Custom Site Furnishings and Bollards

Fabrication and Design Considerations

Custom bench with wood slats and metal supports mounted on a concrete base. — A custom-designed bench featuring wood slats and durable metal supports, mounted on a concrete base.

Public spaces are the lifeblood of any community, serving as venues for social interaction, relaxation, and cultural expression. The furnishings and bollards chosen for these spaces not only enhance their functionality but also contribute to their visual appeal. In this article, we dive into the different ways custom metal products are made, the quality control processes that ensure their durability and functionality, and the design considerations that shape the final product. Custom fabrication plays a pivotal role in creating these elements, allowing designers to tailor site furnishings and bollards to meet specific needs and aesthetic goals. This process can involve crafting unique, high-quality pieces from the ground up or modifying existing products to develop a customized solution. Custom fabrication offers unparalleled flexibility, enabling the creation of elements that are not only functional and durable but also visually striking. Whether you’re looking to add intricate details to a decorative bollard or create robust site furnishings that stand the test of time, custom fabrication provides the tools to bring your vision to life.

Machinist working on a metal component in an industrial setting. — Precision machining is crucial for creating custom metal components for site furnishings and bollards.

Fabrication Techniques

When creating custom site furnishings and bollards, understanding the range of fabrication techniques available is crucial for achieving the desired outcome. Whether through casting, forging, or machining, each technique offers unique advantages that cater to different project requirements, from complex shapes and fine details to superior strength and precise tolerances. By carefully selecting the appropriate methods, manufacturers can ensure that each product meets the highest standards of quality and functionality.

Casting

Casting is a versatile technique where molten metal is poured into a mold to create a specific shape. This process is ideal for producing complex shapes and intricate details, making it perfect for custom-designed bollards and artistic installations. The type of casting chosen depends on the requirements of the project:

Sand Casting: Best suited for larger, less intricate parts. Sand casting is a cost-effective method for high-volume production and can handle a wide range of materials, including ductile iron, grey iron, and carbon steel.

Precision Casting (Investment Casting or Lost-wax Casting): Ideal for complex, detailed parts that require tighter tolerances and a smoother finish. This method is often used for smaller, more intricate components where precision is key.

High-Pressure Die Casting and Gravity Die Casting: Typically used for aluminum parts. High-pressure die casting is suitable for small, high-precision components, while gravity die casting is used for slightly larger parts.

Forging

Forging is another key technique in metal fabrication, offering superior strength and integrity compared to casting. It involves shaping metal using compressive forces, making it ideal for applications that require high durability:

Open Die Forging: Used for large parts that require exceptional strength and integrity. This method is ideal for components like large shafts and cylinders.

Closed Die Forging: Best suited for producing complex shapes in high volumes. This method is often used for creating components like gears and automotive parts.

Rolled Ring Forging: Provides superior strength and uniformity, making it ideal for applications like gears, flanges, and bearings.

Machining

Machining processes are essential in fabricating custom site furnishings and bollards, ensuring that each component is crafted to exact specifications. Common machining processes include:

Milling: A versatile process used to remove material from the workpiece to create complex shapes.

Turning: Used to create cylindrical parts by rotating the workpiece while a cutting tool shapes it.

Drilling: Involves creating holes in a workpiece, essential for components that require precise holes for assembly.

Grinding: Used to achieve a smooth finish or precise dimensions by removing small amounts of material.

Boring: Enlarges existing holes to achieve greater accuracy.

Honing: Improves the surface finish and accuracy of cylindrical parts.

Threading: Creates threads on a workpiece, necessary for parts that need to be screwed together.

Quality inspector reviewing a cast iron bench in a foundry. — Quality assurance ensures that every custom metal product meets high standards of durability and design.

Quality Assurance and The Importance of ISO-Certified Processes

Ensuring the highest quality standards throughout the fabrication process is critical to the success of any project. At Reliance Foundry, we prioritize working with vendors that adhere to ISO-certified processes. Some common certifications include:

ISO 9001: Focuses on quality management systems, ensuring that products consistently meet customer and regulatory requirements.

ISO 14001: Emphasizes environmental management, helping to minimize the environmental impact of manufacturing processes.

ISO 45001: Pertains to occupational health and safety, ensuring that fabrication processes are safe for workers.

By working with ISO-certified vendors, you ensure that every step of the fabrication process is conducted with the highest level of quality, safety, and environmental responsibility.

Detailed engineering drawing for a custom bench design. — Engineering drawings provide the foundation for accurate and successful custom fabrication projects.

