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 | Stalinvest is in the road to complex integrated development |
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Metal structure plant. Modern decisions for building.
During the exhibition “Metal-Expo” installation and commissioning of the equipment for manufacture of steelwork come to an end at the plant in Tula region. At present the plant set about fulfillment of the first order for manufacturing of the steel constructions. Thereby the first step of realization of the investment project in Tula region is completed. Now our company has all possibilities for design different kinds of trade and logistic centers, industrial buildings and to produce not only profiled decking for their construction, but also steelwork. Estimated capacity of the plant on the manufacturing of hardware is 30,000 tons per year.
For many years the company Stalinvest supplies building projects with profiled decking of zinced steel and zinced steel with polymeric coating. One of the most important ingredients of progress is a constant monitoring of our consumers’ opinions concerning the manufactured production, examination of their perspective needs. In practice builders are quite satisfied with work of our company, the quality of profiled metal and delivery engineering deserve only full marks. Meanwhile a lot of builders express a wish for our company to enlarge the range of production, and theoretically also to carry out the complex delivery of steelwork for buildings and constructions, and what would be even better – to supply all range of necessary elements.
The work on the project, which provide the transformation of JSC Stalinvest into a complex supplier of building constructions and materials, started about five years ago. We spent a lot of time to examine the European and North-American experience of industrial engineering, design and delivery of composite building structure; to make the acquaintance of many leading world-wide equipment-producing companies; to familiarize ourselves with activity of companies which design software for construction and production control.
As a result we understand that a simple, from the first sight, issue on enlarging of production line is a complex problem. It is impossible to find an effective decision of this problem without using modern software products, which let fulfill design of buildings and constructions, satisfying consumers and investors’ requirements. Meanwhile an expressive architectural determination of these objects and an effective transmission of project documentation to the production should be reach for maximum automated equipment with CNC to be able to manufacture steelwork of highest quality. It is also necessary to solve an issue on calculation and nesting layout not only of profiled decking ob the roofing but walling constructions (sandwich panels and other).
For realization of this project JSC Stalinvest purchased a production area on the territory of Tula region in 2007. It was a wood-working factory before. All the necessary infrastructure for production: convenient car and train approach, all necessary electric power, gas and so on. Total area is about 40 hectares. A lot of professional people live in contiguous Tula and Shchekino.
The production development plan has agreed with District Administration in 2007-2008. Stalinvest conclude a cooperation agreement with a Governor of Tula region V.Dudka.
As known, professional people is one of the most important things while realizing any project. We succeed in setting up a staff of professional like-minded persons, who are aimed to solve a general issue: product design and release, answering all quality requirements. Within realization of investment project some absolute new department were established at the plant like RD department, where highly skilled design engineers and architects with wide experience work. As always our company pays a special attention to education and training of the personnel. Groups of engineers, foremen and workers had their training courses at the manufacturing plants in France, Italy, The United Kingdom, Austria and Finland.
The investment project developed by the specialists of our company (together with independent experts) includes tree basic stages. Work on realization of the first stage started with capital repairs and modernization of an existent workshop with a total area more than 12,000 m2. Everything was disassembled in the workshop except for column, firms and slab roof. Then we trimmed it with sandwich-panels, windowed, provided base with heat insulation, and replaced the old roofing with a new membrane one manufactured by the Sweden company Sika.
Ten bridge cranes Konecranes with lifting capacity till 20 tons were installed. Concerning lighting of the workshop, the project provides daylight lamp and side illumination for it. This let get very good lighting of all working places, which corresponds to a good ergonomic factor for production.
It is planned to start manufacturing of profiled metal and steel constructions in this workshop (as it was given in project). Production of profiled decking with high structure was started on new equipment made in Finland and German, in fall, 2008. The delivery of equipment for steelwork production is in process since summer, 2009.
The complex of technological equipment combined with rollerways is a united technological chain, which allows to get a finished product in the end. While executing of handling operations radio-controlled bridge cranes with lifting capacity till 20 tons are used. It gave us an opportunity to deny crane operators.
With the help of controlled rollerways all operations on transporting of the materials are executed (without using bridge cranes), including transporting from one aisle to another one.
Independent control of the separate parts of a rollerway is also possible. Bridge cranes are used only for loading of rollerways on the entry level and for unloading of a finished product.
An important factor in a technological chain is usage of TEKLA software complex, wide-known all over the world and used for construction of buildings for Olympic Games in Beijing. This program product established a reputation both in companies manufacturing of steelwork, and in companies designing buildings of steelwork. We chose this software also with a glance to compatibility with high-technology equipment purchased for steelwork production.
