Structural Steel Fabrication | Cedar Falls IA

AFE Fabrication Services

Structural steel fabrication is the process of transforming raw steel into the components used to create large-scale structure is a specialized subset of metal fabrication that focuses on creating steel components used in the construction industry.

Crane manufacturing and installation is our core business where we focus on structural steel fabrication for the construction of Crane Runways and its supporting structure. Our processes, equipment and experienced staff also enable us to offer fabrication services for structural components including beams, columns, headers, and support structure for a wide range of structural applications.

AFE Crane can design, engineer and fabricate custom crane runway systems and supporting structural steel to fit every customer’s needs. AFE Crane is also able to have our runway and structural system stamped by a Professional Engineer licensed by the National Society of Professional Engineers.

Our Fabrication Capabilities

We can design, engineer, and fabricate a wide range of structures and components including but not limited to:

Primary Structural Components

Steel Beams

Horizontal structural elements supporting loads.

Columns

Vertical supports transferring loads to the foundation.

Headers

Main horizontal load-bearing members in a structure.

Trusses

Structural frameworks composed of interconnected elements.

Braces

Diagonal members providing lateral stability.

Hangers

Suspension elements used to support crane runways and structural loads.

Support Steel

Reinforcement elements ensuring stability and strength in crane system applications.

Additional Components

Stairways and handrails

For pedestrian access.

Steel platforms and mezzanines

Intermediate floors in industrial buildings.

Canopies and awnings

For shade and protection.

Steel fencing and gates

For security and enclosure.

Custom steel structures

Tailored to specific project requirements.

Essentially, anything requiring a strong, durable, and versatile framework is a fabrication project we can produce.

Our Process: From Design to Completion

The process of structural steel fabrication is a meticulous one, requiring precision, expertise, and adherence to strict standards. Here’s a breakdown of the steps we use at AFE Crane.

Processes

Design and Engineering

The process begins with detailed CAD drawings and engineering blueprints outlining the structure’s dimensions, load-bearing requirements, and material specifications.

Project Management

We understand the importance of project management to monitor and insure each step of the process is complete and moving forward to the next step. Project management is how AFE keeps our customers up to date on the status of their construction project and final product.

Structural Analysis: Engineers analyze the design to determine the necessary steel sections, connections, and supports to ensure the structure’s integrity and safety.
Shop Drawings: Detailed shop drawings are created from the architectural and engineering plans, providing precise dimensions, tolerances, and assembly instructions for the fabrication shop.

Material Procurement

Steel Selection & Material Sourcing: Appropriate steel grades and sections are chosen based on the design requirements and load-bearing capacities. Steel is procured from reputable suppliers, ensuring it meets the specified quality standards.

Fabrication – Cutting Bending and Assembling

Cutting: Steel sections are cut to precise lengths using various methods like sawing, shearing, plasma cutting, or laser cutting.
Drilling and Punching: Holes are created for bolts, rivets, or welds using drilling or punching machines.
Bending: Steel sections are bent or curved to achieve the desired shapes using bending rolls or presses.
Welding: Steel components are joined together using various welding techniques like MIG, TIG, or SMAW, adhering to strict quality control standards.
Assembly: Fabricated components are assembled into larger subassemblies or complete structural units.

Quality Control

Inspection: Rigorous quality control checks are performed throughout the fabrication process to ensure compliance with design specifications and industry standards.
Non-Destructive Testing: Techniques like ultrasonic testing, radiographic testing, or magnetic particle inspection may be used to verify the integrity of welds and materials.

Finishing (Optional)

Painting or Coating: Steel components may undergo painting or coating for corrosion protection or aesthetic purposes.

Delivery and Erection

Transportation: Fabricated steel components are transported to the construction site.
Erection: The steel structure is erected by a specialized crew following the erection drawings.

Gallery

Columns for Top Running Runway Painted Yellow by Request

Yellow Columns and Grey Monorail | AFE Crane

Columns Painted Yellow and Monorail Painted Grey by Request

Yellow Columns with AFE Crane Decal | AFE Crane

Columns Painted Yellow and included AFE Crane Decal by Request

60-foot runway beams being offloaded for upcoming fabrication and painting

Top Running Runway Steel Painted White

Top Running Runway Columns Painted White

Ceiling Suspended Runway Support Steel | AFE Crane

Support Steel Headers for Ceiling Suspended Runway

Top Running Runway Beams & Columns Being Shipped to Customer for Installation

Top Running Runway Steel Shipped | AFE Crane

Top Running Runway Beams & Columns Being Shipped to Customer for Installation

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FAQs

What is support steel for an overhead crane runway?

Support steel refers to the structural framework that holds up the crane runway beams. It includes columns, headers, and bracing that ensure the runway system can handle the loads imposed by the crane and its operations.

How is the support steel designed for an overhead crane system?

Support steel is designed based on the crane’s capacity, runway span, and expected loading conditions. Engineers calculate deflection limits, lateral forces, and column reactions to ensure the structure meets industry standards and safety requirements.

Can AFE Crane install support steel and evaluate existing buildings for overhead crane systems?

Yes, AFE Crane provides turnkey support steel installation for overhead crane runways. We coordinate with professional engineers to analyze your existing building and determine if modifications or reinforcements are needed. Our team then fabricates the support steel at our Cedar Falls, Iowa facility and completes the installation, ensuring seamless integration with your crane system.

Have A Question?

Contact Us Today.

Submit an inquiry or call us at
(800) 728-0818.