Galvanized Floor Grating Production Process and Tips

Production Process of Galvanized Floor Grating

Raw Material Preparation

Prepare flat steel according to customer requirements. Commonly used flat steel has heights of 25mm, 30mm, and 40mm, with thicknesses of 3mm, 4mm, and 5mm. The round steel is usually 6x6mm in size.

Welding of Galvanized Floor Grating

The welding of galvanized floor grating is done through mechanical pressure welding. High-pressure resistance welding machines are used, where a mechanical arm automatically places crossbars on evenly arranged flat steel. The crossbars are then welded into the flat steel using powerful welding power and hydraulic pressure, resulting in a firmly welded galvanized floor grating with high stability and strength. However, customized irregular galvanized floor grating generates more waste and is more expensive. Manual welding involves punching holes in the flat steel and then welding the crossbars into the holes. It is a cost-effective option and can be customized for smaller quantities.

Cutting

After the welding process, the whole piece of galvanized floor grating needs to be mechanically cut according to the dimensions specified in the grating drawing. During cutting, strict control of dimensional errors is maintained. After cutting, professional quality inspectors perform random checks on the cut galvanized floor grating. If any are found to be non-compliant, they are re-cut.

Welding of End Plates (Edge Banding Plates)

End plates are welded using the same flat steel material as the galvanized floor grating. The welding process involves removing oil and stains from the surface of the galvanized floor grating before welding. The welding seam is a single-side fillet weld. Each flat steel in the galvanized floor grating needs to be welded to an end plate. After welding, the surface is cleaned of slag and smoothed by grinding.

Galvanization

Galvanization is an essential step for galvanized floor grating. Before galvanization, the surface should be treated to remove rust, oil residues, and other contaminants through sandblasting or shot blasting. The average zinc layer weight after galvanization should not be less than 460 grams per square meter, and the quality should comply with the GB/T13912 standard.

Packaging and Transportation

After completing the above processes, the production of galvanized floor grating is essentially finished. The next step involves contacting the construction site manager and obtaining a list of materials. Based on the specifications, quantities, and delivery dates specified in the material list, the galvanized floor grating is packaged, loaded onto trucks, and transported. Typically, the grating is packaged in bundles, with each bundle containing 25 pieces of grating. The weight of each bundle is approximately 2 tons. Forklifts are used for loading the bundled grating.

How to Reduce Zinc Material Waste in the Production Process of Galvanized Floor Grating?

To reduce zinc material waste, it is crucial to control the generation of zinc dross. The following methods can effectively minimize zinc dross production and consequently reduce waste, enabling businesses to maximize profits:

Build a 5mm zinc-resistant layer in the zinc pot’s (iron) walls. This layer effectively prevents or reduces zinc dross formation. Generally, aluminum liquid corrosion welding rods are used for welding.

Use zinc pots made of materials with strong resistance to zinc corrosion. The production of zinc dross results from chemical reactions with materials such as iron. Materials with high resistance to zinc corrosion effectively prevent this situation. This technology has been adopted and utilized by dozens of galvanized floor grating manufacturers in China.

The temperature of the zinc liquid has specific requirements. Fluctuations in temperature can destabilize the zinc liquid, leading to physical reactions and the formation of zinc dross. Therefore, the temperature of the zinc liquid should be maintained between 435-445 degrees Celsius. Additionally, the zinc pot should have a large zinc melting capacity, and attention should be paid to the size of the pot opening. Furthermore, the zinc furnace should be equipped with a well-performing automatic temperature control device to maintain stable zinc liquid temperature and prevent temperature fluctuations.

Avoid adding any impurities, such as iron wire, aluminum, nickel, or rare earth powder, to the zinc liquid during the heating process. Adding these materials hampers the integration of the zinc liquid and can lead to chemical reactions. For example, high aluminum content accelerates the corrosion of the iron pot by the zinc liquid, particularly near the inner wall of the pot. This phenomenon increases the production of zinc dross, resulting in higher zinc material loss. Therefore, it is strictly prohibited to introduce any impurities during the galvanization process to effectively control zinc dross production.

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