak test an operator cab is a critical part of maintaining safety and dependability in any environment.

What Is a Leak Test?

Technicians can perform leak tests in many ways, but the overall goal is to identify the presence and characteristics of leaks, whether they be from liquids, gasses or particles. Different parts and pieces of equipment will call for various methods of leak tests. You might test pipes, hermetically sealed enclosures, cabs and many other components to look for worn seals, punctures, cracks, corrosion and any problem that could lead substances to go where they shouldn’t.

Leaks often occur when a substance moves from a high-pressure space into a lower-pressure space, but they can also occur from more random movements, like silica dust floating around a mining site.

Leak testing usually involves finding:

Why Is It Important to Conduct a Leak Test on an Operator Cab?

Some leaks are less troublesome than others, like a puncture in the line of compressed air equipment that only causes efficiency problems. Others are incredibly hazardous to human health and safety. If a leak causes toxic substances to enter the air or creates a flammable environment, for instance, finding and fixing it is crucial. Operator cabs usually fall under the latter category.

An operator cab is a protective structure that keeps operators safe from visible threats like falling objects and hard-to-spot threats like chemicals and dust. Workers have the right to safety, which is why organizations like the National Institute for Occupational Safety and Health (NIOSH) have established strict standards for leaks. Other organizations, such as the American Society for Testing and Materials (ASTM) and the International Organization for Standardization (ISO), have also created guidance about testing methods and allowable tolerances. Many codes and inspections rely on these standards.

Some things businesses look to achieve with leak tests include the following:

Common Leak Test Methods

You’ll find many types of leak tests available, chosen based on factors like the material involved and the type of equipment being tested. Since leak testing operator cabs often occurs in the field or right off an assembly line, most leak tests are non-destructive methods.

Some common methods of leak testing include:

Leak Testing Considerations

Keep these factors in mind before conducting leak tests and when interpreting results:

Meet Leak-Testing Requirements With Quality Equipment

An uneventful leak test relies on high-quality equipment and assembly. At Superior Manufacturing Company, we know how important leak testing is and what it means for your products. We put over 75 years of engineering expertise to work to deliver fabricated metal products, like operator cabs, that meet precise demands for leak-free performance.

If you need to implement leak testing for operator cabs or are looking to change your system verification processes, our knowledgeable team can help. Reach out to us today to learn more about leak tests for operator cabs and how Superior Manufacturing provides components that pass the test.

 

 

Hydraulic systems rely on large volumes of hydraulic fluid to operate adequately, especially in heavy-duty applications such as construction equipment, heavy machinery or industrial spaces. Hydraulic tanks are an essential part of hydraulic systems, storing and managing the necessary hydraulic fluid so the equipment or machinery can use it effectively and function efficiently. Learn the fundamentals of hydraulic fluid tanks and why they’re a critical part of the hydraulic system as a whole.

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What Are Hydraulic Tanks?

Hydraulic tanks, also called hydraulic reservoirs, are a vital aspect of hydraulic systems. Their primary purpose is to hold excess hydraulic fluid as the system’s oil volume changes and pumps in and out of the hydraulic cylinder. Since hydraulic tanks help regulate fluid levels, they’re most often used in applications where the fluid level fluctuates, like in agricultural, material handling and industrial applications.

In addition to holding a reserve of hydraulic fluid, these tanks play several other crucial roles in hydraulic operations. For example, a hydraulic tank helps cool and aerate the hydraulic fluid and prevents contaminants from circulating through the system by providing space for them to settle in the bottom of the tank. Hydraulic tanks also vent air in and out of the tank as it separates from the fluid.

Depending on the size of the tank, they can also often serve as a mounting surface for several other system components, including electrical control panels, the motor, hydraulic pump assemblies, filters and accumulators.

How Does a Hydraulic Tank Function?

Hydraulic tanks or reservoirs connect directly to the system’s hydraulic cylinder through a pipe or line. Hydraulic fluid moves through this line from the tank into the hydraulic cylinder as it extends and back into the tank as the cylinder retracts.

To allow this circuit to flow smoothly, a breather at the top of the tank allows air to come in and out as the fluid levels fluctuate. This air movement prevents too much pressure from building up and allows the fluid to expand or compress as the temperature changes. Additionally, baffles or partitions inside the tank help circulate the fluid more thoroughly as it returns to the tank. This process helps cool the fluid, separate air from the fluid and settle contaminants at the bottom of the tank.

While the basics are generally the same in most tanks, hydraulic tank functions can vary depending on the type of tank used. Hydraulic tanks are typically categorized into two types:

What Are Hydraulic Tanks Made Of?

