Sheet Metal Fabrication
Sheet Metal Fabrication
We Can Build It.
Picture a commercial kitchen where a custom stainless steel exhaust hood needs to fit precisely against an irregular wall, or a residential HVAC system that requires a specialized transition piece to connect an older duct run to a modern furnace. These moments call for something you cannot pull off a shelf. They call for sheet metal fabrication, and this is where the craftsmanship at Staab & Sons, Inc. becomes essential to getting the job done right.
Sheet Metal Fabrication Rooted in Generations of Craft
Sheet metal fabrication is the process of forming, cutting, and joining flat metal stock into functional components used throughout heating, cooling, ventilation, and refrigeration systems. Our story began in 1929 with Jerome and Edna Staab, and over ninety years and four generations later, we have refined our metalworking capabilities to serve both practical and demanding technical requirements.
The materials we work with most often include galvanized steel, aluminum, and stainless steel, each selected based on the application. Galvanized steel is a workhorse for ductwork thanks to its corrosion resistance and affordability, while stainless steel is preferred for kitchen ventilation and environments where hygiene and heat resistance matter. Aluminum offers a lightweight alternative where weight loads and specific thermal properties are a concern.
The Fabrication Process from Blueprint to Installation
Every fabrication project we undertake begins with precise measurement and layout. Our technicians assess the space, take field measurements, and translate those dimensions into fabrication drawings. This planning stage ensures that a finished component fits its intended location without costly rework. Whether we are producing a straight duct section or a complex multi-angle transition, accuracy at this stage determines the quality of the final product.
From there, the process typically moves through several defined stages:
- Cutting: Flat metal stock is measured and cut to size using shears, saws, or laser and plasma equipment depending on thickness and detail.
- Forming and bending: The cut pieces are shaped using brakes and rollers to create angles, curves, and seams.
- Joining: Sections are connected through welding, riveting, or mechanical seaming to form a rigid, airtight assembly.
- Finishing: Edges are deburred and surfaces are treated to prevent corrosion and ensure a clean, professional appearance.
- Quality inspection: Each piece is verified against the original specifications before it leaves our shop.
This methodical approach is a direct reflection of the principles of Honesty, Integrity, and Value that have guided us for decades. We do not cut corners, and our commitment to doing the job right the first time is why our customers throughout Allegheny and surrounding counties continue to rely on us.
Practical Uses for Custom Sheet Metal
The versatility of sheet metal fabrication means it touches nearly every part of an HVACR system. Because no two buildings are identical, custom fabrication frequently solves problems that off-the-shelf parts simply cannot address. Consider these common scenarios where our fabrication services deliver real value:
- Custom ductwork: Fabricating supply and return ducts tailored to the exact layout of a home or commercial building for optimal airflow.
- Transition fittings: Connecting components of differing sizes or shapes, such as joining a round pipe to a rectangular plenum.
- Kitchen exhaust hoods: Producing durable stainless steel hoods that meet ventilation and safety standards for restaurants.
- Roof curbs and flashing: Creating weather-tight bases and seals for rooftop mounted equipment.
- Register boxes and plenums: Building the housings that distribute conditioned air throughout a structure.
In new construction, our shop-fabricated components arrive ready to install, reducing labor time on site. In retrofit and repair situations, custom fabrication allows us to adapt modern equipment to existing infrastructure without expensive demolition. This adaptability is particularly valuable in older properties across Pittsburgh, PA and surrounding areas, where original ductwork rarely matches contemporary standards.
Why Trust Staab & Sons, Inc. for Fabrication
Fabrication is only as good as the people behind the tools. Our HVACR employees are factory authorized, NATE certified, and EPA certified technicians who bring both technical skill and disciplined professionalism to every project. This depth of training means we can handle a job or system of any size, from a single custom fitting to a full commercial ventilation package.
Our reputation is backed by recognition as well. We are the winners of the 2011 Better Business Torch Award for business ethics, an honor that speaks to the trust we have earned over more than nine decades. When you need sheet metal fabricated with precision, durability, and integrity, Staab & Sons, Inc. delivers work built to last. Reach out to us today to discuss your fabrication needs and experience the quality that generations of customers have come to expect.
