Steel Cutting Blog

There's something truly captivating about large-scale steel fabrication.  

Whether it’s the sight of flames flying during the cutting or welding process or the spawning of awe-inspiring structures that shape entire civilizations, the sheer magnitude of large-scale steel fabrication in construction is unparalleled.  

Steel inspires us because of its strength, robustness, and seeming invincibility, especially when utilized at a large scale. It’s also our bread and butter as a business. 

We’re not talking about steel in a shelving cabinet unit. No, this is a discussion about steel at its most jaw-dropping enormity: heavy metal for heavy machinery, shipbuilding, bridges, and construction. 

In other words, big steel is a big deal. Large-scale steel fabrication is versatile and produces materials up to the task of making the world go round. 

At Amber Steel, we embrace and appreciate the value of large-scale steel fabrication, utilizing techniques such as plasma cutting for precise and powerful cuts. We integrate our skill, precision, and expertise for steel fabrication with cutting-edge technologies that streamline our processes and optimize results. 

From planning to executing a large-scale steel fabrication project, we apply our technical proficiency and vast industry knowledge to deliver results that exceed client expectations. 

Do you have a large-scale steel fabrication project in the works? Are you seeking a top industry technician with top-tier machinery and innovative technology who can cut, bend, and assemble on a grand scale while delivering optimal results? If so, contact Amber Steel today to discuss what our steel fabrication and cutting processes can do for your business. 

While we offer various techniques for steel fabrication and always have an alternative to meet your needs, we typically utilize plasma cutting for fabricating steel at a large scale.  

Below, we’ll delve further into large-scale steel fabrication and the role of plasma cutting in the process. 

A Deeper Dive into Large-Scale Steel Fabrication 

The heavy (or large-scale) steel fabrication process applies to industrial structure/component construction from raw materials.

We already mentioned the structures built with fabricated steel: bridges, heavy machinery, and sky-scraping structures. These human-made works make people feel small and their mouths agape. 

Projections show the steel fabrication industry growing from $22.36 billion in 2023 to $30.64 billion by 2030.  

The above statistic isn’t a brag or boast. It’s to highlight the ubiquity and necessity of large-scale steel fabrication. Steel is everywhere—it provides stability and is the foundation for almost all industries and ways of life. 

Consider the financial implications of projects that utilize large-scale steel fabrication. The average modern cruise ship, for example, can cost a mind-boggling $900 million, while a high-rise office can cost up to $1,000 per square foot. These figures emphasize the need for quality tools and experts to ensure the success and profitability of such ventures. 

Furthermore, heavy steel fabrication is a staple of automotive and aerospace, both high-worth industries involving projects with immense financial stakes. 

The materials used in large-scale steel fabrication reflect that massive scale, as do the final products and associated prices. 

Thus, project leaders need to invest in the best tools available and ensure the top experts in the field use them. This way, the ends will justify the means, and all upfront spending will pay off. 

It’s then worth asking: What are the best types of tools or machinery for large-scale steel fabrication? Several will be required, but our plasma cutter is Amber Steel's most integral tool for these projects. 

Why Choose Plasma Cutting for Large-Scale Steel Fabrication? 

Cutting is one of the first components of steel fabrication, occurring before forming, drilling/punching, welding, and blasting/painting. 

Steel must first be cut to form its desired shape. 

Many cutting processes exist, and Amber offers several of them, including laser cutting and flame cutting. 

However, plasma cutting proves itself time and again the far superior choice for large-scale steel fabrication projects. 

Specifically, plasma is the cutting method that is most efficient at handling thicker materials.  

The electrically charged air in plasma cutting makes it ideal for processing nonferrous and ferrous materials. Alternatively, flame cutting can only cut ferrous materials. 

Furthermore, plasma cutting works faster than oxyfuel with its cutting speed. Plus, its kerf is more precise and smaller than flame cutting. 

Plasma cutting flourishes when processing high-thickness plates (e.g., approximately 2 inches or 50 mm thick). It can even succeed in handling 150 mm (6 inches) thick materials. Thus, it’s ideal for heavy, large-scale steel fabrication. 

