Hot-dip galvanizing, corrosion protection; these are the things we sell in our line of work. We are not fabricators, but from time to time we are needed in this field as well. Every now and then, we come across an item that just isn’t conducive to hot-dip galvanizing. The customer needs our help and we can simply send them a design guide or we can jump in and provide an experienced suggestion. This years entry is just this scenario.

Channell Commercial Corporation in Rockwall, Texas is a global supplier of fiber optic solutions, thermoplastic pedestals and grade level vaults for plant construction. This summer they came to us needing some input on how to stop the lids for their vaults from warping. The lid fit is critical to provide protection for the connection below.

These lids were arriving in groups of 100 with several unusable due to the warping during the hot-dip galvanizing process. Here’s where the experts come in. JBC Steel Products a steel fabricator in Dallas, Texas was hired locally to provide the lids for Channell. JBC plasma cuts the lids and in turn hired EFAB, a steel fabricator in Alvarado, Texas to weld up the lids. Experience is often critical and in this case, EFAB knew that a simple weld was not going to allow the lids to remain warp free and tested 3 different types of welding techniques prior to mass production. With the galvanizer's in house knowledge and EFAB’s willingness to work with with the galvanizer, a technique was discovered that alleviated all of the warping that caused issues with previous orders. With properly fitted lids, the fiber-optic connections below will be protected for years to come.