Customer-Focused Fabrication Process: Engaging with the Custom Fabrication Journey

The custom fabrication journey begins with a detailed consultation where customers discuss their vision and needs with the fabricator. Key considerations include:

Product Drawings: Whether customers have existing product drawings or require engineering support to develop new designs.

Material Selection: Choosing the most suitable materials based on the application, whether it’s ductile iron, carbon steel, or aluminum.

Customization Level: Determining the extent of customization possible, from the intricacy of design details to the choice of finishes.

Once the concept is established, the design phase begins, followed by prototyping, full-scale production, and final inspection. Quality control measures are in place throughout the process to ensure that the final products meet all specifications.

Engineering design of a custom bollard with detailed specifications. — Custom bollard designs incorporate specific requirements for functionality and aesthetics.

Design and Engineering Considerations: The Backbone of Successful Fabrication

Accurate and detailed product drawings are essential to any successful fabrication project. Collaboration with engineers is key to refining these designs, addressing structural concerns, and ensuring compliance with relevant standards.

For example, when fabricating bollards, factors such as impact resistance, environmental conditions, and safety standards influence the final design. Similarly, site furnishings must balance user comfort, durability, and aesthetic appeal. Working closely with engineers ensures that these elements are integrated seamlessly into the final product.

Quality Control and Testing: Ensuring Superior Products

Quality control is a critical aspect of the custom fabrication process. At Reliance Foundry, we conduct rigorous testing and inspection at various stages of production, ensuring that every product meets the highest standards of quality.

This includes material testing for strength and durability, structural inspections, and final testing to ensure that the products perform as intended. By adhering to ISO-certified processes, we maintain a consistent level of quality across all projects.

Worker applying a protective coating to a metal bollard in an industrial environment. — Protective finishes, like powder coating, enhance the durability of custom metal products.

Choosing the Right Finish for Custom Metal Products

The choice of finish is a critical aspect of the custom fabrication process, affecting both the appearance and durability of the final product. Common types of finishes include:

Protective Coatings: Such as powder coating, anodizing, and galvanizing, which provide corrosion resistance and durability.

Aesthetic Finishes: Including painting and polishing, which enhance the visual appeal of the product.

At Reliance Foundry, we offer a proprietary finish known as IronArmor, which provides exceptional protection and durability for our metal products. This finish is designed to withstand harsh environmental conditions, making it ideal for outdoor applications where longevity is a priority.

Person viewing Reliance Foundry's custom casting page on a laptop. — Exploring custom casting options on Reliance Foundry’s website for tailored site furnishings and bollards.

Tips for Choosing the Right Fabricator

Selecting the right fabricator is crucial to the success of a custom fabrication project. Consider the following tips:

Experience and Expertise: Choose a fabricator with a proven track record in custom fabrication, particularly with the materials and techniques required for your project.

Portfolio of Work: Review the fabricator’s portfolio to assess the quality of their previous projects.

Customer Testimonials: Positive feedback from past customers is a good indicator of a fabricator’s reliability.

Communication and Collaboration: Effective communication throughout the project ensures that your vision is realized.

Case Studies: The Versatility of Custom Fabrication

Custom fabrication allows for the creation of unique, high-quality site furnishings and bollards that meet the specific needs of public spaces. Here are a few examples:

Kansas Airport

This project involved the creation of custom stainless steel covers for the Kansas Airport. The covers varied were tailored to meet the specific needs and aesthetic requirements of the airport’s design, ensuring both functionality and visual appeal.

Colorado State Capitol

A large-scale custom decorative bollard project for the Colorado State Capitol. This project involved the installation of custom decorative bollards designed to complement the historic and architectural significance of the Capitol building.

Custom Product for Martello Project

Martello Bollards installed in an urban environment as part of the Martello project.

The Martello project was a collaborative effort between Reliance Foundry, NYC DOT, and Billings Jackson. This joint venture focused on creating bespoke bollards that met the stringent requirements of New York City’s urban environment, balancing durability with modern design aesthetics. The unique design of the Martello bollards was conceptualized by Billings Jackson Design.

Custom fabrication offers unparalleled flexibility and precision, allowing for the creation of site furnishings and bollards that are uniquely tailored to the specific needs of your public space. By partnering with an experienced and reliable fabricator like Reliance Foundry, you can ensure that your project is completed to the highest standards of quality and craftsmanship. Whether it’s choosing the right fabrication technique, adhering to ISO-certified quality control processes, or selecting the perfect finish, each step of the custom fabrication journey is crucial to achieving the desired outcome. Explore our custom solutions and discover how we can help you create places people want to be.