continuous improvement Archives - Astro Sheet Metal

Avoiding Costly Delays: How To Coordinate Metal Fabrication With Other Trades

Eric Johnson — Mon, 20 Apr 2026 21:28:45 +0000

Successful construction projects depend on coordination, and architectural metal fabrication is no exception.

Why Coordination Matters

Architectural metal installation companies often intersect with multiple trades on job sites, including glazing contractors, millworkers, drywall installers, flooring installers, and electrical teams. Without proper coordination, these trades can find themselves stepping on each other’s toes, or, worse, producing work that will later have to be torn out and replaced due to oversight of trade overlaps. Proper coordination can help to avoid this sort of delay.

Common Coordination Challenges

Some of the most frequent issues include:

Conflicting dimensions between trades
Insufficient blocking was placed inside walls to allow for the attachment of architectural metals.
Interference with mechanical or electrical systems
Incomplete or unclear drawings

Best Practices for Coordination

Early Involvement

Bringing architectural metal companies into the project early allows them to provide valuable design input. They can also help to determine whether the architect’s proposed design is actually feasible and suggest small changes that can improve feasibility while maintaining the desired aesthetic. And finally, another set of eyes is sometimes valuable for identifying potential conflicts.

Detailed Submittals and Shop Drawings

Clear, accurate drawings help ensure that all parties understand up front what the finished product will look like. They can also help to establish an order of operations for the various trades involved. And good drawings can also help reduce surprises that can pop up at the time of installation.

Regular Communication

If the various trades are involved in ongoing communication, they can work with each other rather than working against each other. Potential issues can be addressed quickly, coordination can help all trades meet project deadlines, and procedures can be made consistent across the various

Field Verification

Architectural metal companies are typically one of the last trades on the job site. As such, it is common for them to have to absorb the tolerances of the various trades that came before them. Therefore, architectural metals will look their best if the architectural metal fabricator is allowed the time to field-measure once the other trades have installed their goods and then fabricate the custom metals. Too often, “hold-to” dimensions are provided, only to find later that those dimension did not really get held to!

The Value of Experience

Experienced fabricators understand how to work within a multi-trade environment. They anticipate challenges, communicate effectively, and deliver solutions that keep projects moving forward.

Final Thoughts

Coordination isn’t just a project management task—it’s a critical factor in delivering high-quality architectural metalwork. When all trades are aligned, the result is a smoother process and a better finished product.

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Recycled Content in Architectural Metals: What to Know

Eric Johnson — Mon, 13 Apr 2026 07:00:00 +0000

Sustainability is a growing priority in construction, and architectural metals play a key role in environmentally responsible building practices.

Why Metal Is a Sustainable Choice

Many metals used in construction—especially aluminum and steel—are highly recyclable. In fact:

Aluminum can be recycled repeatedly without losing quality
Steel is one of the most recycled materials in the world

This makes metal a strong candidate for sustainable design.

Understanding Recycled Content

Recycled content typically falls into two categories:

Pre-consumer (post-industrial): Scrap generated during manufacturing
Post-consumer: Material recovered after end-use

Both contribute to reducing environmental impact.

Benefits of Using Recycled Metal

Incorporating recycled content offers several advantages:

Reduced energy consumption during production
Lower environmental footprint
Contribution to green building certifications

For projects pursuing sustainability goals, this can be a significant benefit.

Considerations for Fabrication

While recycled content is beneficial, it’s important to ensure:

Material quality and consistency
Compatibility with required finishes
Compliance with project specifications

Working with experienced fabricators helps maintain performance while supporting sustainability goals.

Supporting Green Building Initiatives

Architectural metals with recycled content can contribute to:

LEED and other certification programs
Corporate sustainability goals
Long-term environmental responsibility

As sustainability continues to shape the industry, recycled metals will remain an important part of the conversation.

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How Fabrication Quality Impacts Field Installation of Brake Metal

Eric Johnson — Mon, 06 Apr 2026 07:14:00 +0000

Brake metal plays a critical role in glazing, drywall, and waterproofing systems—but its success in the field depends heavily on fabrication quality.

Why Precision Matters

If brake metal is not fabricated precisely, a wide variety of issues can arise. For one, if long pieces of brake metal are not formed on quality press brakes, the angle can vary along the length of the part. Or, if a large profile is fabricated with metal that is too thin, the installed piece may exhibit “oil-canning.” Brake metal that is fabricated on a hand brake may also have a large bend radius, as opposed to a sharp, crisp bend radius that can be achieved on a press brake with sufficient tonnage. These types of problems can lead to field adjustments, or worse, remakes.

