As a result of supply chain issues — directly related to COVID-19 — Badger Sheet Metal Works began to receive quite a bit of lead time for each of its industrial ductwork, prefabrication/manifolding and welding projects.
These longer than normal lead times were critical, especially as the Green Bay, Wisconsin-based metal fabricator required more time to obtain materials than usual. However, such long lead times (a trend from 2020 to 2023) are no longer necessary. In fact, the typically short lead times of the past have once again become the norm.
“We specialize in finishing our projects very quickly,” stressed Chris Bares, lead programmer and IT specialist, American Alloy, the parent company of Badger Sheet Metal Works. “For large-scope projects, we take roughly 12 weeks or less to finish. Mid-scope projects take about six weeks, while small projects take two to four weeks.”
The primary reason for such short turnarounds? Badger Sheet Metal Works conducts all of its projects in its shops, rather than in the field. At the same time, roughly 70% of East Chicago, Indiana-based Vidimos, Inc.’s projects are fabricated in its shop.
“Any work that’s done in the shop takes about half the time as the same work in the field, due to working in a controlled environment and having ready-to-access equipment,” said owner Scott Vidimos.
FABRICATE: Vidimos, Inc., fabricated 12-foot x 4-foot ductwork sections for steel mill exhaust. (Courtesy of Vidimos, Inc.)
Aside from Badger Sheet Metal Works’ project timeliness, the sheer sizes of its projects also stand out. After all, its assembly bay is 70 x 320 feet. Additionally, the metal fabricator can cut items that are up to 80 x 160 inches in size, while lifting up to 60,000 pounds at a time, too.
Therefore, its welders can conduct industrial ductwork projects for virtually any type of client throughout the United States, from small, Midwestern paper mills to Fortune 500 companies.
Multiple components can be completed simultaneously as well, while turnkey projects, such as pneumatics and valves, are finalized in a consistently timely fashion. The concurrent, consistent and quick results are two-fold, according to Kenny Coe, American Alloy’s sales manager. First, Badger Sheet Metal Works’ Green Bay, Wisconsin-based shop floor has 110,000 square feet of space. And second, its other shop floor, located in Spokane, Washington, has even more manufacturing space: 130,000 square feet.
In turn, Coe has found that Badger Sheet Metal Works’ accounts’ longevity is generally very high.
“We make sure all of our customers’ questions are answered,” Coe said. “I recommend all metal fabricators to establish pre-kickoffs, so to speak, with potential customers to determine what their requirements and standards are.”
“Every customer has different expectations,” Bares added. “Continue to communicate well with your customers throughout each project as well, so that any potential design issues or flaws are resolved before products are finished. By doing so, your customers’ expectations won’t just be met — they’ll be exceeded.”
SQUARE FOOT: Badger Sheet Metal Works’ Green Bay, Wisconsin-based shop floor has 110,000 square feet of manufacturing space. Meanwhile, its other shop floor, which is located in Spokane, Washington, has 130,000 square feet of space. (Courtesy of Badger Sheet Metal Works)
Serve customers with loyal employees
Unlike Badger Sheet Metal Works, Vidimos, Inc. conducts nearly all of its ductwork projects for local manufacturing companies. For example, it’s currently fabricating and installing a watertight, welded stainless steel HVAC duct for a nearby corn processing plant.
At the same time, it’s also fabricating an 18-foot-wide x 48-foot-tall bin, comprised of a 0.375-inch and 0.50-inch plate. To decrease field assembly time considerably, it will be shipped in three bolt-together sections.
Moreover, the metal fabricator has recently fabricated and installed a dust collection duct for four dust collectors at a nearby plant.
To say the least, Vidimos, Inc. oversees practically any type of ductwork project at its 60,000-square-foot shop. Set to feature a new, 10,000-square-foot addition soon, the shop will now have two 30-ton overhead cranes, along with a crane hook that’s 30 feet high. In turn, the metal fabricator will be able to assemble larger fabrications than ever before.
QUICK TURNAROUND: Badger Sheet Metal Works specializes in finishing its projects rather quickly. For instance, the fabricator’s large-scope projects are completed in roughly 12 weeks or less. Additionally, its mid-scope projects are executed in six weeks, while its small projects are fully conducted in two to four weeks. (Courtesy of Badger Sheet Metal Works)
“Our customers, including owners and general contractors, are relying on us more and more for constructability, design and cost savings ideas,” Vidimos said. “To reduce our installation times, we’re manifolding and fabricating in larger pieces too — the shop’s addition and new overhead cranes will allow us to fabricate in even larger pieces now.”
