Luke Cahill
What is custom metal fabrication?
Reading Time: 7 minutes and 13 seconds
When we worked on the Swan Street Bridge project, the design called for hundreds of metres of stainless steel handrails, all fabricated to strict specifications. I recall standing on-site, watching our team carefully measure, cut, and weld each component with precision because even a millimetre of deviation could compromise the final structure. It was a proud moment for us at Mechcon, showcasing the impact of expert craftsmanship in public infrastructure.
For over two decades, we’ve been at the forefront of steel fabrication across Melbourne, delivering architectural steelwork, complex structural components, and high-volume production for major projects. Our experience spans everything from residential builds to high-profile government works, all completed with a focus on precision, safety, and compliance with Australian standards. In this blog, I’ll explain what custom metal fabrication involves, its core processes, and why working with experienced fabricators like us makes a difference. Quality fabrication doesn’t just shape metal—it ensures lasting results built to perform.
Table of Contents
What is custom metal fabrication?
When we talk about custom metal fabrication at Mechcon, we’re referring to the precise process of designing, cutting, and assembling metal components tailored to meet unique project specifications. Unlike standard fabrication, which relies on pre-made components with fixed dimensions, custom fabrication is about creating made-to-order steelwork that fits a project’s exact requirements—down to the millimetre.
Our expertise in architectural steel fabrication can be seen across Melbourne, from structural elements like staircases and balustrades in commercial buildings to decorative handrails on public infrastructure, including the Swan Street Bridge project. Custom metal fabrication is essential when precision, durability, and safety are non-negotiable, especially in large-scale government and commercial projects where every detail must meet Australian standards such as AS/NZS 1554 for structural steel welding.
At Mechcon, we don’t just cut and weld metal. We collaborate closely with architects, builders, and project managers to deliver steelwork that aligns with design intent while ensuring compliance with safety and structural regulations. Our in-house shop drawing and detailing team ensures every component, whether a stainless steel handrail or a custom steel frame, is fabricated with precision, ready for installation without modifications.
Core Processes in Custom Metal Fabrication
At Mechcon Welding & Fabrication, every successful project relies on a mastery of core metal fabrication processes—cutting, forming, assembly, and finishing. Our work on the Sunbury Station Balustrade and Handrail Upgrades perfectly highlights the importance of these fabrication stages when working on large-scale infrastructure projects.
Cutting
Cutting is where steel fabrication begins, and precision matters most. For the Sunbury Station project, we used CNC laser cutting and plasma cutting techniques to prepare the mild steel components, including 500 lineal metres of kickrail and multiple handrail sections. Each piece had to be millimetre-perfect to ensure a seamless fit when retrofitted to the existing balustrade structure. Our advanced cutting equipment allowed us to accurately prepare the components offsite, reducing the need for adjustments during installation.
Forming and Shaping
Once the steel was cut, the next step was forming and shaping the components to meet AS 1428.1 standards for disability access. Using our press braking and rolling equipment, we crafted the galvanised handrails and kickrails with precise bends and curves for wheelchair ramps and the car park areas. Our expertise in forming metal ensures every curve and angle fits the functional requirements while maintaining a polished, professional appearance.
Assembly and Welding
The assembly phase required us to ensure every handrail and balustrade section met strict structural and safety standards. Our team employed MIG and Stick welding, fully compliant with AS 1554 structural welding standards, to fabricate the new sections offsite before installing them at Sunbury Station. This pre-fabrication approach minimised onsite work, ensuring a faster turnaround while maintaining safety and accuracy.
Finishing
Protective coatings play a vital role in ensuring our work withstands Melbourne’s outdoor conditions. For the Sunbury Station project, we applied sandblasting to Class 2.5 AS 1627.4 standards before completing a hot dip galvanising finish. This process not only enhanced the steel’s durability but also provided long-term corrosion protection, essential for public infrastructure exposed to weather elements.
How Custom Metal Fabrication Works (Step-by-Step Process)
We believe that delivering exceptional results in custom metal fabrication starts with a clearly defined, expert-led process. Our successful delivery of the Heathdale Christian College Werribee project exemplifies this. Despite tight deadlines, we designed, fabricated, and installed custom folded perforated stair panels, spiral stainless steel handrails, and architectural balcony balustrades, all while ensuring a flawless finish under challenging constraints.
| Stage | Key Actions | Compliance Standards |
| Consultation & Design | CAD shop drawings, design refinement, architect collaboration. | DDA Compliance (AS 1428.1) |
| Material Selection | Stainless steel, mild steel, batch tracking, mill certificates. | AS/NZS 1554.1, AS/NZS 1554.5 |
| Fabrication & Quality Control | CNC cutting, press braking, welding, NDT inspections. | AS/NZS 1554.5, Structural Integrity |
| Delivery & Installation | Prefabrication, efficient delivery, professional onsite assembly. | Final Quality Assurance |
Step 1: Consultation and Design Collaboration
Every custom fabrication project starts with a deep dive into the design vision and structural requirements. For the Heathdale Christian College project, the client’s initial design concepts for the stair balustrade panels were both complex and ambitious. Our in-house detailing and shop drawing team collaborated closely with the architects and builders from Becon Constructions to refine the design, ensuring it could be executed without compromising structural integrity.
