Arch-Fab’s Powder Coating Process

Powder Coating Process

Powder coating is a preferred finishing method that provides a long-lasting, durable surface with virtually unlimited selections of solid colors and wood grain patterns.

At Arch-Fab, we take pride in our unique in-house powder coat operation and we also collaborate closely with trade partner, QPC to deliver the industry’s most comprehensive offering. Arch-Fab has developed a meticulous step-by-step powder coat process that ensures repeatable success.

The Powder Coating Process

Step 1

Powder coating is only as good as the surface on which it is applied, and the first step in the process in preparation. Inspecting the surface, looking for heavy contaminants, organizing, counting, handing, and labeling so that everything runs smoothly.

Step 2

We then wash the aluminum components with a special surfactant, rinse with water and then air dry or oven dry. Sometimes you need to force the rinse out of corners and you may find our crew with a shop vac getting into the nooks and crannies.

Step 3

The products are moved into fully enclosed and filtered spray booths and uniformly coated with dry powder applied, by our expert powder coat technicians, and held in place with an electric charge.

Step 4

Once coated, the components are moved into the oven where they are baked (like an apple pie!) at 400 degrees for about 35-40 minutes, removed and allowed to cool. Quality control checks are performed between each stage.

After Installation & Beyond

At Arch-Fab, we offer a standard one-year finish warranty for powder coating after installing the finished product; however, we can offer warranties of up to 15 years.

If you have any questions about our powder coating process, please give us a call.

Arch-Fab’s Project Management Process

Arch Fab's Project Management Process

Architectural Fabrication’s project management team oversees the planning and executing of our products that end up on the walls of each building we complete. They are an integral part of our End to End solution heading over the transition from Pre Construction all the way to project completion. The project management team is equipped with knowledge and resources to help your project be as successful as possible.

We have an in-depth operations process for how our project management team operates to make sure information is communicated clearly for all parties and details are obtained during the project’s life. With the following blog, we want to give you some insight into how to complete our project successfully and how our Project Managers and Assistant Project Managers execute their responsibilities.

Arch-Fab's Operation Process

Turnover

Precon presents all relevant information to the Designer, Project Manager (PM), Assistant Project Manager (APM), and other imperative team members. The Project Manager reviews the project and prepares any important questions and documents the most important information to help each project be successful such as schedule, details, budget, and promises made to the client.

After Turnover

The Project Manager with the Assistant Project Manager will send an introductory email to the most important members of the project team to clarify any remaining questions and get on the same page as the project team.

Submittal Process

The PM and APM will then oversee the creation of the submittal package for the project. The assigned designer and project manager will determine the due dates of the submittal package for each release. Once all details are satisfactory, the submittal package is sent to the client for approval. Learn more about our detailed submittal process.

Production Release

Once the submittal package is approved by all parties, the PM will request a production release from our design team. The release includes all the parts and pieces required to create the final product for our fabrication team. This includes the dimensions of each material and fasteners and any detail imperative to the success of the product fabrication and finishing.

Fabrication & Finishing

Materials are pulled and assembled to the greatest extent possible and readied for the jobsite.

PAcking

The material management team will count, pack, wrap, and load all parts of the projects in crates and pallets. The project management team checks their work to confirm everything is accounted for before their transport to the next location – whether they ship to site or the installation team travels to the jobsite to install them.

Once billing is complete and the job work is punched and satisfactory, the work of the PM and APM is complete for a finished project.

Arch-Fab's Project Management Team

Arch Fab's Project Management Team
Pictured from Top to Bottom: Ean Phy, Sydney Hicks, Taylor Garner, Jose Riviera, Philip Beaird, Chase Hammit, Wendy Miller, Kennan Marino, Shelby Sides, Mandy Hollenback.

Arch-Fab’s Submittal Process

Arch-Fab's Submittal Process

As an End To End Architectural Metals solutions provider, Arch-Fab is committed to the meticulous review of project information, extensive interaction with clients, and the creation of comprehensive documents and plans to ensure success. Our Design & Engineering Team plays a crucial role by producing and providing accurate, detailed submittals for each project.

