As a manufacturer of highly exclusive metal-based staircases, MetallArt Treppen GmbH, Salach, has earned a very good reputation worldwide. To maintain this, all processes in the company must mesh perfectly. Qualified employees are just as important a basis for this as high-quality technical equipment. In addition to a laser cutting system, these include bevellers from Trumpf’s TKF series.
© Trumpf
A lot has changed at the company now known as MetallArt from the Swabian town of Salach since it was founded around 100 years ago. Started as a simple blacksmith shop, it evolved into a versatile metal fabricator, eventually culminating in a highly specialized operation that produces premium stairs like few others can.
In the meantime, numerous projects in Germany, Europe and all over the world are in the reference catalog. MetallArt’s cantilever staircases are always unique and give noble hotels, private dream villas as well as innovative office buildings a clear “more” in exclusivity. For example, the Taunus Tower in Frankfurt and the Hotel La Maison in Saarlouis received uniquely beautiful staircases. And in a major project in the high-rise office building of the Roche pharmaceutical group in Basel, as many as 16 spiral staircases were integrated over 30 floors.
In the past eight years alone, MetallArt’s turnover and number of employees have increased massively. In addition, according to Managing Director Andreas Wahsner, the order books are more than full. Reason enough to look to the future with optimism and, at the same time, vigilance. “We continue to grow, but we are also constantly adapting our logistics to the appropriate conditions and investing in employees, machines and tools,” explains Wahsner.
In order to be able to fulfill the wishes and requirements of the demanding clientele in the best possible way, MetallArt’s planners are usually already involved in the initial planning phases of the architects and building owners. At this stage, the specialists already match design requirements with static conditions and discuss time schedules.
After the final confirmation of the order, the design of the stair specialists is required, because no two projects are alike. Experienced engineers and technicians design the individual elements of the staircase on the basis of the customer’s requirements and pass on the digital component drawings to the internal work preparation department. Managing Director Wahsner clarifies: “Primarily former skilled workers from manufacturing work here, who have further qualified themselves and now act as an interface between design and production.”
© Trumpf
After laser cutting, weld edges are prepared
The first station in MetallArt’s production is the raw material cutting or laser processing. This means that the sheet steel panels, which can be up to four meters long and two meters wide, are cut to the required dimensions on a TruLaser 4050 laser cutting system from Trumpf. After that, the sheets go directly to weld seam preparation, as Giovanni Aiello, plant manager at MetallArt, explains: “One hundred percent high-strength weld seams are an absolute must for us, and the basis for this lies in precise weld edges.”
Since the individual components vary greatly in size and weight, it is important to Industriemeister Aiello that the tool can be brought to the workpiece for edge preparation. About ten years ago, employees discovered Trumpf’s large TruTool TKF 1500 edge formers for this purpose. This tool is capable of producing chamfers up to 15 millimeters long. The sheets may be between four and 160 millimeters thick.
For smaller edges, angle grinders were still frequently used until a good four years ago. Giovanni Aiello is glad that those days are over: “When grinding, it is enormously difficult to maintain the right angle along the entire machining length. This is because the fine grinding dust is not only extremely unpleasant, it also obstructs the clear view. Our employees therefore had to constantly stop and check whether the angle and dimensions were correct. The interruptions and corrections ultimately made this work process not only unpleasant, but also very time-consuming.”
© Trumpf
Quickly achieve the perfect chamfer with TKF 700 edge former
Meanwhile, MetallArt also produces the smaller edges in a highly productive manner. Provided with markings and indications of the edge to be produced, the skilled workers dip in and out of the material with the TKF 700. In this way, they create chamfers up to seven millimeters long. The material thickness may be up to 20 millimeters for this tool.
According to the plant manager, the workflow with the TKF 700 is actually as simple as just described: “Our employees adjust the required chamfer height and sheet thickness without tools. Then they switch on the machine, which weighs around five kilograms, and press it into the material at the marked points. Already, the TKF 700 “nibbles” forward evenly with a little pressure.”
Since heat generation is very low in the process known as the impact steel principle, there are no structural changes in the metal. The surfaces are metallic bright after machining without any finishing. Angle and chamfer length always comply with the specifications. “For later welding work, this is the decisive basis. This allows us to produce highly stressable joints,” affirms Aiello.
For the plant manager and his managing director, however, the Trumpf edge formers are not “only” higher quality, faster and more economical in terms of results than other processes. They are also convincing in terms of handling, ergonomics and safety. “During the machining process, there is no dust, fumes or gases, and of course no sparks fly. Accordingly, our employees feel much more comfortable doing this work than they used to,” explains Giovanni Aiello, while Andreas Wahsner adds: “This is a very important factor for us, which helps keep the fluctuation rate in our company at the lowest possible level.”
© Trumpf
Old bending machine performs impeccable work
Once all chamfers for subsequent welds have been applied, the individual sheets enter the forming shop. Here they are rolled, bent and canted. Regularly in use – the TrumaBend V200 bending press from Trumpf. The machine is no longer young, “but it has been working flawlessly for us – for over 20 years,” says Managing Director Wahsner happily.
After that, it’s off to the welding shop. Here, the individual parts are firmly welded together to form prefabricated assemblies, and this is where the quality of the weld seam preparation ultimately becomes apparent. In fact, since the TruTool TKFs have been in use, we have not heard any complaints from the welding technicians and engineers.
Finally, it is necessary to sand the welds and apply a primer, which is very similar to the final color. “This then pleases the painters on the construction site, among others, because it is easier for them to execute a perfect final coat,” Wahsner explains.
In general, MetallArt always has the customer’s construction site in mind. This is one of the reasons why his employees assemble each staircase in the factory on a test basis before delivery. If any assemblies do not fit together perfectly, the problem areas can be solved quickly and easily. On site, the assembly then always works perfectly. In the end, only the final welding work remains to be done there. Thanks to MetallArt’s qualified welders and the chamfers perfectly prepared by Trumpf edge formers, this final step also goes safely, quickly and reliably.
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