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Production Process

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Bipin Vihari Das
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6 views5 pages

Production Process

Uploaded by

Bipin Vihari Das
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Telephone/Electric Poles

The Steel poles manufactured in the industry are mainly two types i.e
telescopic poles and swaged poles. For manufacturing of telescopic
poles, the steel coils are slited to different width depending upon the
pipe diameter requirement. The slit in the form of coils is fed to the
uncoiler and the slit is leveled by passing through a set of rolls and
sheared to required length. The slits are tapered depending upon the
requirement by shearing and then folded and subjected to tacking by
applying pressure. By this stage, the job takes the form of a pole.

Welding of the pole is done by gas welding. The pole is hammered to


make the shape perfect. Drilling is done to clean the remainances of
welding. Quality Control tests such as visual inspection, drop test,
defalcations test etc is carried out to discard low quality products.

The pole has to be galvanized. Before galvanizing, degreasing, water


rinsing, acid pickling, water rinsing, flux dipping and drying. It is now
dipped into galvanizing bath and chromic acid tank for galvanizing stage
is bypassed and painting is done as per specification.

Cut to Length Sheets

The raw material of this section may be HR sheet or CR Sheet on the


form of coil. The coil is uncoiled and the continuos sheet passes
through the following set of equipment before cut to length sheet/slits
are obtained

 Uncoiler
 Leveler
 Cut shear
 Slitter
 Recoiler

The uncoiled sheets are passed through rolls for leaving the sheets. The
leveled sheet is cut depending upon the specification. For
manufacturing of slits the leveled sheet is silted into slitter and again
recoiled in recoiled.

Black Pipes

For pipe manufacturing, slits of different width are raw material. The
slits in the form of coil is uncoiled in the uncoiler and passed though the
following set of equipment.

 Uncoiler
 End shear
 Hoop Joining
 Hoop feeder
 Hoop cage
 Leveler
 Monogram Stamping
 Forming
 High frequency welding
 Cooling
 Sizing
 Straightening
 Flying cut off saw
 End facing
 Hydraulic test
 Threading
 Marking
 Degreasing
 Water ringing tank
 Acid pickling tank
 Flux tank
 Drying furnace
 Galvanizing
 Cooling tank
 Threading and inspection

The uncoiled slit is leveled, stamped and formed to the shape of pipe.
High frequency welding machine will weld the open edge of the pipe.
The pipe is cooled in cooling tank which contains solution of cutting oil
in water the pipes are than sized and straightened to obtain the perfect
shape. The pipes in perfect shapes are cut to length depending upon
the specification. End facing operation smoothens the uneven edge. To
test any leakage or flaw in the pipe, hydraulic testing of the pipe is
carried out by passing pressurized water into the pipe. After
ascertaining perfect quality, threading of the pipe is done. Before
delivery of the product to the market, the pipes will be properly
inspected.

Galvanized Pipes

For manufacturing GI pipes, pre-treatment of the pipe is carried out.


The pre treatment stages comprises of degreasing, water rinsing, acid
pickling, water rinsing, flux coating. For degreasing purpose alkaline
degreasing solution is used.
HCL is used for pickling. The concentration of the acid in the tank is
maintained to about 10%. After pickling the pipes are rinsed and dipped
into flux tank to stop the reaction initiated in the pickling tank. Before
galvanizing the pipes they are perfectly dried. The galvanizing the bath
is diesel/furnace oil fired furnace that contains zinc, zinc chloride, lead,
aluminum alloy, special flux etc. After galvanizing the pipes are
threaded, inspected and dispatched to market.

Pre-Fabricated Structure for Building

Steel truss fabrication is a complex process that takes special skills,


tools, and techniques to form specific structures and products. Metal
fabricators create steel structures in three main stages: cutting,
forming, and assembly.

Fabricators use several tools to cut the steel of a truss, including high-
tech equipment such as plasma cutters, lasers, and water jets. Saws
create straight cuts; while lasers and plasmas are reserved tor more
complex shapes and curves. The metal fabricator punches holes using
high-pressure notches. Once the fabricator cuts the metal into the
correct shape,. The forming process begins. To form trusses, fabricators
use both press braking and rolling. These techniques allow for an
enormous range of metal thicknesses!, sizes, and shape for versatile
applications, Standard trusses use a series of triangles. During the
forming process, fabricators create the correct truss type for its
purpose. Most roof trusses, for example, use C-shaped metal studs.

Assembly is the final process. The manufacturer will need to know the
truss type, location, wind exposure, span, desired roof slope, and more
to correctly assemble and join the steel. This process includes welding
pieces together, bringing the final product together to serve its
intended purpose as a truss. There is specialized software the fabricator
will use throughout the design and construction process, to meet the
builders needs.

Mechanically worked Steel (Purline GI/MS & Shutter Profile)

GI/MS sheets of desired width are taken in coil form and fed to roller
type sheet in forming machine in 'which the rolling profiles are formed

Pole fitting and accessories

Angle, channel etc are used as starting materials. The raw materials are
cut in the required sizes. After straightening, hole punching/drill
operation is carried out. Then sections are bent for clamping. After
grinding the parts are assembled. Finally painting and packing is done.

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