At the end of the day, our reasoning is simple: We opt for plasma cutting for large-scale steel fabrication because it’s most suited to the type of work required, offering optimal cuts in these scenarios. 

How Amber Approaches Plasma Cutting for Large-Scale Steel Fabrication Projects 

We’ll note that—within reason—Amber is precisely what our clients need us to be. Thus, our services will shape and mould whatever your project and desired outcomes demand. 

Still, we can give you a general idea of what to expect when you hire us for a large-scale steel fabrication project. 

Read on as we break down some typical elements of the large-scale steel fabrication process with Amber. 

The Project Planning Stage 

Rigorous planning is the cornerstone of any successful large-scale steel fabrication project. 

At Amber, we excel and relish the planning stage because it allows us to familiarize ourselves with customers and their project specs. We combine our philosophies with our client's needs and help create budgets, schedules, and a final product blueprint. 

Our detailed planning process ensures we finish projects on budget and on time.  

To the above point, punctuality is one of our core tenets at Amber Steel.  

Our passion and dedication to delivering on time reflect our desire and commitment to helping you succeed. We will work tirelessly during the planning stage to ensure we meet deadlines which are non-negotiable for us. 

Still, even the best-laid plans can fall victim to unforeseen circumstances.  

As such, we build our plans with flexibility and adaptability in mind. We prepare in advance with the idea that your needs will evolve. We have processes in place to ensure we adjust seamlessly, continuing to shape our solutions to your objectives. 

We consider all large-scale steel fabrication processes as we plan your project. Say you’re building a bridge, for instance. We’ll consider the types of vehicles going over the bridge, factoring their weight into the materials we select for the project. 

Aligning Our Services with Your Requirements 

The most precise, beautifully cut piece of steel means very little if the client doesn’t want it. 

Thus, Amber prioritizes familiarizing ourselves with your large-scale steel fabrication requirements before we plasma-cut a single material.  

Here are some of the requirements we refer to: 

• The structure’s purposes. 

• It’s load-bearing capacity. 

• Environmental conditions 

When we understand your needs, we can deliver the structures and final product that meets and exceeds expectations. 

Our team of top-tier professionals might be proficient at plasma cutting. However, they’re equally skillful as communicators and utilize these skills with our clients. 

We’ll share our developed designs with you for approval. This way, you can give us feedback, which we’ll enthusiastically receive during each stage of your large-scale steel fabrication project. 

Taking An Honest Look at Ourselves in the Mirror 

Large-scale steel fabrication is an intensive process saved for projects that often feature high difficulty.  

Often, companies in our sector will perform a SWOT analysis to assess whether they can give prospective clients what they need for their projects. Specifically, these are the questions asked: 

• Do we have the resources available to finish the project? 

• Does our expertise and experience align with what’s needed to fabricate the structure in question? 

• Where are our core competencies? 

• How do our current finances line up with the needs of a fabrication project? 

There’s rarely a project we won’t take on. Nevertheless, transparency with clients is vital to us at Amber. We want to be honest through all project facets, which means asking ourselves if we’re up to the challenge and giving clients a straightforward answer. 

Suppose we find a gap or a weakness that may prevent us from working on a large-scale project. We'll investigate solutions and ways to bridge the gap, typically leading to top-tier work and happy clients. 

At Amber, Steel Is Our Bread and Butter 

Do you have a large-scale steel fabrication project in your sights? 

Given the financial investment it requires, such work has a slim margin for error. You owe it to yourself and your fellow colleagues, partners, or investors to only work with the industry's best fabricators. 

Speaking of the industry’s best large-scale steel fabricators, Amber Steel provides plasma-cutting services for heavy-duty projects that demand a sure hand.  

We work with other materials, but steel is our bread and butter. Our work is highly efficient, rigorously planned, exactly precise, and guided by cutting-edge technology to ensure optimal results.  

Amber Steel has spent years differentiating itself with top-quality products and competitive pricing. 

