Manufacturing Capabilities

Manufacturing Capabilities

Steel City Bolt operates out of a single 85,000 square foot facility located in Birmingham, Alabama, USA. The facility is composed of an anchor bolt and construction fastener manufacturing plant, a hot-dip galvanizing line, a stocking warehouse, and office.

Our manufacturing facility produces nonstandard rods, bent bolts, and headed bolts in imperial (inch) sizes for a variety of industries. We stock a full range of fasteners, nuts, washers, and other accessories to compliment the bolts we produce. Inventory consists of black and galvanized fasteners from both domestic and foreign sources. All domestic and high strength products manufactured or stocked are fully traceable and will include chemical and physical test reports.

Cutting/Shearing
Steel City Bolt has the capability to cut a wide array of materials that we use to manufacture our fasteners. We have two different ways to cut materials into the proper length in order to manufacture the parts that our customers require.

Shearing (1/4″ – 1 1/4″)

The first method we use to cut the materials to length is shearing. Shearing is preformed when the materials are slid into a die on a shearing machine and the dies come together to actually “break” the material into the proper length. This is a very quick process and is the most economic method of cutting materials to length.

Saw Cutting (1/4″ – 6″)

The second method we use to cut materials to length is sawing, or cutting the material with a blade. Large band saws are used to cut larger materials, special requests, and any all thread rod that we may saw cut to length. Saw cutting is slower than shearing and thus is less economical than shearing.

At the cutting or shearing process Steel City Bolt starts the lot traceability process. As the material is pulled to be cut to length the bin and paper work are tagged with the heat lot number from the mill. This allows us to trace the material back to the original melting mill.

Threading

Steel City Bolt uses two different threading methods to apply threads to the raw materials for the fasteners.

Roll Threading (1/2″ – 2″)

Roll threading is the most common method of applying threads to raw materials. A “pitch diameter” (undersized diameter) material is used and moving dies are used to cold form the threads. Basically, the dies are spread at a lesser distance from one another than the material diameter and the thread design is achieved by pressing the steel together and upsetting the threads. This upsetting is actually very strong and achieves a greater pulling strength than cutting the threads. Steel City Bolt has the ability to roll thread material from 1/2″ up to 2 1/4″ in diameter.

Cut Threading (1/2″ – 4″)

Cut Threading is another method we use to apply threads to the raw materials. Cut threading is the process where the threads are literally cut into the material. Cut threading uses a full size material to start with and then material is cut away to achieve the lower part of the threads. Steel City Bolt has the ability to cut thread material from 1/2″ up to 4″.

Heading

DSC_0288Steel City Bolt has the ability to head raw materials in many different head configurations from 1/2″ up to 3″ in diameter. We us hot forge presses to apply heads to our raw materials. Hot Forging is the process of heating the material through a furnace to a certain temperature required. Once the part is heated up to the proper temperature the part is then placed into the heading machine. The heading machine then grips the material with hydraulic powered dies and strikes the end of the hot part upsetting the material into a head.

After a certain number of bolts are headed, a QC test is preformed to ensure each lot has the proper head dimensions and tolerances.

Bending
Steel City Bolt has the ability to bend raw materials from 1/4″ up to 4″ in diameter. We use several different machines to obtain the proper bend that a fastener requires. Bending of anchor bolts and tie rods are also reviewed by our QC Department randomly for testing to ensure that proper bending has been preformed. 
Plate Fabrication
Steel City Bolt has the ability to supply plates, angles or specialty plates of most any design that you require. We can supply sheared, punched or burned out holes of a variety of designs.

From anchor bolt templates, to square washers Steel City Bolt has the capability of supplying you with the correct plates for the job. Also, if you need parts that have nothing to do with a fastener, please ask and we will be happy to provide you with a quote.

Assembling
The assembling process at Steel City Bolt is a very important step in fulfilling some orders. If a customer requests that we assembly parts the order is taken to a certain area of our Shipping department to await the assembly process.  We can then prepare the order for shipment per the customers request. From simple requests of assembling nuts and washers; to assembling anchor bolt templates or other customer required hardware we will be happy to accommodate your assembling requests per  your order.
Quality
Although Steel City Bolt does not have a full in-house testing facility, we do incorporate two important Quality Control practices to ensure parts are made correctly.

Quality Control

Steel City Bolt incorporates a full Quality Control Program (*link*) throughout the manufacturing process. Briefly, we manage this by lot tracking from the moment the raw material is received, tracking throughout the manufacturing process and random in-house testing for physical characteristics. We provide full material certifications for every order that is passed through the shop (some charges might apply if certifications are requested after the order has been invoiced or if special tests are required). Please contact us for any information that you might need. Also, visit our Quality Control page (*link*) to download our Quality Control Manual or to learn more about our Quality Control procedures.

Accredited Testing Lab

Steel City Bolt maintains a strong relationship a certified and accredited testing lab within 2 miles of our facility. By having our products tested by an outside testing facility this provides quality testing reports and data this is both un-biased and accurate. They provide the following tests and many others upon request:

  • Axial Tensile
  • Dimensional
  • Wedge Tensile
  • Rotational Capacity
  • Proof Load
  • Shear Testing

Any testing not mentioned please inquiry and we will try our best to accommodate your request.

Coating
Steel City Bolt has the ability to have parts coated with the finish of your choice. Coatings are applied per the customers request. Steel City Bolt utilizes several different coating facilities to obtain the coating of choice in a timely and quality manner.

Hot Dip Galvanizing

Hot dip galvanizing is the most common corrosion prevention coating that Steel City Bolt provides. Hot dip galvanizing, also called galvanized is the industry standard for bolts used  outdoors where corrosion protection is a must. Galvanizing of products is a process where a thick zinc coating is applied under heat to the part. This thick coating provides a very robust protection against the elements. The galvanizing process can take a couple of hours up to two or three days depending in the quantity and dimensions of the products.

Zinc Coating

Zinc plating is very similar to hot dipped galvanizing, except it is a thinner coating applied at lower temperatures using electricity to help bond the zinc to the parts. Zinc plating, also called electroplating, is usually more costly than the hot dipped galvanizing process. The parts are submerged in a zinc bath as an electrode is placed in the tank and energized. This energizes the particles and cause the zinc to adhere to the parts in the zinc bath. This process is not as durable as hot dipped galvanizing and usually costs slightly more. Parts that a customer requests zinc coating usually take from 3-6 days to be coated.

Electro Polishing

Electro Polishing is a process applied primarily to stainless steel fasteners to remove the impurities usually brought to the surface of heated stainless steel. When stainless steel fasteners are heated up in order to hot forge the head onto the part, the bolt will discolor and even turn black. In order to have a more cosmetic stainless steel look, electro polishing is preformed to remove and polish the fasteners.

Other Coatings

Steel City Bolt has many other coatings and additional part processing abilities. If you have a special coating requirement please contact us for more information.

Shipping
The final process in the manufacturing process is shipping. Steel City Bolt uses this last process to pack up all items requested on the customers order, final quality checks are preformed and any required paperwork is prepared. Steel City Bolt employs a staff of shipping employees qualified to inspect assemble and ship out a customers order with high accuracy and as efficiently as possible. 
Misc.
One thing Steel City Bolt has learned is there are no standard orders. If a customer asks for something special we will be happy to evaluate the request and either adapt to provide the service or outsource with a reliable partner.