Manufacturing technology

The scope of technology processes can be divided into following phases:

• initial machining,
• composing and cementing,
• mechanical machining,
• heat treatment,
• assembly of machines and equipment,
• anticorrosion protection

1. Initial machining:

1.1. Cleaning

Type		Plate/chamber dimensions	Degree of cleanness
Continous	GW 2500-615 (Gietart)	2500 x 6000	Sa 2½
Continous	PP-8R	2500 x 12000	Sa 2½
Chamber		16000 x 5000 x 6000	Sa 2½

1.2. Cutting

Cutting of bars, tubes, sections, and profiles on the automatic tape cut-off machines in sizes up to Ø 330 mm, 330x510 and at angle of 0-60^o

Type	Cutting setup	Max cutting diameter at  right angle	Max. dim. of section	Max cutting diameter at  angle of 45o	Max cutting diameter at  angle of 60°	Length of material	Steering
S-20A (HYD-MECH) automatic	shear	Ø 330	330x457	Ø 305	-	400	conventional
Indyvidual 510.330 GANC (BOMAR) automatic	horizontal	Ø 330	330x510	Ø 330	Ø 230	600	numeric

Cutting of shape profiles and plates in thickness up to 25 mm on guillotine shear

Shape sockets				Max. plate dimensions	Max. bar size	Stand’s clearance	Stand’s overhang
Universal	NU 25A	sections	180x180x18	25	round 65 square 55
			180x120x18
		T iron	140x15
		flat bar	160x28
Guillotine	NG13 ScTP25 CNC typ TruShear 5163			13x3000		3200	600
				25x3150		3250	630
Guillotine				16x3050		3050

Flame cutting of carbon steel plates in thickness up to 200 mm and dimensions 2500 mm x 6000 on numeric burners. Plasma cutting of alloy steel and non-ferrous metals in thickness up to 15 mm and dimensions 2500 mm x 6000 mm on sutomatic burner.

Name	Type	Scope of thickness	Max. cutting lenght	Max. cutting width	Auxiliary equipment
CORTA	DP 5000	0-100/200	6000	4000	Plasma burner – cutting thickness 0,5 - 15 mm
OMNICUT	5000	0-100/200	6000	4000	Plasma burner – cutting thickness 0,5 - 15 mm
ECONOGRAPH	EC-2500 (KOIKE)	0-100/200	6000	2500
CORTINA	DS-3100 (MESSER)	0-100/200	6000	2500	Plasma burner – cutting thickness 0,5 - 15 mm

Semi-automatic flame  cutting, chamfering of straight parts of plate

Type	Thickness of cutted plates	Range of cutting angles
PPA-100A	3-100	0-45°

1.3. Plastic forming

Bending on folding press

Type		Nominal pressure [Mg]	Slider distance of travel	Max. dimensions of bended plates	Column spacing	Slider’s adjustment
Edge	PXA - 250/5600	250	100	1000x24 5000x10	3300	125
Edge	TruBend 8600-40	600	400	1-30	3050

Levelling of details and plates

Type		Nominal pressure [Mg]	Slider distance of travel	Distance slider-table	Table dimensions	Corpus clearance	Slider’s adjustment
Eccentric	PM-25B	25	100	355	560x370	270
	PMS-160A	160	140	580	1140x760	840	120
Hydraulic	PH-Wn 25	25	500		500x550	800
	GANTRY	250	400	400-800	2500x5000	3100

Rolling of plates

Type	Dim. of rolled plates		Range of rolled diameters	Upper roller diameter	Spacing between lower rollers
	Thickness	Width
PS460	30	3000	Min. 700	460	adjustable

2. Welding:

2.1. Welding methods

Methodes of arc welding::

• coated electrode (MMA)
• semi-automatic gas- shielded (MIG/MAG)
• TIG-welding
• hidden arc

Possibility of welding following materials:

• carbon steel
• low-alloy steel with higher durability and abrasion resistance
• high-alloy steel, stainless and acid resistant

high-alloy steel, stainless and acid resistant:

• heat treatment
• vibrating annealing

2.2. Possibility of weld joints testing, methods

Non-destructive:

• visual (VT),
• penetrative  (PT),
• magnetic-powder (MT),
• ultrasonic (UT),
• radiographic (RT).

