Case studies

How the work gets done

Four recent jobs off the shop floor — what the customer needed, how we approached it, and what left the workshop. Client names withheld; the steel speaks for itself.

Welded heavy-plate baffle assembly standing on the workshop floor

Welding inside the assembly before the top frame was fitted

Case study 01 · Process plant

Heavy-plate baffle assembly, built inside and out

Material

Mild steel plate

Services

CNC plasma profiling · Fabrication · MIG welding

Scope

One-off, to customer drawing

The brief

A one-off welded plate structure for a process installation: a series of tall plate baffles with cut apertures, tied to a drilled base plate and a top frame. Supplied as a customer drawing with tight hole positions for site fixing.

What we did

Every plate was profiled on our own CNC plasma table, including the apertures, then fitted and welded square on the shop floor. Access inside the structure was tight, so the internal welds were made from within the assembly before the top frame closed it off. Fixing holes were drilled after welding to keep them true.

The result

Delivered as one finished assembly, checked against the drawing, with base fixings landing on the customer's bolt pattern first time.

Case study 02 · Engineering / OEM

Batch of profiled mounting plates with bored apertures

Material

Mild steel plate

Services

CNC plasma profiling · Drilling

Scope

Batch run, repeat order

The brief

A repeat batch of thick mounting plates, each with large circular apertures and a pattern of fixing holes, needed to a consistent size across the whole run.

What we did

Plates were nested and profiled from plate stock on the plasma table, then the aperture edges dressed and the smaller fixing holes drilled with a mag drill so they stayed clean and to size. Every plate was checked against the first-off before stacking.

The result

A full batch delivered on a single pallet, identical from first to last, with the nest and drawing kept on file so the next run is quicker to quote and turn around.

Batch of plasma-profiled mounting plates stacked on a pallet

Fixing holes drilled with a mag drill after profiling

Finished plates checked and stacked for delivery

Fitter dressing a welded stiffener on a universal beam

Item-numbered plate being welded to drawing

Case study 03 · Structural

Universal beam with welded stiffeners and end plates

Material

Universal beam, mild steel plate

Services

Structural fabrication · Welding

Scope

To engineer's drawing

The brief

A structural beam to an engineer's drawing, requiring web stiffeners, end plates and connection details — the kind of job where a millimetre out at the shop means a bad day on site.

What we did

Stiffeners and end plates were profiled in-house, marked up to the drawing item numbers, and fitted and welded to the beam with the section clamped true. Welds were dressed and the finished member checked end to end before it left.

The result

Fabricated, checked and delivered ready for the erector, with every item traceable back to the drawing.

Case study 04 · Industrial

Gusset brackets, profiled and welded in one place

Material

Mild steel plate

Services

CNC plasma profiling · MIG welding

Scope

Small batch

The brief

A set of heavy gusset brackets for an industrial installation — plate profiles that had to be welded square and consistent so they could be bolted up interchangeably on site.

What we did

Profiles cut on the plasma table, then jigged and MIG welded so each bracket matched the first. Doing the cutting and the welding under one roof meant no waiting on a cutting bureau and no surprises when the parts came together.