Thank you for respecting the authenticity of the video and letting the machine's sounds be the way they are without adding music or speeding up the video. Thank you so much.
So they just weld 3 metal plates together? I thought there would be some kind of process to form the beam out of a single piece of metal. Won't it break at the welds?
this is called a built-up shape. hot rolling a beam is common for common sized regular cross-sectioned beams, but built-up shapes are used to meet certain loading requirements not capable of being met by hot rolled sections. Built-up shapes are typically larger than hot-rolled shapes
To be fair, the title says, "T and I beam manufacturing line" and doesn't say anything about welding. I believe they are just showing a new line and how the line operates and is just for demonstration purposes. Notice how nice and shiny or scratch free all of the wheels and rollers are. There's also no flux, heat or smoke of any kind on this "beam".
H beams are also a rolled shape. The submerged arc welding process has been around and used for some time. It is used on flat and round shapes for welding. Once set up and going it is almost automatic but needs to be followed by the welding operator for the best outcome.
@@Renaldo015 What do I not know? I spent my career as an Engineer working in highway and bridge construction. That is a plate girder. Plate girders are made by cutting steel plates to the desired with and then welding those plates together to made the shape shown in this video. With plate girders the thickness of the top and bottom flanges can be different if that is what is required. The same applies to the width of the top and bottom flanges. The web thickness can be the desired thickness. An I-beam is a rolled shape, no welding of the top and bottom flanges to the web. Both flanges will be the same width and thickness. The only what those dimensions will change is to go to a different weight of that shape. All those shapes are either a W, M, S or HP shape in the Steel manual published by the American Institute for Steel Construction.
what's the return on investment time on this! is it state owned? what kind of structure needs this much steel in 1 i beam! I think i'm out of place here
By coincidence I saw a video this morning of I beam fabrication in China. It was a hysterical contrast. They were heating with torches and hammering into shape, wearing, I kid you not,,, sandals. The welding consisted of a guy with no helmet, jabbing the stick into the joint and wiggling around while he looked in the opposite direction.
It is called submerged Arc Welding. the weld metal melting is performed under a small pile of granualr flux, and if done correctly, no welding arc ever pops out to be seen. It is a very efficient form of welding.
@dothemathright 1111 You are correct. SAW does produce fume. However, it produces a lot less fume than the open arc welding processes. To the average observer, the fume produced with neutral flux SAW is mostly invisible. You have to get really close with the correct lighting to see it come out of the flux pile.
That might work for short sections, However I do not think that machine will have the capacity to create a plate girder 90+ feet long with camber to account for the deflection and sweep for a curve built in.
I don't see why everyone is saying that it was submerged-arc welded...it looks like regular MIG welding to me. There's no flux delivery or recovery hoses.
Aren't I-beams usually made by hot extrusion? All the I-beams I have ever seen were a single piece - no weld. Also as others have pointed out, what a slow line. Not going to make many this way. Is this line for highly specialized custom beams?
This is not actually that slow. an industry average for building girders is between 18 and 30 inches a minute for the welding speed, whereas the speed for bridge girder welding is more like 12 to 18 inches per minute. Hand welding with a stick electrode might only progress between 3 and 7 inches per minute.
Wait a minute... I thought I-beams and T-beams were hot-rolled from a single steel billet? Wouldn't that make a stronger product, as opposed to welding?
+agentorange153 Universal beams can be hot-rolled from single steel blooms as you say, however there is a largest size for these beams. If a larger section is required then they would need to be welded. You may be surprised to find out that the weld is likely to be stronger that the surrounding steel (providing welding is done correctly and in controlled conditions)
They used to roll these jumbo sections directly. How times have changed... The web only holds the two flanges apart anyways. There isn't really that much stress on those welds, they mainly just hold the pieces together.
This is interesting in that there is no preheating shown, no flux recovery shown, no tacking of the run-off tabs shown, no squeezing or web to flange tack welding shown and no inspection shown. This was a relatively short girder. It also has a relatively thick web, (it appears to be at least 18 MM thick), which does not warp as badly as say a 10 MM web, so, maybe in process welding inspection was not required. If this was used for bridges in the USA, and the girders were considerably longer, (Let's say 30 meters or so,) there would be considerable camber, verified preheat, progressive inspection, and some indication of considerable squeezing. After flip-over, flange tilt verification inspection and root opening would be required prior to welding the second side. This must be a simple short demonstration piece for sales purposes. Far too little is shown to interest me in even looking at this machine for purpose of evaluation for purchase!