The Impact on Installation

When brake metal is fabricated correctly, installations go more quickly. When their pieces fit correctly, field modifications are minimized, and alignment between metal pieces or with adjacent materials is better. In addition, tighter seams mean less time spent caulking gaps. Often, the brake metal installation is one of the last items completed on a job site, so normally, time is of the essence. In cases like this, accurate brake metal can be a huge time saver.

The Bottom Line

High-quality fabrication doesn’t just improve the product—it improves the entire construction process. Investing in precision brake metal helps contractors stay on schedule, reduce risk, and deliver better results.

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How Custom Metal Elevates Retail and Hospitality Spaces

Eric Johnson — Mon, 30 Mar 2026 21:06:59 +0000

In retail and hospitality environments, first impressions matter. Custom architectural metal plays a critical role in shaping those experiences.

Creating Memorable Experiences

Custom metal elements help define a space and reinforce brand identity. Common applications include:

Entryways and storefront accents
Branded feature walls
Custom bar fronts and backdrops
Decorative screens and partitions

These elements create visual impact while maintaining durability.

Balancing Aesthetics and Durability

Retail and hospitality spaces experience constant use. Materials must withstand:

High foot traffic
Frequent cleaning
Wear and tear from daily operations

Metal excels in these conditions while maintaining its appearance over time.

Flexibility in Design

Custom fabrication allows designers to bring unique concepts to life:

Curved or complex shapes
Integrated signage and branding
Custom finishes and colors
Seamless integration with wood, glass, and stone

This flexibility is essential in competitive industries where differentiation is key.

Speed and Precision Matter

Retail and hospitality projects often operate on tight timelines. Custom metal fabrication supports:

Prefabrication for faster installation
Reduced on-site modifications
Improved coordination with other trades

The result is a smoother construction process and a higher-quality final product.

Long-Term Value

While custom metal may have a higher upfront cost than some materials, it delivers long-term value through:

Reduced maintenance
Extended lifespan
Timeless aesthetic appeal

For brands focused on quality and experience, custom metal is a smart investment.

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The Advantages of Using Point Cloud Data for Architectural Metal Fabrication

Eric Johnson — Mon, 09 Mar 2026 08:30:42 +0000

Recent advantages in three-dimensional scanning can make seemingly impossible custom metal fabrications a little more possible. Companies can either hire third-party scanning companies, or they can take the plunge and invest in the scanning equipment for themselves. Either way, there are certainly many benefits to utilizing this technology on job sites.

It’s a Time Saver

Picture a room with a large curved overhead furdown that an architect wants to clad in sleek brushed stainless steel. The classic approach would have been to either (A) Make cardboard templates that could be taken back to the shop and drawn; or (B) Finding the center point of the curve to determine the radius and measuring the arc length, and using those dimensions to re-create the curve. Being overhead, either approach would have involved multiple ladders or lifts, and at least two people.

With a 3D Scanner, the measuring process is much simpler: make sure the view is unobstructed, set up the device on its tripod, power it up, and let it go to work! This will allow you to pick up every nuance of the surface within a couple of minutes, with data that can be taken back to the shop and imported into your CAD program.

2) It Is Accurate

In the past, metal fabrication companies may have been hesitant to trust scanned data. However, today’s devices can routinely measure complex contours within 1/16” of an inch, and some can achieve even closer tolerances. Simply put, the data is good and can be trusted.

3. It Can Pick Up Details You Missed On Site

Human observations have limitations, and human memories are not perfect. 3D Scanners, on the other hand, pick up all of the details and do not forget them. As an example, when scanning a room on an out-of-town project to obtain dimensions, we got back to the shop and found that a wall had been prepped for metal base. The architectural elevation was unclear, and neither of the two employees sent to scan the room had noticed this detail. Review of the point cloud data kept us from missing this detail, saving lots of additional travel time, hassle, and expense had we gone back to install the project without this base in hand.

4. However, It Has Its Limitations

Why not just scan every job site, then? For one, scanners can have trouble getting accurate readings on reflective surfaces, unless additional steps are taken to reduce reflectivity. Also, if the job site is congested and filled with scaffolding or other tradesmen, they will be picked up by the scanners and may be in the way of the surfaces you need to scan. And finally, working with point cloud data in CAD does take time. For simpler details, getting out your tape measure and note pad may still be your quickest option.

