PETROLEUM DIRECTORY: STEELFAB offers widest capacity, capabilities in state

Largest volume capacity in Alaska offers clients infinite possibilities

Special To PNA

When STEELFAB President Richard Faulkner and Vice-President Janet Faulkner purchased the company in 1988, they embarked on an intensive capital expansion plan for the 10-acre plant site, located just off Post Road in Anchorage. They brought fresh energy and vision to the 40-year old company, and transformed STEELFAB into the largest steel service center and fabricator in Alaska.

During the next 14 years the Faulkners tripled the plant size to nearly an acre of covered plant space, and added major capabilities like all-indoor storage of materials, and all-indoor processing. STEELFAB has a dedicated railroad spur, and is ocean dock accessible. Up-graded equipment, like a computer guided plasma-fueled flame cutter, new shears, new forklifts and cranes, added industrial lighting and an expansive, ultra-modern central office considerably increased STEELFAB’s capabilities for their customers.

The capital expansion was complemented by the recruitment of qualified and knowledgeable staff. Long-time Plant Superintendent Larry Larson works with a full-time crew of around 30, a number that can double during a busy season in the plant. A quality control department, a scheduling project coordinator, steel detailers and structural and mechanical engineer consultants ensure STEELFAB customers get top performance, quality and safety. The entire goal, says Richard Faulkner, was to ensure that fabrication and manufacturing most recently done outside Alaska, because of a lack of Alaska infrastructure, could now be produced by STEELFAB.

Today STEELFAB is the largest locally owned steel service center and fabricator in Alaska, fulfilling the Faulkners’ vision. It is the company of choice for oilfield repairs and tank fabrication. Richard Faulkner is justifiably proud that STEELFAB has always been 100 percent locally owned. Its facility is equipped with the largest range of processing equipment in the state. STEELFAB is the only fabrication facility that maintains an ASME code certification and stamps for pressure vessels (U), pressure piping (PP) and repairs (R). The company holds welding qualifications from the American Welding Society (AWS), the American Petroleum Institute (API) and a stamp from Underwriters Laboratory (UL). STEELFAB produces pressure vessels, modules, special design items, a premier sewage treatment plant, and raw steel products for the oil and construction industries. Just last year STEELFAB earned the American Institute of Steel Construction’s (AISC) certification for “Complex Steel and Conventional Building Structures and Simple and major Steel Bridges, with Fracture Critical Endorsement and Sophisticated Paint Endorsement” categories. This stringent program requires STEELFAB to be re-certified every year, but it’s an expense, says Faulkner, which is worth the guarantee of readiness and capabilities it provides to STEELFAB customers.

The Faulkners’ latest acquisition is an automated plate girder/beam welding machine. The machine can weld the same amount of beams together in 10 hours that it formerly took four men working for an entire week. STEELFAB is using the machine to fabricate the 200,000-pound railroad bridge for Unit Construction use at Ted Stevens International Airport.

“We’ve always looked at the acquisition of modern, labor-saving equipment as an advantage to our business, and certainly a benefit that we can pass along to our customers,” notes Richard Faulkner. “We know that while it’s a big overhead expense for us, that special tools demonstrate STEELFAB’s commitment to providing Alaska companies the best and most modern services.” STEELFAB’s plasma burning table fits that criterion. The largest in Alaska, it cuts stainless, carbon and aluminum products up to two-inches thick. With a capacity of 10 feet by 45 feet, this shearing and processing tool can cut up to 200 inches per minute, saving time and ultimately money for STEELFAB’s customers.

Another product that distinguishes STEELFAB is the fabrication of a self-contained sewage treatment plant. Manufactured for over 25 years by STEELFAB, the ALASKAPAK contains many Arctic modifications pioneered by STEELFAB. Used throughout Alaska in remote work sites and villages, the ALASKAPAK can be tailored to any size of community, and used for additional purposes like laundrette, shower and flush toilets, incineration and water treatment and storage units. STEELFAB manufactures, installs, trains, sells or leases ALASKAPAK plants, which they proudly state are, “Alaska-designed, Alaska-built and Alaska-proven.”

The Faulkners’ long and genial partnership began over 30 years ago in their native Arkansas. Both were students at Arkansas State University when Richard enlisted in the army. They came to Alaska over 30 years ago, by way of Korea, where Richard was a U.S. Army helicopter pilot. He has worked for over two decades in the steel business in Alaska. Before acquiring STEELFAB, the Faulkners owned Faulkner Supply and Services. If you cannot find Richard at the STEELFAB plant during the summer, you’ll find him fishing at his favorite fly-in river. Richard earned a B.S. degree from Alaska Methodist University.

Janet Faulkner, vice president of Finance for STEELFAB, has worked with financial matters her entire professional life. She remembers her father’s advice: that she should take as many math courses as she could throughout her education, and she wisely followed that path. She graduated from the University of Alaska Anchorage with a BA in Accounting and brings her work at major financial institutions to STEELFAB. Janet enjoys all aspects of exercising. Her latest challenge is bicycling classes at her health club.

The Faulkners’ ultimate goal was to have the steel capacities and capabilities in Alaska so it becomes unnecessary for any Alaska industry to go Outside to make purchases. “We’ve very competitive right now,” notes Richard Faulkner. “The considerable investment we’ve made in STEELFAB is beginning to pay off in terms of the more and more complex and interesting jobs we’re handling, especially if you compare our workload today with it about 10 years ago.

“But I guess,” he shrugs, “It’s like the old saying goes, ‘The proof is in the pudding.’”

The Faulkners are careful managers, which shows in their relatively low turnover of employees, and the presence of a major year-round workforce, in an industry known for a hiring and lay-off pattern that follows a varying workload.

“And we recognize that providing excellent customer service is as important today as providing a top quality product,” acknowledges Richard Faulkner. “We think we’ve built a winning combination of a modern facility, top quality products, a broad-based, knowledgeable staff, and excellent customer service that is proved up by the fact that STEELFAB steel is in every corner of Alaska.

“Whatever the size — large or small — we’d invite everyone to be sure to consider our services for their next steel project,” he continues. “Alaska pride is alive and well down here at STEELFAB. We know we can run with the big dogs…now we are waiting for the big dogs to find that out!”