Here’s the Deal: Hitting the Target With Custom Fab

Having clearly defined goals and precisely established specs going into a custom fabrication project can make all the difference between a finished product that’s “just right” and one that’s “not quite.” Kristen Horn, COO of Johnson-Lancaster and Associates in Clearwater, Fla., knows this, as she helps oversee Johnson-Lancaster’s own custom fabrication shop and works with specialty fabricators across the country.

“Custom fabrication is a daily part of our workflow, ranging from high-volume chain rollouts to one-of-one architectural pieces,” she says. Recently, the company wrapped up work on a high-end private club and dining concept in Miami that featured custom-built elements with premium finishes—a project that required “tight coordination between design intent and fabrication reality,” says Horn.

Johnson-Lancaster fabricates custom stainless, stone and millwork components (think expo counters, service counters, pass shelves, integrated counter-shelf assemblies and the like) for chain restaurants, hospitality/club clients, and colleges and universities. Custom fab elements are carefully constructed to meet operators’ needs and priorities: consistency from location to location, of course, but also cleanability, durability, and the ability to meet ADA and workflow requirements.

When planning a custom fab project, Horn says, “treat it like a mini construction project—because it is.” Start with the “why,” she advises: What is the problem you’re looking to solve, design need you’re trying to meet or pain point you’re trying to find a way to address with this custom element?

“Share the operational goal first,” she says, whether it’s speed of service, labor reduction/reallocation, an enhanced guest experience or meeting a regulatory requirement. “The fabrication should solve a problem, not just fill a space.”

Additionally, says Horn, it’s important to involve your dealer or fabricator during the design and schematic process, not after, to avoid the need for rework. Where are needed utilities/hookups located? What kind of surface will the custom-built piece interface with? Field conditions such as a slightly sloping floor also need to be taken into account before fabrication begins. Think about installation, too. For example, does your location have access constraints? Will you have rigging needs?

“Field-verify everything,” Horn urges. “Agree on stainless gauge, edge details, reinforcements, welded vs. bolted construction, finish levels, exact material selections and any integrated accessories” as well as who will approve any changes to the project.

Standard custom stainless fabrications can often be produced within around four weeks, Horn says, whereas custom projects involving a combination of stainless work, millwork and stone/laminate will often take around 10-12 weeks, depending on approvals and materials availability.

Horn’s final piece of advice? “The most successful outcomes happen when operators align early on scope, constraints and decision-making,” she says.