MANUFACTURING PROCESS OF STEEL BASE PLATE FOR ZERO TOE LOAD FASTENING SYSTEM

MANUFACTURING
PROCESS OF STEEL BASE PLATE FOR ZERO TOE LOAD FASTENING SYSTEM

 

·        
Raw Material

After
receiving raw material, i.e. rolled plates, inspection and testing to be done
according to ‘IRS specification for steel base plates (provisional) 2019’.
Results of testing shall be documented in a suitable format and shall be verify
with the raw material manufacturer’s test reports.

·        
Shearing of Rolled Plates

Accepted
rolled plates are to be cut by shearing to length as per drawing. Dimensions to
be checked and to be documented in a suitable format.

 

·        
Machining

After
shearing, machining of 1: 20 cant of blank of steel base plate to be done
according to the drawing.Dimensions to be checked and to be documented in a
suitable format.

 

·        
Forming of Shoulders

Forming of
shoulders to be done by hot pressing and edge machining to be done according to
the RDSO drawing.Dimensions to be checked and to be documented in a suitable
format.

 

·        
Welding of Shoulders with Steel Base Plate

Welding of
shoulders with Steel Base Plate shall be done according to following Work
Instruction.

 

a.     
WORK INSTRUCTION FOR WELDING SHOULDER TO
STEEL BASE PLATE

 

1.      
Process used is Metal Inert – Gas Arc Welding (Gas Metal – Arc
Welding) with 100% Carbon-di-

oxide gas as
shielding gas.

2.      
Welding wire specification is to AWS A5.18, ER 70S6 equivalent
to DIN – 8559:SG2/BS 2901 Type A18/IS 6419.

3.      
Details of Specification, date of expiry, make of wire shall be
checked before opening the reel.

4.      
The wire must not be rusted. If the reel has been previously used,
the storage should be in polythene cover with specification, date of expiry,
make and type recorded.

5.      
 The shoulder is to be
checked for edge preparation.

6.      
The surface to be welded shall be cleaned so as to be free from
rust, oil, dirt, moisture etc.

7.      
Welding shall be done by firm’s approved welders as per IS
7310 (Part 1) & IS 7307 (Part 1).

8.      
The shoulders are to be placed on the base plate by using suitable
fixtures before welding.

 

Inspection procedure for welding of shoulders
with steel base plate shall be done as per following Inspection Procedure.

 

b.     
INSPECTION PROCEDURE FOR WELDING OF SHOULDER
WITH BASE PLATE

1.     
PRELIMINARY STAGE INSPECTION

i)                  
All materials used should be to job specification.

ii)                
All materials to be used should be examined for surface, defects,
rust, corrosion products, presence of contaminants, laminations etc.

iii)              
The welding wire/electrode shall confirm as given in welding
procedure manufacturer`s label.

iv)              
Qualification test certificate of the welder is to be verified.

v)                
The welding wire/electrode shall be stored and handled with care
and in accordance with manufacturer’s recommendation. Wire/electrode that show
signs of deterioration, damaged etc. shall not be used.

 

vi)              
The welding wire/electrode shall be stored in original packets or
cartons in a dry place adequately protected from the effects of the weather.