Turnkey factory engineering

When designing we use hot-dip galvanising lines based on gas and electric furnaces with a steel bath.

The flux regeneration unit precipitates the di- and trivalent iron contained in the flux.

The zinc ash recycling unit processes zinc ash waste and recovers zinc at 99.2%. The recovered zinc is suitable for reuse in the process.

We design areas and plants for producing round and multi-sided steel poles (lighting, telecom, power lines) and lines for road safety barriers.

The price depends on the type of workshop (galvanising, poles or barriers), output, floor area, automation requirements and the scope of services: design, supply, supervision of installation, start-up, training.

• Describe the task: type of production, output, available floor area.
• We carry out a site survey and propose the equipment list.
• We calculate the price and lead time of the project.

Start with the products, not the equipment. List the range of diameters, lengths and wall thicknesses and the annual quantity. This information determines the line composition, and the slowest stage of the flow sets the pace of the whole workshop.

• poles: diameter and wall thickness determine the press and the welding machines (in the line we offer, the press force is 1250–2000 t and the press bends plate 3.0–25.0 mm thick, while automatic marking is rated for plate 3.0–12.0 mm), and a section must fit the press, the galvanising bath and the workshop;
• galvanising: the largest product sets the bath size, and the annual tonnage determines which sections the plant needs (the two galvanising schemes are compared in the next section);
• barriers: the composition of road barrier lines depends on the products (two-wave and three-wave barriers, C and U support posts, base plates, bracing) and on the required output.

For a galvanising shop we design two schemes; which one you need depends on the products. The figures below are from the documentation of the equipment we offer.

• line for structures: a gas or electric furnace and a steel bath that withstands up to 480 °C. The articles travel on crossbeams, moved by double-trolley overhead cranes and, between bays, by rail cars. The largest article sets the bath size; as an example, the documentation gives a bath of 12.5 × 1.6 m, 3 m deep, weighing 47 t;
• plant for fasteners and small parts: a reverberatory gas furnace with a ceramic bath, in which the zinc does not touch metal parts, so the plant can work at up to 460–480 °C. After galvanising the parts are centrifuged: baskets 500 mm in diameter and up to 500 mm high, loaded up to 200 kg, at up to 2000 kg/h.

Besides the galvanising lines themselves, we offer a flux regeneration unit, which prevents excessive formation of hard zinc in the bath, and a zinc ash recycling unit, designed for producers with large, continuous output. More in the article on galvanising plant equipment.

Starting up pole production is covered in separate articles:

• launching multi-sided pole production: the workshop and utilities, the team, the start-up stages, typical mistakes and the data worth sending for a calculation;
• equipment maintenance: how to organise maintenance and scheduled repairs, something worth planning for before start-up;
• designing for hot-dip galvanising: how to allow for galvanising already at the drawing stage;
• quality control of steel structures: from incoming metal inspection to zinc thickness measurement.