KEPCO+ has over twenty-one years of experience fabricating and installing custom panel systems. Our well-equipped prefabrication facility, organized into the five departments described below, regularly fabricates panels of all sizes and shapes. Through our experience, we have learned that panel systems can provide solutions to the construction industry's most critical constraints, including:
Panels can be fabricated while the building superstructure is being constructed. The building skin can then be installed in large sections, dramatically reducing the installation time required.
Panels can be engineered to incorporate weep systems and other project specifications. Also, off-site assembly allows adherence to KEPCO+'s rigid quality control program and strict inspection schedule.
Panel systems reduce both the amount of time required for installation and the manpower requirements, resulting in a lower field labor cost.
Material Handling Department:
When materials are received, whether steel, stone, tile, or terra cotta, KEPCO+'s material handling department cleans and inventories the shipment.
It is then checked for breakage and dimensional accuracy before being placed in the appropriate department within the plant.
Steel Fabrication Department:
KEPCO+'s steel fabrication department maintains “Approved Fabricator” status and is dedicated to the fabrication of both traditional steel and light gauge metal stud fabrication. KEPCO+ has four typical truss options to which a multitude of variations can be designed to meet the specifications required for a project. All options are cost-effective and light weight as they allow for use of a thinner material than what is often required for a handset installation. The four options are:
- Standard Truss
- Light Gauge Metal Stud Truss
- Cygnus Panel
Steel fabrication is accomplished by utilizing any of eight horizontal jigs where all connections are completed by certified welders. The frame is checked for quality control and when applicable, the selected coating is applied.
Based on the conditions the cladding will be exposed to, the goals and budgets of the client, and the desired lifespan of the project, KEPCO+ can recommend the most efficient weatherproofing method.
Listed below are four possible options, ranked from the most cost-effective coatings to those requiring higher budgets. As the cost rises, so does the anti-corrosion effectiveness and the ability of the coating to withstand more extreme exposure:
- Galvanized (Lt Gauge Metal Stud Truss System) Standard Corrosion Resistance
- Painted Truss (shop primer – epoxy paints) Standard to Medium Corrosion Resistance depending on coating chosen
- Hot-Dip Galvanized (Standard Truss System) Up-Graded Corrosion Resistance
- Stainless Steel (not an applied coating – panels are constructed from stainless steel) 100+ years Corrosion Resistance
When complete, the frame is returned to KEPCO+ for cladding attachment.
Cladding Assembly Department
Typically, individual cladding pieces are placed in the assembly jigs, which are adjustable to accommodate even uniquely shaped panels and elaborate stone profiles, providing for consistent alignment and jointing.
This department also installs any necessary guttering or water diversion systems on the panels prior to the final caulking of the cladding material joints.
Quality Control Department:
KEPCO+ has developed a detailed multipoint checklist to ensure the quality of each individual panel.
The company's full-time quality control inspector closely monitors each step in the assembly process, from frame fabrication welding and dimensional tolerance to the accuracy of the cladding assembly process.
Every panel has its own quality control tag which must be signed off for each specific step prior to acceptance by the next department.
When complete, each panel is cleaned and inspected by our shipping department.
Positioned on specially designed racks, the panel is carefully loaded and braced for shipment on air-ride trailers for safe, breakage-free jobsite delivery.