Hydraulic tanks can be made from several different materials, each offering different benefits depending on your application or system’s needs. Most tanks are made from metal, though they can also be plastic. Here are the four most common materials used to make hydraulic tanks:

Hydraulic Tank Sizing

 

The size of a system’s hydraulic reservoir is crucial to the success of the entire hydraulic system. It’s best to leave tank sizing to a professional manufacturer who can calculate the appropriate size based on the system’s heat balance and how much heat needs to be dissipated through the hydraulic tank. Since every hydraulic system has different reservoir sizing needs, having a professional hydraulic tank manufacturer measure your system’s unique requirements is the best way to ensure you have an appropriately sized tank.

In most cases, it’s best to size up when you can to ensure your hydraulic reservoir is large enough to accommodate fluctuating fluid levels and thermal expansion as fluid sits in the tank. Generally, most reservoirs should hold at least twice the pump output.

What Are the Benefits of Hydraulic Tanks?

One of the biggest benefits of having a hydraulic reservoir is that it serves multiple functions. From simply holding excess fluid to regulating and conditioning the fluid, hydraulic reservoirs are an advantage to any hydraulic system. Here are a few other benefits of having a hydraulic tank:

 

Get a Custom Hydraulic Tank From Superior Manufacturing Company

Hydraulic tanks don’t have a one-size-fits-all solution. At Superior Manufacturing Company, we create custom hydraulic tanks for OEMs and other heavy-duty manufacturers. With over 75 years in business, we have the expertise to make high-quality metal hydraulic tanks that meet your specifications and equipment requirements. We handle every aspect of production, from fabrication and painting to assembly and quality control.

Contact us to learn more about our process and get a quote today.

All metal surfaces rust and degrade over time, which is why they require extra protection to ensure long-lasting quality. When finishing metal products and equipment, it’s vital that you use a dependable solution that will deliver the best results.

Powder coating and wet paint are both widely accepted metal finishing processes designed to accomplish the same goal — creating a long-lasting, high-quality finish for metal products. Despite their shared aim, these finishing methods have many key differences between them.

There are many characteristics to consider when comparing powder coating vs. wet paint. This guide will discuss the differences between these common finishes.

What Is the Difference Between Paint and Powder Coating?

Knowing and understanding the specifics behind powder coating and wet painting enables you to better determine which best serves your metal finishing needs. These finishing methods have vastly different processes behind them, as well as varying benefits.

Powder Coating

The powder coating process uses plastic powders comprising finely ground particles of colored acrylics, polyester or polyurethane. Unlike wet paint finishing, powder coating is a dry finishing process due to the powder’s nonliquid composition.

The positively charged plastic powder is sprayed onto the negatively charged metal substrate, causing the coating to cling to the surface. Once the powder has coated the metal product to the desired thickness, the substrate is then heated and cured for 10 minutes to create a uniform seal.

Modern manufacturers typically finish metals with one of two types of powder coatings:

Powder coating offers many significant benefits for metal fabrication compared to wet painting, such as:

Wet Paint

Wet paint is a traditional finishing method comprising color particles suspended in a liquid solvent. This paint mixture is fed into a pressurized applicant like a pump or spraying device, which delivers it onto the dry metal surface. You must clean the metal surface of oil and dirt residue before applying the paint. It may take multiple coats of paint to ensure an even finish.

Unlike powder coating, wet paint does not require heating to cure — instead, it evaporates as the substrate dries. However, wet paint must dry for much longer than powder coating, as it can take up to 24 hours for the paint to fully cure.

Like powder coating, wet paint finishing also has numerous advantages for users. These benefits differ greatly from those of powder coating processes:

Does Powder Coating Last Longer Than Paint?

Does Powder Coating Last Longer Than Paint?

How long powder coatings last depends on factors like the type of powder, preparation quality and environmental conditions. However, these finishes typically last up to 20 years or more due to their excellent durability and wear resistance. Because powder coatings are much stronger than wet paints and have greater damage resistance, they last much longer.

Can You Tell the Difference Between Paint and Powder Coat?

In most cases, it’s possible to differentiate between powder coatings and paint. Powder coats have distinct physical and visual properties that set them apart from wet paint coatings. First, powder has a more noticeable texture than liquid paint and appears more rounded at the edges, making it easy to identify visually.

You can also use a thickness gauge to measure the density of the film. Standard liquid coatings usually range from 0.5 to 1.5 thousandths of an inch (mils), while powder coatings are much thicker at 1.5 to 4 mils.

Another way to differentiate powder from liquid is to apply an aggressive stripping solution to the finish and observe the results. Most wet paints will break down quickly, while powder will take much longer to erode due to its chemical resistance.

Is Powder Coating More Expensive Than Painting?

The powder coating process varies in cost, depending on the number of items needing coating during production. The larger the object you want to coat and the more items in your batch, the more you can expect to pay.