Contact Amber today to learn about the game-changing difference our plasma-cutting services can make for your large-scale steel fabrication project. 

Plasma cutting is a game-changer in industries like automotive manufacturing, metal fabrication, and construction, where precision is everything. Whether you're creating parts for the next big car model or putting together pieces for a new building, getting those clean cuts and avoiding warping is key. 

But here's the thing: when you decide to go for plasma cutting, you're putting your money on the line. You want to make sure you're getting top-notch work. No one wants to see their materials go to waste because the edges aren't clean enough or the metal is twisted out of shape.  

That's where we come in. We're all about providing plasma cutting services that hit the mark every time — clean edges, no distortion, just the way you need it. 

Now, the nuts-and-bolts cutting of the matter is out of your hands. You’re hiring someone else to do it for you, meaning the techniques and technologies don’t apply directly to you.  

In other words, you need someone you trust to complete the job correctly. You also require the criteria for finding such a service provider. 

So today, we want to discuss how you can ensure the plasma-cutting service provider you partner with achieves clean cuts and minimal distortion in steel. 

We can tell you with the utmost confidence how Amber Steel works with clients like you (e.g., in automotive manufacturing, metal fabrication, and construction) to deliver the results you seek. Our plasma-cutting services cater to your project’s needs, applying our solutions to your specifications. 

The team at Amber is highly skilled and expertly trained to deliver precise cuts with minimal distortion and clean edges.  

Contact us today to learn more about our plasma-cutting services and how we can optimize your project. Or, read below as we discuss how you can ensure you hire a plasma-cutting service provider who can deliver the precise final product you demand (and deserve).  

Choosing the Right Plasma Cutting Tools 

No tool in the world can make up for a lack of skill. The plasma-cutting service provider most suited to your project should have undeniable technical expertise that you can count on.  

However, there’s no denying that the tools play a part as well. Those with the higher tier of equipment will be able to execute superior cuts. 

Here’s a list of topics to discuss with a plasma-cutting service provider to ensure they’re working with machinery and technology that can give you the results your project demands: 

• Discuss output power with your potential service provider. The optimal amount depends on the type and thickness of the material being cut. A plasma-cutting service professional you can trust will have machines able to handle the maximum thickness levels involved in your project. 
  • Broach the topic of rated and severe cuts — these are what experts use. Rated cuts involve mild metals’ thicknesses. These can be cut at 15 inches per minute (IPM). Severe cuts are the highest thickness levels a plasma cutter can successfully manage. 
• Time is money. Yes — clean edges and minimal distortion are paramount, but the labour cost increases the longer a job takes. Thus, cutting speed is a crucial component of your project and a topic you should discuss with all potential plasma-cutting service providers. Inches per minute (IPM) are vital for production time since the project gets done quicker with higher rates.  
• Ask potential plasma-cutting service providers about their duty cycle, which measures how long a plasma cutter can continuously cut over ten minutes before overheating. Hot environments, high productivity applications, and long cuts all demand a higher duty cycle.  
  • Higher duty cycles ensure machines can operate efficiently for longer times without requiring cooling breaks, optimizing efficiency. This will reduce the time your project takes. 
• Determine a potential plasma-cutting service provider’s relationship with technology. Today’s plasma cutters are designed for the utmost precision. While your budget might have constraints, seeking service providers using the most cutting-edge tools will yield the most precise cuts that reduce distortion and achieve clean edges. Moreover, the best technology can often streamline costs, fitting into tighter budgets. 

Using the Correct Technique 

As you’re not a plasma-cutting technician, it can be hard to know whether an industry pro is following best practices. 

