Fabricating Excellence: King Salman Park – Corten Steel Fab

Project: King Salman Park, Riyadh
Scope: Corten Steel Handrails, Horse Fences, and Range Fences
Status: Approved for Mockup and Mass Production

At Henan TROYIKER , we take pride in delivering fabrication that meets the highest standards of engineering and aesthetics. We are proud to announce a significant milestone in our ongoing collaboration for the prestigious King Salman Park project in Riyadh. After a rigorous and highly detailed approval process involving the client, consultant, and main contractor, our custom Corten steel fabrication mockups have been officially approved for mass production.

A Collaborative Effort

The road to approval was paved with many stages. 

The first stage, We hosted the project team for a review (see the meeting photos in follow).

The project team highly recognized our manufacturing capabilities, professional expertise, and teamwork, and reached an agreement to collaborate. where we discussed the critical nature of this prestigious project. The collaboration between our fabrication team and the international project stakeholders was key to moving forward.

corten project term

The second stage, Weathering steel rust color samples approved.

The corten rust samples we produced match the project team's specifications and perfectly meet their requirements. 

corten rust sample

The Secret to Success: Rust Acceleration and Stabilization

To meet the stringent color requirements, We employed a specialized Rust Accelerator and Rust Stabilizer process (Utilizing a medical-grade catalyst that is harmless to humans, animals, and plants).. This chemical treatment ensures that the steel develops a deep, consistent, and stable oxidized layer that will not rub off or continue to deteriorate, providing both the desired visual uniformity and long-term protection.

weathering steel sample

We provided comprehensive MSDS (Material Safety Data Sheets) and TDS (Technical Data Sheets) for all chemical treatments to the project team, ensuring full transparency and compliance with health and safety standards.

corten rust color

The Third stage, the Mockup of Corten Steel Handrails, Horse Fences, and Range Fences we fabricated has been approved.

When dealing with a prestigious project like King Salman Park, standard fabrication is not enough. The mockup phase is the ultimate test of precision, material understanding, and aesthetic control. Before mass production could begin, our workshop undertook the meticulous task of fabricating physical mockups for the Handrail, Horse Fence, and Range Fence.

Corten fence

1, We sourced high-quality Corten steel plates and tubes specifically graded for atmospheric corrosion resistance. 

2, Corten Tube & Plate Cutting, welding, polishing and assembly: Achieves dimensional checks against a ±2mm tolerance. The form is robust, stable, and smooth.

3, The Art of the Patina: Rust Acceleration & Stabilization: Achieving a uniform, consistent color that matches the corten sample is extremely challenging; without professional expertise, it is difficult to attain such a result. This is because there are no standard color charts for weathering steel rust, and the color is difficult to control, relying entirely on manual execution.

4. Quality Control & The Presentation: The final mockups served as a tangible representation of the project's quality standards.

corten strip mockup

The Challenge: Strict Specifications and Aesthetic Uniformity

King Salman Park is a landmark development with a multitude of stakeholders, including the client, consultant, and main contractor. The approval process is rigorous, requiring every detail to align perfectly with the project specifications.

The primary challenge was achieving uniformity in the rust color across all sections. Corten steel is renowned for its weathered, earthy aesthetic, but achieving a consistent, stable finish that satisfies a strict consultant requires precise control over the oxidation process.

The Approval Journey

Navigating the approval process for a project of this magnitude involved multiple stakeholders: the Client, the Consultant, and the Main Contractor.

We presented the physical mockups alongside the technical drawings, the MSDS/TDS documents, and our color samples. The strict adherence to the ±2mm tolerances and the successful achievement of the uniform rust finish were the key factors that led to the final sign-off.

“The project team is very strict and would like to stick to the specifications... they approved our color sample. Finally, we get approval for more batches to order according to the stage.”

This mockup approval is a testament to our team's ability to bridge the gap between architectural vision and industrial fabrication. We are now fully mobilized for the mass production phase for King Salman Park.