Though powder coating is generally more expensive than wet painting, it is considerably more cost-effective. That’s because this process produces less waste and requires less time and labor due to its high process efficiency. Powder coatings also last much longer than paint coatings, meaning you don’t have to reapply them as often.

Learn About the Benefits of Powder Coating in Tool Fabrication

Learn About the Benefits of Powder Coating in Tool Fabrication

You can invest in high-quality fabricated metal products for your customers at Superior Manufacturing Company. We’ve spent over 75 years providing our customers with manufacturing solutions that set the standard for quality, cost and delivery. Our advanced engineering capabilities also allow us to develop custom metal parts designed with your unique specifications in mind. Whatever your needs, we have the superior technologies and production capabilities needed to deliver.

Contact us to get in touch with our experts, or learn about the difference between soft and hard tooling to decide whether powder coating would be a good fit for your project!

Fabricating your metal enclosures to withstand the demands placed on them is crucial to your business. Durable metal enclosures provide your customers with equipment protection they can rely on, whether in construction, utility or industrial applications. The finish you use for your metal enclosures plays a significant role in their quality and longevity.

If you’re considering what type of metal finish to use on your enclosures, powder coating could be your best option. Powder coating provides superior durability and cost-effectiveness for a uniform finish. Discover the top reasons to use powder coat paint on your metal enclosures.

What Is a Powder-Coated Enclosure?

A powder-coated metal enclosure is a metal cabinet or housing unit finished in powder coating. These metal enclosures are typically made of steel or aluminum to protect equipment from environmental conditions and electromagnetic interference. Uses for metal enclosures include outdoor propane tank storage, circuit breaker housing units and generator and air compressor enclosures.

Because metal enclosures are vital for protecting equipment and people nearby, these units must be durable and resistant to corrosion. Powder coating is a popular metal finishing solution for metal enclosures because it provides superior durability that reduces wear and tear on the enclosure. Powder coating on enclosures also improves rust and corrosion resistance and requires little maintenance.

8 Reasons to Powder Coat Your Metal Enclosures

8 Reasons to Powder Coat Your Metal Enclosures

Powder coating offers superior benefits compared to other finishing options for metal enclosures. Here are the top eight reasons to use powder coat paint on your metal enclosures:

1. Durability

One of the essential benefits of powder coating in metal fabrication is its durability. During the powder coating process, dry powder is applied electrostatically to the metal surface. Manufacturers then heat treat the metal parts to cure the coating and form a high-quality film. The colored finish is highly durable and long-lasting. Powder coating resists chips, scratches, rust and corrosion.

2. Cost-Efficiency

The efficiency of the powder coating process reduces wasted paint and improves cost-efficiency for manufacturers. Using powder coating on metal enclosures takes less time than other coating processes and wastes very little powder. Powder coating only involves three steps:

3. Uniformity

The electrostatic application of powder coating creates a uniform color across the surface with an even spray. As the dry powder undergoes heat treatment during the curing stage, the powder melts into the metal’s surface and makes a consistent coating.

4. Aesthetic Appeal

The consistency and effectiveness of the powder coating process create a high-quality, professional look for your metal enclosures. While paint can leave streaks, ripples or bubbles, powder coating creates uniformly colored metal enclosures that will maintain their appearance for several years.

5. Customization

Powder coating offers a wide range of color and gloss options so your business can achieve the precise look it wants for its metal enclosures. Manufacturers will pigment the dry powder to your specifications and typically offer gloss options from high gloss to matte.

6. Low Maintenance

While paint may need new applications over time, dry powder coating requires far less maintenance. The only thing you need to do to keep powder coating on enclosures looking its best is to clean the enclosure occasionally.

7. Environmentally Safe

Paint often contains volatile organic compounds (VOCs) that harm the environment and adversely affect humans. In contrast, powder coating has a lower environmental impact because it does not contain harsh chemicals and solvents, although professional powder coating applicators must still wear protective gear during application. The powder coating process also produces less waste, creating less need for waste disposal once the coating is complete.

8. Versatility

Manufacturers can powder coat any metal that can hold a negative electrical charge, making this metal finishing technique extremely versatile. Whether your metal enclosures are smooth, ridged or have a unique shape, powder coating can effectively color and protect them.

