ADAM Fabrication is providing fabrication services to process industry and contractors for their stainless steel component and equipment needs. Process manufacturers for hygiene sensitive industries such as food, beverage and pharmaceutical are also benefiting from our fabrication services. We have a wide variety of experience and expertise in engineering and fabrication of stainless steel tanks, vessels, silos, process plants and equipment together with piping and pipe bridges. We can shape all grades of austenitic or duplex stainless steel materials such as 304, 316, 410, 416, etc. From single components to complex processes or systems from prototypes to large scale projects we can fabricate almost everything by being competitive, with upmost quality and within the required timelines.
We embrace European standards and European approaches such as pre-engineering and procedural operation as our principles. We resolve your custom (bespoke) projects, determining the optimal fabrication method by taking latest technologies, our capacity and capabilities of our subcontractors into consideration, fabricating the components compatible with European standards and deliver on time.
We have been providing fabrication services to international companies for a long time. Our whole team gained a high level of experience in communicating with international company officers at every level. We quickly grasp the issues and proceed to solutions immediately. We form a close and collaborative relation so we are able to prevent a vast majority of problems from occurring.
It is our great pleasure that we managed to develop long term and mutually beneficial relationships with our Clients. You can learn more about our Clients’ experiences from our Testimonials section by reading their comments.
Your business enquiries are highly welcome, please do not hesitate to Request a Quotation from us.
Your projects will be handled with high confidentiality. No information or drawing related to your project will be shared with third parties or companies except for the purposes of job making.
Characteristics that differs us can be summarized as below;
▪ We are certified and competitive; we are applying international standards to ensure quality while keeping costs at minimum
▪ We are experienced in working with top international companies; we are organized, elaborative and collaborative
▪ We take responsibility for the sake of the project and always being part of solutions not problems
▪ We complete challenging and sophisticated projects in time
▪ We are taking precautions against common faults and generally overlooked important details
▪ We are handling revisions and additional works as inherent aspects of the projects
Besides basic mechanical applications like cutting, drilling, bending, shearing, rolling, machining, welding etc. by using the latest technology CNC and Laser machines we can also provide special applications like multi-axis cutting and machining. We can perform dishing and flanging applications. We also have the capabilities to apply almost all kind of surface treatments like pickling, passivation and polishing to achieve qualities starting from satin up to mirror finishes.
PROCESS FLOW
1. CUTTING
1.1. Sheet Metal Cutting
1.1.1. Shearing Machine (Guillotine)
Shearing stainless steel plate is an efficient way to cut common squares or rectangles from larger stainless steel plates. The shear angle effects the distortion of the cut stainless steel plate. While smaller shear angle uses higher power and causing less distortion larger angles need less power and increases distortion. We are using CNC Automated Guillotine Machines for shearing stainless steel materials.
1.1.2. Laser Cutting Machine
Laser Cutting is a non-contact process resulting in high quality, dimensionally accurate cuts. Laser is the most precise method for cutting. The material melts, burns, vaporizes, or is blown away by a jet of gas, leaving an edge with a high-quality surface finish. Waterjet is applying high forces on the material so small parts may be deformed or even can’t be cut at all, for small pieces laser cutting shall be preferred. If for example engraving a serial number on the material is needed, laser cutting shall be used as engraving is not possible with waterjets.
1.1.3. Waterjet Cutting Machine
As it is a cold process waterjets don’t cause heat originated problems like burn marks or dark colored cut sides. Two-layered (sandwich) materials which can’t be cut by lasers because of different burning and melting points can be cut by waterjets. Waterjets can cut thick materials unlike lasers. Waterjet cutting is less precise than laser cutting.
1.2. Profile & Pipe Cutting
1.2.1. Sawing Machine
High speed steel blades shall be used for all types of sawing. When cutting austenitic grades (300 series) the cut must be initiated without any riding of the saw on the work, a positive feed pressure must be maintained, and no pressure, drag or slip should occur on the return stroke. An emulsion of soluble oil should be used as a cutting fluid.
