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A Comprehensive Guide to the Production Processes and Procedures of Galvanized Grating
Release time:
2025-05-16
In the modern industrial and construction sectors, galvanized grating is highly favored for its excellent performance. Whether in industrial platforms, municipal engineering projects, or sewage treatment facilities, its presence is ubiquitous. Behind its wide - spread use lies a rigorous and complex set of production processes and procedures that endow galvanized grating with robust performance and reliable quality. Let's now take an in - depth look at the entire journey from raw materials to the finished product.
I. Raw Material Preparation
The first step in the production of galvanized grating is the selection and preparation of raw materials. The main raw materials are high - quality low - carbon steel flat bars and twisted square bars (or round bars). For flat bars, their materials must comply with relevant national standards, featuring good strength and toughness. Common specifications include 20×3, 25×3, 30×3, 32×5, etc., and different specifications are suitable for various load - bearing requirements and application scenarios. Twisted square bars serve to connect the flat bars, enhancing the overall stability and anti - slip performance of the grating.
Before entering the production process, raw materials need to undergo strict quality inspections. Check the dimensional accuracy, surface quality, mechanical properties, and other indicators of flat bars and twisted square bars to ensure they meet production requirements. Only raw materials that pass the inspection can enter the subsequent production process, guaranteeing product quality from the source.
II. Processing of Flat Bars and Twisted Square Bars
Processing of Flat Bars
First, according to design requirements, use high - precision shearing equipment to cut the purchased long flat bars into specified lengths. The ends of the cut flat bars should be neat and free of burrs to ensure the subsequent welding quality.
Subsequently, punching or slotting operations are carried out on the flat bars. This step is mainly to better fix the position when welding the twisted square bars and enhance the firmness of the connection. Usually, a CNC punching machine is used for operation, which can precisely control the position and size of the holes to meet the production requirements of different specifications of gratings.
Processing of Twisted Square Bars
Twisted square bars are generally formed by twisting round bars through special equipment. During the twisting process, the twisting force and angle need to be strictly controlled to ensure that the spiral shape of the twisted square bars is uniform. After forming, the twisted square bars are inspected again for their dimensions and appearance to ensure they meet production standards.
III. Welding and Molding
Welding is a crucial part of the galvanized grating production process, directly affecting the product's quality and performance. Currently, the commonly used welding method is resistance welding. It utilizes the resistance heat generated when an electric current passes through the contact points of flat bars and twisted square bars, melting and fusing the metal at the contact points to form firm solder joints.
During production, the processed flat bars and twisted square bars are neatly placed on a special welding platform according to the designed spacing and arrangement. An automated welding device is used to weld the intersection points of the flat bars and twisted square bars one by one. During the welding process, parameters such as welding current and welding time need to be strictly controlled to ensure the strength and quality of the solder joints. At the same time, to ensure the stability and consistency of welding, the equipment needs to be regularly maintained and calibrated.
After welding, a preliminary quality inspection of the grating is carried out. Check whether the solder joints are firm and if there are any cases of missed welding or poor soldering. For unqualified products, immediate re - welding or rework is required.
IV. Cutting and Shaping
According to actual usage requirements, the welded galvanized grating still needs to be cut and shaped. Use a CNC cutting machine to precisely cut the grating into the specified size and shape to meet the installation requirements. During the cutting process, pay attention to controlling the cutting speed and accuracy to avoid dimensional deviations and uneven edges.
After cutting, the grating is shaped. Through special shaping equipment, the flatness, diagonal dimensions, and other aspects of the grating are corrected to ensure that the overall shape of the grating is regular, the surface is flat, and there are no warping or deformation phenomena.
V. Galvanizing Treatment
Galvanizing is a key process that endows galvanized grating with excellent anti - corrosion performance, and the hot - dip galvanizing process is generally adopted. First, the cut and shaped grating is pickled to remove impurities such as rust and oil stains on the surface, exposing the pure metal substrate of the grating. After pickling, thoroughly rinse the grating with clean water to remove the residual acid solution.
Then, immerse the grating in the flux solution to form a uniform salt film on its surface, enhancing the adhesion between the zinc layer and the substrate. Subsequently, immerse the grating in a zinc bath with a temperature of about 450 - 480°C for hot - dip galvanizing. At high temperatures, the zinc in the zinc bath reacts with the iron on the surface of the grating to form a dense zinc - iron alloy layer and a pure zinc layer, effectively isolating air and moisture and achieving anti - corrosion.
After galvanizing, cool the grating to bring its temperature down to room temperature. Finally, check indicators such as the thickness, uniformity, and adhesion of the galvanized layer to ensure that the galvanizing quality meets the standards. The surface of a qualified galvanized grating should be smooth, flat, with a uniform color, and free of defects such as missed galvanizing and zinc tumors.
VI. Finished Product Inspection and Packaging
After completing all production processes, a comprehensive inspection of the galvanized grating is conducted. In addition to re - checking the appearance quality, dimensional accuracy, welding quality, and galvanizing quality, the mechanical properties of the grating, such as its load - bearing capacity, are also tested to ensure that the product meets the design requirements and usage standards.
For qualified galvanized gratings, packaging is carried out according to customer requirements. Generally, materials such as plastic films and steel straps are used for bundling and packaging to prevent damage during transportation and storage. After packaging, attach relevant documents such as product certificates and quality inspection reports, and then the product can be delivered to customers.
From the careful selection of raw materials, strict control of each production process, to the meticulous inspection of the finished product, a complete and rigorous set of production processes and procedures creates galvanized grating with excellent performance. It is precisely these seemingly complex processes that ensure galvanized grating can still function stably in various harsh environments, providing reliable support for industrial production and urban construction.
