Fabrication and manufacturing are industrial terms linked to the process of production or construction. Often, the two processes are confused, yet they are very different from each other.

The key difference between manufacturing and fabrication is how much of the process a job involves. Fabrication involves the assembly of standard or specialized parts to form parts of a product to be used in the manufacture of the finished piece. Manufacturing, however, is a start to finish movement, from the creation of parts through to the final assembly to produce a finished product, often using areas of fabrication within the manufacturing process.

As with other manufacturing processes, both human labor and automation are commonly used. A fabricated product may be called a fabrication, and shops specializing in this type of work are called fab shops. The end products of other common types of metalworking, such as machining, metal stamping, forging, and casting, may be similar in shape and function, but those processes are not classified as fabrication.

Fabrication comprises or overlaps with various metalworking specialties:

• Fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on metal preparation and assembly. Machine shops cut metal, but focus primarily on the machining of parts on machine tools. Some firms do both fab work and machining.

• Blacksmithing has always involved fabrication, although that term has not always been used.

• Welder-produced products, often referred to as weldments, are examples of fabrication.

• Boilermakers originally specialized in fabricating boilers, but the term is now used more broadly.

• Millwrights originally specialized in setting up grain mills and saw mills, but now perform a wide range of fabrication.

• Ironworkers, also known as steel erectors, also engage in fabrication. They often work with prefabricated segments, produced in fab shops that are delivered to the site.

Cutting is done by sawing, shearing, or chiseling (all with manual and powered variants); torching with handheld torches (such as oxy-fuel torches or plasma torches); and via numerical control (CNC) cutters (using a laser, mill bits, torch, or water jet).

Bending is done by hammering (manual or powered) or via press brakes, tube benders and similar tools. Modern metal fabricators use press brakes to coin or air-bend metal sheet into form. CNC-controlled back gauges use hard stops to position cut parts to place bend lines in specific positions.

Assembling (joining of pieces) is done by welding, binding with adhesives, riveting, threaded fasteners, or further bending in the form of crimped seams. Structural steel and sheet metal are the usual materials for fabrication; welding wire, flux and/or fasteners are used to join the cut pieces.

A variety of tools are used to cut raw material. The most common cutting method is shearing.

Special band saws for cutting metal have hardened blades and feed mechanisms for even cutting. Abrasive cut-off saws, also known as chop saws, are similar to miter saws but have a steel-cutting abrasive disks. Cutting torches can cut large sections of steel with little effort.

Burn tables are CNC (computer-operated) cutting torches, usually powered by natural gas. Plasma and laser cutting tables, and water jet cutters, are also common. Plate steel is loaded on the table and the parts are cut out as programmed. The support table consists of a grid of bars that can be replaced when worn. Higher-end burn tables may include CNC punch capability using a carousel of punches and taps. In fabrication of structural steel by plasma and laser cutting, robots move the cutting head in three dimensions around the cut material.

Forming converts flat sheet metal into 3-D parts by applying force without adding or removing material. The force must be great enough to change the metal's initial shape.

Forming can be controlled with tools such as punches and dies. Machinery can regulate force magnitude and direction. Machine-based forming can combine forming and welding to produce lengths of fabricated sheeting (e.g. linear grating for water drainage).

Proper design and use of tools with machinery creates a repeatable form that can be used to create products for many industries, including construction, civil and architectural.

Machining is a specialized trade of removing material from a block of metal to make it a desired shape. Fab shops generally have some machining capability, using metal lathes, mills, drills, and other portable machining tools. Most solid components, such as gears, bolts, screws and nuts, are machined.

Welding is the main focus of steel fabrication. Formed and machined parts are assembled and tack-welded in place, then rechecked for accuracy. If multiple weldments have been ordered, a fixture may be used to locate parts for welding. A welder then finishes the work according to engineering drawings (for detailed welding) or by their own experience and judgement

The India fabrication market is expected to grow at 5.5% during the period 2022-2027. This is owing to factors, such as the increasing demand from the manufacturing sector, the rising preference toward pre-engineered buildings and components, and government initiatives toward infrastructure development activities.

It is intended to prepare a Feasibility Report to install 5000 Ton/Month Fabrication Facility of Steel Items as a Green Field Project.

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Attempt may be made to find the broad limits of the industry in terms of the basic processes undertaken, which include cutting, welding, bending, grinding & painting etc.

