What is the steel structure construction process?

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Steel structure construction is a widely adopted method in modern architecture and engineering due to its strength, durability, and efficiency. From high-rise buildings and industrial warehouses to bridges and stadiums, steel provides a versatile solution for a wide range of construction needs.

The steel structure construction process involves a series of systematic steps that ensure the structural integrity and safety of the final build. These steps typically include planning and design, material procurement, fabrication, transportation, site preparation, and on-site erection. Each phase plays a crucial role in transforming raw steel components into a fully functional, load-bearing framework.

Steel structure construction process

Steel structure

Phase 1: Planning and Design

Conceptual Design & Feasibility: The client, architect, and engineers define the project requirements, budget, and overall building concept. Initial studies determine if a steel structure is the most suitable option.

Structural Engineering & Analysis: Structural engineers perform detailed calculations to determine loads (dead load, live load, wind, seismic, etc.) and design the steel frame. This includes selecting appropriate steel grades, member sizes (beams, columns), connection types (bolted, welded), and bracing systems for stability.

Detailed Drawings & Specifications: Architects and engineers produce detailed construction drawings (plans, elevations, sections, connection details) and technical specifications. These documents outline exactly how the structure should be built, the materials to use, and the quality standards required.

Shop Drawings: The steel fabricator (selected later) will create highly detailed shop drawings based on the engineering drawings. These drawings specify exact dimensions, cuts, hole locations, weld types, bolt types, surface finishes, and assembly marks for each individual steel member. These must be reviewed and approved by the structural engineer before fabrication begins.

Erection Plan: Often developed collaboratively between the engineer, fabricator, and erector, this plan outlines the sequence of lifting and assembling the steel members on site, crane locations, safety procedures, and temporary bracing requirements.

Phase 2: Fabrication (Off-Site)

This happens in a controlled factory environment (the fabrication shop):

Material Procurement: The fabricator orders the required raw steel shapes (I-beams, W-sections, channels, angles, plates, hollow sections) from steel mills based on the approved shop drawings and material specifications.

Cutting & Shaping: Steel members are cut to precise lengths using saws, shears, or thermal cutting (plasma, oxy-fuel).

Drilling/Punching: Holes for bolts are accurately drilled or punched according to the shop drawings.

Fitting & Welding: Components (e.g., base plates, connection plates, stiffeners) are fitted together and welded as specified in the shop drawings. Skilled, certified welders perform this work.

Surface Treatment: Steel members are cleaned (usually by shot blasting) to remove mill scale and rust. Then, a primer paint or other specified coating (like galvanizing) is applied for corrosion protection.

Quality Control (QC): Throughout fabrication, QC checks are performed (dimensional checks, weld inspection using visual or non-destructive testing methods like UT/MT/PT, coating thickness checks).

Marking & Labeling: Each finished piece is clearly marked with an identification number/code corresponding to the shop drawings and erection plan, ensuring it can be easily identified on site.

Phase 3: Transportation

Loading & Logistics: Fabricated steel members are carefully loaded onto trucks or trailers in a sequence that often aligns with the planned erection sequence on site.

Shipping: Steel is transported from the fabrication shop to the construction site. Special permits and escorts may be required for oversized loads.

Steel structure

Phase 4: Site Preparation

This happens concurrently with or before fabrication/transportation:

Foundation Construction: Concrete foundations (footings, pile caps, raft foundations) are constructed based on the engineering design. Crucially, anchor bolts are accurately embedded into the concrete where steel columns will be placed. Their position and elevation are critical.

Site Logistics: The site is prepared with clear access roads, designated laydown areas for storing steel deliveries, and stable pads for crane setup.

Phase 5: Erection (On-Site Assembly)

This is the process of assembling the steel frame on site:

Receiving & Sorting: Steel deliveries are received, checked against delivery tickets, and sorted in the laydown area according to their erection marks and the erection plan.

Crane Setup: Mobile or tower cranes capable of lifting the heaviest steel members are positioned strategically on site.

