Corten Metal Structure
Our machining experts at Horner Fan & Fabrication manufactured this corten steel sculpture using laser cutting and other machining capabilities for a client in the art industry, Thomas Ramey. With a four week deadline, we assigned only the employees with the most extensive experience with the processes used, in order to ensure efficient production within the tight time constraint.
The production order for this artistic sculpture called for seven individual pieces, manufactured from corten steel in varying thicknesses: 10 gage, 3/8″, and 3/16″ (1.5 x 1.5 angle). Each piece measured 15′ tall by 4.5′ wide, with a thickness of 10″ and an inside radius of 126.4″. The customer required tolerances of ± 1/32″ for the base plate holes, and ± 1/16″ for body to base dimensions.
Our process began with laser cutting using CAD/Sigma Nest programming, to cut the raw corten steel to a useable shape, as well as to cut the two large cavities in each piece. Band saws were used to cut angle iron. We then used our roll forming machines to form the components to the customer’s design, and used MIG welding to assemble the sculpture. Finally, we applied a grinding process to grind the weld joints smooth. To achieve the customer’s final finishing requirements, we allowed the raw material to rust evenly, applied a clear vinegar brush coat finish, and worked with one of our partners for a sand blasted surface texture.
The final 1,500 lb. units were hauled on a flatbed trailer to our customer’s location, well within the promised delivery time.
Project Highlights
| Product Description | This custom corten steel structure sculpture is used within the Art Industry. http://www.essentialsinsteel.com/ |
| Capabilities Applied/Processes | Laser Cutting Roll Forming MIG Welding Grinding Saw Cutting Sand Blasting |
| Overall Sculpture Dimensions | Height: 15′ Width: 4.5′ Thickness: 10″ Inside Radius: 126.4″ Material Thickness: 10 Gage 3/8″ 3/16″ (1.5″ x 1.5″ Angle) |
| Tightest Tolerance | ±1/32″ (Base Plate Holes) ±1/16 (Body to Base) |
| Material Used | Corten Steel |
| Color | Raw Finish Steel Allowed to Rust Evenly Standard Operations |
| Standard Operations | Laser Cutting: CAD/Sigma Nest Programming Material Cut to Workable Shape Roll Forming: Form Components to Customer Design MIG Welding: Assemble Sculpture Grinding: Grind Welds Smooth |
| Estimated Part Weight | 1,500 Lbs |
| Volume | 7 |
| Turn Around Time | 4 Weeks |
| Industry for Use | Art |
| Delivery Location | Customer Specified |
| Standards Met | Customer Design Only Our best Employees Worked on This Project to meet the 4 Week Deadline |
| Product Name | Metal Sculpture |