1.2.2. Tube & Pipe Laser Cutting Machine
Laser cutting provides high precision cuts. Laser Cutting Machines not only cut the material but can also drill and bevel the material. Thus, increases the speed of fabrication greatly by providing more productivity and flexibility. As lasers enable multi axis cutting up to 5 axes, shapes that are almost impossible with traditional methods can be achieved by laser so it is offering flexibility for designers, too. As lasers can precisely cut and bevel edge of the profiles they also increase the welding quality.
2. BENDING
All of our bending machines are CNC automated for precise results.
When choosing the right bending method for an application centerline radius, outside diameter and wall thickness are the most important variables. For all bending methods springback effect shall be taken into consideration for both sheets and tubes.
We mostly use four methods for bending;
Press Brakes: Generally used on sheet metal to form sharp bends.
Roll Bending Machine: Usually used for bending sheet metals to form cylindrical shapes. Roll Bending Machines are also used to create conical shapes which are vital components of silos, boilers, vessels, tanks, etc.
Ram Bending Machine: Mostly preferred for bending square tubes.
Rotary Bending Machine: Preferred for low tolerance jobs and precision works. Rotary Draw Bending Machine provides the best results with tight radius bending applications. You can control wall thinning and ovality of the profile while bending.
3. HEAD DISHING & FLANGING
Forming dished heads with flanges requires expertise, advanced machinery and experience. Using dish head forming hydraulic presses and flanging machines we are able to provide all types of heads for silos, tanks, vessels, boilers, etc.
4. WELDING
Welding is the key element in the fabrication of stainless steel components. Welding of stainless steel is different from steel, but not necessarily difficult.
4.1. Robotic welding
Robotic Welding increases productivity greatly and ensures welding quality.
But Robotic Welding can’t automatically provide most efficient and the highest quality welds, there are some important points to consider like suitable wire, correct fixturing, compatible gun and its consumables. By robotic welding we are able to weld even the thinnest stainless steel materials with high sensitivity and without deformation.
4.2. Orbital welding
Orbital Welding is an automated welding of two tubes in one uninterrupted tour around the circumference of the pipes. By other methods it is almost impossible to finalize it with one continuous weld. Orbital Welding doesn’t provide perfect results automatically, there are also some important points to consider:- Ends of pipes shall be cut with high quality and precision; Thanks to our tube laser cutting machinery we are able to provide this in all cases.
- Axial alignment of two pieces shall be correctly arranged with a well-engineered fixture.
- Depending on the material and thickness power and time shall be adjusted.
- Lastly, mking the operation with experienced orbital welders will ensure the desired results.
5. SURFACE TREATMENT
We can categorize surface finishing of our fabricated stainless steel products as below;
5.1. Chemical Finishes
Chemical Acid Treatments are used on stainless steel to remove contaminants on the surface. Pickling and Passivation don’t remove grease or oil on the surface, detergent or alkaline can be used to achieve this. Our guide for chemical applications is ASTM A380 - Standard Practice for Cleaning, Descaling and Passivation of Stainless Steel Parts, Equipment and Systems.
5.1.1. Pickling
When stainless steel is welded or heated, the chromium level on the top layers significantly decreases which also makes stainless steel vulnerable to corrosion. In order to remove this damaged layer pickling is an option which is generally a solution of nitric and hydrofluoric acids.
5.1.2. Passivation
Passivation is usually a nitric acid solution or paste which is used to clean iron contaminants and helps formation of a passive oxide film on the surface of stainless steel material. To achieve the best result first we are removing lubricants, oils and greases from the surface by detergents or alkaline, apply pickling to remove oxide layers after this and perform passivation as the last step.
5.2. Mechanical Finishes
5.2.1 Grinding
Grinding is an abrasive application to remove excess metal from the stainless steel surface by usually using disc grinders. Grinding Wheels with different grit sizes can be used for desired surface quality. Grinding is usually applied as a progressive process starting from larger grits initially and using finer grinding wheels for subsequent applications. Changing the direction of the wheel by 90 degrees with each grit is vital for removing grinding lines.
