Ask any metal fabrication shop owner what the first two machines they purchased were, and often the answer will be “a shear and an ironworker.” Shears are important for cutting down sheet metal to size, while ironworkers offer a wide range of functions like punching, notching, and profile shearing.
A person or machine that is referred to as a “workhorse” is one that can be counted on to do a great amount of work, day in and day out, regardless of whether the projects are glamorous or not. Industry professionals have referred to ironworkers as workhorses because of their heavy use in fab shops and other metalworking facilities where they are depended on for producing consistent results regardless of the task.
Benefits of an Ironworker
Ironworkers are essential machines for metalworking shops because they combine several metal fabrication functions into one versatile machine, saving time, space, and labor. Reasons why fabricators usually consider them invaluable include:
- Multi-functionality. Ironworkers can perform multiple tasks such as punching, shearing, notching, bending, and coping. This versatility allows shops to handle various fabrication needs without switching machines.
- Efficiency. By integrating multiple processes, ironworkers significantly reduce the need for multiple setups and changeovers, which speeds up production and reduces downtime.
- Cost-effectiveness. Investing in a single ironworker can be more economical than purchasing multiple machines for different processes, as it consolidates capabilities. It also saves on maintenance and operational costs over time.
- Space-saving. Metalworking shops, especially smaller ones, benefit from these employees. It reduces the need for multiple machines and frees up floor space for other tools and materials.
- Durability and Power. Ironworkers are designed to handle tough materials like steel and iron, providing the high power needed for cutting and shaping heavy metal. This makes them ideal for both heavy-duty and precision tasks.
- Improved Safety. Modern ironworkers often include safety features like protective guards and easy-to-use controls, which enhance worker safety compared to manual methods or multiple separate machines.
- Consistency and Precision. With calibrated settings and controls, ironworkers can provide consistent results in punching, cutting, and forming metal, which is essential for high-quality fabrication work.
Products of the Ironworker
Some of the products and components that can be produced or shaped on an ironworker include:
- Mounting Plates. Ironworkers can cut and punch mounting holes into metal plates for industrial machinery, construction equipment, and general fabrication needs. Mounting plates, base plates, and flange plates with custom shapes and hole patterns are common products made using an ironworker.
- Automotive and Transportation Components. Metal brackets, supports, and other parts for vehicles, trailers, heavy machinery, and even aerospace equipment can be fabricated using ironworkers, particularly when specific hole patterns or cuts are required.
- Agricultural Equipment Parts. Ironworkers can cut and punch parts used in farm equipment, such as frame components.
- Custom Metal Parts for Machinery. Small parts, such as machine guards, flanges, and gussets, often require precise punching and cutting that ironworkers can perform efficiently.
- Sheet Metal Components. Ironworkers can shear small pieces of sheet metal into specific sizes and shapes for products like covers, panels, and shields for equipment.
- Angles and Channels. Ironworkers can process angle iron and channel iron into desired lengths and shapes, making them ideal for products like bed frames, shelves, and support structures.
- Pipe and Tubing. Some ironworkers have attachments that allow them to notch, cope, or cut pipes and tubes, which are used in handrails, frames, and structural supports.
- Ornamental Ironwork. Although more decorative work may be done by other means, ironworkers can prepare materials for decorative ironwork, such as gates, railings, and custom architectural elements.
The Past and Future of the Ironworker
Often compared to a multitool pocketknife for its versatility, the modern ironworker combines many of the major pieces of metal fabrication shop equipment into a single compact and convenient machine.
While originally coined in the last quarter of the 19th century as a term for a laborer working on large metal construction projects, the word “ironworker” was co-opted to refer to the multipurpose metalworking machines that were invented by the end of that century. Adapting a flywheel-driven punching machine to use its same force for different functions at different stations, the ironworker was born, and it evolved over the course of the 20th century to become the hydraulic marvel found in workshops around the world today.
Since its introduction, the popularity of the ironworker has never diminished. From a hobbyist just tinkering with metal in his garage to an aerospace firm sending rockets into orbit, ironworkers are in use at every level of metal crafting. As technology advances, they will continue to evolve to meet the needs of metal fabricators across every industry, performing functions that would astonish the metalworkers of a century ago.
In the past, the present, and the future, the combination of improved productivity and reduced costs has and will always make an ironworker a vital asset for any metalworking shop.