Submittals are defined as the shop drawings, material data, samples, and product data that are required primarily for the architect and engineer to verify that the correct products will be installed on the project

In this blog post, we give you a glimpse into our Design & Engineering Team and our process of creating and delivering professional, comprehensive submittals.

Arch-Fab's Submittal Process

Pre-Con PLanning

The process of reviewing projects we’ve been asked to bid, developing comprehensive proposals, negotiating, and ultimately contracting to provide an “end to end” project solution. Want to know more? Check out our Pre-Construction process.

Pre-Turnover Analysis

The Designer and Project Manager review all relevant documents (Architectural Plans, Takeoff, Budget, Quotes, etc.) to develop ideas and questions to be answered during the Turnover Meeting.

Turnover

At Turnover, Precon presents all relevant project information to the Designer and Project Manager. The Designer comes to the meeting with questions that need to be answered and gives a timeline for Submittal Completion. This is where the designer’s real work begins.

Submittal First Draft

The Designer must clean elevations, meticulously design models, and compile all submittal pages. The submittal includes edited elevations and reflected ceiling plans, perspective page with notes, plan view, sections view, and applicable color charts.

Submittal Final Draft

An internal process of review is performed by the Design Supervisor/Manager and Project Manager and the Designer makes recommended edits. The approved final draft is ready to be sent to the client for review and approval.

Client Review

The Client Reviews the submittal and determines if changes need to be made to the project. Typically the submittal is returned as Approved, Approved as Noted, Revise & Resubmit, or Rejected.

Pre-Production

The approved submittal is then converted into the pre-production package. The computer models used to create the submittal are used to create all of the documents necessary for fabrication and installation.

Engineering

Arch-Fab’s engineers frequently provide analysis and calculations to assist the design team to ensure designs are suitable for the intended use of our projects. In many cases, our engineers provide “site-specific” calculations on the loads and conditions they will encounter when installed.

Production First Draft

The Designer completes a first draft of the Production Package and it undergoes a similar review process as the submittal.

Production Final Draft

The Designer makes recommended edits provided by the Design Supervisor/Manager and Project Manager to the Production Package.

BOM Review

The project Bill of Materials “BOMs” are reviewed and uploaded. If the BOM has any errors, the Designer will be contacted to make corrections.

Fabrication

The Designer is formally complete with the design project; however, some changes made later can involve the Designer for updates and corrections.

March 2022 Update

March 2022 Update

For the past two years, we have endeavored to provide frequent and transparent communication with you as together we have navigated through extreme global challenges. In the three weeks that have passed since my last communique that expressed cautious optimism, the world has been shaken by yet another crisis that, in addition to stirring our hearts with humanitarian concern, is causing disruption in the supply chain and greater market uncertainty.

Below is a link to a notification letter from one of our largest aluminum suppliers which provides a more detailed explanation of the immediate and potential long-term impacts of this new crisis for your review. It cites March aluminum pricing, according to the Platts Previous Month Midwest Average has increased 23% from January.

It is important to note that, in most cases, Arch-Fab does not lock in its raw materials pricing until the date of shipment which can be 6-12 months from award. Below, I outline what we are doing, what you can do, and how we move forward together.

What Are We Doing?

  • We are being proactive and transparent in our communication with you.
  • We have narrowed our focus by eliminating outside powder coating and discontinuing service work to direct the entirety of our energy to serving our core business and you, our core customers.
  • We continue to increase our raw materials inventory to all-time levels in order to protect your project budgets and timelines. Our current inventory levels are 3x as much as this time last year.

What Can You Do?

  • Submit subcontracts, color selections, and confirm the scope of work within 2 weeks of formal notification of award and be executed by both parties within 30 days of award. Delays may require re-pricing.
  • Ensure timely processing and payment of pay applications for stored materials.
  • Commit to increased communication and cooperation between project management and onsite teams and comply with reasonable requests for accommodations as the need arises or as opportunities present themselves. Examples include onsite storage or reduced mobilizations to maximize onsite efficiency.

How Do We Move Forward?