5.2.2 Polishing
Polishing is actually grinding with finer grits. Wheels or belts are used for application. In order to achieve a finer result again finer grits shall be used gradually. While the purpose of grinding is mainly to remove the excessive metal, for polishing the aim is to provide smoothness. (and gloss -brightness)
5.2.3 Buffing
When cloth wheels with an addition of a compound including very fine abrasives is used, it is called buffing. The first step is cut buffing during which polishing lines are removed. Final step is called finish/color buffing which provides a bright luster finish.
5.2.4 Blasting
Bead or Shot Blasting is another option as mechanical finish. Depending on the mediums used such as; Sand, Glass bead, Silicon carbide, Stainless steel shot, Ground quartz surface qualities starting from dark to light and coarse to smooth surfaces can be achieved.
5.3. Electropolishing
Electropolishing is an electrochemical process used to remove microlayers from stainless steel and smoothing the surface to reach an aesthetic, mirror finish. Electropolishing is usually not a standalone process but rather a complementary process after chemical and/or mechanical finishes. Electropolishing also improves the corrosion resistance. While it is usually a tank process large pieces can also be electropolished by wand polishing where the piece itself becomes the anode. Electropolishing is largely used at food processing, medical and pharmaceutical applications as it increases smoothness, reflectivity, cleanliness and passivity (and gloss -brightness) of the surface.
ISO 15730:2000 - Metallic and other inorganic coatings -- Electropolishing as a means of smoothing and passivating stainless steel is the European standard we apply for electropolishing.
We are dedicated to customer satisfaction so we continually improve our infrastructure, services and processes in order to achieve a higher quality.
We are applying a highly strict quality control process for our fabrications. We are not only realizing the requirements of ISO 9001:2015-Quality management systems and ISO 3834-2:2005-Quality requirements for fusion welding of metallic materials certificates but also exceeding these standards in many cases by enabling a sustainable quality environment. Thanks to our fabrication systematics we are able to monitor the fabrications continuously and preventing defects and setbacks by interceptive actions.
ADAM Fabrication applies requirements of ISO 3834-2: Quality requirements for fusion welding of metallic materials for Welding Quality Assurance and associated standards to ensure correct and safe end-products. Our welds are predefined and implemented with the supervision of International Welding Engineers and executed by our Certified Welders. Our Quality Control team strictly applies controls at every stage of fabrication to minimize faults and to keep final components within limits of tolerances set in relevant standards and technical specifications of the projects. ADAM Fabrication Quality System is periodically audited by Internationally Accredited Certification Bodies.
Welding is the most technical and vital stage of the fabrication. We possess almost every standard weld at our broad WPS (Welding Procedure Specification) library. And for a special weld our Welding Engineers can prepare a WPS in a short time and we apply these welds by certified welders who hold the required WPQ (Welder Performance Qualification).
Despite the fact that we also worked with different standards such as ASTM and GOST, ADAM Fabrication and its business partners fundamentally master all the details of EN Norms as we delivered countless projects compatible with European Standards. This also brings us flexibility to adopt to different requests from Clients like lower tolerances and higher quality than International Standards like ISO or EN Norms.
Quality Process of a project starts with specification and code reviews, drawings and project schedule. In addition to our standard quality procedures, we are also creating custom ITPs (Inspection Test Plans) for each project depending on the Technical Specifications provided by our Clients. We are aware of the important fact that every project schedule shall be planned including quality processes in order to achieve deadlines and our given delivery times are always including quality applications in order to prevent any inconvenience. Quality Control of a project is handled as a continuous process starting from reception of enquiries, advancing with proper material procurement, strict inspections at fabrication and finalized with preparation of the Comprehensive Quality File at the end of the project. We apply controls at every stage of fabrication which can be classified as incoming, first article, in-process, pre-finish and final product inspections.
Our almost idealized QC (Quality Control) and QA (Quality Assurance) systems are results of our feedback practices over our well-evaluated, vast experiences. As a result of these Quality Systems we are able attain International Standards and transcend these standards in most cases.