Frequently Asked Questions About Powder Coat Painting on Metal Enclosures

If you’re still unsure about whether to use powder coating for your metal enclosures, the answers to these frequently asked questions may help you decide whether the process is right for your needs:

1. Is Powder Coating Better for Metal Enclosures Than Other Options?

Powder coating offers several benefits that paint and electroplating, two popular alternatives for metal finishing, do not provide:

2. How Long Will Powder Coating Last Outside?

Because the powder coating process creates a durable seal on the metal surface, powder coating on enclosures has impressive longevity even in harsh conditions. For example, powder-coated steel will last up to 20 years if properly primed and maintained. The priming stage of the powder coating process should effectively remove all surface irregularities and debris from the metal before the manufacturer applies the dry powder. Once complete, powder-coated metal enclosures only need an occasional with a solvent-free, non-abrasive cleaner.

3. What Are the Best Metals to Use With Powder Coating?

For the most part, manufacturers can use powder coating with any metal that can hold an electrostatic charge and withstand the high temperatures of the curing stage. The metals most frequently used with powder coating include:

Choose Superior Manufacturing Company for Your Metal Fabrication Production Needs

Choose Superior Manufacturing Company for Your Metal Fabrication Production Needs

Selecting powder coating for your metal enclosures offers benefits like durability, cost-efficiency and uniformity. At Superior Manufacturing, we strive to provide our customers with the highest quality precision metal parts and finishes. We are an industry-leading precision sheet metal fabrication company specializing in operator cabs, fuel and hydraulic tanks, and metal enclosures. From product design and production manufacturing to powder coating, our full-service in-house capabilities can accommodate a range of production volumes for quick turnaround without sacrificing quality.

We have more than 75 years of experience, which enabled us to develop and implement cost savings as we work with you to design products that fit your specifications. Contact us today to learn more about our precision manufacturing and engineering capabilities.

From heavy equipment manufacturing to consumer goods, there are seemingly endless applications for powder coatings on metal fabrication projects in various industries. Its popularity is easy to understand — powder coating is a high-quality, long-lasting finishing process that adds value and longevity to metal parts and products.

This post will explain what metal finishing is and why it’s important, how powder coating works and the great benefits of powder coating for metal products.

The Importance of Metal Finishing

Metal finishing is a catch-all term for several different processes. Metallic parts — also called substrates — are cleaned and coated with a top layer of metal, paint, powder or other material.

Metal finishing is an important step for many products because it:

What Is Powder Coating?

Powder coating is a finishing process that covers a substrate with an electrostatically charged plastic powder and cures it to create a uniform seal. This process is known as a dry finishing process because the powder spray does not contain a liquid element. Powder coating protects the metal product from environmental damage and excessive wear.

Typically, manufacturers will use two types of powder in this process:

 

Common applications for powder-coated metals include:

How to Cure Powder-Coated Products

The powder coating process is quicker and more efficient than other finishing processes. It produces significantly less waste and involves just three steps:

  1. Priming: Before applying the powder coating, you must first prep the surface with an abrasive method like sandblasting or vapor honing. This step creates a smooth, uniform surface, ensuring that the coating will stick to your product without leaving any gaps.
  2. Application: Once you’ve prepped the surface, you apply a positive electrostatic charge to a pigmented dry powder and spray it directly onto the negatively charged metal surface. The electric polarization promotes adhesion, completely coating the product.
  3. Curing: Finally, you cure the coating by baking the product in a specialized oven where the coating melts and gels together to create a smooth, unified surface.

Because powder coating is a dry finish, you don’t need to wait for it to dry and most products are ready for use immediately after curing.

The Benefits of Powder Coating for Steel Fabrication

You can powder coat aluminum and most steel alloys — in fact, you can apply powder coating to any metal that can hold an electrostatic charge. Powder coating is especially beneficial for steel fabrication projects because of its:

The Advantages of Powder Coating vs. Alternatives

The advantages of choosing powder coating over other options include:

If you’re looking for an affordable finishing process you can use on various metal fabrication projects, powder coating is a great choice. Be sure to ask your manufacturer about their powder coating services before making a final decision.

Contact Superior Manufacturing Company for Powder-Coated Metal Finishing

At Superior Manufacturing, we pride ourselves on providing our customers with the highest-quality metal parts and products. When you work with us, you have ultimate control — we work to your unique specifications, creating highly customized products to meet your application’s specific requirements. We also complete every project in-house, so when you choose to partner with us, you can do so with confidence.

We offer several finishing options, including powder coating. Our automated paint system efficiently applies powder and liquid finishes, allowing us to provide a quick turnaround without sacrificing quality.

Contact us today to request a free quote or to learn more about our manufacturing capabilities and custom engineering services. We look forward to working with you.

In the manufacturing world, the term “tooling” can apply to many different items used when creating something else. Molds, fixtures, cutters and jigs all fall within this broad category. From there, these resources can be assigned to narrower classifications such as soft tooling and hard tooling to better describe their characteristics and purposes.

Both of these tooling types allow manufacturers to create complex parts by injecting liquid material into a mold, where it takes on the shape of the vessel and solidifies. The primary difference between soft and hard tooling is in the material used to make the mold itself, which is a determining factor in its longevity and typical purposes.

