The metal cattle fence panels are an integral part of modern animal husbandry, playing a vital role in keeping cattle safe and improving animal welfare. The production process of cattle fence panels requires precise craftsmanship, professional technology, and high-quality materials to ensure that their durability, strength and functionality meet the highest standards. As a professional manufacturer, we follow a comprehensive eight-step production process to provide customers with reliable and durable agricultural fencing solutions. The following will detail each step and explore the key accessories and connection methods that enhance the overall quality of cattle fence panels.
Cattle Fence Panel Production Process
Raw Material
The first step in the cattle fence panel production process is the thorough inspection of raw materials. This stage is crucial for ensuring the quality and durability of the final product.
- Tube Diameter and Wall Thickness: The pipe’s outer diameter and wall thickness are measured to ensure they meet the specifications outlined in the product blueprint. Any deviation from these dimensions could compromise the panel’s structural integrity.
- Welding Wire Quality: Welding wire must also meet specific standards, as it plays a vital role in the welding process. High-quality welding wire ensures strong and long-lasting welds.
- Surface Condition of Tubes: The pipes must be free of rust, oil, and debris. Clean materials are essential for both welding quality and, in the case of coated panels, powder adhesion.
Strict raw material inspection can effectively avoid up to 80% of potential quality problems in the subsequent production process, ensure that the panel meets the required durability standards from the source, and extend the product life by at least 15%.
Cutting
Once the raw materials pass inspection, the next step is cutting the tubes to the correct length based on the blueprint. The cutting process must be precise to ensure that the horizontal and vertical bars of the panel fit together accurately.
- Tube Cutting: Tubes are cut to the required length using high-precision cutting equipment. Accurate cutting ensures that each piece aligns perfectly during the welding phase.
- Attachment Stamping: Any attachments, such as brackets or clips, are stamped and formed during this step. The stamping process involves shaping metal to create customized parts that fit the final product.
We use imported CNC cutting equipment with a cutting accuracy of up to 0.1 mm. This high precision ensures perfect alignment of each component during the subsequent welding stage, significantly reducing the misalignment rate to less than 0.5%.
Welding
Welding is one of the most critical steps in the metal cattle fence panel production process. This stage involves joining the horizontal and vertical tubes along with other necessary components.
- Horizontal and Vertical Tube Welding: Following the blueprint, the tubes are welded together to form the basic structure of the fence panel. This process is done using advanced welding machines that ensure consistency and strength.
- Attachment Welding: Any necessary accessories, such as clamps or brackets, are welded to the panel during this phase. The correct positioning of these attachments ensures that the panel is functional and can be easily installed.
Quality welding ensures that the cattle fence panels are strong enough to withstand daily use and outdoor conditions, especially in farm environments.
Galvanizing the Welds (For Non-Coated Panels)
For panels that do not require coating, it’s essential to perform zinc treatment at the weld points to prevent rusting and corrosion.
- Zinc-Rich Paint Application: Welds are coated with zinc-rich paint to restore the galvanized coating that may have been removed during the welding process. This step is critical for ensuring the panel’s long-term corrosion resistance.
- Spot Galvanizing: Some manufacturers may also apply a hot-dip galvanization process specifically to the weld points, depending on the customer’s request.
- This step ensures the durability of the fence panels, preventing rust and corrosion even in harsh outdoor environments.
Pre-treatment (For Coated Panels)
When customers request coated panels, pre-treatment is a necessary process that prepares the metal surface for powder coating.
- Phosphating or Sandblasting: A dense and uniform phosphate protective layer is formed on the metal surface with a thickness of about 1-3 microns. This not only significantly improves corrosion resistance, but also increases coating adhesion by 30%.
- Improved Adhesion: This treatment ensures that the powder coat sticks firmly to the metal, providing long-lasting protection from environmental wear.
A proper pre-treatment process is essential for ensuring a durable, high-quality coating finish.
Powder Coating (For Coated Panels)
After spraying, the cattle fence enters the high-temperature curing furnace and is baked at a temperature of about 200°C for 15-20 minutes. Under the action of high temperature, the powder particles melt, level, and cross-link to form a highly corrosion-resistant protective film.
- Epoxy Polyester Powder Application: An epoxy polyester powder is sprayed onto the panels. The powder coat provides superior protection against UV rays, rust, and other elements.
- Thickness Requirement: The coating must meet a minimum thickness of 80μm to ensure adequate protection. This thickness is crucial for longevity and performance.
This coating process ensures that the panels can endure tough outdoor conditions without deteriorating.
Quality Inspection
Whether the panel is coated or uncoated, quality control is a critical step in the cattle fence panel production process. At this stage, we check the panel for structural integrity, proper welding, and coating consistency.
- Structural Testing: Panels are checked for any signs of weakness at weld points, ensuring that they meet load-bearing requirements.
- Coating Check (For Coated Panels): For coated panels, inspectors verify that the powder coating is evenly applied and that it meets the required thickness.
- Dimensional Accuracy: Every panel is measured to ensure it adheres to the design specifications.
Quality inspections guarantee that each panel meets the high standards expected by customers.
Packaging
The final step is packaging the finished cattle fence panels. Proper packaging ensures the panels arrive at their destination without damage.
- Stretch Film and Corner Protectors: Panels are wrapped in stretch film, and corner protectors are added to prevent damage during transport.
- Straps and Palletizing: The panels are then strapped securely and placed on pallets for easier handling and shipping.
- Custom Packaging: As a professional manufacturer, we can customize the packaging according to customer needs, thus providing extra protection for long-distance or international transportation
Packaging plays a crucial role in delivering a high-quality product that reaches the customer in perfect condition.
Key Accessories and Connection Methods
C Brackets and L Brackets:
These brackets are welded to the fence panels, providing essential connection points. The C Brackets offer robust horizontal support, while the L Brackets provide vertical reinforcement. When assembling two panels, Drop Pins are suitable for passing through the brackets to connect them firmly. This method not only simplifies installation but also ensures a strong and durable connection.
The overall design of the Drop Pins is easy to assemble, and it is very secure and stable when passing through the C Brackets and L Brackets. The use of Drop Pins provides flexibility, allowing for quick disassembly and reassembly without compromising the panel’s strength.
Installed on the top of each fence post, Post Caps serve a dual purpose. They prevent rainwater and debris from entering the hollow posts, which could otherwise lead to corrosion and weaken the structure over time. These caps also give the fence a polished, finished appearance.
Conclusion
In summary, the cattle fence panel production process involves a series of crucial steps. It ensures the final product meets high-quality standards. Additionally, our C Brackets, L Brackets, and Post Caps further enhance the ease of installation and longevity of our products. As a trusted manufacturer, we can provide reliable fencing solutions. We meet the specific needs of our customers, backed by precision engineering, quality control, and exceptional customer service.