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For more detailed information about the steel structure construction process, please click here: https://www.meichensteel.com/a/news/steel-structure-construction-process.html

What are the common problems of flange slewing bearings and how to solve them?

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Flange slewing bearings are robust components, but they can experience problems over time. Here are some common issues and their solutions.

Flange Slewing Bearing Common Problems and Solutions

Flange slewing bearings

1. Irregular Rotation or Jamming:

Problem: The bearing rotates unevenly or gets stuck, even without a load. This could be due to the ring becoming out of round during transport or storage.

Solution: This issue should ideally be caught during the fitting process. If it occurs after installation, the bearing might have been deformed. In such cases, the bearing may need to be replaced. Ensure proper handling and storage to prevent this.

2. Abnormal Noise During Operation:

Problem: Unusual sounds like squealing or grinding can indicate issues. Squealing often suggests insufficient lubrication, while grinding noises might mean internal wear or contamination.

Solution:

Squealing: Apply the correct type and amount of lubricant. Refer to the manufacturer’s recommendations for lubrication intervals and grease type (EP2 grease is often recommended).

Grinding: Stop operation immediately and inspect the bearing for wear, damage, or foreign material. Clean and relubricate or replace the bearing if necessary.

Flange slewing bearings

3. Lubricant Leakage:

Problem: Grease leaking from the seals.

Solution:

Over-lubrication: Ensure you are not lubricating too frequently. A typical cycle is 150-250 hours, but adjust based on the operating intensity.

Thinned grease: Check if hydraulic or gear oil from the slewing motor has contaminated the bearing grease, making it thin. Repair any leaks in the motor seals.

Incorrect grease: Using the wrong type of grease can cause it to thin, especially with temperature increases. Use the manufacturer-recommended grease.

Damaged seals: Carefully inspect the seals for damage or displacement and replace them if necessary.

4. Excessive Wear and Increased Clearance:

Problem: Over time, the rolling elements and raceways wear, leading to increased play or tilting.

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For more detailed information on common problems and solutions of flange slewing bearings, please click here: https://www.mcslewingbearings.com/a/news/flange-slewing-bearing-common-problems-and-solutions.html

How to Adjust Slewing Bearing Clearance

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Adjusting the clearance of a slewing bearing is crucial for ensuring smooth operation, reducing wear, and extending its service life. The process varies depending on the bearing type (single-row ball, double-row ball, or cross-roller) and the manufacturer’s specifications.

Slewing Bearing Clearance Adjustment Method

slewing bearing

1. Initial Assessment

Before adjusting the slewing bearing clearance, it’s important to assess the condition of the bearing and machinery:

Inspect the Bearing: Look for signs of wear, damage, or corrosion. If the bearing is significantly worn or damaged, it may require replacement.

Check Manufacturer Specifications: Ensure you know the recommended clearance values provided by the bearing manufacturer. These values are essential for setting the correct adjustment.

2. Required Tools

To adjust slewing bearing clearance, you will need the following tools:

Dial indicator or laser measurement tool

Feeler gauges

Torque wrench

Shims or spacers (if applicable)

Jack (if lifting the structure is necessary)

Lubrication (specific grease or oil for the bearing)

3. Measuring Existing Clearance

Before making any adjustments, it is important to measure the current clearance. This will help determine whether the bearing is within the desired tolerance or if adjustments are needed.

Axial Clearance:

Place a dial indicator perpendicular to the raceway.

Lift the upper structure (if applicable) slightly using a jack or lifting mechanism.

Measure the axial movement along the bearing’s axis.

Radial Clearance:

Attach the dial indicator parallel to the bearing’s radial surface.

Apply side force to the structure to check the movement in the radial direction.

Tilting Clearance:

Measure the angular clearance by placing the dial indicator at multiple points along the bearing. Check for any tilting or angular movement.

