For many years, KGHM ZANAM S.A. has been a recognised manufacturer of large-scale welded steel structures. Experience of the crew and the Department's technological potential, as well as approvals and certificates held by it, guarantee the high quality of the manufactured structures. Our products are provided with technical support. We have our own, modern design office.
Manufacturing technology
The scope of technological operations performed by the Department can be divided into the following phases:
•    pre-treatment,
•    assembly and joining,
•    mechanical treatment,
•    heat treatment,
•    installation of plant and machinery,
•    rust proofing.
1. Pre-treatment
1.1. Cleaning
Cleaning 2500 x 6000 [mm] plates using Gietart GW2500-615 shot blasting machine.
The resulting plate surface cleanliness after shot-blasting complies with PN-ISO 8501-1: Sa21.
Cleaning of structures using 12 x 5 x 5 [m] blasting chamber.
The resulting plate surface cleanliness after shot-blasting complies with PN-ISO 8501-1: Sa21.

 

Type

Plate/chamber dimensions

Standard of cleanliness

Shot blasting

GW 2500-615 (Gietart)

2500×6000

Sa 21

Shot blasting

PP-8R

2500×12000

Sa 21

Blasting chamber

 

16000x5000x6000

Sa 21

 

1.2. Cutting

Cutting of rods, tubes, sections and closed profiles using automatic tape cut-off machines of dimensions up to 330 mm and 330 x 510 at an angle of 0-60°

Type

Cutting system

Max. cutting diameter at a right angle

Max. dimensions of the cut profile

Max. cutting diameter at an angle of 45°

Max. cutting diameter at an angle of 60°

Length of a single material fed to the machine

Control

S-20A (HYD-MECH), automatic

scissor

O 330

330×457

O 305

-

400

conventional

Individual 510.330 GANC (BOMAR), automatic

horizontal

O 330

330×510

O 330

O 230

600

numerical

Cutting shapes and plates measuring up to 25 mm in thickness using guillotine shears

Shaped cavities

Max. plate dimensions

Max. rod dimensions

Rack clearance

Rack throat capacity

Universal

NU 25A

angles

180x180x18

25

round 65, square 55

 

 

 

180x120x18

T-section

140×15

flat bar

160×28

Guillotine

NG13ScTP25CNC type TruShear 5163

 

 

13×3000

 

3200

600

 

 

25×3150

 

3250

630

Guillotine

 

 

16×3050

 

3050

 

 

Gas cutting of up to 200-mm-thick carbon steel plates of dimensions 2500 mm x 6000 mm using numerically controlled thermal cutting machines. Plasma cutting of up to 15-mm-thick alloy steel plates and non-ferrous metal of dimensions 2500 mm x 6000 mm using numerically controlled thermal cutting machine.

 

Name

Type

Thickness range

Max. cutting length

Max. cutting width

Accessories

CORTA

DP 5000

0-100/200

6000

4000

Plasma-cutting torch, cutting thickness of 0.5-15 mm

OMNICUT

5000

0-100/200

6000

4000

Plasma-cutting torch, cutting thickness of 0.5-15 mm

ECONOGRAPH

EC-2500 (KOIKE)

0-100/200

6000

2500

 

CORTINA

DS-3100 (MESSER)

0-100/200

6000

2500

Plasma-cutting torch, cutting thickness of 0.5-15 mm

Semi-automatic gas cutting, bevelling on straight plate sections

Type

Thickness of the cut plates

Cutting angle range

PPA-100A

3-100

0-45°

1.3. Forming processes

Bending on a bending brake

Type

Nominal pressure [Mg]

Ram stroke

Max. dimensions of the bent plates

Clearance between the columns

Ram stroke adjustability

Bending brake

PXA – 250/5600

250

100

1000×24
5000×10

3300

125

Bending brake

TruBend 8600-40

600

400

1-30

3050

 

Straightening of parts and sheet metal

Type

Nominal pressure [Mg]

Ram stroke

Distance ram-table

Table dimensions

Body clearance

Ram stroke adjustability

Eccentric

PM-25B

25

100

355

560×370

270

 

PMS-160A

160

140

580

1140×760

840

120

Hydraulic

PH-Wn 25

25

500

 

500×550

800

 

GANTRY

250

400

400-800

2500×5000

3100

 

Rolling plates with the use of rollers

Type

Dimensions of the rolled plate

Range of rolled diameters

Upper roller diameter

Spacing of lower rollers

Thickness

Width

PS460

30

3000

Min. 700

460

adjustable

 

 

2. Welding

2.1. Welding methods

The following methods of arc welding are used:

  • welding with coated electrodes (MMA),
  • semi-automatic, (MIG/MAG) gas-shielded welding,
  • tungsten-inert gas (TIG) welding,
  • submerged-arc welding.

It is possible to weld the following materials:

  • carbon steels,
  • low-alloy steels with high strength and abrasion resistance,
  • high-alloy steels, stainless steels and acid-resistant steels.

Relieving welding stress by:

  • heat treatment,
  • vibratory stress relief.
 
 

2.2. Weld control possibilities, testing methods

Non-destructive:

  • visual (VT),
  • penetrant (PT),
  • magnetic-particle (MT),
  • ultrasonic (UT),
  • radiographic (RT).

Destructive testing of fragmentary[AD1]  or monitoring joints (testing mechanical properties), including the following tests:

  • joint tangential tension tests,
  • joint bend tests,
  • joint impact strength tests,
  • joint break test,
  • hardness test,

and also checking:

  • chemical composition of the steel,
  • steel weldability.

2.3. Heat treatment

  • normalization,
  • stress relief annealing.