  • There will be impacts resulting from this newest situation and we are committed to being transparent and responsive with you going forward.
  • We will do everything we can to hold our pricing, as stated on our quotes, for 30 days. However, please contact us to confirm your pricing before you award us or lock-in with ownership.

We pray for a successful resolution to the crisis in Ukraine and that we become more unified as a world community and as business partners. Please don’t hesitate to contact us with any questions or concerns. We are in this together!

Regards,
Philip Klement
Vice President of Preconstruction

Arch-Fab’s Preconstruction Process

Arch-Fab 's Preconstruction Process

Architectural Fabrication’s Preconstruction team is dedicated to serving our general contracting and architectural partners the highest quality of service and solutions. Our vision is to follow a proven, efficient and effective process of pre-qualifying, proposing, bidding, and securing projects to make our trade partners’ lives simpler.

We are experts in Division 10 Sun Protection; so you don’t need to be. Below is Arch-Fab’s preconstruction process and an introduction to the team.

Arch-Fab's Preconstruction Process

Invitation to Bid

We receive your ITBs and provide timely notification of our intent to bid.

Prequalification

We methodically review plans, specs, renderings, etc. to determine what scope we intend to bid.

RFI

We submit RFIs to clarify owner/architect intent.

Design / Engineering

We engage with our design and engineering team to determine how we will perform the scope of work and determine suggestions for improvements, alternate methods, and/or VE savings.

VE Alternatives

Assemble subject matter experts, as needed for a more comprehensive collaboration to achieve greater savings at the request of GC, architect, and/or ownership.

Proposals

We present comprehensive proposals “as drawn,” with suggested VE options, and other recommended additions or exclusions.

Scope Review

We conduct thorough scope reviews in-person, via video conference, or in a pre-recorded video format.

Contracts

We request, receive, and provide subcontract agreements and submit them to our Contract Administrator for quick, thorough review and execution.

"Turnover" to Operations

We conduct a meeting with key personnel to “turnover” awarded projects to our Operations Team. A Designer is assigned who will create submittals and production documentation. A Project Manager with his/her team will take overall planning, scheduling, and onsite performance.

After we “turnover” to operations, our work is not complete. We continue to build relationships with our trade partners to ensure we are delivering maximum value.

AEC Representative

Engagement with the specifying community has been integral to Architectural Fabrication’s success and our AEC Representative, Marley Fischer, collaborates with architects, owners, and general contractors to clarify design intent and provide solutions that improve outcomes on job sites and on project budgets.

Lunch and Learns, project meetings, specification writing, review meetings, and membership in key industry associations keep Arch-Fab integrally connected to the people who bring our products to life.

(L-R) Bailey Klement, Scot Burton, Philip Klement, Joseph Beas, and Marley Fischer. Not pictured is Melissa Galua.
(L-R) Bailey Klement, Scot Burton, Philip Klement, Joseph Beas, and Marley Fischer. Not pictured is Melissa Galua.

Aide De Camp, 2022

Arch-Fab Leadership Development Program

“Leadership and learning are indispensable to each other.”
– John F. Kennedy

Arch-Fab’s Annual “Aide-De-Camp” Leadership Development Program provides our emerging leaders the opportunity to advance their skill sets through external coaching, internal mentorship, and cross-training in core business functions and processes. This serves to not only broaden the aide-de-camp’s core knowledge and understanding of our industry in a hands-on learning environment, it also provides the opportunity for fresh perspectives and approaches to the challenges encountered in our business.

Borrowed from the military, the term aide-de-camp denotes a position of an assistant to a high-ranking officer. In the United States Army, aides-de-camp are appointed and serve as confidential assistants to senior-level officers, specifically general-grade officers. This tour of duty typically lasts two years and exposes junior-level officers to broader leadership roles and responsibilities.

The candidates selected from our application and interview panel process will spend the remainder of this calendar year working with Jeff Cash, Arch-Fab’s president, to prioritize, plan, and execute on strategic objectives within our business. All this in aim of making Architectural Fabrication a better company to work for and work with.