Record the measurements and compare them with the specifications. If the clearance is out of the acceptable range, proceed to adjustment.

slewing bearing

4. Adjusting the Clearance

The adjustment process will vary depending on the bearing design. There are two main types of slewing bearings: adjustable bolt-type and gear-type.

For Adjustable Bolt-Type Bearings:

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For more detailed information on how to adjust the slewing bearing clearance, please click here: https://www.mcslewingbearings.com/a/news/slewing-bearing-clearance-adjustment-method.html

How to lubricate a slewing bearing

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Lubricating a slewing bearing is critical for ensuring smooth operation, reducing wear, and extending its service life. Here’s a step-by-step guide on how to properly lubricate a slewing bearing.

There are generally two main areas that require lubrication:

The Raceway: This is where the rolling elements (balls or rollers) run between the inner and outer rings.

The Gear Teeth: If the slewing bearing has integrated internal or external gear teeth.

Key Principles:

Right Lubricant: Using the correct type and grade of grease is paramount.

Right Amount: Too little or too much can cause problems.

Right Frequency: Lubrication intervals depend heavily on operating conditions.

Right Method: Applying the grease correctly ensures it reaches the critical areas.

Cleanliness: Contamination is a major enemy of bearings.

Slewing bearing lubrication

slewing bearing

I. Preparation & Safety:

Consult the Manufacturer’s Manual: THIS IS THE MOST IMPORTANT STEP. The equipment or bearing manufacturer’s manual will specify the exact type of grease, the recommended lubrication frequency, and potentially specific procedures or grease fitting locations. Always prioritize their recommendations.

Safety First:

Ensure the machine is shut down, de-energized, and properly locked out/tagged out (LOTO) according to your site’s procedures before performing any maintenance.

Wear appropriate Personal Protective Equipment (PPE), including safety glasses and gloves.

Gather Supplies:

Correct type and grade of grease (as specified by the manufacturer, typically an EP lithium complex grease, often NLGI Grade 2).

Grease gun (manual or powered). Ensure it’s clean and loaded with the correct grease. Avoid mixing different grease types.

Clean rags or cloths.

Solvent (if needed for cleaning gear teeth, ensure compatibility).

Stiff brush (for cleaning gear teeth, if applicable).

Small tool or pick (for cleaning grease fittings).

slewing bearing

II. Lubricating the Raceway:

Locate Grease Fittings: Find the grease fittings (zerks) located around the circumference of one of the bearing rings (usually the stationary one). There may be one, two, or several fittings spaced evenly.

Clean Fittings: Thoroughly clean the grease fittings and the area around them with a clean rag. Use a pick to remove any hardened grease or dirt from the fitting opening. This prevents contaminants from being injected into the bearing.

Attach Grease Gun: Securely attach the grease gun coupler to the fitting.

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For more detailed information on slewing bearing lubrication, please click here:https://www.mcslewingbearings.com/a/news/slewing-bearing-lubrication.html

How to install flange slewing bearing

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A flange slewing bearing has mounting holes directly drilled into the face of either the inner or outer ring (or both). This flange allows for direct bolting to the supporting structure without needing separate clamping rings, often simplifying the mounting arrangement.

Flange slewing bearing installation

flange slewing bearing

Safety First!

PPE: Wear appropriate Personal Protective Equipment (safety glasses, gloves, steel-toed boots).

Lifting: Slewing bearings can be heavy. Use appropriate lifting equipment (cranes, hoists, slings) and techniques. Never lift by the seals or gear teeth if applicable.

Use designated lifting points if provided.

Lockout/Tagout: Ensure the machinery the bearing is being installed on is properly de-energized and locked out/tagged out before starting work.

Clear Area: Keep the work area clean and free of obstructions.

Tools and Materials Needed:

The new flange slewing bearing

Manufacturer’s installation manual

Appropriate lifting gear

Correct grade, size, and length fasteners (bolts, potentially nuts and washers) – Crucially important! Use new fasteners of the grade specified by the bearing or equipment manufacturer (often Grade 10.9 or 12.9).