@540 MUDSTAIN Ok Mudstain - Perhaps this is a production fabrication for a customer. with a building as you say. I have thirty four years welding, fabricating and INSPECTING welded fabrications. So I repeat my observations as an INSPECTOR! I do not know what you mean by ..."as I have proof in my channel that I am more qualified than you on the subject of bridge girders. Your channel has nothing proving you know what your talking about and more than likely is repeated information from Wikipedia." Where are you located? What controlling jurisdiction governs the engineering and fabrication of the building this beam is destined for? I am basing my observations on what I would expect in the USA or Canada for beams built to a Welding Code, Building Code, or Bridge Code. I do not think I have Maligned you at all!!! I just think that your bright new shiny machine is not very impressive, because I have seen several different types of semiautomated beam fabricators in my career as an Inspector. 1) Your machine appears to be bright shiny new, with no flash rust, no flux droppings, no evidence of flux dust, and no scaring on the rollers. The tubing heat marks are still seen on the first horizontal roller on the starting end. I note that the tubing heat marks are in English. 2) There appears to be no preheat used, and no provisions for preheat torches on your weld head gantry. 3) I think I see that you have ground back the mill scale on the weld edges of the web plate. I do not see any grinding to remove the mill scale in the weld footprint area on the centerline of the flange plate. Have these plates been pre-blasted or otherwise treated to remove the mill scale? 4) I see that you have not tack welded the flanges to the web plate. The web plate you have here looks relatively thick, so web plate warpage during welding probably will not cause the web plate to move off the centerline of the flange plates. How would you control heat induced web warpage when using thinner webs. 5) I do not see a run-off tab tack welded to the starting ends of the beam. I do see some welded on the other end just before you roll the beam over. Is there enough steel left to trim the beginning end? 6) What kind of controls are you using to control the tilt of flange caused by weld cooling shrinkage on the first side? I did not observe any QC checking of the flange tilt after you flipped the beam. 7) Does your WPS and WPQR (or the Equivalent if using ISO System norms) allow for the welding of this thickness metal without preheat? 8) I do not observe any flux recovery mechanism attached to the weld head gantry. There is no fused or unfused flux visible as the beam comes out of the far end of the machine before you flip How do you recover the unmelted flux? 9) How do you properly add and mix new flux to the flux hopper if you do recover? 10) There does not appear to be any camber in the beam you are making here. What depth of camber can be accomodated when you squeeze the flanges to a precut cambered web?
540 MUDSTAIN Joseph Kane has legitimate questions that you could address with a voice over, text, and by close and better filming in your next video. *Quit being so defensive* and thank him for his comments and interest. You might also comment that bridge beam work is handled on different machines in a different line. PS; I know very little about this topic and I actually learned more from Joseph's comments than from the video. Quit being so defensive and do a voiceover or add text that explains some of the things Joseph is talking about. I know what submerged arc is, but it would have been nice to see a diagram or explanation as the welding looked a little like some type of preheating and I was left wondering what was going on. Watching this video was a little like watching paint dry and only started to make sense when I read Joseph's comments. The people watching this video could be your potential customers, so remember that "the customer is always right". PPS; Video editing should also consider speeding up the welding part in the middle if voiceover or text aren't provided.
