Peerless Hi-Temp

Peerless Hi-Temp Fabrication LLC specializes in the custom fabrication and distribution of non-metallic materials.

5 factors that can impact your quote for Non-Metallic Fabrication

5 factors that can impact your quote for Non-Metallic Fabrication

When engineering, project managers and supply chain personnel find themselves requesting quotes for fabricating non-metallic products, it is important to understand the variables that can impact the numbers. 

Here are the top 5 things that can impact the quote price for fabricating non-metallic products such as insulation or surface materials.

1. Material density

Generally speaking, ceramic fiber alumina-silica products such as paper, blankets and stone wool products (such as cavity rock), are less expensive per square foot than harder and denser materials (such as phenolic, epoxy or cement-based refractory boards).

With increased product thickness comes an increase in cost of materials as well. Harder and more dense materials require slower cutting and machining speeds that add time to the fabrication process.

2. Design complexity

Programming a 3D model is generally performed at the engineering and/or machinist level but for smaller runs, the impact can be more evident than longer runs or recurring orders where the cost is amortized over a higher number of units.

Also, the overall quantity and complexity of holes (i.e. through, angle, counterbores, cut-outs, etc.) can increase programming time and overall machine run time.

3. Machine time

Certain materials can be softer and more susceptible to indentation when fixturing is not performed properly. It is paramount to use diligence to align and hold material in place without damaging the integrity of the insulation and avoid unwanted movement during machine run time.

4. Proper aesthetics

If your application requires tapping threads or edges such as chamfers, bevels, fillets, or bull noses, the most appropriate and well-maintained tooling must be utilized to ensure the proper aesthetics.

5. Packaging and shipping

Insulation products such as refractory material and surface products such as phenolic and epoxy; are susceptible to damage in transit. Opening a crate or box of your specialty product fabricated to precise tolerances only to see broken pieces or chipping in a package can be avoided with thorough and properly secured packaging techniques that take time and experience. 

So that’s our list of the top 5 things that can impact your quote price for fabricating non-metallic products. Is there anything else you’ve experienced that we did not include on our list? Let us know in the comments.

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Scratching the Surface: The Custom Fabrication of Non-Metallic Materials

In April of 2017, Peerless acquired the Hi-Temp Fabrication operation that specializes in the fabrication and distribution of non-metallic materials. Now it’s two years later and we’re just starting to scratch the surface of possibilities (see what I did there?).

Our fabrication shop makes a wide variety of specialty products including insulation boards, panels, blankets, rolls, and laboratory tops for the aluminum, steel, gas, furnace, refractory, electrical and petrochemical industries. Some of the products we routinely fabricate include:

Thermal Grade Glass Polyester
Glastherm HT200
Glastherm HT220
SG-200

Glass Polyester
GPO-1
GPO-2
GPO-3

Fiber Cement
Transite HT
Transite 1000
Nad-11
Minerit HD

Stonewool
Cavity Rock
Acoustical Fire Batt (AFB)

Calcium Silicate
Marinite A
Marinite C
Marinite I
Marinite M
Marinite P
CS-85

Ceramic Fiber – Alumina Silica
Duraboard HD, LD, 2600, 3000
Durablanket
Fiberfrax Paperent

There’s always room for Improvement

Our customer satisfaction and on-time performance rates are very important to us and over the last two years, we’ve made several improvements that have had a positive impact on both us internally, and our customers. Some of these improvements include:

Updating our CAD Software

The materials we work with are sensitive to tool speeds and clamp pressures which require the utmost diligence during fabrication. Since aquiring our fabrication shop we’ve updated our CAD and manufacturing software to Fusion360 to be able to fabricate accurately, import customer 3D models directly into the software providing for tighter tolerances, and significantly reduce the rate of non-conformance’s, repairs, rework and scrap.

We have multiple CNC machines dedicated specifically to machining non-metallic materials to tight tolerances. The board stock is accurately machined and inspected to match customer drawings and then carefully packaged & delivered on-time meeting customer production deadlines and expectations.

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Implementing an ERP system

We migrated our database over to a sophisticated ERP system handling all of our inventory control, production and manufacturing needs. Our inventory and production schedules are now updated in real-time and all members of the team have visibility into the status of the quote, job, sales order, etc.

All incoming requests get entered promptly into the ERP system allowing us to get back to you within just a couple of hours. This allows us to be more proactive at monitoring the order status and sending communications out throughout the process.

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New Dust-Controlled Facility

We recently moved into a new facility where we undergo periodic inspections of indoor air quality by our suppliers. The health and safety of our employees and visitors are very important to us and we had new dust-controlled equipment installed with the purpose of regulatory compliance regarding employee exposure to potentially harmful airborne contaminates. 

Sustainability

We also identified that the operation was generating a significant amount of scrap insulation being disposed of at the landfill.  We discussed the matter with the manufacturer and as a result, we developed a new program where we could start returning the scrap back to their plant to be reclaimed and reused in their manufacturing cycle; instead of going to the landfill. This was a huge win for the environment. The program cut the amount of scrap going to the landfill down by 50% and the manufacturer has now expanded the program throughout the world!

More improvements to come

These are just some of the improvements we’ve made over the past two years. Stay tuned for more announcements soon but in the meantime… Happy Birthday Peerless Hi-Temp! We look forward to celebrating many more birthdays to come. 

What do you think of these improvements?  Tell us in the comments!

Transite 1000 vs. NAD-11

A Comparison of Two Common Structural Insulation Options

Are you trying to select the right insulation product to use that requires strength, thermal stability, electrical insulation or machinability?