In order to identify issues and validate corrective and improving actions we continuously monitor, analyze and enhance all internal and external processes affecting the quality of our fabrications and other services.
We strictly require Mill Certificates according to EN-10204 for all raw materials procured. And all of our welders are certified according to EN ISO 9606-1. Our surface treatment activities such as polishing, pickling and passivation are monitored, measured and controlled by certified inspectors.
We provide Traceability of the material throughout our fabrication process. As a result of traceability records and documentation, all of our processes can retrospectively be tracked down.
We also apply all kind of NDT (Non-destructive Tests) such as Visual inspection (VT), Liquid penetrant inspection (PT), Magnetic particle testing (MT), Radiographic inspection (RT), Ultrasonic testing (UT), Eddy current testing (ET) or other required methods like tension test, pressure test, leakage test, etc. determined at the technical specifications and ITPs (Inspection Test Plans) of the projects.
Depending on client needs our fabrications can be delivered with a Quality Sticker or Quality Tag which can include Barcodes or any brief information required by our Client.
ADAM Fabrication possesses ISO 3834-2 : 2005 - Quality requirements for fusion welding of metallic materials Certificate to ensure the Welding Quality of its fabrications.
Our welders are certified according to EN ISO 9606-1 - Qualification testing of welders. Fusion welding. Steels.
Our Welding Procedures are prepared according to ISO 15614-1:2017 - Specification and qualification of welding procedures for metallic materials -- Welding procedure test -- Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys
We can also fabricate pressure vessels which are compatible with Pressure Equipment Directive (PED) (2014/68/EU)
ADAM Fabrication is able to fabricate all types of Stainless Steel Alloys. But like all stainless steel fabricators we also mostly use 304, 316, 409, 410 and 430 grades.
Stainless Steel alloys are classified into 5 main groups; Austenitic, Duplex, Ferritic, Martensitic and PH (Precipitation-Hardening). Below you can find the grades we use mostly in EN (European Norms) classification and their AISI/ASTM (American Iron and Steel Institute / American Society for Testing and Materials) standard equivalents.
Austenitic Stainless Steel Grades
1.4372 (201), 1.4373 (202), 1.4310 (301), 1.4305 (303), 1.4301 (304), 1.4303 (305), 1.4841 (314), 1.4401 - 1.4436 (316), 1.4541 (321), 1.4550 (347), 1.4864 (330)
Duplex Stainless Steel Grades
1.4462 (2205), 1.4362 (2304), 1.4410 (2507), 1.4507 (255)
Ferritic Stainless Steel Grades
1.4512 (409), 1.4002 (405), 1.4016 (430), 1.4113 (434), 1.4510 (439), 1.4521 (444), 1.4526 (436), 1.4749 (446)
Martensitic Stainless Steel Grades
1.4006 (410), 1.4021 - 1.4028 - 1.4031 - 1.4034 (420)
PH Stainless Steel Grades
1.4542 (630), 1.4568 (631)
SECTORS
We are providing services to a wide range of different sectors for their stainless steel fabrication needs.
Stainless steel is widely used at food processing industry and their fabrications demand more attention along with higher quality due to hygiene sensitivity. We are providing food grade stainless steel fabrications. We apply enhanced quality control procedures for food processing fabrications to make sure that lines, grooves, pits, divots and other type of crevices don’t occur so that food particles can’t be trapped in these openings and become a source of contamination and also to enable easier cleaning of surfaces that come into contact with food.
Sectors we serve can be summarized as below;
Food Processing and Beverage Industry | Dairies, Bakeries, Meat and Poultry, Fruit and Vegetables, Frozen Foods, Animal and Pet Foods, Wine Making, etc.
Pharmaceutical
Cosmetics and Personal Care
Chemicals | Detergents, Paint, Building Chemicals, etc.
Petrochemical | Plastics, Polyester Resin, Mineral Oil, Polyurethane Foam
Architectural Structures
Renewable Energy | Solar, Wind, geothermal, hydro
Mining
Medical
Treatment Facilities
Bulk Handling
PRODUCTS
Below you can find some of the components, equipment, systems and processes we fabricated previously;
