The complete production cycle is one of the main advantages of the "“Plant of platform gratings”", because in order to obtain a high quality product, it is necessary to be confident in quality at every stage of production, from procurement of raw materials to packaging of the finished product.
In addition, full-cycle production gives an opportunity to provide the Client with the best price and offer short production times, since we do not depend on any subcontractor and control all technological processes ourselves.
Despite the great popularity, many of our Customers who have not visited our production site do not know at all how grating is made. So, today we would like to describe you this process in detail.
Stage 1. Purchase of raw materials
“Plant of platform gratings” purchases raw materials in the form of coiled steel and wire rods directly from metallurgical plants. Steel is poured and rolled with individual characteristics specifically for our plant, which ensures the ideal coil thickness and the appropriate chemical composition of the steel, which provides for the perfect zinc coating.
Stage 2. Cutting steel into strips
Cutting steel into strips of a certain width, which will subsequently form the basis of the grating, is carried out on a special slitting machine for coiled steel, which makes it possible to cut a strip with a width of 10 mm! Cutting error does not exceed 0.05 mm and guarantees the same mechanical characteristics in the future. In addition, a special knife cooling system eliminates the use of any lubricants during cutting, which is also important in the future during welding and hot-dip galvanizing of the grating.
Stage 3. "Twisting" from crossbar
A cross bar in the welded grating serves to keep the bearing strips in a vertical position and to give the grating better anti-slip properties. This stage of production takes place in parallel with the cutting of coiled steel and is a drawing of wire rod through special dies and heads, which during the drawing process not only calibrate the wire rod, but also twist it, giving it the shape of a spiral. Subsequently, the finished transverse bar enters the automatic drawing-and-cutting machine, leveling and cutting the bar of a given length at a speed of 90 m/min.
Stage 4. Manufacturing of grating blanks
At present, an automatic welding line is based on contact pressing of transverse bearing strips and rods. It is here where the sizes of cells of the future grating are formed. Automatic line installed at our enterprise allows producing of up to 1000 tons of gratings per month. At this stage gratings are produced in the form of so-called “mats” - large-sized unmounted arrays, mainly 6100x1000 mm, which are then used as raw materials for the manufacture of concrete gratings for individual orders. A specific feature of “ZRN” production line is the ability to flexibly and quickly adjust the grating cells and to produce “mats” with a width of 500 to 1250 mm, which minimizes waste during cutting, as well as length from 2000 to 12000 mm. The range of bearing strips is from 20x2 mm to 70x6 mm. Mesh size - from 25x25 mm to 68x101 mm.
Step 5. Cutting of blanks
Floor gratings made in the previous step are cut into finished gratings on a special high-speed saw based on individual order. If the finished grating should be square or rectangular, it goes to banding welding section immediately after cutting. If the finished product has a complex geometric shape or special types of banding, after being cut by the saw the blank first goes through the stage of cutting shapes and completing them with banding.
Step 6. Cutting out shapes
Step 6. Cutting out shapes At this stage the necessary additional cuts are made or a grating is given a complex geometric shape in accordance with the drawings developed by “ZRN” Engineering Center or provided by the Client using a modern automatic gas-oxygen cutting machine with CNC. In fact, our enterprise has no restrictions on the shape or dimensions of the future product. However, our specialists will always offer the Client exactly such dimensions and shapes of gratings that will minimize the production time and the amount of waste.
In addition, the product is equipped with a grating frame of various types based on the given technical documentation.
Step 7. Welding of the frame
In order to provide the grate with an aesthetic look, all sawing points are banded with a strip. By default, the band matches the bearing strip. However, in many cases the banding plays not only an aesthetic role, but also gives the grating other functional purpose, for example, special banding for shelving, drainage systems, etc. The frame can also serve as a safety feature, for example a “high” frame replaces the separation on the guardrails. More information on frame types can be found in the "“Technical Manual”".
Step 8. Stripping and galvanizing
Before galvanizing and after banding the grating undergoes a cleaning stage, at which all sharp edges are dulled and visible welds are cleaned.
Hot-dip galvanizing is the best and most reliable method of anti-corrosion protection of gratings today. We provide a guarantee for “ZRN” galvanized gratings for up to 30 years. Hot-dip galvanizing provides not only barrier, but also electrochemical protection against corrosion.
Stage 9. Packaging and labeling of products
Sorting, marking and final packaging of the gratings is carried out before shipment to the Client. “ZRN” gratings are delivered to Customers on pallets, securely fastened with metal tape. Packaging is made in accordance with the requirements of the Customer.
In such a short way we tried to convey to you the basic information on how we make galvanized grating from steel rolls.
Naturally, each stage has its own peculiarities and nuances, so if you want to learn more, we are happy to invite you to visit the production line of “Plant of platform gratings”. Due to excellent wear resistance and durability properties, our gratings will take care of safety and comfort for many years!