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Fabricated Steel Structures
Indiana continues to be an early mover into new verticals and anticipating the growing demand for shop fabricated structural steel over site fabricated structural steel, Indiana set up a state of the art fabrication facility in Jejuri, near Pune. The advantages of shop fabrication over site fabrication are excellent welding quality, dimensional accuracy, faster delivery in volumes and long lasting paint finish.
In our endeavor to establish a world class facility, Indiana has a series of machines imported from USA which includes band saw machine, plate processors and beam drilling machines.
Indiana fabricates two types of structural steel sections:
- HOT ROLLED SECTIONS (products fabricated from rolled sections)
- BUILT-UP SECTIONS (products fabricated from steel plates)
Indiana fabricates steel structure using section of various international standard like, EUROPEAN, ENGLISH, JIS, IS and AISC.
The sections that are used from the above standards are UC, UB, HEA, W, ISMB, IPN, UPN and PFC of various sizes which are uploaded in our CNC data bank for processing as required by the customer drawings.
Our shop for the hot rolled beams is well equipped with state of the art fully automatic CNC machines to process all types of materials sections like beams, plates, channels, and angles.
The machines are connected with LAN through which nested numerical codes are being transferred from nesting software computers.
The entire operation of marking, cutting and drilling is CNC operated in accordance with nesting files without any manual interference in the operation cycle eliminating any room for manual error.
Fabrication efficiency and quality both are controlled by the machines.
The Built-up beam section shop is equipped with submerged arc welding line with conveyor system for the manufacturing of various types of beams such as “H”,“T”,“I”, BOX and PLUS type.
The fabrication facility is installed with state-of-the-art material handling system with cross bay trolleys, using hydraulic and electrical operated roller conveyors and 18 EOT cranes with maximum SWL capacity of 25 tonnes to handle the structural steel safely and efficiently.
The fabrication area of built-up sections is equipped with
- 14 nos - Saw welding machines
- 03 nos - CNC profile cutting machines
- 02 nos - I/ H beam assembly Machines
- 01 nos - Flange straightening machine
- 01 nos - Face milling machine used for column
- Flange width: 200-900 mm
- Web height: 400 - 2000 mm
- Length of beam: 4000 - 20000 mm
- Flange thickness: 6 -100 mm
- Web thickness: 6 -100 mm
- Wlidth: 400mm x 400mm-900mm x 900mm
- Length: up to 12000 mm
- PLUS Beam Max Weight of Individual Piece: 35 Ton
- Max size of column: 900 x 900 mm
- Range of plates used: 16 -100 mm
- Length of beam: 4000 -20000 mm
- Width: 900 mm
- Height: 400 - 2000 mm
- Length: Up to 13000 mm.
Manual Work
- Manual layout required to cut the beam or to drill all holes
- Cutting quality is not satisfactory and one more operation of grinding is required
- Since the operation involves manual materials handling for cutting and drilling, the turning of the beams occurs at least 3 to 5 times, leading to chances of handling damages and accidents.
- Time taken to drill 100 holes of dia 22 mm in one beam of size 500x300x25x15x9000 mm long is approximately 400-420 min with a good fitter and cutter
- Manpower required for material handling is more hence the man-hour spent per hour will be more
- Chances of human error are more as the drawings have o be referred to on the shop floor
- When percentage of components is high in structures, time taken to prepare is long resulting in delay in fabrication
Work using CNC Machines
- Auto measurement is done and cutting and drilling operation is automatic, 70-80 % cycle time can be saved
- Smooth finish is obtained since grinding is avoided and accuracy is achieved upto 0.1mm
- No material handling is involved since cutting and drilling of holes takes place for all the sides of sections with the beam in one position.
- Time taken by CNC is approximately 30 minutes
- Only two machine operators (For cutting and for drilling machines ) required to perform entire operation and hence less man – hour per ton
- Since CNC files are downloaded directly from the drawing software, chances of errors are almost negligible
- When the percentage of components is high, mass production is possible which helps in cutting down the cycle time for fabrication.