“We will be students in pursuit of a deeper knowledge of how our business functions, leadership philosophy, and overall leadership development. We will be relentless in our efforts to share the knowledge we gain with the rest of our team.”
– Jeff Cash

2022 Aide-De-Camp Selections

Nicholas Mitchell

Senior Project Manager

Kevin Wampler

Production Manager

1st Quarter, 2022 Update

Q1 2022 Announcements

Midway through Q1 2022, at Architectural Fabrication we continue to see a very robust market and we’re grateful for the partnerships that were forged and strengthened in the crucible that was 2021. While industry and economic projections reflect uncertainty, in this update we will share where we are, what we have done to strengthen our value, and what we can do together going forward to ensure our mutual success.

Where We Are

We’ve begun to see pricing and lead times stabilize. We work closely with our vendors to monitor current conditions and our leadership team is strategically planning and communicating to key internal and external stakeholders.

Here is a link to an informative Market Update provided by vendor partner MBCI and Cornerstone:

What We Have Done

Estimating Solution

In Q4 21, we implemented a new estimating system, utilizing timely cost data and delivering the most accurate pricing.

Product Improvements

Our Product Improvement Team created significant enhancements to various products including our Helios and Atlas canopy systems. These changes allow us to maintain competitive pricing, shorten lead times, and improve product performance.

What We Can Do

At Arch-Fab, we have historically locked in our pricing at the time of award; however, we do not place orders for materials until after we have executed contracts and approved submittals. In most cases, our price is not guaranteed until our material orders ship from our suppliers. This creates a significant gap in timeline for prices to escalate.

In order to maintain this practice going forward, we are emphasizing the need to:

  1. Get contracts executed as quickly as possible
  2. Receive approved submittals and color selections within 30 days of contract execution
  3. Submit pay applications for stored materials with timely processing and payment
  4. Have greater cooperation between our teams (i.e. onsite storage, reduced mobilizations to, etc.) to ensure mutual project success and maximize onsite efficiency

With your support in maintaining these important timelines, we will ensure our ability to profitably and successfully perform.

 

Architectural Fabrication is poised for continued growth and service to you in 2022. If you have any suggestions or questions, please feel free to contact a member of our Preconstruction team at (817) 926-7270.

Ryan Jeansonne Earns PE License

Ryan Jeansonne Earns PE License

Fort Worth, TX, Announcement: January 28, 2022.

We are excited to announce that Ryan Jeansonne from our design & engineering team recently earned his Texas Professional Engineer license!

With an additional engineer on the team, this accelerates our expert review & stamp of approval process for submittal packages. We also love having our new PE review existing & future projects. Well done, Ryan!

Arch-Fab Promotes Nick Mitchell to Senior Project Manager

Arch-Fab Promotes Nick Mitchell to Senior Project Manager

Fort Worth, TX, Release: October 15, 2021.

Architectural Fabrication Inc. announced today that Nick Mitchell has been promoted to Senior Project Manager under the leadership of Asim Hasan.

“Nick Mitchell has proven to learn quickly and succeed in the Account Manager role in the past and more recently in the Project Manager role. He is very process-driven and great with systems. He also has a great mindset that will help him lead the Project Management department successfully at Arch Fab. I’m excited to see him succeed and create an environment where people thrive,” said Asim.

Nick has been an active part of the Arch-Fab team for the last four and a half years. In three years as a Preconstruction Specialist, Nick was awarded more than 250 projects and was consistently a multi-million dollar producer. Transitioning into the Project Management role, he managed and completed 93 projects with Arch-Fab’s leading clients in the multi-family, commercial tilt-wall, and retail verticals.

“I am very excited about the opportunity to lead our talented project management team. Architectural Fabrication has given me the tools to grow as a professional and I’m looking forward to taking this next step with this amazing company. Eric Locke has created a team-centric atmosphere and pushed us to be problem-solving resources for our clients,” said Nick.

Nick graduated with a degree in Public Relations from Texas Tech University. In his free time, Nick enjoys spending time with friends and family, attending concerts and sporting events, and traveling to beautiful locations for camping, fishing, and hunting.