When used properly, 3D scanning and point cloud data can be a game-changer for custom metal fabrication.

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Three Ways to Reduce Stress on Architectural Metal Products

Eric Johnson — Mon, 02 Mar 2026 08:30:41 +0000

Construction is a challenging and often thankless field, and the projects that general contractors bring to life are remarkable, with a healthy dose of stress along the way. When it comes to custom metal fabrication, we see a few stress-inducing scenarios keep popping up on projects. In this article, we will share a few concepts that can help you reduce stress and help your project run more smoothly.

Low Bidder Is Not Always The Best Choice

Every construction project has a budget, and rising costs stretch it. By the time the project is nearing completion, funds are often lower than expected. This can lead some contractors to seek low-bid options to wrap up the project. However, this approach can be both costly and time-consuming.

As an example, let’s say a project has a complex curved metal feature in the ceiling. Metal Fabricator “A.” not understanding the fabricating steps required to achieve the complicated geometry, bids the metal component at $10,000 and says they can have it done in a week. Metal Fabricator “B,” on the other hand, understands the steps and the timeframe involved to complete the job. They bid the metal component at $20,000, with a lead time of four weeks.

Here’s what we see in a lot of cases. The contractor goes with Metal Fabricator “A.” Once on site, they begin to understand the complexities involved. They will either attempt the complex fabrication and fail, or they will throw up their hands when they realize that they do not have the knowledge or experience to accomplish the job. The contractor is now stuck. They will either have to (I) Call Metal Fabricator “B,” in a panic, begging for help getting their project completed; or (II) Call Metal Fabricator “B” and see if they can persuade the fabricator to come and tear out shoddy work and replace it with quality work.

Contractors should realize: If it sounds too good to be true, it probably is. Save yourself a lot of stress and heartache, and hire an experienced metal fabrication company for those difficult features!

2) Architectural Metal Fabrication Often Needs To Be Field Measured Before Fabrication Begins

Every construction trade knows that construction components rarely jump into place as perfectly as they appear to be on architectural drawings. Every trade has generally acceptable tolerances, and those tolerances can aggregate by the time you get to the interior finishes. For this reason, architectural metal fabricators are often tasked with “squaring things up.”

It seems that it would be easy to say, for example, “The elevator entry jambs need to be 12” wide,” and that a general contractor could release the fabricator to proceed with the fabrication of all of the jambs in the building. However, field measurement often reveals that, for example, the stock elevator entry is 1/8” out of plumb, and the wood base that abuts that entry has been left 1/8” short. This often means that, in order to avoid unsightly gaps, the architectural metal needs to be fabricated on a taper, to “hide” the inherent site imperfections.

If those decorative metal jambs were all fabricated ahead of time, the metal fabrication company installing them is likely to hear, “Those jambs need to be re-made – there are gaps,” when the architect does a walk-through. At that point, the options are either (A) Have the other trades come back out and rework their areas so that the pre-made metal jambs fit; or (B) Scrap the original jambs and re-make new ones that taper as needed.

The alternative to either of these two expensive options is: wait until the other trades are finished, and let the metal fabricator field-measure actual jobsite conditions when the site is ready for architectural metal. Can this cause the final release of an area to be delayed slightly? Yes. But, the two more expensive options also result in delays, and at higher costs.

Being realistic about the obstacles facing the “last trade in” and allowing sufficient time in the job schedule for them to do their work will result in less stress and a better looking final product.

3. Live” Finishes Are Different Than Coated Finishes

With a powder coated or kynar painted finish, an owner or architect can look at a small color sample and know exactly what they’ll be getting – a uniform color over the entire coated surface. However, when a “live” finish (such as blackened steel or antique brass) is selected, owners and architects should be aware that the actual fabricated metal features will likely not match their 4” x 4” finish sample exactly or uniformly. Subtle differences in the chemical composition of the sheets, even within the sheets themselves, can cause the metals to react differently to the finishing chemicals. Within the same sheet, you can have “light” or “dark” areas. In addition, streaked finishes are often accomplished by hand, not by machines, so large surfaces can have variations within them.

Keep these things in mind on your next architectural metals scope – you’ll be glad you did!

