Fabrication Shop

             

The production of metal structures involves four technological departments: the workpiece area, the fabrication shop, the assembly shop and the painting area. The total area of the shops is 13,425 sq. m. It consists of 3 aisles: one blanking and two main, as well as utility and amanity spaces. The painting area of the fabrication shop is located in a separate shop. If it is necessary to perform additional types of machining for parts of various degrees of complexity, shapes, dimensions; these parts are sent to the machining shop.

Fabrication shops are equipped with modern equipment. An machine for laser cutting of materials, together with getting the task directly from the manufacturing plan, allows to reduce metal consumption. A plasma cutter, a chamfering machine for pipes of different diameters, bending and rolling machines with computerized numerical control, allow to obtain parts with high accuracy, without subsequent manual processing. Protection of finished products against corrosion is manufactured by modern coating systems of both domestic and foreign production. Surface is prepared in shot-blasting chambers, in accordance with the GOST R ISO 8501-1-2014 standard. Painting materials are applied by airless spraying. There is also equipment for coating the inner surface of pipes. If there is a requirement for non-destructive testing of weld joint, there is the necessary equipment and certified specialists for this type of work. We have a lot of experience in manufacturing metal structures, such as cooling towers, spans, antenna and searchlight towers, production buildings, piles, pipe supports.

We perform the following activities:
   1. Metal cutting with guillotine shears up to 20 mm thick and 3000 mm long; with the IK heat-cutting machine – up to 40 mm thick, the length of the cut is not limited; with the "STRELA PL" machine – up to 100 mm thick with a master form; with the Laser Cut machine – up to 20 mm thick.
   2. Arc welding in an atmosphere of shielding gas.
   3. Machining.
   4. Bench assembly.
   5. Shot-blasting of 2000x4500 mm blanks.
   6. Painting.
   7. Drying.

The productive capacity of the shop is currently 900 tons per month. At the same time, the potential capabilities of the manufacturing equipment and area allow for a threefold increase in capacity. Eight overhead cranes with a carrying capacity up to 10 tons are installed and used in the shop. The following types of process equipment are installed and functioning in the shop:

Equipment Group	Name
Blanking	Н3222 guillotine shears up to 16 mm
	НД 3318Г guillotine shears up to 5 mm
	АКНА 3223 guillotine shears up to 20 mm
	И 2220А rolling mills
	press shear
	К274 press with the force of 315 tons
	metal-forming equipment 40–160 tons
	bandsaws
	PARMIGIANI four-roll hydraulic machine
Heat-cutting	"STRELA PL" by PURM, IK 12 MAX oxy-fuel and plasma cutting
	Laser Cut laser machine
Welding equipment certified by NAKS (National Agency for Testing and Welding)	TAURUS semiautomatic welders, 8 pcs
	ESAB semiautomatic welders, 18 pcs
	ВДУ 601 semiautomatic welders with ПДГО 547 power source, 6 pcs
Metal-working	2Н135 vertical drill
	rough grinding machine, 4pcs
	radiall drilling machine
	Magnetic drilling machines, 6pcs
Blasting	Three DSG shot-blasting machines
Paint Equipment	Air and airless spraying, 16 machines
Urethane-foam Equipment	Urethane-foam production machine for pipe insulation

             

Our advantages are:
   1. High qualification of engineers and workers, conditioned by long-term cooperation with enterprises of the oil and gas sector and the fuel and energy complex, fulfillment of high-technology orders for manufacturing of metal structures of the highest complexity that require the highest accuracy and responsibility.
   2. Quality control system at all stages of production and construction.
   3. Direct cooperation with the largest metallurgical combines, which makes it possible to purchase rolled metal products at special prices.
   4. Low cost per ton of metal structures with the highest quality of design.
When designing project by the Metal Structures and Detailed Metal Structure documentation, we offer you solutions that reduce metal consumption of metal structures to 40%.