Integration of the program product used for objects design into software of the manufacturing processes lets optimize an order control: from a building design to production, stocking and shipping of the finished product. The unity of working processes helps to correct all mistakes and to increase efficiency, and stipulate a high profitability and adherence of terms.
Different specialists can use a model jointly, reflect an interaction of structures, complete conflict tests and make reports for coordination of the activity. A full complex of the equipment for welded I-beam manufacturing made by leading European companies is installed at the plant:
-thermal cutting machines-for shredding (flange and web of the beam);
-lifting system-for transporting of ready flats with the help of crossbeam with magnets from an output table of thermal cutting machine to a rollerway of a shot-blasting machine;
-shot-blasting machine-cleans a flat before welding;
-manipulator with magnets-unloads flats after shot-blasting and loads to a welding line.
Welding line in complex with a transfer table executes an assembly and welding of beams. Technical facilities of the line allows to produce welded beams with a flange height from 200 till 1500 mm, flange thickness from 8 till 40mm. It is possible to produce beams of variable cross section. The process of beam production does not require any preliminary assembly of elements with tack welds. Leveling of beams is made while welding of belt seams, using two arcs with a wire 2 mm. After wilding finished product goes to conservation sector, where it is shot-blasted and then painted and dried in a painting and drying cabin.
Workflows of production parts in premachining installation are divided into processing of sheet metal and processing of profiled metal. Processing of sheet metal is executed in an automatic CNC line for marking, drilling and thermal cutting. It is possible to conduct a full cycle of processing of sheet metal on the installed model, which means, i.e. to produce a finished piece from a plate 2500x12000 for further welding of bearing components (firms, columns, longitudinal beams and so on). It is possible for this line to execute plasma cutting of plates with thickness up to 25 mm, oxygen cutting of plates with thickness 100 mm and more, punching with diameter 30 mm of plates with thickness up to 25 mm, drilling of plates with thickness till 100 mm. so the process of drilling the plate with thickness 20-25 mm takes less than 2 seconds. The line can change several separate machines for cutting, drilling or punching. CNC lets produce pieces of high quality: accuracy of manufacturing is 0,1 mm. The machine is operated with only one person. Operation of profiled metal is executed on a complex of technological equipment connected between each other with rollerways and transfer table.
Processing of profiled metal starts with shot-blasting of metal in the shot-blasting machine manufactured in Germany and installed in different aisles. After shot-blasting goes cutting of pieces on band sawing units, then drilling and thermal cutting on a CNC line.
It should be noted that facilities of thermal cutting line allow to mark so called “main” assembly mark, that makes the assembly easier, lets reduce the human factor and raise the accuracy of assembly.
CNC line for processing of angles, channel bar and flats allows producing full operating of mentioned profiles, viz. punching and cutting. It is possible to make holes of different diameters in webs of angle profiles. This line helps to produce semi-finished product for tangent tower.
CNC allows execution of all technical operations with high accuracy; operations of cutting, punching and drilling secure deviation from design sizes in the range of 0,1 mm.
The issue of providing a production with compressed air is solved with the help of machinery, delivered by the company “Atlas Copco” – the world-wide leader in production of compressor equipment.
Special-purpose equipment allows executing of rolling of different kinds of profiles and bending of sheet material with length 8000 mm.
Two hydraulic presses in tandem with CNC controller allow production of bended components of roofing and timber framing of building with length till 8000 mm. CNC using instrument data of a machine (puncher and die) and raw data of material (steel grade, bending angle, bending length) allows to calculate bending force (and if it is necessary to correct the bending conditions). Thereby finished pieces have high quality after bending, and the limit deviation of angles is less than 1°. All pieces are identical. The equipment, unique for Russia and CIS, is installed in a workshop for production of different semicircular architectural components of buildings and constructions. We optimized this laborious and distressful process by installation of hydraulic machine which allows rolling of I-beam with drag torque till 1750 sm3. Due to this fact it is possible to execute all architectural operations. As a result labour inputs and cost price of a process are minimized.
Welding of constructions are executed with Ar+CO2 using high-performance equipment manufactured by the company Lincoln Electric. All working zone are equipped with local ventilation which allows to solve a problem of pollution of working places with gasses and to reduce damage effect for people.
The issues of corrosion prevention are solved professionally at the plant. The quality of a paint and varnish system depends on preparation of metal surface. That is why technological process of corrosion prevention is arranged that finished pieces are shot-blasted, painted and then dried.
The first stage of realization of investment project is completed after commissioning of the equipment for production of steel construction in Tula region. The company set up to execute orders for manufacturing of hardware in scope of 700 tons. The production technology and the connection between subdivisions will be adjusted additionally on-stream. It will raise a certainty that the following orders will be executed in a highest level and a consumer will have a production with a best quality, that is a distinctive feature of JSC “Stalinvest”.
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