The team at Superior Manufacturing Company has extensive experience with tooling of all kinds, as well as the knowledge of when to use soft tooling versus hard tooling. Learn more about what makes these categories distinct and which might be best for your production needs.

What Is Soft Tooling?

Soft tooling comprises injection molds made from materials like fiberglass or silicone and is popular for casting urethane and other plastics. Since these molds are made using lightweight, highly workable materials, fabricators can often make them in-house to keep their costs low.

The more workable nature of soft tooling makes it ideal for designing complex molds that would be difficult to create using a harder substance. However, these soft molds come with the natural disadvantage of wearing out more quickly.

What Is Hard Tooling?

Hard tooling is made using steel, aluminum or other metals or alloys, allowing fabricators to use a single mold for many production cycles. Since metal is unyielding, hard tooling offers a high degree of precision and can turn out a large volume of virtually identical parts.

While some manufacturers can produce their own hard tooling, many outsource this job to a third party specializing in the field. Creating a metallic mold requires adherence to tight tolerances for machining and surface finish to ensure the completed parts meet all fit, finish and function specifications.

What’s the Difference Between Soft and Hard Tooling?

The materials used to create soft and hard tooling determine the capabilities and applications of each type of mold. While substances like silicone, carbon fiber and fiberglass can generate quality parts, they simply don’t have the longevity of metal. The material and nature of the part being produced will determine how many pieces a fabricator can expect to create using a single soft tool mold, but in any situation, it is understood that soft tooling is not a long-term investment.

Conversely, hard tooling is very much an investment, as creating a metallic mold is time-consuming and expensive. A company without the ability to create hard tooling in-house can expect to pay a significant amount for a single mold. Each design requires advanced machining and finishing capabilities, plus additional steps such as heat treating to provide the mold with the longevity to produce a high volume of parts.

When Do You Use Hard Tooling vs. Soft Tooling?

Since creating a silicone or fiberglass mold is far less expensive than making one out of metal, soft tooling is ideal for early production phases like prototyping or manufacturing limited runs of a part. It can also provide substantial cost savings on designs without strict requirements for surface finish or critical dimensions.

For large production runs, the investment in hard tooling is often far more worthwhile. A single metallic mold can generate thousands or even millions of parts while maintaining close adherence to exacting specifications. If your project calls for repeatable output over numerous bulk orders, you can expect an exceptional return on the time and money involved in designing and creating hard tooling.

With highly complex parts, the question of when to use a soft tool versus a hard tool may be more difficult to answer. The more intricate the design, the more challenging and expensive it will be to create hard tooling for it. If you need a sophisticated mold, it’s best to contact a professional tooling fabricator to discuss whether the size of your order justifies the investment in a metallic version.

 

Contact Superior Manufacturing for Premier Fabrication Services

As a professional fabrication company founded in 1945, Superior Manufacturing has the capabilities and expertise to engineer and produce a wide variety of components for numerous industries. We fabricate operator cab enclosures and components for heavy equipment, hydraulic and fuel tanks, and an extensive selection of other parts with the precision and longevity to serve in demanding applications.

We also provide design and engineering services to help customers overcome emerging challenges in their industries. Our shop equipment comprises solutions for shearing, forming, welding, grinding, powder coating, and other processes to enable us to meet diverse manufacturing needs.

The Superior Manufacturing team is committed to furthering our customers’ success in any way we can. Connect with our team today to discuss your needs and our fabrication capabilities.

What Is a Generator Enclosure?
Reasons to Build a Generator Enclosure
Types of Generator Enclosures
Safety Considerations When Building a Generator Enclosure
Build Your Outdoor Generator Enclosure With Superior Manufacturing Company

Commercial generator enclosures are a necessary part of using these power solutions. They protect the generator from the elements, vandalism and more while providing safety benefits for everyone in the area. Generator enclosure designs can vary widely, and building the right one for a generator is key to getting the most out of it. We’ve put together a guide on how to build a generator enclosure that meets the machine’s needs, supports optimal operating conditions and keeps employees safe.

What Is a Generator Enclosure?

Generator enclosures are large protective barriers surrounding a permanent or portable generator. In commercial settings, outdoor generator enclosures are typically made of heavy-duty materials and designed specifically for the generator’s needs, with appropriate ventilation and access points. They support optimal operation, such as cool temperatures and maintenance demands, while offering protection from the weather, theft and vandalism.

Durable portable generator enclosures support:

 

Reasons to Build a Generator Enclosure

Along with protecting the equipment, outdoor generator enclosures affect the work environment, system reliability and upkeep. Here’s how:

 

Types of Generator Enclosures

There are several different styles of industrial generator enclosures to meet varying budgets and environmental demands. Explore the following to see what works best for various types of operations.