Still, you can discuss the techniques below with potential service providers to ensure their cuts are precise, minimize distortion, and have clean edges. Their methods might differ from what’s laid out below, but they’ll offer insights into their process, further building trust: 

• A technician should use their non-cutting hand to support their other hand to ensure steadiness while ensuring free movement and maintaining a constant 1/16th to 1/8th inch standoff space. You’ll find that most technicians don’t push the torch away but pull it toward their body. 
• The service provider performing the plasma cutting will preferably hold a consistent standoff distance. Doing so will increase a smaller machine’s cutting capacity while extending the consumables’ lifespan. 
• Does your service provider/technician have a machine with a drag shield? If so, they should use it. A drag shield allows technicians to keep the optimal standoff with the torch on the workpiece while not touching the metal tip. The cut quality and consumable life will be hampered if the metal is touched. 
• The technician you hire should place the torch as close to the base metal edge as possible. They should then press the trigger to activate the pre-flow air, initiating the pilot and cutting arcs. Best practices then dictate the technician to slowly move the torch across the metal. From there, they’ll ensure cutting sparks are generated from the bottom by adjusting speed. 
• Plasma-cutting technicians should either pause briefly to finish the cut or angle the torch slightly toward the end of the cut. Doing so will garner a smooth, clean edge. 
• In the immediate aftermath of the technician releasing the trigger, post-flow air will continue as the consumable parts and torch begin the cool-down process. 
• Ensure the technician you hire has steady hand movements. This way, they’ll make controlled and precise cuts. 
• A trusted technician will base their travel pace on amperage settings, desired results, and material thickness. They won’t rush a job because it would risk poor-quality cuts. However, they won’t go too slow because they won’t want to create dross buildup. 
• Your plasma-cutting service provider should check consumables for wear or damage, including worn-out electrodes/nozzles, spatter accumulation, or consumed hafnium inserts (when applicable). 

The Importance of Consumables 

Swirling rings, nozzles, retaining caps, shield caps, and electrodes are all plasma-cutting torch consumables. 

Discuss with prospective plasma-cutting service providers whether they regularly inspect these consumables, as it’s a vital element of making quality cuts. 

Industry experts will prioritize the condition of their consumables, replacing their tip holes if they’re covered in spatter or irregular in any way. They’ll also discard the electrode if it develops a pit.  

Excessive moisture, high thickness levels, and lackadaisical technique can all adversely impact consumables, lessening cut quality.  

Balancing Speed and Quality 

A plasma-cutting service provider understands the delicate balance of speed and quality. 

With thicker materials, they’ll rigorously monitor their travel pace with clean, precise cuts in mind. They’ll also adjust the amperage to lower for thinner material and higher for thicker material.  

Plasma-cutting experts will find the correct speed and ensure a 15–20-degree plasma arc exit angle opposite the travel direction.  

When moving too slowly, it will go straight down. If the technician moves too fast, it will spray back.  

Heat and speed must also be balanced by your plasma-cutting service provider during the cutting process.  

Doing so will prevent metal surface distortion and reduce rubbish on the bottom of the cut. When the heat-speed combination is optimized, distortion won’t be a factor. Also, there will be a minimal need for post-cut rework or grinding. 

The best in the business will prioritize control as they determine how much speed should be applied. 

Working with Industry-Best Service Providers 

Plasma cutting steel with clean edges and minimal distortion is a complex notion for many prospective clients — like you — for one reason: Much of the process is out of your hands. 

You aren’t cutting the steel yourself because it doesn’t fall within your area of expertise. You’re relying on someone else to get the job done right. Thus, you can only do so much to impact the cut quality. 

The information in this article has provided you with a set of criteria to watch for—this will be crucial in deciphering whether the company you’ve hired is up to the challenge. 

We’ll never doubt the value of learning about your investments. Knowing what yields clean, precise plasma cuts will give you a leg up. Nonetheless, the fact remains: You can’t complete those clean cuts yourself. 

When you partner with a service provider like Amber Steel, you’ll have someone handling your plasma-cutting needs with an industry-leading track record for optimal results and satisfied clients.  

We work within the framework of your project, aligning our solutions to your needs, budget, and project scope.  

Our plasma-cutting equipment and technology are cutting-edge, highly scalable, portable, and cost-efficient, and we utilize automation to streamline our processes. 

Amber Steel’s passion for steel-cutting is unparalleled, and our commitment to our clients can’t be rivalled. Contact us today to discuss a plasma-cutting project or to investigate our other top-tier services.