The flat bottom 2-rail fence is a popular choice for both residential and commercial applications due to its sleek design, durability, and ease of installation. This type of fence not only enhances the aesthetic appeal of any property but also provides reliable security. As a professional manufacturer, we take pride in our comprehensive flat bottom 2-rail fence production process, which ensures the highest standards of quality. From the precise extrusion of aluminum profiles to the final packaging, each step is meticulously designed to deliver a product that meets both functional and decorative needs. In this blog, we will explore the detailed 8-step production process, discuss the installation methods, and highlight the key advantages of our flat bottom 2-rail fence.
Flat Bottom 2-Rail Fence Production Process
1. Profile Extrusion
The first step in the flat bottom 2-rail fence production process involves profile extrusion, a technique essential for shaping the raw materials. We start by heating aluminum billets until they reach a malleable state. The aluminum is then forced through a die, which shapes the material according to the fence’s design specifications. The extrusion process is crucial for obtaining accurate, durable profiles used in ornamental fence panels.
Not only does this method provide consistency, but it also allows for custom designs based on client specifications. Custom extrusion ensures flexibility in design, whether for residential or commercial applications.
2. Material Cutting
Once the extrusion profiles have cooled, the next step is cutting the material. Using advanced cutting machinery, the extruded profiles are cut to the precise length required for assembly. Accurate cutting is critical as it ensures that the fence sections fit together seamlessly, maintaining the structural integrity of the flat bottom 2-rail fence.
Precision is key at this stage since incorrect cuts can lead to poor alignment during assembly, affecting the final product’s strength and appearance.
3. Rail Punching
Rail punching involves creating holes in the horizontal beams where vertical slats or pickets will later be inserted. This step is particularly important for the flat bottom 2-rail fence as it ensures that all parts can be assembled securely. Using CNC machines, we achieve high precision in hole placement, preventing any misalignment during the final assembly process.
Moreover, our rail punching process allows for customization in terms of spacing between pickets, depending on customer requirements for design and security.
4. Panel Assembly
With the materials cut and punched, the assembly of fence panels begins. Horizontal rails are attached to the vertical posts and pickets, creating the ornamental fence panel structure. The number of our cross tubes can be set to two or three tracks to meet the different needs of customers. Proper assembly requires attention to detail, ensuring that each part fits snugly together for maximum durability. This step also includes fastening with screws or welding, depending on the customer’s preference for structural integrity.
The flat bottom 2-rail fence production process allows for a sleek, modern look, and this assembly stage is critical in ensuring the fence’s aesthetic appeal and strength.
5. Pre-Treatment (Chromium-Free Passivation)
Before the fence undergoes powder coating, we perform a chromium-free passivation process. This method involves treating the aluminum surface to form a dense oxide layer. The primary purpose of this treatment is to increase the adhesion of the powder coating and enhance corrosion resistance. Unlike traditional treatments, chromium-free passivation is an environmentally friendly option that meets global standards for sustainability.
The pre-treatment process ensures that the fence will withstand harsh weather conditions, providing long-lasting protection without compromising the environment.
6. Powder Coating
One of the most critical steps in producing a flat bottom 2-rail fence is the powder coating process. We apply an epoxy polyester powder coating with a thickness of at least 80μm. This coating not only enhances the fence’s visual appeal by providing a smooth, uniform finish but also increases its resistance to corrosion, UV rays, and abrasion.
Powder coating is preferable to traditional painting methods because it results in a more durable, attractive finish while being more environmentally responsible due to reduced emissions of volatile organic compounds (VOCs).
7. Quality Inspection
After the powder coating process, we conduct a rigorous quality inspection. Our technicians check for any defects, ensuring that all components meet the necessary safety and durability standards. The inspection includes visual checks for coating uniformity, thickness measurement, and structural integrity tests. Quality control is crucial to maintaining our reputation as a professional flat bottom 2-rail fence manufacturer.
This comprehensive inspection guarantees that the final product will perform as expected in a variety of conditions, offering reliability and longevity.
8. Packaging
The final step in the flat bottom 2-rail fence production process is packaging. We use robust packaging methods to protect the fences during transportation. We use iron pallets + wrapping film + four-corner cardboard protection + packing tape to pack the products, so as to ensure the safety of the products and avoid bumps and scratches. Each component is carefully wrapped and secured to prevent scratches, dents, or other damage. Additionally, we offer custom packaging solutions for international shipments, ensuring that the product arrives at the client’s location in perfect condition.
Installation Method of Flat Bottom 2-Rail Fence
Our design prioritizes ease of installation while ensuring long-term stability and durability. The following points explain the connection methods used during installation:
1. Horizontal Rails to Posts Connection
The horizontal rails are connected to the vertical posts using self-tapping screws. This method provides a secure and reliable attachment, ensuring that the rails remain firmly in place under various weather conditions. The use of self-tapping screws simplifies the installation process, allowing for quick assembly without the need for specialized tools or welding.
2. Vertical Tubes to Horizontal Rails Connection
The vertical pickets (or tubes) are inserted through pre-punched holes in the horizontal rails. Once positioned, they are securely fastened using self-tapping screws. This method not only ensures a tight fit but also enhances the overall structural integrity of the fence. The vertical pickets are aligned precisely to maintain uniform spacing, contributing to both the fence’s aesthetic appeal and security features.
Advantages of Our Flat Bottom 2-Rail Fence
Our flat bottom 2-rail fence stands out due to several key advantages, making it an ideal choice for both residential and commercial applications. These advantages include:
1. High Durability
Our fences are built using high-quality aluminum, which offers excellent resistance to corrosion, weathering, and impact. The combination of advanced pre-treatment and powder coating further enhances the durability of the fence, ensuring a long-lasting product that requires minimal maintenance.
2. Ease of Installation
Thanks to the use of self-tapping screws for assembly, our fences are easy to install without requiring welding or complex tools. This design allows for quick installation while maintaining the fence’s structural integrity. The assembly process is straightforward, making it accessible to both DIY enthusiasts and professional installers.
3. Customizable Design
We offer extensive customization options for the flat bottom 2-rail fence, allowing customers to choose from a range of dimensions, finishes, and configurations. Whether you need specific spacing between vertical pickets, different rail dimensions, or a unique powder coating color, our production process accommodates various design preferences.
4. Aesthetic Appeal
The sleek design of the flat bottom 2-rail fence provides a modern, elegant appearance that complements a wide range of architectural styles. The smooth, powder-coated finish and clean lines enhance the visual appeal, making it a popular choice for ornamental applications.
5. Environmentally Friendly Production
We prioritize sustainability by using environmentally friendly production techniques, such as chromium-free passivation and powder coating. These processes reduce harmful emissions and waste, making our fences an eco-conscious choice without compromising on quality or performance.
6. Enhanced Security
Our fences are designed not only for aesthetics but also for security. The strong connection between rails and pickets, combined with durable materials, creates a sturdy barrier that provides effective security for both residential properties and commercial sites.
Conclusion
The production of a flat bottom 2-rail fence involves a highly specialized and detailed process, from the extrusion of aluminum profiles to the final packaging. Each step plays a crucial role in ensuring the fence’s durability, structural integrity, and aesthetic appeal. In addition to understanding the production process, it’s also essential to consider the ease of installation and the numerous advantages this fence design offers. With its high durability, easy installation using self-tapping screws, customizable options, and eco-friendly production methods, our flat bottom 2-rail fence stands out as a superior choice in the fencing industry. By choosing us as your flat bottom 2-rail fence manufacturer, you are guaranteed a high-quality product backed by professional expertise and outstanding customer service.