Weather-Protective Generator Enclosures

Protection from the elements is a must-have for outdoor generators, so weatherproof enclosures are the most basic option. They’ll keep machinery safe from rain, snow, wind and sunlight, as well as threats like particulate matter, which is common in some industrial environments. A weather-protective enclosure might also help with temperature changes and extreme cold or heat.

These enclosures are typically made of a solid metal, like steel or aluminum, that’s been weatherproofed.

Noise-Reducing Generator Enclosures

The Occupational Safety and Health Administration (OSHA) warns against hearing damage caused by loud sounds. If noise exposure exceeds 85 decibels (dB) when averaged for an 8-hour workday, employers must implement hearing conservation programs. While some generators are louder than others, noise-reducing enclosures can bring down the overall noise level at a work site or facility and are almost always necessary.

Typically, commercial facilities also have to limit noise levels according to zoning laws and noise-ordinance policies. A business in a residential area may have more need for a noise-reducing enclosure than one in an industrial location.

These sound-attenuating enclosures are typically larger and slightly more expensive than weatherproofed models, thanks to the insulation packed onto the walls. They significantly reduce a generator’s noise but won’t completely silence it. Mufflers can also help minimize sound.

Walk-In Generator Enclosures

Walk-in enclosures are the most comprehensive option, offering weather protection, noise reduction and fireproofing. As the name implies, these enclosures also allow workers to enter the space for easy maintenance and operation. This design is typically custom-created to fit the specific generator in use.

Safety Considerations When Building a Generator Enclosure

Commercial generator enclosures can help create a safer environment, but there are a few things to keep in mind when building one. Users should:

 

Build Your Outdoor Generator Enclosure With Superior Manufacturing Company

When a company’s contingency plan is at stake, high-quality supplies are essential. Superior Manufacturing is an industry leader in metal fabrication, with a specialty in designing and engineering generator enclosures. We have over 75 years of experience in the industry, and our customers reap the benefits of everything we’ve learned. We use high-quality materials, expert craftsmanship, cost-effective methods and sophisticated machinery to bring your vision to life. Throughout the process, we’ll work closely with your team to identify ideal custom solutions for your generator and business.

To learn more about building outdoor generator enclosures, reach out to one of our knowledgeable team members today.

Request a quote

Uses for a Fuel Tank at a Construction Job Site
Features to Consider
Environmental Compliance and Features
Considerations by Job Location
Security and Fuel Tracking
Temporary Fuel Tank Safety Considerations
How to Store Fuel at a Construction Site
Benefits of Working With a Precision Metal Manufacturer for OEM and Custom Fuel Tanks
Partner With Superior Manufacturing Company for Custom Fuel Transfer Tanks

While some companies might use permanent fuel tanks, above-ground transfer tanks provide more mobile solutions so that businesses can transport essential materials across several locations. Construction companies use steel, aluminum or stainless steel transfer fuel tanks to move fuels, typically diesel, between sites or different parts of a site. Workers must have a transfer pump to pump fuel directly into the equipment from a transfer fuel tank.

An above-ground fuel transfer tank is much easier to clean, maintain and inspect than other fuel tank alternatives, as inspection professionals and crews can access above-ground tanks without digging. Below, we’ll discuss the uses and benefits of fuel transfer tanks and environmental considerations, as well as how to choose a tank.

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Uses for a Fuel Tank at a Construction Job Site

A fuel transfer tank keeps equipment on a construction site running, saving the time it takes to fuel off-site. The construction industry uses site tanks to minimize fueling times and, therefore, downtime.

The benefits of using fuel transfer tanks for construction sites include the following:

 

Features to Consider

When selecting a fuel transfer tank, you’ll want to contemplate the specific fuel storage and transfer requirements for each site. Because different job sites necessitate various construction site transfer tanks, you’ll want to select a tank with features to suit your purposes:

 

Environmental Compliance and Features

Above-ground transfer tanks are regulated under the Environmental Protection Agency’s (EPA) Spill Prevention, Control and Countermeasure (SPCC) regulation (40 CFR 112). The SPCC rule strives to protect bodies of water from oil spills. Because the policy considers above-ground fuel transfer tanks larger than 55 gallons to be bulk oil storage containers, construction companies must ensure the tanks are compliant.

Companies must follow two types of secondary containment requirements:

 

The EPA requires companies to regularly test tanks. While trained personnel can conduct external visual inspections, a specialized technician must complete integrity tests. Evaluations should follow industry standards.