Structural fabrication finds extensive use in various developmental activities though the range and extent of their utilization may vary from one sector to another. Traditionally the most important fabrications are the general structurals used for all types of residential buildings, commercial complex, Multi storied Buildings etc. are scaffolding material.

The fabrication of scaffolding materials takes recourse to Acrow Props, Acrow Span Floor Farms, H-Frame Systems etc.

Acrow Props vary in sizes 0-3'5" to 6'0", 1-5'9" to 10'3", 2-6'6" to 10'3", 2-6'6" to 11'0", 3-8'6" to 13'0" etc.

Slab Forms eliminate use of cut pieces of timber as they can field up odd shapes of slab.

Floor Forms primarily find their field of application in bridges and industrial building construction; these are fabricated out of sheets with processed flanges and stiffener.

H-Frames and cross brace Frames exhibited the specialty of very good concrete finish. H-frames comprise of together with scissor type cross braces secured by spring clips. They are braces secured by spring clips. They are available in various standard sizes.

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Single towers for antennae, floodlight projectors or platforms for inspection, supervision or tourist purposes.

Systems of towers and wires serving transport purposes, such as ski lifts, ropeways, or power transmission lines.

For all kinds of towers the designer should thoroughly study the user's functional requirements in order to reach the best possible design for the particular structure. For example, it is extremely important to keep the flexural and torsional rotations of an antenna tower within narrow limits in order to ensure the proper functioning of the equipment.

The characteristic dimension of a tower is its height. It is usually several times larger than the horizontal dimensions. Frequently the area which may be occupied at ground level is very limited and, thus, rather slender structures are commonly used.

Another characteristic feature is that a major part of the tower design load comes from the wind force on the tower itself and its equipment, including wires suspended by the tower. To provide the necessary flexural rigidity and, at the same time, keeping the area exposed to the wind as small as possible, lattice structures are frequently preferred to more compact 'solid' structures.

Bearing in mind these circumstances, it is not surprising to find that the design problems are almost the same irrespective of the purpose to be served by the tower. Typical design problems are:

• Establishment of load requirements.
• Consistency between loads and tower design.
• Establishment of overall design, including choice of number of tower legs.
• Consistency between overall design and detailing.
• Detailing with or without node eccentricities.
• Sectioning of structure for transport and erection.

A lattice tower, also called angle steel tower or electrical tower, is one kind of freestanding framework tower for power transmission line of all voltages, often designed as a space frame or a hyperboloid structure. They are widely used as an electricity transmission towers especially for voltages above 100 kilovolts, being as a self-radiating tower or a carrier of aerials, even an observation tower.

Lattice steel towers comprise of several different metal structural elements linked as well as products or welded. A variety of types of lattice steel towers exist. These towers may also be called self supporting transmission towers or free-standing systems, due to their power to help themselves. These systems are not always made from steel; they can also be made from aluminum or galvanized steel.

Lattice steel towers are made up of many different steel structural components connected together with bolts or welded. Many different types of lattice steel towers exist. These towers are also called self-supporting transmission towers or free-standing towers, due to their ability to support themselves.

Lattice towers provide the advantage of a smaller cost investment compared to others, since they use about half as much material as tubular towers. Yet the lattice tower still provides similar stiffness and reliability as tubular towers. Lattice towers allow wind to pass through the base and tower sections, decreasing the pressure and resistance on the structure. One disadvantage according to some people is the appearance of lattice towers.

Lattice structure Lattice steel towers are made up of many different steel structural components connected together with bolts or welded. Many different types of lattice steel towers exist. These towers are also called self-supporting transmission towers or free-standing towers, due to their ability to support themselves. These towers are not always made of steel; they can also be made of aluminum or galvanized steel. Self- supporting lattice structure are used for electricity transmission line tower. The lattice structure can be erected easily in very inaccessible location as the tower member can be easily transported. Lattice structures are light and cost effective.

A lattice tower is a framework construction made of steel sections. Lattice towers are used for power lines of all voltages, and are the most common type for high-voltage transmission lines. Lattice towers are usually made of galvanized steel. A lattice tower is usually assembled at the location where it is to be erected. This makes very tall towers possible (up to 100 meters - in special cases even higher). Assembly of lattice steel towers can be done using a crane. Lattice steel towers are generally made of angle-profiled steel beams (L- or T- beams). For very tall towers, trusses are often used.

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