Loft Conversion
Service Plus Sheet Metal
Behind the Scenes - Loft Conversion
Before installing the diner style kitchen, Bob toured the Service Plus Sheet Metal facilities in Weymouth, MA to see how the stainless steel counter was built. First stop on the tour with Ed was at the sheet stock area. Stainless steel comes as tubing or as sheet stock with a protective vinyl covering to protect the factory shine.
The stainless steel chosen for the loft kitchen is a 14 gauge which is a little under a 1/8" thick. Made with a nickel alloy, this stainless steel product offers many features desired in commercial kitchens. A hard, rust-proof, non-porous surface is ideal because food juices will not sink into the counter. Stainless steel is also preferred for its longevity. Cost effective also, stainless steel is priced per pound at $1.10 to $1.20.
The steel fabrication process starts at the shear machine where the stainless steel stock is cut to size, width, and length. The shear machine cuts the stainless steel stock according to the breakdown plan from the engineer. The breakdown plan has all the cut sizes and layout for notching, bending, and hole location. The scribe or layout process has to be very accurate, as the proper construction of the unit depends on it. From the layout station, the steel is then transported to the hole punch location, for faucets, and then onto the plasma cutting station.
The plasma cut is used for interior cuts in the stainless steel, like a sink cavity. The corners are cut first and then tied together and the sink is then welded in. The plasma cut superheats the steel to melt it and compressed air blows the slag away at the point of melting for a very neat cut.
One of the last areas of fabrication that Bob and Ed visited was the power brake. This two step process creates a bullnose or circular edge. This particular power brake controls 65 tons of pressure with a foot pedal, though there are machines rated higher than this one.
Before leaving, Bob and Ed took a quick look at the completed counter for the loft. Bob's counter featured some of the fabrication elements just demonstrated such as bullnose edges achieved with the brake. The unit was constructed with 1 5/8" steel tubing welded to a galvanized channel for structural support. Galvanized steel was used as a cost saver for the channel since the underside of the counter will not be visible. The last thing that Ed showed Bob was the field joint. This is where the counter will be welded in place after it is delivered to the loft. Bob can't wait to see installed!!
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