Construction companies can also equip tanks with specific features to prevent and manage spills. Such gauging systems include:

 

Considerations by Job Location

Each job location has different characteristics. Therefore, various job sites will require different types of transfer tanks. Crews should evaluate whether certain features may improve a site’s operations. Remote locations, in particular, may necessitate portable, sturdy tanks with remote fuel tracking capabilities and additional power sources like batteries and solar.

How much fuel a site needs and how mobile crews need the fuel supply will determine the fuel tanks’ sizes. For example, a larger area with many pieces of equipment requiring fuel may need more or larger transfer tanks. The amount of space available on a job site also influences the number and size of tanks needed.

Managers in charge of sites that require highly mobile fuel should select tanks approved by the Department of Transportation for trailer mounting. These tanks typically hold between 200 and 1,000 gallons and are ideal for supplying fuel to remote job sites. Because many of these sites are only accessible via rough roads or rocky terrain, these tanks must be sturdy enough to withstand these harsher environments. Consider selecting a tank that multiple global safety organizations have certified, as it has passed rigorous testing.

If a tank can hold more than 1,000 gallons, crews should consider how to move the tank around the site. While crews may have to move round tanks with a crane or loader, some larger cube tanks may include pockets for forklifts.

Security and Fuel Tracking

Keeping fuel transfer tanks on your job site helps your company better track fuel usage, including whether employees are honestly using company credit cards to refuel equipment off-site. All companies hope employees properly use these company assets. However, employees can, unfortunately, take advantage of a business’s trust by stealing fuel for their personal uses. On-site fuel transfer tanks prevent this problem by allowing crews to refuel without leaving the site.

While on-site above-ground tanks may prevent crews from stealing fuel with company credit cards, construction site fuel storage tanks are also vulnerable to fuel theft from strangers. These people may sneak onto sites and siphon fuel with a tube or pump during the night. However, you have several ways to help ensure your fuel stays secure.

When installing a new tank on a site, consider its location. Tanks located in easily visible areas close to a road or pathway may be more vulnerable to theft. Instead, try to place tanks in a spot that is not easily visible to the public but where crews can still easily access them.

Construction crews should also secure all manual tanks and surrounding gates with high-quality padlocks that tools may struggle to cut through. Tanks with electric pumps should have the power turned off at night or when not in use and features locked.

Fuel monitors offer another solution to increase security, tracking fuel levels to ensure fuel is secure on a site and crews are using it at an appropriate rate. Remote fuel monitoring also allows you to track different types of fuel usage to tell which fuels crews have used. Beyond helping prevent fuel theft, these systems can optimize fuel management. Fuel tracking systems reduce the need for manual fuel checking, freeing your crews to complete more pressing tasks.

Many fuel monitoring systems send alerts when fuel levels are low to optimize refilling and fuel delivery schedules, saving time and money. Others may offer automatic tank refilling. Authorized personnel can track historical fuel usage trends to streamline fuel use and management.

Temporary Fuel Tank Safety Considerations

Safe fuel handling and storage are crucial for any construction operation. You should be aware of the following when making a transfer fuel tank purchase and creating a fuel tank safety plan:

 

How to Store Fuel at a Construction Site

Construction companies often store on-site fuel above the ground. An above-ground tank has a simpler installation that eliminates the need for excavating and backfilling. Further, above-ground tanks provide a portable, easy-to-maintain on-site fuel storage solution. The benefits of using above-ground on-site fuel transfer tanks include:

 

Benefits of Working With a Precision Metal Manufacturer for OEM and Custom Fuel Tanks

A reputable precision metal manufacturer can supply quality, dependable fuel transfer tanks for your needs. These professionals work with original equipment manufacturers (OEMs) and other heavy-duty equipment manufacturers to provide high-quality fuel and hydraulic tanks. They can discuss your specific needs with you to develop the best fuel transfer tank solution, whether you’re creating a new product or updating an existing one.

Working with a precision metal manufacturer comes with many benefits, as they thoroughly test steel, stainless steel and aluminum fuel transfer tanks to ensure they’re rust and leakproof. Metal manufacturers make custom tanks in a range of sizes. They handle the entire process, from product design and engineering to shearing, punching, forming, welding, deburring and polishing. After working with you to create a fuel transfer and storage solution for your needs, a metal manufacturer will ship the finished product to you, already assembled and ready to install.

Working with a company with engineers on its team is incredibly beneficial. They have the technical expertise and design capabilities to create custom, cost-effective products for your needs, meaning you don’t have to spend time trying to build a fuel transfer tank in-house. The design process is as follows:

 

Following design, a precision metal manufacturer will then create, assemble and ship your products.

