Our Frames

Made from Mild Steel

It is fair to say that we are proud of everything we do and everybody who works at ZAC, so it is sometimes difficult to pick a subject to write about. On this occasion, the topic has been made very easy by the sharing of some photographs taken in the factory of a mild steel frame being made for a customer.

Each of our bespoke frames is manufactured by hand using mild steel, with each component being cut, appropriately shaped and then welded to create the different sections of the frame. The below shows a sunburst bracket that has been attached to the valance (that will span across the top of the frame) and pilaster (that will form one of the legs). The frame is in its raw state before it has been sanded or powder coated.

It is perhaps an interesting side note to mention that some of our customers have initially searched for wrought iron or cast iron when looking for metal framed porches and verandas. I will leave it up to the experts to explain the difference between these metals and processes, but at a high level, from a construction point of view:

• cast iron is made by melting, pouring it into a mold and leaving it to cool
• wrought iron is made by heating it and working it with tools
• mild steel is cut, bent and machined in its solid state

Our use of mild steel is in part due to its strength, but also because its ductile nature means it is the perfect metal to allow us to form the wide selection of shapes we use in our frames.

To ensure the different sections of the mild steel frame fit perfectly together, all of the sections are fitted together in the factory. As has been mentioned in a previous blog, we use the tap and die system to fix the different parts of the frame together. Fundamentally, this is done by cutting threaded holes (the tap) into the frame and making threaded bolts (the die) to fit into the holes.

The photograph below is zoomed in to where the tap and die system has been used to join some of the sections together.

This particular frame is for a porch that was being made to span across the front entrance of a house. Now all fitted together, the below photographs show how solid and strong the frame is and how perfectly it joins up.

Once the frame has been fitted together, it is sanded to make sure any minor blemishes are removed. It will then be taken apart again before being powder coated.

You will see below, that the bottom of the two pilasters have plates welded to them.  This will allow relevant fixings to be fitted so that the frame can be secured.  Typically this is done with stainless steel fixings and a chemical resin anchor.  You may be able to see where the holes have been drilled into the plates in readiness for its installation.

The construction method used for our frames has inspired a wide selection of design ideas and, importantly, allowed us to create frames that can span across large areas. This means that our frames can be used for porches and verandas. Some of our other frame designs also allow you to create the perfect portico entrance. This wide selection of designs along with your choice of zinc or copper canopy means that your bespoke product is truly unique. We have proudly made both porches and verandas to add both style and luxury to properties ranging from Georgian and Victorian to modern builds, and equally from quaint cottages and bungalows to detached houses and manor houses.

Just to finish off, below is a photograph showing the completed bespoke porch installed around the front door of this beautiful wood-clad and brick house. Now with a powder-coated frame and a beautiful quartz grey zinc canopy roof. Not just adding the finishing touch to the front of the house, but giving everyone somewhere to keep dry whilst standing at the front door.