Calibrated torque wrench(es) covering the required torque range

Feeler gauges

Cleaning supplies (lint-free cloths, appropriate solvent)

Lubricant for bolt threads (if specified by manufacturer, e.g., molybdenum disulfide paste)

Grease gun and the correct type/grade of grease (as specified by the manufacturer)

Measuring tools (tape measure, calipers)

Soft mallet (optional, for minor adjustments)

Pry bars (use with extreme caution and protection to avoid damage)

Installation Steps:

flange slewing bearing

Phase 1: Preparation

Read the Manual: Thoroughly read and understand the specific installation manual provided by the bearing manufacturer. Pay close attention to torque values, bolt grades, tightening sequences, and lubrication requirements.

Inspect the Bearing:

Carefully unpack the bearing. Check for any shipping damage.

Verify the part number matches your requirements.

Check the manufacturing date (grease has a shelf life).

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For more detailed information about flange slewing bearing installation, please click here: https://www.mcslewingbearings.com/a/news/flange-slewing-bearing-installation.html

Glass Tempering Furnace Installation: Step-by-Step Professional Guide

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Alright, let’s get into the nitty-gritty of installing a glass tempering furnace. This is a complex piece of machinery, so a professional approach with meticulous attention to detail is crucial for safety and optimal performance.

Glass Tempering Furnace Installation

glass tempering furnace

Phase 1: Pre-Installation and Site Preparation

Detailed Site Assessment:

A thorough inspection of the intended installation area is the first step. This involves verifying floor load capacity to support the furnace’s weight (which can be substantial).

Measurements of the space are taken to ensure adequate clearance around the furnace for operation, maintenance, and potential future removal or servicing.

Access routes for bringing in the large furnace components are carefully evaluated. This might involve planning for temporary removal of doors or even wall sections.

Utility Infrastructure Check and Preparation:

Electrical Power: The furnace’s power requirements (voltage, phase, current) are strictly adhered to. Dedicated electrical lines with appropriate circuit breakers and safety disconnects are installed by qualified electricians.

Gas Supply (if applicable): If the furnace uses gas for heating, the gas line capacity, pressure requirements, and safety shut-off valves are meticulously checked and installed according to local codes.

Compressed Air: Many tempering furnaces rely on compressed air for various functions, such as cooling and operating pneumatic cylinders. The existing compressed air system’s capacity and pressure are verified, or a dedicated compressor with appropriate piping is installed.

Water Supply (if applicable): Some advanced cooling systems might require a water supply. The water pressure, flow rate, and drainage system are assessed and prepared.

Ventilation System: Proper ventilation is critical to remove heat and any potential byproducts. The design and installation of the ventilation system must comply with environmental regulations and safety standards.

Foundation Preparation:

Depending on the furnace’s size and weight, a reinforced concrete foundation might be necessary to ensure stability and prevent settling. The foundation must be perfectly level.

Anchor bolts or embedded plates for securing the furnace frame are precisely positioned during the foundation pouring process.

Safety Perimeter and Access Control:

Before the furnace arrives, the installation area is clearly marked with safety barriers.

Access to the site is restricted to authorized personnel only.

glass tempering furnace

Phase 2: Furnace Delivery and Positioning

Careful Unloading and Handling:

Specialized lifting equipment (cranes, forklifts with sufficient capacity) is used to unload the furnace components from the transport vehicles.

Rigging and lifting procedures are meticulously planned and executed by experienced personnel to prevent damage to the equipment and ensure the safety of the workers.

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For more detailed information about glass tempering furnace installation, please click here: https://www.shencglass.com/en/a/news/glass-tempering-furnace-installation.html

What are the properties of tempering furnaces for the architectural glass industry?

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Tempering furnaces for the architectural glass industry are designed to meet strict performance, safety, and quality standards. And the key properties of tempering furnaces specifically designed for the architectural glass industry. These furnaces are distinct due to the scale, quality requirements, and types of glass used in buildings.