Partner With Superior Manufacturing Company for Custom Fuel Transfer Tanks

Working with a precision metal manufacturer is especially beneficial for OEMs specializing in bulk orders. For more than 75 years, Superior Manufacturing has been an industry leader in precision metal manufacturing. We handle the entire fuel and hydraulic tank manufacturing process from design to assembly without using third-party contractors. The result is consistently high-quality products.

Superior Manufacturing offers:

 

Contact us today to learn more about how our team can create custom products for you or request a quote!

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An efficiently designed machinery operator cab can make a big difference in how the operators perform during a shift and how they feel afterward. Tailoring your cab designs to create a more ergonomic environment ensures that your operators have the most effective workspace possible. There are numerous factors that can affect the ergonomics of an operator cab, including the seat position and back support. Find out what factors you should consider when designing the optimal operator cab environment.

How to Design an Ergonomic Operator Cab

Designing the operator cabs for your equipment gives you the opportunity to account for specific design elements that can help increase the comfort of the cab. An ergonomic design keeps the operator’s comfort a top priority so they can work efficiently. Because each cab and each operator have different sizes and preferences, making several components of the cab adjustable is important for optimal comfort and productivity. Consider how making these aspects of the cab adjustable can help create an ergonomic cab:

Adjustable features in the operator cabs will help to improve the operator’s experience, thus helping them be more efficient and productive.

Consider Operator Comfort

Studies have found that 100% of operators spending their shifts in machinery cabins suffer from some level of back, neck, leg, arm or shoulder pain. In many cases, this pain reaches high levels within just three hours of continuous work. The quick onset of pain and discomfort is often due to minimal comfort features in operator cabs. When planning your operator cabin design, be sure to consider how these features can improve the performance of enclosed cabs

Vibration Felt Through the Floor and Controls

To create more comfortable operator environments, ensure the vibrations from the machinery can’t be felt through the floor, seat or controls. According to the CDC, this is an important guideline in machine cab design, and in over half of the machinery studied, operators felt vibrations through the floor and controls. After continuous exposure, vibrations absorbed through the hands and feet can lead to musculoskeletal disorders like Hand-Arm Vibration Syndrome (HAVS).

More mildly, vibrations cause fatigue and discomfort, which will impact the operator’s performance.

The Temperature in the Cab

Much like the temperature of a classroom or office, the temperature in a cab can affect the operator’s productivity and comfort. Temperature controls help create a more comfortable environment to work in. When workers are able to adjust the temperature to meet their preferences, they’ll stay comfortable whether it’s hot or cold outside the cab.

Back and Lumbar Support

Heavy equipment operators are typically seated for the majority of their shift, often without getting up for hours at a time. Without the right back support, this can have detrimental effects on posture and back condition. A seat with proper lumbar and back support helps operators maintain proper posture and supports the lower back during long hours in the seat. Back support is crucial for helping to minimize back pain and create an ergonomic cab design.

Design Efficient Placement for Controls

Another aspect of operator cab design to keep in mind is the placement of controls. The position of cab controls can have a significant impact on the ergonomics of the cab as a whole. When primary controls are out of immediate reach, the operator is forced to stretch, lean or sit in unnatural positions for long periods of time to use that control. Many cabs have controls on the armrests for easy access, though it’s critical that all the primary controls go on the armrests.

With an ergonomic control placement, operators can avoid straining themselves to reach the primary controls. With primary controls assembled on the armrests, other operations like temperature control and other less frequently used controls can go on additional stands or displays. Keeping the primary controls of the machine on the armrest assembly can also boost productivity, as their location will be much more convenient and easy to use.

Additional Space for Extra Gear

When considering ergonomics for operator cabin design, it’s helpful to think of the cabin as the operator’s office. While many employees have lockers or offices to keep their belongings in, machinery operators often lack storage for their extra gear and personal belongings. When designing your cabs, it can be helpful to incorporate additional space for operators to keep their gear, extra clothing layers, keys, wallet and more. For example, the control panel on the armrest could lift up to uncover a compartment built into the seat.

Providing additional space keeps coats, drinks, paperwork and more out of the way and in a safe place rather than covering controls or laying on the floor.

Fabricate Operator Cab Solutions With Superior Manufacturing Company

The design of your operator cabs can make all the difference in your employee’s efficiency, comfort and overall productivity. When we design and build cabs for heavy machinery, we prioritize comfort, safety and productivity. With over 35 years of cab manufacturing experience and more than 75 years of industry experience, our team at Superior Manufacturing specializes in a variety of cabs for machinery ranging from cranes to highway equipment.

We’ll work with you to create operator cab designs that fit your needs and offer benefits like reduced noise and vibration, temperature control and 360-degree visibility. Our experienced team will assist you from design to assembly and will deliver your finished products as soon as needed. To request a quote and find out how we can create solutions for you, contact our team or browse our products online.

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