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Fabrication of a Steel Bottom Block Base Assembly for the Primary Aluminum Smelter Industry

At A & S Fabricating Co. our expansive facility houses an impressive amount of equipment for creating large structural fabrications, and the base assembly pictured here is a result of some of our fabrications.

Featuring overall dimensions of 10’.0” in length x 7’6” in width x 3.0’ in height and weighing in excess of 8,500 lbs., this bottom block base assembly was constructed for use in an aluminum smelting plant. Built from ⅜” to 1½” thick A36 steel plate and 6” solid round bars, it sits on Delrin® pads for stability and cushioning. Primary operations involved multiple cutting, machining, grinding, and welding processes to fabricate the structure to within 1/16” dimensional tolerances and overall height parallel to within 0.030”. Vibratory stress relief enhanced the dimensional stability and mechanical integrity to ensure it would withstand heavy loads over an extended lifecycle. We finished up by sandblasting and painting with a 2-part Wise Chem® epoxy coating to inhibit rust formation and create a protective barrier against molten aluminum.

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Steel Bottom Block Base Assembly Project Highlights

Project Name

8” /59 Strand Bottom Block Base Assembly w/Delrin Pads

Product Description

This bottom block base assembly is used in the aluminum smelter industry.

Capabilities Applied/Processes

Saw Cutting
CNC Burning/Plasma Cutting
Large Machining
Blanchard Grinding

Vibratory Stress Relieving
Wise Chem Coating

Overall Part Dimensions

Length: 10’
Width: 7’6”
Height: 3’
Weight: 8,500 lbs.

Tightest Tolerances

±1/16” Tolerance
O.A.H Machined Parallel within 0.030”
Machined Surfaces Milled to 125 RMS

Material Used

A36 Steel: ⅜” to 1½” Plate Thickness
Delrin Pads
6” Solid Round Bars

Material Finish

Sand Blasted and Coated with 2 Part E212 Wise Chem

In process testing/inspection performed

Dimensional Inspections, Visual Inspections

Industry for Use

Primary Aluminum Smelter


As Needed Basis

Delivery/Turnaround Time

Per Customer Requirements

Delivery Location

Southeastern USA

Standards Met

Customer Specifications, CAD Drawings
AWS D1.1, Paint Mil Requirements