Performance of tempering furnaces for the architectural glass industry

Tempering furnaces

Large Size Capacity:

Architectural glass often comes in large sheets (standard float sizes, jumbo sizes). Furnaces must accommodate dimensions frequently reaching 3.3 meters wide and 6, 7, or even 12+ meters long.

The transport system (rollers) must be robust enough to handle the weight and dimensions of these large lites without causing damage or excessive deflection.

Advanced Convection Heating:

Crucial for Coated Glass (Low-E): Modern architectural glass heavily utilizes Low-E (low-emissivity) coatings for energy efficiency. These coatings reflect infrared heat. Pure radiation heating struggles to heat coated glass evenly and efficiently without overheating the coating.

Forced Convection: These furnaces employ powerful forced convection systems (using heated air) alongside radiation. This allows for:

Faster heating cycles.

More uniform temperature distribution across the glass surface and through its thickness, regardless of coatings.

Reduced risk of overheating and damaging sensitive soft coatings.

Better processing of thicker glass.

Types of Convection: Can be top convection only, or more commonly, top and bottom convection for maximum efficiency and uniformity. Some use compressed air-assisted convection for even higher heat transfer rates.

Precise Temperature Control and Uniformity:

Achieving a consistent temperature (around 620-650°C / 1150-1200°F) across the entire large sheet is critical for avoiding optical distortion and ensuring proper tempering.

Sophisticated control systems use numerous thermocouples and/or pyrometers to monitor glass temperature in multiple zones within the furnace.

Advanced algorithms adjust heating elements (and convection flow) dynamically to ensure uniformity, compensating for edge effects or variations in glass loading.

Tempering furnaces

High-Performance Quenching System:

The quenching (rapid cooling) section uses high-pressure air blown through precisely positioned nozzles (top and bottom).

Must deliver powerful, uniform, and controllable airflow across the entire glass surface to create the necessary surface compression for strength and safety fragmentation.

Control over air pressure, nozzle distance, and potentially oscillating patterns is needed to optimize quenching for different glass thicknesses and types, minimizing distortion.

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For more detailed information on the properties of tempering furnaces in the architectural glass industry, please click here: https://www.shencglass.com/en/a/news/performance-of-tempering-furnaces-for-the-architectural-glass-industry.html

What are the intelligent control systems for glass tempering furnaces

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The goal of tempering is to heat glass uniformly to near its softening point (around 620°C) and then rapidly cool (quench) it with air jets. This creates compressive stress on the surface and tensile stress in the core, resulting in stronger, safer glass. However, achieving consistent quality (flatness, low distortion, uniform stress, no breakage) across different glass types (clear, coated, Low-E, patterned), thicknesses, and sizes is challenging. Intelligent control systems aim to address these challenges.

Glass Tempering Furnace Intelligent Control

glass tempering furnaces

Here are key aspects and techniques used in intelligent control systems for glass tempering furnaces:

Advanced Sensing and Monitoring:

Thermal Scanners/Cameras: Provide detailed real-time temperature maps of the glass surface as it exits the furnace, crucial for identifying non-uniform heating.

Pyrometers: Multiple non-contact temperature sensors strategically placed within the furnace and quench.

Stress Measurement Systems: Online or offline systems (e.g., using photoelasticity) to measure residual stress patterns

Dimensional/Flatness Sensors: Laser or optical systems to measure glass flatness and warp.

Energy Consumption Monitoring: Tracking power usage of heaters and blowers.

Data Acquisition and Processing:

High-speed collection and storage of data from all sensors, furnace settings (heater power, convection levels, quench pressure, conveyor speed), and glass properties (type, thickness, dimensions).

Data cleaning, filtering, and feature extraction to prepare data for analysis and modeling.

Sophisticated Modeling:

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For more detailed information about the intelligent control system of glass tempering furnace, please click here: https://www.shencglass.com/en/a/news/intelligent-control-system-for-glass-tempering-furnace.html

How to maintain glass tempering furnace?

