Sheet metal processing and powder coating

Complex challenge - fence project

For the G3 project, the architects Pitsou Kedem designed much more than just a fence. It's an architectural object that creates a connection between interior and exterior spaces through the interplay of light and shadow. The Israeli company Shahaf Ltd. was commissioned to implement the project and sought a competent partner for manufacturing the fence elements. ALUTECTA rose to the challenge and, in close collaboration with Shahaf Ltd., developed a feasible solution that meets the design's aesthetic requirements, is technically viable, and ensures the necessary stability to minimize the number of fixing points required during final assembly. Following the planning phase, the first challenge was creating the contour using computer-controlled sheet metal milling machines. Diamond-shaped cutouts and aluminum surfaces were milled from 8 mm thick aluminum sheets. Extremely high precision in the craftsmanship was required in the next step. The elements were bent up to 14 times per sheet to create a 3D zigzag pattern. Each of the 14 bends had to be made at a precisely defined point and at the correct angle – any errors would have accumulated and made combining the elements impossible. The connection was achieved by welding precisely at the seams of the rhombuses. In some cases, small triangular elements, which were integrated into the contour as connecting flanges, were used. Here, too, the delicate balance between aesthetic requirements and technical necessities was paramount. The welders had to push themselves to the absolute limits of their craftsmanship to satisfactorily meet both conditions. Because the welds were made precisely at the visual interfaces, they then had to be ground down and smoothed. The edges of the interfaces were finished so precisely that the joined parts appear to have been made from a single workpiece.

Aluminum machining

1. Planning and Design
2. Provision of suitable materials
3. The sheet metal panels are milled to the desired contour on a CNC machine.
4. Each sheet metal strip is bent up to 14 times.
5. The strips are joined together by aluminum welding.
6. Removal of the welds by precise grinding and finishing.
   

Powder coating

1. The aluminum sheet elements are suspended.
2. Electrically grounded.
3. Because every contact point remains visible, these points are precisely determined beforehand.
4. Pretreatment in baths serves to clean and create an adhesive layer.
5. 100% drying in an oven.
6. Coating No. 1 with epoxy resin-based corroprimer.
7. Coating No. 2 with RAL 9016 fine texture HWF (high weather resistance).
8. Powder coating in the system is carried out with precisely controlled spray guns under supervision, with manual rework in inaccessible areas.
9. The welds and ground, finished areas are masked.
10. Quality control and assurance. After GSB and Qualicoat
11. Unhooking, packing, and handing over to the shipping company

Video - fence project