Destructive (research of joints mechanical features):

• tension test
• bending test,
• impact test,
• breaking test,
• hardness test

and verification of:

• chemical composition of steel
• steel welding possibility

2.3.  Heat treatment

• normalizing
• stress relief annealing

Additional information:

Welders posses welding approvals acc. to PN-EN 287-1

- steel (first material category) welding acc. CR ISO 15608.
Welding method 111 (coated electrode) 
Welding method 135 (semi-automatic gas- shielded)
Welding method 121 (hidden arc)
- steel welding (third material category) acc. CR ISO 15608
Welding method 135 (semi-automatic gas- shielded)
- steel welding (eight material category) acc. to CR ISO 15608
Welding method 135 (semi-automatic gas- shielded)

Welding method 141

We have technological possibilities to weld according to  PN - EN 288-3

a. Inspection unit SLV Berlin – WPQR  54/1-3/OS/06
Welding method 135
Material category -  3-3, 1-1, 2-1, 2-2, 3-1, 3-2 acc. to CR ISO 15608
Weld joints: groove – mat. thickness  3 – 80 mm
fillet – mat. thickness ≥ 5 mm
Welding position – PA, PB.

b. Inspection unit  UDT – WPQR nr 32/111/O1-02.
Welding method 111
First material category according to CR ISO 15608
Basic material thickness category:

for plates  3 – 24 mm
for tubes   3 – 12,6 mm
Tube’s outer diameter - > 84,1 mm
Welding position – PF

c. Inspection unit TÜV - WPQR nr 398/03/A; 399/03/A; 400/03/A; 397/03/A
Welding method 141
Eight material category acc. to CR ISO 15608
Basic material thickness for tubes -   2 – 4 mm
Tube’s outer diameter  -  12,5 - 50 mm
Welding position – PC/PF
Basic material thickness for tubes  3 – 7,2 mm
Tube’s outer diameter  -  57,5 – 228,6 mm
Welding position – PC/PF

We have modern welding equipment, for example:

• semi-automatic welding machines „FRONIUS” TPS 4000 and TPS 5000
• ESAB  column&boom  for hidden arc welding of  tubes and containers
• machine for hole regeneration (padding) ø30 /mm/ - ø600 /mm/ max length 500 /mm/

3. Mechanical machining of contructions

Milling on vertical, conventional, numeric milling machines and on milling planer

Type		Max machining width	Max machining height	Table dimensions	Max table shift	Distance between  table and vertical spindle		Distance between horizontal spindles		Spindle cones
						max.	min.	max.	min.
Longitudinal double-column	1Y612	1250	1250	1250x4000	4500	1330	260	1490	860	7:24(60)

Machining on drilling-milling machines with rotating tables (spindle diameter – to Ø 160 ) equipped with electronic position readings

Type	Max boring diameter	Max boring diameter by means of support plate	Spindle diameter	Spindle shift	Table shift		Rotating table surface	Allowed table load	Spindle axis lift over the table	Spindle socket
					transverse	longitudinal
2620B	320	600	Ø90	600	1000	1120	1120x1250	3 Mg	0-1100	5
AD-115	450	1100	Ø115	700	1600	2000	1400x1600	5 Mg	0-1500	6
2A635	450	1100	Ø125	700	1400	1600	1600x1800	8 Mg	50-1300	80 (7)
2K636	450	1100	Ø125	700	1400	1600	1600x1800	8Mg	0-1300	80 (7)
BFP160/2	1000	1000	Ø160	1250	6710	500	2000x2000		1900	ISO 50

Machining on „Dubler” drilling-milling machines (two drilling-milling machines with spindles positioned across from each other) with spindles (Ø 115 diameter) equipped with electronic position readingss and with numeric driven spindles (Ø 130 diameters) and HEIDENHAIN iTNC530 steering system

4. Anticorrosion protection:

4.1 Painting

Painting of machines, welded constructions and other details in cabin dryers in sizes:

6 x 16 x 5 [m] and 5 x 6 x 5 [m].

Hydrodynamic and pneumatic painting by means of one and two component paints. Following sets of paints are used: three-layer paints (primer, sub-layer, surface layer) or acc. to customer request.

Total thickness of painting layer amounts 140-160 [µm].

4.2. ZINGA - zinc coating

This product is used for:

• protective layer assurance for different steel constructions ( bridge and overpass constructions, road guard rails, containers, mast towers, silos, chassis of heavy equipment, building machines, wagons, culverts etc.)
• repairs (after drilling, welding, riveting) or reconstruction of zinc layers
• time protection assurance
• protection assurance for reinforcement bars (very good Zing adherence to concrete), in place of contact between steel and concrete, in hydrotechnical structures and during contact with water (including drinking and sea water)
• protection assurance as a primer in duplex system – with surface paint (epoxy, polyurethane or other)