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Maintaining a glass tempering furnace is crucial for ensuring consistent product quality, maximizing uptime, minimizing energy consumption, and guaranteeing operator safety. It requires a systematic approach involving regular inspections, cleaning, lubrication, and calibration.

Glass Tempering Furnace Maintenance Guide

glass tempering furnace

Key Principles:

Safety First: Always prioritize safety. Follow Lockout/Tagout (LOTO) procedures before any maintenance. Be aware of extreme heat, high voltage, and moving parts.

Use appropriate Personal Protective Equipment (PPE).

Follow Manufacturer’s Recommendations: The furnace manufacturer’s manual is the primary resource. Maintenance schedules and procedures may vary significantly between different makes and models.

Keep Detailed Records: Log all maintenance activities, inspections, repairs, and part replacements. This helps track trends, predict potential issues, and manage spare parts inventory.

Cleanliness is Key: Dust and debris can interfere with sensors, block airflow, damage components, and create fire hazards.

Maintenance Schedule Breakdown (Example – Adjust based on Manufacturer & Usage):

glass tempering furnace

Daily / Per Shift:

Visual Inspection:

Check the overall condition of the furnace exterior and surrounding area.

Look for any unusual noises, vibrations, or smells during operation.

Check control panel indicators, alarms, and temperature readings for normalcy.

Inspect loading and unloading areas for debris or obstructions.

Check quench section airflow (listen for consistency, check pressure gauges if available).

Visually inspect rollers (loading, heating, quenching, unloading) for obvious damage or debris.

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For more detailed information on glass tempering furnace maintenance, please click here: https://www.shencglass.com/en/a/news/glass-tempering-furnace-maintenance-guide.html

How to extend the service life of vibrating screen

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To extend the service life of your vibrating screen and ensure efficient operation, a consistent and thorough maintenance program is essential.

How to extend the service life of vibrating screen

vibrating screen

1. Regular Inspection

Frequency: Daily, weekly, and monthly inspections are crucial.

What to check:

Screen Media: Look for tears, holes, wear, proper tension, and cleanliness. Ensure it’s correctly installed and that gaskets (if required) are in place.

Structural Components: Examine the frame, supports, and cross beams for cracks, fatigue, or damage.

Fasteners: Regularly check and tighten all bolts, nuts, and other fasteners, especially on screen panels, clamping systems, and motor mounts. Re-tighten bolts after the initial 7 hours of work.

Springs: Inspect for wear, damage, and proper compression. Measure springs against OEM tolerances and replace as a complete set if out of tolerance.

Crown Bars: Ensure proper and continuous crown on all decks. Repair or replace according to the manufacturer’s guidelines.

Drive System: Inspect V-belts for wear, damage, and proper tension. Check for leaks in the drive system.

Mounting System: Ensure the machine is securely mounted and free from damage.

Safety Guards: Confirm they are firmly in place and not compromised.

Why: Early detection of issues prevents more significant damage and downtime.

vibrating screen

2. Proper Lubrication

Frequency: Follow the manufacturer’s recommendations for lubrication intervals. Daily lubrication of drive bearings and ensuring grease lines are intact is often necessary.

What to do:

Lubricate bearings, drive mechanisms, and other moving parts with the recommended lubricant and quantities.

Inspect grease lines for leaks or blockages.

For central lubrication systems, perform thorough inspections weekly.

Monitor bearing temperature; overheating can indicate lubrication issues.

Why: Reduces friction and wear, preventing premature failure of moving parts.

3. Screen Cleaning

Frequency: Clean the screen surface regularly, the frequency depends on the material being screened. Daily cleaning is often necessary.

How to do it: Use a brush, air blower, or water spray (depending on the material and screen media) to remove buildup of material, debris, or blockages.

Why: Maintains efficient screening performance and prevents excess weight and strain on the screen.

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For more detailed information on how to extend the service life of the vibrating screen, please click here: https://www.zexciter.com/en/a/news/extend-the-service-life-of-vibrating-screen.html