Additional information:
Welding qualifications of our welders comply with PN-EN 287-1
– welding of steel classified to material group 1 in accordance with CR ISO 15608
Welding method 111 (with the use of a coated electrode).
Welding method 135 (semi-automatic, gas-shielded).
Welding method 121 (submerged arc).
– welding of steel classified to material group 3 in accordance with CR ISO 15608
Welding method 135 (semi-automatic, gas-shielded).
– welding of steel classified to material group 8 in accordance with CR ISO 15608
Welding method 135 (semi-automatic, gas-shielded).
Welding method 141

We employ recognised welding technologies in accordance with PN-EN 288-3

a. SLV Berlin inspection authority – WPQR no. 54/1-3/OS/06.
Welding method 135
Material Group 3-3, 1-1, 2-1, 2-2, 3-1, 3-2, in accordance with CR ISO 15608
Welds: butt welds, mat. gr. 3 – 80 mm
fillet welds, mat. gr. ? 5 mm
Welding position – PA, PB.

b. UDT inspection authority – WPQR no. 32/111/O1-02.
Welding method 111
Material group 1 in accordance with CR ISO 15608
Standard material gr. for 3-24 mm plates
3-12.6 mm tubes
Outside diameter of the tube – > 84.1 mm
Welding position – PF.

c. TÜV inspection authority – WPQR no. 398/03/A; 399/03/A; 400/03/A; 397/03/A
Welding method 141
Material group 8 in accordance with CR ISO 15608
Standard material gr. for 2-4 mm tubes
Outside diameter of the tube – 12.5-50 mm
Welding positions – PC/PF.
Standard material gr. for 3-7.2 mm tubes
Outside diameter of the tube – 57.5-228.6 mm
Welding position – PC/PF.

We use state-of-the-art welding equipment, e.g.:

  • FRONIUS semi-automatic welding machines, i.e. TPS 4000 and TPS 5000
  • ESAB column-and-boom manipulator for submerged arc welding of longitudinal joints, peripheral tanks and tubes,
  • automatic machine for regeneration of holes (weld surfacing) with a diameter of O 30 /mm/ up to O 600 /mm/ and max. length of 500 /mm/

 
3. Mechanical treatment of structures

Milling with the use of vertical and universal milling machines, as well as conventional, numerically controlled and gantry milling machines

Type

Max. processing width

Max. processing height

Table dimensions

Greatest table shift

Distance from the table surface to the vertical spindle head

Distance b/t the heads of the horizontal spindles

Spindle cones

max.

min.

max.

min.

Closed planer

1Y612

1250

1250

1250×4000

4500

1330

260

1490

860

7:24(60)

                     

Treatment by means of conventional drilling and milling machines with rotary table and spindle diameter of up to O 160, equipped with electronic position reading

Type

Max. boring diameter

Max. reboring diameter by means of the carriage disc

Spindle diameter

Ram spindle extension

Table shift

Rotary table surface

Allowable table load

Spindle axis rise over the table

Spindle seat

transverse

longitudinal

2620B

320

600

O90

600

1000

1120

1120×1250

3 Mg

0-1100

5

AD-115

450

1100

O115

700

1600

2000

1400×1600

5 Mg

0-1500

6

2A635

450

1100

O125

700

1400

1600

1600×1800

8 Mg

50-1300

80 (7)

2K636

450

1100

O125

700

1400

1600

1600×1800

8Mg

0-1300

80 (7)

BFP160/2

1000

1000

O160

1250

6710

500

2000×2000

 

1900

ISO 50

Treatment by means of “Dubler” plate drilling and milling machines (two plate drilling and milling machines with spindles facing each other), with spindle diameters of O 115, equipped with electronic position reading, and with spindle diameters of O 130, numerically controlled, using HEIDENHAIN iTNC530 control system

Type

Max. boring diameter

Max. reboring diameter by means of the carriage disc

Spindle diameters

Ram spindle extension

Max. shift

Rotary table surface

Working plate surface

Allowable table load

Spindle axis rise over the table

Spindle seats

of spindle columns along the working plate

transverse shift, of the rotary table

ADP-115 “Dubler”

600

-

O115

700

4500

-

-

1500×4000

 

50-2000

ISO50

WHA-130N CNC “Dubler” HEIDENHAIN iTNC530

600

treatment with circular interpolation

O130

700/700

80005000

1500

1600×1800

2000×5000

12 Mg rotary table

100-2100

ISO50

B440A

1000

 

O160

1250

5880

 

1800×1800

6000×4000

 

2770

ISO50

 
 
4. Rust proofing

4.1. Painting

Painting of machines, welded structures and parts in the drying booths of the following dimensions:
6 x 16 x 5 [m] and 5 x 6 x 5 [m].
Painting by means of hydrodynamic and pneumatic painting methods, with one-component and two-component paints. We use three-layer paint sets (primer, sub-layer and surface layer) or other paint sets according to the customer's request. Total paint coat thickness: 140-160 [µm].

4.2. ZINGA galvanizing

This product is used:

  • to provide a stand-alone protective coating for various types of steel structures (e.g. bridge structures, road safety barriers, containers, mast towers,
  • silos, heavy equipment chassis, construction machinery, freight wagons, culverts and many others),
  • for repairs (after drilling, welding, riveting, etc.) or reconstruction of galvanized coatings,
  • to provide temporary protection,
  • to provide protection for reinforcement bars (very good Zing adhesion to concrete), especially at points of contact between steel and concrete in hydraulic structures, and in contact with water, including sea and drinking water,
  • to ensure protection as a primer in a duplex system, i.e. with topcoat (epoxy paint)