As Vidimos reflects on his company’s recent and continuous growth, he believes its success is mainly due to its highly skilled and motivated workforce. Throughout the year, he has roughly 70 employees. Each employee is a Union sheet metal worker that does “what is necessary” to make Vidimos, Inc. the “go-to sheet metal contractor” in its area, particularly with regard to “fast turnarounds and tight schedules.”
Likewise, Badger Sheet Metal Works also has a dedicated workforce. Comprised of several seasoned veterans, the metal fabricator’s workforce “can do everything” that customers need them to. As an example of employee loyalty and low turnover, Bares has been employed for 35 years, while Coe has been working for Badger Sheet Metal Works for 12 years.
“Our employees aren’t doing the same thing every day. They get to use their creativity,” Bares stressed. “Because of this, our average tenure is 8.5 years.”
In addition to providing employees an array of projects to work on, Coe believes the metal fabricator stands out for three other key reasons: its culture, community and communication.
“We’ve created an environment in which our employees truly like to work here,” he emphasized. “And, as a result, they work to the best of their abilities, time after time.”
Along with creating this type of working environment, Vidimos advises metal fabricators to offer employees an opportunity to acquire professional and technical training, via trade associations like the Sheet Metal and Air Conditioning Contractors’ National Association (SMACNA).
“SMACNA is the standard in our industry in the technical, legislative, safety and management arenas,” Vidimos said. “Through its organization, large and small contractors’ employees will receive adequate training that will benefit their future careers.”
STEEL MILL: Vidimos, Inc. fabricated standpipes for a coke oven at a steel mill. (Courtesy of Vidimos, Inc.)
Exceed expectations with various resources
The significance of top-notch technology, along with a wide range of certifications and materials, must not be overlooked either. For instance, as it conducts its industrial ductwork, prefabrication/manifolding and welding projects, Badger Sheet Metal Works utilizes many types of high-end, innovative technologies.
As an example, to conduct laser cutting projects, it has an Amada F04020NT with Step 1 Automation, which is capable of cutting 80-inch x 160-inch sheets. To complete tube laser cutting projects, it also uses an Amada 3015 RI (Rotary Index), which can be utilized for several table shapes, including angle, channel, rectangular, round and square.
Furthermore, it uses a Mandrel Bender for tube bending projects. To conduct machining projects, it utilizes lathes, along with an assortment of Haas vertical machine centers — with sizes ranging up to a VF-11. And, finally, to complete its welding projects, it uses a Bancroft Linear Seam Welder.
“Our welders hold American Welding Society (AWS) D1.1 (carbon steel), D1.2 (aluminum), D1.3 (structural sheet steel) and D1.6 (stainless steel) certifications too,” Bares said.
While looking back at Vidimos, Inc.’s latest successes, Vidimos believes his investment in new technologies has kept his company more “competitive and efficient in the last few years.” For instance, the company’s laser burning capabilities have either been replaced or upgraded, while it’s also increased its crane and material handling capacities by more than 50%.
Along with investing in new technologies, Vidimos, Inc. is focused on welding a wide assortment of alloys, aluminum, stainless steels and steels as well. Similarly, Badger Sheet Metal Works conducts projects with numerous types of materials, too — on all types of grades. From aluminum and galvanized steel, to mild steel and stainless steel, the metal fabricator strives to remain open minded.
“We don’t just specialize in one or the other,” Coe said. “Instead, we strive to specialize in all materials and grades.”
As yet another example of Badger Sheet Metal Works’ open-mindedness, the metal fabricator will also acquire its International Traffic in Arms Regulations (ITAR) compliance soon. Consequently, it will be able to fabricate defense-related items as well, thereby increasing its clientele base even more.
In preparation for the future, Vidimos advises other metal fabricators to follow suit and simultaneously focus on their employees and technologies.
“Invest in your people and stay on the cutting edge of technology,” he concluded. “With talented, loyal employees and new technology, your metal fabrication business will be able to exceed your customers’ expectations, over and over again.”