Project: Mobile Crusher with discharge belt conveyor and slewable boom conveyor
Location: Texas – Hondo
Project Status: Finished
Inspected By: QCTurk
QCTurk’s Role: Manufacturing Supervision and Expediting
Project Weight: 525 Tons
Purpose: Control of the welded manufacturing of the mechanical parts of the 2300-ton semi-mobile crusher to be used in the iron mine in Canada was carried out. Despite the difficult conditions brought by the region due to the production to be made in Canada, we are happy to have successfully completed our project.
The manufacturing process, carried out in 2 separate factories, was controlled from beginning to end by QCTurk inspectors. If we talk briefly about the manufacturing parts, the mobile crusher is made in two units and named as CR and SCR. In both groups, there are carrier legs (pontoons), platforms, conveyor belts and chutes and several connection parts like bracings.
Since the production will be used in Canada, all materials have been designed with materials that will meet the desired conditions at -20 ᵒC, taking into account the weather conditions there, and orders have been requested as J2 or NL accordingly. As QCTurk, all incoming materials were followed up in this process, their certificates were meticulously examined, and the necessary information flow was provided by warning the companies in advance against a possible delay.
The biggest problem that could occur in materials was that almost all profiles were made of build-up sections and the wall thickness of these profiles was around 40mm-50mm. All of these structural steels used in the platform were required to be welded with full penetration according to the technical drawings and full penetration welding of the head plates in the same way. All welds were also requested to be evaluated by ultrasonic testing. In this section, after all welds have been checked and approved by QCTurk, the measures that can be taken against weld shrinkage have been determined. The ultrasonic tests were witnessed by 3rd party surveillance and the companies were warned about pre-assembly as much as possible.
Since the back-gouging process required to ensure full penetration during welding cannot be performed on every piece due to the geometry of the piece, a test piece (mock-up part) was fabricated first and the welding gaps were left 2-3mm, the desired penetration was achieved without back-sgouging with MAG welding, and the welding process of such pieces continued under these conditions.
After all the manufactured parts were checked for dimensions one by one, deformations that may occur during welding were checked with a template within the tolerances given in the drawing, and welding visual controls were made, the approval for coating was given.
Since the surface quality was requested as Sa2½ according to the given specification, all areas were checked in detail after sandblasting and approval was given for the paint. The desired paint application as primer-intermediate and topcoat was checked at each stage by measuring the paint thickness and visually.
The parts, all of which are controlled in detail, have been checked by QCTurk during packaging and transportation, and finally, they have been supervised during the loading on the truck and approved by us for shipment.
You can follow our website or social media accounts to be informed about our other projects that have been successfully completed.
Purpose; Manufacturing inspections of the space roof cage part of the fertilization system, which allows the fertilizer to be transported with the help of the rail on the belt conveyor in the space cage, to be poured into the silo and stored, were carried out by us.
The dimensions of the building are 382×68 meters and the storage area is 26,000 square meters. The vaulted roof has a static working span of 61 meters.
The building with a total roof length of 382 meters also has a conveyor belt attached to the roof.
The building is designed in 3 phases and the roof is divided into sections as 1,2 and 3.
Manufacturing controls of 9189 purlins and 3255 purlin elements with a total weight of approximately 464 tons, 28369 pipes with a total weight of approximately 600 tons and 7437 nodes, as well as the above-mentioned conveyor belt steel manufacturing controls with an approximate weight of 210 tons were carried out by us.
All WPS’s and welder certificates of the factory were examined before the welding operations started, and the welding parameters were observed at intervals throughout the entire work.
Without unloading the incoming materials from the truck, measurements and visual controls were made and the certificates were checked as an incoming material inspection.
In accordance with the given specification, visual and dimensional checks were made, together with the cones welded at the ends, to connect all pipe elements to the support, in addition to this, since all pipes are electrostatic paint over galvanized coating, visual and thickness controls were made separately.
Welding, measurement and paint checks of purlins and purlin elements were made.
Spheres (nodes) and supports made on the CNC machining machine were measured and approved with a caliper, since pre-assembly could not be made with pipes. Since epoxy paint is required on electrogalvanized spheres and supports, paint thickness measurements were made separately in both stages.
Since the bucket on 210 tons of steel fabrication will walk on the rail, ±2mm tolerance was given in drawing for welded rail, pre-assembly has been made and all welding processes have been checked with gauges. All steel parts were sandblasted and electrostatic paint was applied and visual, dimensional and paint thickness measurements were taken.
In order to prevent deformation of all packages during transportation, it was planned to pack the two steel parts in such a way that they would not come into contact with each other, and they were made and controlled accordingly.
Visual, dimensional and paint related reports of all productions are made separately and put in the quality file. The certificates of all manufactured materials are also included in the quality file.
All these inspection stages have been completely under our control, and all inspections carried out by us have been recorded in the required format with reports, photographs and videos. In addition to the technical quality controls carried out in this project, we informed the customer by regularly reporting the weekly/daily process monitoring (expediting) in an appropriate format.
We have successfully completed the ‘Space Roof’ project, with complete audits and reports carried out by experienced and trained team members of QCTurk, who are professionals in the sector in Turkey. You can follow our website and social media accounts to be informed about our other successful projects.
Trust our know-how and experience.
Contact us for receiving third party inspection service: info@qcturk.com