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Comparing MIG, TIG, and Fiber Laser Welding

Eric Johnson — Mon, 23 Feb 2026 08:30:07 +0000

Astro Sheet Metal utilizes three types of welding: MIG, TIG, and Fiber Laser welding. All three types of welding have their applications, and in this post, we will highlight the differences between them.

How do they work?

MIG Welding – An electric arc is created between a consumable electrode and a metal plate on the weld zone. The welding pool (made from the melted metal) is shielded by an inert gas, which protects the area from contamination.

TIG Welding – A nonconsumable electrode (typically tungsten) forms an electric arc that melts filler material onto the weld zone. TIG Welding also uses a shielding gas to keep the weld zone free from contamination.

Fiber Laser Welding – A concentrated laser beam is used as the heat source to melt and join metals. The laser’s intensity can be adjusted, and filler wire can be added as well.

2) What are their applications?

MIG Welding – Useful for a variety of materials, MIG Welding is often associated with faster, less precise joining. It is also frequently employed for heavier fabrication.

TIG Welding – Generally used for higher-quality, more precise welds on thin metals for cosmetic finishes. It is also useful when a cleaner weld is needed (i.e., corrosion-resistant applications).

Fiber Laser Welding – Useful for high-speed precision joining of metals in applications requiring smaller weld beads, minimal distortion, and clean welds. It also has the capability of joining thick metals to thin metals, and even dissimilar metals in some situations.

3. Which process is fastest?

Without a doubt, fiber laser welding is the fastest welding method. Fiber laser welding generally goes 4-5x faster than TIG welding. Next fastest would be MIG welding, which is more of a “quick and dirty” welding process to join materials together when appearances are not as important. The slowest process is TIG welding, but TIG is probably the most precise method.

4. How does Astro utilize the various welding techniques?

The specifics of each job dictate which welding method will be used, but in general terms:

MIG welding is used for joining thicker plate, such as industrial bracketry..
TIG welding is used for shorter welds of thin metals, and in particular, stainless steel, or in food grade welding applications where contamination must be minimized as much as possible.
Fiber Laser welding is used in cosmetic areas, as its small bead requires minimal cleanup. It is also used when long welds on thin metals must be accomplished, such as across the wide face of a long stainless steel countertop. It also creates beautiful welds on brass, bronze, and copper.

No matter what your project requires, Astro has both the talent and the equipment to accomplish any welds that you may need to the highest level of quality. Give us a call, and let’s see how we can help you with your next custom metal fabrication project!

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Various Finishes of Stainless Steel

Eric Johnson — Mon, 16 Feb 2026 08:30:00 +0000

Stainless steel is widely used in architectural metal fabrication, popular for its durability and corrosion resistance. It can also be finished in a wide variety of ways to create different aesthetics for all types of projects. Here are a few finish options that you might consider for your next stainless steel project.

Mill Finish – 2B

This is called “mill finish” for a simple reason – this is the way the sheet looks straight from the mill. While stainless steel is generally thought of as a shiny metal, a 2B finish is more of a dull, matte finish. Also, because it is not typically handled in the mill as an architectural product, it frequently has blemishes or hairline scratches visible in the surface. It also is not a finish that can be re-created by typical finishing tools, so it is not recommended in areas where maintaining this finish is critical. Think of mill finish as more of an industrial finish, when you need the corrosion resistance of stainless steel without high concerns for the cosmetic appearance of the metal.

2) Orbital / Non-Directional Finish

This is called an “orbital” finish because it is most often accomplished with an orbital sander. When you need a uniform finish in an area that might need to be touched up over time due to traffic, an orbital finish is a good finish to consider. We recommend this finish for a lot of outdoor kitchen countertops, where things will inevitably be drug across the surface. Over time, as scratches appear, the finish can be re-touched with the help of an orbital sander.

3. Sandblasted / Beadblasted Finish

By putting the stainless steel in a sandblaster or bead blaster, a uniform finish can be achieved that is not as shiny as polished options. However, this finish is sometimes more difficult to touch up over time, especially if the finished product is in an area that is not conducive to sandblasting.

4. Brushed (#4) Finish

This finish provides a uniform, grained finish. It is very popular because it is available in prefinished sheet. When you think of brushed stainless steel, think of the fronts of most of the stainless steel appliances that you see in a kitchen.

If you ever have questions during your design phase about whether aluminum or steel would be the better fit for your project, please feel free to reach out to Astro, and we will be glad to offer input and advice!