@540 MUDSTAIN Mudstain. Many times as an inspector, and often as a consultant, I have seen this type of equipment at work. I have even purchased this type of equipment used at auction for my clients. "Let me tell you it is very scary to travel around with $300,000.00 cash in your briefcase to an auction, because everyone knows that you must have the cash on you to buy at an auction. ) I have recommended for and against this type of equipment in consultation for my clients. I do not have a bias against this machine. (Actually, I do have one bias based on the video. The hydraulic noise is too loud. You will have problems with OSHA if you are in the USA. I solved this problem for one of my clients by simply moving the hydraulic pump to a small acoustically suppressed enclosure with ducted cooling.) You did not respond to my request for your location. If you are in Canada, and you get the opportunity, you can see the best home made version of your machine if you can get a tour of the CANAM MANAC plant in Vanier (Quebec City area). I have only seen one better machine than this, and it was in Norway, (Back in 1984) where they manufactured it. Now, you say the the beam you were making in this video was out of cold rolled steel. Now, I am really curious, because I have never heard of any jurisdiction that allows Cold Rolled Steel for structural applications! You said in an earlier post reply that this was not for a bridge, but for a building! I did once review a NASA Specification for fabricated shapes made from CRS but that was for a solid rocket booster transporter. There aren't even any AISC specs that I know of that would allow the use of CRS without some sort of special engineering testing program. The Engineer of Record would really be putting his license on the line. As you say, much of my answers were of what I could observe in your video. I know that you did not show everything. However, In my job as in independent third party inspector, I would often spot code or specification violations on my first pass through the fabricating plant. I did assume that your machine was brand new because it was shiny. I then noted that you did not have provisions for travelling preheat, so I made a guess that the beam you were making was for a customer demonstration. I also noted at this time that the hydraulic noise was so loud that your "Time Weighted Average" threshold level value was already excessive. (However, I now admit that this noise might just be because you did not have a good sound engineer to select a better place for pick-up microphone placement.) Mudstain - Despite what you think, I do have a LOT more experience than you think. Please answer the questions, Where are you located in this video? What codes or regulatory Jurisdictions are you fabricating this beam for? How much camber can the machine you show handle? Will you be using that machine for longer beams? Will you be using this machine for Hot Rolled Steel? Now, I do not think I am a "typical troll...". I am an inspector, who can and has found so many violations and deficiencies in so many facilities over the years, that I can say with "betting" certainty that you do not want to be inspected by me. The only thing worse than hearing "Allahu Akbar" being yelled by some man running toward you with an AK 47, is to hear that a man with my name is coming to perform third party inspections and audits of your facility. There is an old saying "Arguing with the inspector is like wrestling with a pig in the mud hole. Too late, you realize that the pig really enjoys it."
Mudstain. I did go to the WWW.Deuma.de web site, and scrolled down to the videos section and saw the exact same video you show above, as well as the other flat beam line fabricator animation. So, Is this video a video from your fabrication facility of from the Deuma Factory floor ? -The reason I wanted to know where you were located, is that some countries do not have extensive requirements to follow EN norms,and AISC / ASTM,/AREMA, /AASHTO Etc. rules. , So, please answer. -As for the chain turn-over, such girder flippers have been around since well before I started in the business in 1976. In the Deuma flat beam fabricator animation, they show a different type of flipping mechanism than the chain roller that you have. -Generally, I am not a fan of fabrication machines where the girder rolls along under the welding heads. I prefer the rolling gantry type where the beam is stationary and the weld head can float and run smoothly on a precision rail. I have observed that when the girder rolls along under the stationary head, small divots or cutting slag on the torch cut edge of the flange can cause jumps and disrupt the welding process. (Now - I admit that the flange should have been cut without the imperfections in the first place. However In real life, deviations and imperfections often do exist, and many fabricators leave discontinuity and error and slag clean-up till the end of the process.) One other advantage of a stationary beam flange is that you can weld the shear studs on before you weld the flanges to the web. - Did you look into getting a machine like a 2108 Dart Welder from Ogden Engineering? Many fabricators find that being portable that type of machine can free up floor space to make the fabrication plant more adaptable for other work. Floor space can easily be cleared and repositioned. -I was impressed by some of the other Deuma machines, such as the cylinder roller / welders. -Come on Mudstain answer the questions.
Guessing why this was published, but the name of the publisher looks like Deuma "Positioning Systems," which would explain why they left out the welding part. Welding is not their business but precision positioning platforms for large stock, to which welding gear is attached and material is moved about, is. Makes perfect sense, given this framing.
How do they make the really big, or really long ones? Sane idea, just a bigger machine? Or do they weld shorter lengths together? Because I see the these massive bridge beams that must be a couple hundred feet long and 6ft wide, and wondered how they made them (let alone how they got them to some of these places. There's one big bridge in a town near here, I can't image how they got them there. Must have used the railroad that runs through town, because the roads into town are tiny and winding.
This is roughly the same way those long and tall bridge girders are made. However, this video shows only the most basic fabricated simple girder being fabricated, perhaps for sales purposes! longer and taller girders have a lot moore steps involved that were not shown here!
@Dr Moriarty Nah they actually just satelite down links with really long choker cables made of light weight ferro-manuerium to carry them from the fabrication plant.
Made them in my hometown. Welded up plate stock. Transported by Rail. Center Rail Flat bed is Chained down. End cars have rollers for taking curves. Several Semi trailers are extendable for beam transportation .
