How it’s made: Mobile phone mast’s cabling enclosure - Constant Manufacturing
Constant Manufacturing are experts in precision sheet metal fabricated parts, displays, components and fully assembled pieces, based in Oldham.
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How it’s made: Mobile phone mast’s cabling enclosure

Most of us will have walked past one of these cabinets, whether it’s popping to the post box or walking the dog, however you probably didn’t even notice!

These cabinets are in fact enclosures that wrap around a structure, a telephone mobile mast in this case, to house equipment and cabling for the structure. This telecoms metal enclosure is made from pieces of stainless steel with a powder coated finish.

How it’s Made Stages and Processes

CAD Engineer Services

1: Design specification

Our client, let’s call them Client A for this case study, provided all the drawings and instructions for the enclosure. Constant’s team of CAD engineers imported the CAD files and aligned them for our machines and procedures, to give the most efficient manufacturing process for the enclosure.

Please note this CAD image is from stock.

How its made metal cabinet - sheet metal

2: Raw Materials

The enclosures are constructed from several sheets of special grade stainless steel at 1.5mm thick.

How its made metal cabinet - laser cutting

3: Punching and Laser Cutting

The phone mast’s enclosure main body was cut on our Trumpf TruPunch 3000, and the secondary parts such as internal pieces and the top hood were cut on our Trumpf TruLaser 3030 machine.

Having a range of machines at Constant allows us the flexibility to use different machines for different parts, producing the best and most cost effective method of manufacturing for the project at hand.

How its made metal cabinet - press brake

4: Press Brake

Up next is the bending phase on the Trumpf TruBend machines aka Press Brakes. The metal enclosures are quiet large, so long resting braces are used to prevent the pieces warping and aid the operator in performing the bends. You can see them extruding out from the press brake.

How its made metal cabinet - tack welding

5: Welding: Tacking

All the pieces are combined together with one of our welders.

Firstly he tacks the hood roof pieces together, somewhat like pinning a piece of clothing before using a sewing machine. See photo and video clip below.

6: Welding: Bracing

Then he secures the main body of the telecoms enclosure together with a bracing clamp, and begins to tack the arc shape roof onto the main unit.

How its made metal cabinet - welding

7: TIG Welding

Once the unit has been tack welded together, the welder proceeds to TIG weld the enclosure’s side and roof sealing the unit.

How its made metal cabinet grinding

8: Finishing the metal enclosures

Next the team get to work smoothing down the edges, grinding and linising to give the best surface for the end product and for the powder coating to adhere too.

How its made metal cabinet finished polishing

9: Polished pieces

The metal cabinets are now finished off, and polished down ready, to go to powder coating department.

How its made metal cabinet noggings

10: Powder coating stage: Preparation

As this cabinet has several captive nuts for assembly, we plug them with small ultra bake caps/plugs, in the industry known as ‘noggings’. This prevents any paint build up in the threads during the powder coating process.

How its made metal cabinet powder coating cleaning

11: Powder coating stage: Cleaning

The telecom cabinets are hung on the powder coating line and go through the pre-treatment line to remove any dust or grease on the metal, and then make their way through the drying ovens to be spot on for the paint process.

How its made metal cabinet powder coating spray

11: Powder coating stage: Powder coating

We have a team of powder coaters who get to work on the units by systematically spraying them inside and out.

How its made metal cabinet powder coating exitThose little ‘noggings’ have done their job and protected the holes from a build up of paint.

 

How its made metal cabinet - hood

12: Assembly

Once the enclosures are cool, it’s off to assembly.

We painted several colours for our clients, including green, brown, grey and blue. The finished colours are designed to blend into backgrounds such as nature reserves, housing complexes or town centres.

This contract is classed as a ‘full assembly contract and packing’ job. This means we have been provided with, or sourced, parts to add into the cabinet when assembling. This includes cables, labels, customer branding and customer branded hinges.

How its made metal cabinet - hinges

13: Assembly: Hinges

The metal enclosure has branded tamper proof hinges which the client provided for us to attach during assembly.

How its made metal cabinet - bolts

14: Assembly: Bolts

The two pieces are clamped together with bolts. This allows the unit to be delivered on site easily in one piece, and then the technician can unscrew the bolts, separate the two parts, position it around the mobile telephone mast and bolt it back together.

How its made metal cabinet - ancillary

15: Assembly: Sealant

A tube of sealant is cable tied to the base, as each unit’s joins are sealed when bolted into place. Seals include the top hole in the hood (where the mast goes) and the joints if required. This creates a water tight seal to protect the electrics inside the metal cabinet.

How its made metal cabinet - label bolts

16: Assembly: Labels & Cables

The customer requires two labels to be affixed to the enclosure. The first is their company branding label with technical information and contact details (blurred for contractual reasons) and another to indicate the wiring bolt.

How its made metal cabinet - labels How its made metal cabinet - cables

How its made metal cabinet - final cabinet

Finish: Completed Metal Telecoms Enclosure

The customer attaches their own locking mechanism when they install their electrical components inside and place on site. This unit is designed to fit around a telephone mast/mobile phone mast and reduce the amount of ground space used up by metal cabinets on pavements and path ways.

The unit fits snugly around the mobile phone pole, so working closely with the client is pivotal at the design stage to produce a perfect fit product in the assembly stage.