At Red Dot Buildings, our manufacturing process for metal buildings involves in-house fabrication of steel components, ensuring superior quality and precise customization. We take great pride in our ability to transform raw materials into high-quality steel components ready for construction, employing a series of meticulous steps and advanced equipment.
To begin, we carefully select and procure top-grade raw materials, such as steel coils or plates, from trusted suppliers. These materials undergo stringent quality checks to ensure they meet our rigorous standards and project-specific requirements.
Once the materials are secured, our skilled craftsmen utilize state-of-the-art cutting machines, including plasma to precisely cut the steel into the desired sizes and shapes. We employ CNC technology to ensuring clean cuts and accurate dimensions.
Welding plays a crucial role in our manufacturing process. All Red Dot welders and fitters are qualified and in compliance with AWS D1.1 and D1.3 codes of welded construction. Their expertise ensures the structural integrity and durability of the final product.
Next, we employ specialized forming techniques to shape the steel components according to the specific design requirements. We use a Franklin PTW-72, an automatic submerged twin-arc welding system utilizing Lincoln Electric’s Power Wave AC/DC 1000. It is designed for fabricating three-piece built-up beams consisting of a web and two flanges, as quickly as possible, while ensuring the absolute best quality. Our PTW has the capacity to handle web as wide as 72” and flange up to 20” wide x 1.5” thick. The system consists of a web loading gantry, web seaming station, a tacking station unit, a CNC flange loading gantry, and the pull through welder station.
We have a BeamMaster by AGT Robotics. This is a fully automatic robotic welding solution for structural steel. This machine has the capacity to nearly fully weld fabricated beams, both straight and tapered, as well as hot rolled mill shape beams that have been previously fit up. The use of this robotic welder allows for the utmost weld quality completed in the fastest time possible. This robotic welding system has been optimized through the use of automatic beam rotators and automatic robotic programming to maximized the shops capacity while minimizing the required footprint and material handling necessary for traditional welding stations.
Surface treatment is a crucial step in our manufacturing process. We apply multiple coatings, including Red-Oxide primer, Dark Grey primer and galvanizing, to enhance the corrosion resistance and visual appeal of the steel components. This ensures they are well-protected and aesthetically pleasing.
Throughout the manufacturing process, we maintain strict quality control measures. Our dedicated quality control team conducts thorough inspections, verifying dimensions, weld quality, surface finish, and overall compliance with project specifications and industry standards. This commitment to quality ensures that our fabricated steel components meet the highest standards of excellence.
Once the steel components are fabricated, we carefully load them to protect against damage during transportation. Our efficient logistics team ensures timely delivery to the construction site, enabling a smooth transition from manufacturing to construction.
By conducting in-house fabrication of steel components, Red Dot Buildings maintains complete control over the manufacturing process. This vertical integration allows us to ensure superior quality, precise customization, and efficient coordination between design, detailing, and fabrication. We take pride in delivering high-quality steel components that exceed our customers expectations and contribute to the success of their construction projects.