The Beginning
The Staley Steel shop started in an 18,000 sq. ft. Quonset hut on Preston Road in Frisco in 1973. Years of hard work and dedication grew the Frisco location to 33,000 sq. ft., but in 2005 due to site constraints Staley Steel made the decision to relocate to our current home on 54 acres in Pilot Point.
The Present
Initially 70,000 sq. ft., in 2019 the Staley Steel shop grew to over 100,000 sq. ft. of manufacturing space with the latest in fabrication technology. Recent updates include a Phyton-X 3D CNC fabrication system, Shot Blaster and wireless technology to electronically track production status.
Inside Our Facility
Capabilities
Staley Steel delivers precision structural and miscellaneous steel fabrication at scale—combining automated drilling/milling, robotic plasma coping and beveling, large-format plate cutting, angle/flat-bar processing, stud welding, and in-line blasting for consistent speed and quality.
- Beam/Column Processing: Up to W44×408 (approx. 48–50″ × 18–41″ envelopes depending on machine).
- Robotic Plasma Coping/Beveling: 4-side structural processing with Hypertherm True Hole™ capability.
- Plate Table: 130″ (10′-10″) × 516″ (43′-0″) with HD plasma (HPR400xd).
- Sawing: CNC band saw to 13.25″ × 19.5″ with automatic indexing.
- Angle & Flat Bar: Punch to 1-9/16″ Ø; flat bar to 1-1/4″ × 8-1/2″.
- Stud Welding: ¼” to 1-1/4″ diameters, fully integrated system.
- Blasting: Conveyor blast cabinet to 86″ × 96″.
- Cambering: In-house camber machine for rolled shapes.
Automated Structural Line (Voortman)
Voortman fully integrated production line. Designed for high throughput and repeatability across drilling, milling, scribing/layout, and robotic thermal processing.
V631 – CNC drilling/milling/tapping & scribing
- Multi-spindle drilling and high-speed milling
- Layout marking/scribing for downstream fit-up
- Capacity: up to 50″ × 41″ (W44×408)
V807 – Robotic plasma processing for structural members
- Copes, bolt slots, notches, bevels, flange/web cuts
- Hypertherm HD plasma with precision holes
- Capacity: up to 44″ × 18″ (W44×335)
- Plasma source: HPR300xd
V1250 – Integrated line component (material handling/processing)
- Works in concert with the drill/mill and robotic coping for continuous flow
- Optimized for automated throughput and minimal handling
Robotic Structural Plasma (Lincoln Electric)
Lincoln Electric – Python-X2
- 4-side robotic plasma cutting and beveling for beams, channels, tubes, and HSS
- Hypertherm True Hole™ capable
- Plasma source: HPR260
- Capacity: up to 48″ × 18″ (W44×408)
Angle & Flat-Bar Processing
Controlled Automation – ABL 100 (Large Angle Line)
- Automated drilling/punching/processing for angles and flat bar
- Punch up to 1-9/16″ Ø
- Flat bar capacity: up to 1-1/4″ × 8-1/2″
- Ideal for clip angles, connection plates, and miscellaneous hardware
Hill Acme – 7-Station Metalworker
- Punching, shearing, and coping operations for bar, angle, and small shapes
- Max punch diameter: 1-9/16″ Ø
- End copes and common misc. fab operations
Plate & Thermal Cutting
Controlled Automation – HD Plasma/Oxy-Fuel Table
- High-definition plasma with Hypertherm HPR400xd and True Hole™
- Oxy-fuel capability for thicker plate profiles
- Table size: 130″ (10′-10″) × 516″ (43′-0″)
Sawing
DoAll – S-500CNC
- CNC band saw with automatic indexing and bundling
- Optimized for multiple material feeds
- Capacity: 13.25″ × 19.5″
Stud Welding
Tru-Weld – SC3400 Stud Welding System
- Fully integrated system
- Stud range: ¼” to 1-1/4″ diameters
Surface Preparation (Blasting)
LS Industries – STRB 8496 Structural Blasting System
- Conveyor-style blast cabinet for beams, channels, tube, and plate
- Heavy-duty manganese rollers for continuous material flow
- Capacity: 86″ × 96″
Cambering
In-House Camber Machine
- Controlled cambering for wide-flange beams
- Improves fit-up and field performance per design requirements
Full Equipment List
- Voortman Integrated Line: V1250 • V631 CNC drill/mill/tap with scribing • V807 robotic plasma coping (HPR300xd)
- Lincoln Electric: Python-X2 robotic plasma (HPR260), True Hole™ capable
- Controlled Automation: ABL 100 angle/flat-bar line • HD plasma/oxy-fuel plate table (HPR400xd), True Hole™ capable, 130″ × 516″
- DoAll: S-500CNC band saw, 13.25″ × 19.5″, automatic indexing
- Hill Acme: 7-station Metalworker, punch to 1-9/16″ Ø, end copes
- Tru-Weld: SC3400 stud welding system, ¼”–1-1/4″
- LS Industries: STRB 8496 structural blasting cabinet, 86″ × 96″
- Camber Machine: Beam cambering in-house