5. Mirror Polished (#8) Finish

A mirror-polished finish is a very high-end finish. It is also available in prefinished sheet, but any fabrication to the sheet may require manual touch-up and/or repolishing of the finish afterward. This is generally considered to be on the more expensive side of stainless steel finishes.

6. Champagne

Many people do not know that stainless steel can be tinted to different colors. While the options are not limitless, one popular coloration that we see is champagne. This is generally a more expensive finish, as it sometimes must be applied by hand.

7. Aged / Blackened

Stainless steel can also be aged, or blackened, with chemicals to create a very unique look. This is a labor-intensive finish that is not easily touched up, but it is striking and creates a memorable appearance.

If you have an upcoming stainless steel project and would like to explore finish options, please contact Astro and we will help you find the right solution!

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Choosing Your Metal: Aluminum vs Steel

Eric Johnson — Mon, 09 Feb 2026 09:02:36 +0000

Here at Astro, we often see projects in their infancy. As designs begin to take shape, we sometimes get asked about the differences between aluminum and steel. Which is better? Which one is the least expensive? Today, we will try to shed some light on the differences between these two metals, so that you can begin your next project with some handy metal knowledge.

1. Strength

When considering strength, the correct material to use really depends upon the application. Steel, in general, is considered to be stronger than aluminum. It contains more carbon, and it is a denser metal. However, if weight is a concern, note that aluminum is roughly 1/3 as heavy as carbon steel. In some cases, such as in wind-resistant applications, the additional flexibility of aluminum can be an advantage.

2. Corrosion Resistance

The simple answer is: Aluminum does not rust, and carbon steel does rust. Both materials naturally oxidize, but in aluminum, this “oxide film” tends to protect the metal. If steel is used in an area exposed to the elements, it must be coated (paint, galvanize, or powder coat) to prevent rust.

3. Cost

Both aluminum and steel are global commodities, so prices for both materials can fluctuate based on global supply and demand. Steel costs substantially less per pound than aluminum. However, aluminum is substantially lighter per square foot than steel. Prices can vary in both materials depending on alloys and availability. In general, steel is thought to be cheaper than aluminum.

4. Malleability

Aluminum is much more malleable than steel. Aluminum is less dense and more ductile than steel, so it can be stretched and formed more easily in most cases. Steel, on the other hand, contains a large amount of carbon, so it is generally more rigid than aluminum.

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Prefinished Aluminum: A List Of Options

Eric Johnson — Mon, 02 Feb 2026 08:10:00 +0000

Aluminum sheet comes in many finish options, and utilizing prefinished sheet can save both time and money when compared to post-fabrication finishing. Here are some of the options available to improve the appearance of the aluminum on your next project:

1. Mill Finish

If your project needs to have a very specific custom color of paint or powder coat, it is best to fabricate the parts from mill finish sheet and have them post-finished. Sometimes, there is no talking an architect out of the exact color they have in mind. Mill finish should also be used if the project requires the metal to be welded, since pre-applied finishes will most likely be marred or burned during welding.

2. Anodized Aluminum

Anodizing is a chemical process by which the top layer of an aluminum sheet is hardened and tinted to a specific color. The sheet becomes more resistant to abrasion, and fading is generally not an issue for many years on anodized aluminum. The most common colors available in prefinished sheet are: clear, medium bronze, dark bronze, champagne, and black. If you are providing brake metal that needs to match anodized extrusions, it may be best to first request a sample of the prefinished sheet to insure that the colors match closely enough.

3. Fluropon (Kynar) Painted Aluminum

A fluropon finish is a baked-on coating. It is largely resistant to corrosion and maintains excellent color consistency. Pre-finished fluropon coated sheets are available in a wide variety of colors. It may be worth investigating to see if there is a pre-painted sheet option that will work for your project. If so, you can save a great deal of time and money!

4. Aluminum Tread Brite

When you think of shiny diamond-plated toolboxes in the backs of pickup trucks, think of aluminum tread brite. It comes in a variety of gauges and sheet sizes, and this material can be used to line corridors of industrial areas for wall protection. It can also be used for corner guards, stair treads, and a wide variety of applications. We have even seen it used for bar fronts for purely aesthetic reasons.

Astro regularly works with all types of prefinished aluminum sheet, and we keep a wide variety of materials in stock. Please contact us for your prefinished aluminum needs, and we will be glad to assist!

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