Only single run, we put in plenty of runs day after day on the same beam pre-heat every morning. Our plates start at 50mm on the web going up to 140mm never cold in winter but melting in summer all free hand no sub arc.
The automatic jig looks so flimsy and too slow. The technicians (operators?) don't use hard hats, gloves and safety goggles. I don't think this system would last a decade of use. Are the hydraulic cylinders synchronized? The chainlinks should not be rubbing onto the project. Cheaply constructed product. Sorry, it's just my honest opinion. I could point more and more, but you go figure it out. Fire your design engineers, to start.
Deuzer, can I please share some of your video content with others? I will of course, show them your channel and hopefully they will subscribe to your channel.
the weld shown is a "FIllet" weld. It is a weld of roughly triangular cross section. (NO it is not pronounce Fillet as in Fillet (Fillay)of Fish, but as fill - ett). Penetration only has to extend to the actual root of the weld and not beyond for engineering purposes. However in real life the submerger arc welding process usually produces substantial penetration into the root.
@@josephkane825 If this is a strength weld, there should be a penetration, preferably, in both sides, and if not full, partial penetration is required. Nevertheless, I am sure that structural engineer must have considered in his design to omit the penetration.
in the USA, the AISC rules and the pertinent occupational use rules (I. E., Nuclear, Power Plants, Petroleum plants, Chemical plants, Sports Venues...ETC.) apply for structures other than bridges. For highway bridges, Section 10 and 11 of the AASHTO rules apply as modified by the individual State blue pages, and the State Bridge Fabrication Manuals. For Railroad Bridges, AREMA rules apply and the State Steel Construction manuals apply. Most often AREMA rules call for full penetration web to flange welds and all splice welds. Structural building, web to flange welds usually only require fillet welds, as the joints are considered to be loaded in "Shear". As usual, the registered Professional Engineer of Record has the final say, depending on the State and his license requirements, as he is the legal "Responsible Person". Usually all web and flange splices and flange cover plate splices are full penetration welds. Structural column splices are often full penetration welds as well as some "Moment Connection Joint" welds are full penetration. Then there are SEISMIC rules, which vary widely even within a single structure! We usually do not use the term "Strength Weld". Weld definitions are made by the American Welding Society.
@540 MUDSTAIN Don't bother answering my questions. There is no need. I just hope and pray you aren't fabricating or inspecting high rises or bridges anywhere!
Seems like an awfully slow process with a great amount of machinery for an I beam.this is strictly for custom dimension beams as standard beams are rolled seamlessly,no welding,at great speeds,a hundred fifty feet a minute..
Doc Moore This is Submerged Arc Welding. It is quite common, and is a very common, economic and reliable welding process. The welds are generally of a very high quality, and it is usually required by law on bridges in the USA.
DUN dundundundundundundundundundundundundundun DUN dundundundundundundundundundundundundundun dundundun dundundun dundundun dundundun dundun DUN dundundun dundundun dundundun dundundun DUNDUNDUDUDUUUUUN dundundun dundundun dundundun dundundun DUN DUN (drumroll) *D U N*
Here’s a tip for future viewers .... don’t waste your time watching this. All you see is some very slow hydraulics that moves steel plates around! BORING!
So all the plates are dead straight ? Yeah right what's the heaviest (thickness) that the machine is capable of? We go up to 140mm thick on Foundation steelworks all set by hand. Didn't spot anything on your machine of trueing the plates up. Nice bit of kit though 👍
I think this is exactly and I beam. I think of an H beam as having a narrower web compared to the flanges than this one does. If you look at the cross section, doesn't it resemble an I more than an H to you? I'm pretty sure there is a technical standard or ratio for which gets called which, but this looks like an I beam to me.
@@josephkane825 What are you saying "NO" to? This video shows the production of a non-standard ratio fabricated section of girder with an "I" cross-section, not an "H" cross section. An I-beam is a form of girder, and as this is not rolled, and even though the flanges aren't tapered, it still qualifies as having an I cross-section. I concur with the title of the video given it by the patent holding German producer, and after reading Nishant Gupta's question in that light, I feel the answer is correct and makes sense. While the parts you add can be included, what are you saying "No" to?
@@CuriousEarthMan It was not the normal convention to specify a "built up" section as an I or H section. I beams, H beams, W beams and other rolled sections were specified this way on the drawings but built up sections were notated differently on drawings.
Slow and boring. I thought the process would be much faster. Can't imagine how long it would take to manufacture enough I- Beams to make a bridge and the expense must be astronomic.