Step 2: Material Selection and Compliance
Choosing the right materials was critical for balancing aesthetics and durability on this project. We worked with stainless steel for the spiral handrails and mild steel for the perforated stair panels, ensuring the highest quality while keeping the design’s complexity manageable. Our team prioritised batch number tracking and mill certifications, maintaining full traceability and compliance with AS 1428.1 accessibility standards.
Step 3: Fabrication and Quality Control
The custom metal fabrication phase was where our expertise truly shone. The custom perforated stair panels presented a unique challenge due to the tight tolerances and brake press folding limitations. Our team adapted techniques to meet the exact design while keeping structural strength intact.
With three specialised workshops dedicated to architectural, stainless, and heavy fabrication work, we ensured precision at every stage. NDT testing and compliance with AS/NZS 1554.5 for structural steelwork guaranteed the integrity of every weld and joint.
Step 4: Delivery and Installation
Despite the project’s complexity, our team completed fabrication and installation within four months. We prefabricated the handrails and balustrades offsite, ensuring minimal disruption during installation. By pre-assembling key elements, we reduced onsite adjustments and delivered a high-end finish that now sits proudly in the $32 million Victorian school project.
Advantages of Custom Metal Fabrication with Mechcon
When we say we specialise in custom metal fabrication, we’re not just talking about cutting and welding steel. At Mechcon, every project we deliver is a reflection of the care, expertise, and precision we’ve built over the past 20 years. Whether it’s a school balustrade, a stainless steel tank, or public infrastructure, we ensure every detail is measured, tested, and perfected.
Precision & Compliance
Custom fabrication demands absolute accuracy, especially when working on projects like public infrastructure and DDA-compliant handrails. Our CNC cutting technology and adherence to AS/NZS 1554 structural welding standards ensure every component we produce meets exact specifications.
Flexibility & Customisation
One of the key advantages of partnering with us is our ability to fabricate unique components that fit your exact design needs. Whether it’s custom perforated stair panels for Heathdale Christian College or stainless steel tanks for food-grade processing, we thrive on projects that challenge conventional fabrication.
Our in-house design and detailing team works closely with clients from concept to completion, ensuring that every component, no matter how complex, is crafted to match both functional requirements and aesthetic vision.
Durability & Quality Assurance
We don’t just build components—we build reliability. Every project we deliver is backed by certified welding, traceable batch numbers, and protective coatings designed for long-term performance.
For example, during our work on the Heathdale Christian College balustrade project, we applied protective coatings compliant with AS/NZS 1627.4 to prevent corrosion while maintaining a flawless finish. Every component was fabricated using premium stainless steel and mild steel, ensuring the project would stand the test of time in a high-traffic educational setting.
Cost Efficiency
Many assume that custom metal fabrication means higher costs. However, with Mechcon’s streamlined production process, we reduce both material waste and rework costs. Our high-volume production capacity ensures cost-efficiency, even for complex architectural and industrial projects.
For instance, during our collaboration on the Sunbury Station project, our pre-fabrication process allowed us to cut, shape, and assemble components offsite, reducing onsite labour and avoiding costly delays. By using CNC cutting and batch tracking, we ensure every part fits perfectly the first time, eliminating unnecessary adjustments.
Why Work with Mechcon for Custom Metal Fabrication?
Over the past two decades, we’ve built more than just steel structures—we’ve built trust and reliability with our clients across Melbourne. From delivering DDA-compliant handrails for Sunbury Station to tackling the unique design challenges of the Heathdale Christian College balustrades, our experience speaks for itself. Every project we take on follows a certified process with batch number traceability, ensuring quality control at every stage, while our in-house team handles both design collaboration and precision fabrication to bring your vision to life.
When you work with Mechcon, you’re not just getting a custom steel fabricator—you’re gaining a partner committed to excellence. Our Melbourne-based workshop is equipped to handle everything from stainless steel handrails to large-scale infrastructure components with the same level of detail and care. We’re proud of our reputation for on-time project delivery, structural integrity, and exceptional workmanship. If you’re looking for a custom metal fabrication expert who prioritises quality, compliance, and craftsmanship, we’re ready to help you build something remarkable.
FAQ
Custom metal fabrication involves creating metal components tailored to unique specifications, ensuring a precise fit for the project’s design and structural requirements. Unlike standard fabrication, which relies on pre-made or mass-produced components, custom fabrication allows for flexibility in material choice, measurements, and design complexity. At Mechcon, we specialise in custom architectural steel fabrication where every detail is crafted for projects like Sunbury Station and Heathdale Christian College. Our adherence to AS/NZS standards guarantees safety, compliance, and long-term durability.
Yes, we can!
Our Melbourne-based workshops are equipped to manage both small architectural builds and large-scale infrastructure projects. Whether it’s stainless steel handrails for public spaces or complex industrial components for government projects, we have the expertise and resources to deliver. Our three specialised fabrication workshops—for stainless steel, high-volume production, and heavy fabrication—ensure we can handle projects of varying scopes while maintaining batch number traceability and certified welding standards.
Custom metal fabrication is essential across multiple industries, including construction, infrastructure, transportation, food processing, and manufacturing. At Mechcon, we’ve supported projects in Melbourne’s public transport upgrades, educational institutions, and Tier-One infrastructure developments, such as the Sunbury Station and Melbourne Water facilities. Our ability to customise steel handrails, balustrades, tanks, and structural steel components makes us a trusted partner across both government and private sectors.