There are two popular materials being used — Transite 1000 and NAD-11.  Let’s compare them and help you decide which to use.

High Temperature Applications

You can use Transite 1000 and NAD-11 to insulate load-bearing gaskets, industrial oven shelving, soldering plates, spacers, supports, collars, bushings, transformer spacers or laboratory bench tops.

Board Composition

Transite 1000 is a monolithic non-asbestos fiber cement board and NAD-11 is a glass-mica-quartz non-asbestos cement board.

Sizes & Thicknesses

NAD-11 is available in 48 x 36 inch boards with thickness options ranging from 0.25 to 3.0 inches.

Transite 1000 is available in 48 5/8 x 96 5/8 inch boards with thickness options ranging from 0.25 to 3.0 inches.

Using the same thickness in order to compare the two,  a sheet of Transite 1000 has an extra 20 square feet per board than NAD-11.

Density and Compressive Strength

The density of NAD-11 is 109 pounds per cubic foot with compressive strength of 17,110 pounds per square inch.

Transite 1000 is lighter than NAD-aa and has a density of 98 pounds per cubic foot with compressive strength of 13,350 pounds per square inch.

NAD-11 is a heavier, stronger and more load-bearing board with a density of 109 pounds per cubic foot with compressive strength of 17,110 pounds per square inch.

Temperature

Transite 1000 is a non-combustible board and can withstand operating temperatures up to 1000°F.

NAD-11 is suitable for applications that require continuous operation in temperatures up to 932°F. It will begin to break down at a lower temperature than Transite 1000. 

Thermal Conductivity

At a higher temperature, Transite 1000 has a lower conductivity than NAD-11 and less heat travels through it.

Transite 1000’s thermal conductivity is 2.40 btu-in/(hr-ºF-ft²) @ 250º F.  NAD-11’s thermal conductivity is 2.57 btu-in/ (hr-ºF-ft²) @ 212º F.

Cost Comparison

Cost comparison differs based on thickness. On a 1″ thick board, the price per square foot for Transite 1000 is approximately 7% higher than it is for NAD-11 which means NAD-11 is a little less expensive than Transite 1000.

Handling, Engineering Controls

Both materials can generate a lot of dust depending on your application so make sure there is a proper process enclosure, local exhaust ventilation or other engineering controls installed while working to prevent exposure from any potential airborne contaminants below the recommended or statutory limits.

Power equipment should be fitted with a properly designed dust collection device and we can provide SDS sheets upon request

So those are the differences between the two materials. Which one have you used? Let us know in the comments.

 

Epoxy vs. Phenolic

Epoxy or Phenolic Work Surfaces

Considering Phenolic or Epoxy for your worktop or cabinetry application? Architects, B2B engineers and procurement personnel very often find themselves choosing between these two scientific surface solutions.

For a 1″ thick surface board, let’s take a look and compare 10 things you should consider between these two types of scientific surfaces when making a selection.

1. Cost

A black Epoxy resin board costs approximately 15% more per square foot than phenolic resin.  Advantage: Phenolic.

2. Lead Time

Lead Time for standard colors of phenolic and Epoxy resin tops are 1 to 2 weeks. Advantage: Push.

3. Warranty

Standard conditional warranty is 10 years for both phenolic resin and epoxy resin. Advantage: Push.

4. Color Options

Phenolic colors are the same price with the exception of speckled grey which is an up-charge.

Epoxy colors other than black fall into 3 tiers, each carrying an upcharge ranging from 10% to 25% over the previous tier. Advantage: Phenolic.

5. Seniority

Epoxy resin surface tops have stood the test of time as the standard for lab-grade work surfaces for decades whereas phenolic resin surface tops are not as seasoned. Advantage: Epoxy.

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6. Sustainability

Phenolic resin uses recycled wood fibers as the bonding agent for the resin which is non-toxic when fabricated whereas epoxy resin uses silica, which is a carcinogen that is toxic when fabricated. Advantage: Phenolic.

7. Machineability

Epoxy resin can be more difficult and time-consuming to fabricate due to its heavier weight coupled with requiring diamond tipped tooling. Phenolic resin can be easier on machinery due to its wood fiber consistency and is able to be fabricated with standard wood tooling. Advantage: Phenolic

8. Weight

Phenolic resin weighs approximately 10 pounds per square foot whereas epoxy resin weighs over 11 pounds per square foot and more weight means spending more money on shipping costs. Advantage: Phenolic.

9. Chemical Resistance

Both surfaces are non-porous and highly resistant to chemicals. A comparison of chemical resistance of epoxy resin vs. phenolic resin yielded similar effects in many areas with the exception of certain (Acetone, Phosphoric Acid 85%, Sulfuric Acid 25% to 33%) where phenolic resin showed no detectable change in the material surface and epoxy resin showed slight detectable change in color/gloss but no change in function or life of the surface.

Sulfuric acid 96% showed slight detectable change in color/gloss but no change in function or life of the phenolic surface versus epoxy surface which showed an objectionable change in appearance due to discoloration or etching. Advantage: Phenolic.

10. Heat Resistance

Phenolic resin counter tops can withstand temperatures up to 350 degrees Fahrenheit whereas epoxy resin can handle temperatures over and above 350 degrees Fahrenheit, including some epoxy that can withstand temperatures up to 600 degrees Fahrenheit. Advantage: Epoxy.

That just about does it. Which one do you like using? Let us know in the comments.