Hot-dip galvanization & steel structures
About us
Orion is founded in 1992 with main activity of TV networks integration. In 1994 company expands into the telecommunication with footprint in Romania and Moldovian Republic, where, over 2.500 GSM sites were implement for the mobile operators. Year 1992 represents a new milestone and we start the investment in our facility for steel structures, in order to cover requirements from the telecom sector. Since 2002, Orion is acting only as steel structures producer and also hot dip galvanization supplier.
Production area description Total surface Production facility Galvanization Plant Raw Material Warehouse Finished Products Warehouse Storage Warehouse
37.000 m² 6.000 m² 1.600 m² 14.000 m² 15.000 m² 1.200 m²
Products Machinery and Equipments Welding BWE XTS350, 500 + MIG500 6 + 7 pcs.
Telecommunication towers + all steel accessories Transmission lines towers
Cutting, Processing and Production CNC FICEP GEMINI 25 (cutting OXY+ plasma, drilling, boring) SOITAAB (plasma cutting) 2 pcs. FICEP P803 PEGAS (saw) 3 pcs. FICEP T200, FICEP T2, FICEP A164 & Vernet Behrniger (processing, punching and marking) Abkant ERMAK HAP4160 (bending) Pluto (deburring & edge rounding)
Overhead railway catenary system
Other Geka, Omera, Ficep (combined press) 7 pcs.
Alternative for custom design and projects according to technical specification
Fences Industrial Buildings Supports for Solar Panel + a wide range of structures according to beneficiary design
Production Capacity for Steel Structures Constructive solutions Lattice tubular structures All Welded Structures Europrofiles All Angles Structures
tons/ month 650 200 800 1.100
Hot-dip galvanization Hot-dip galvanization is a modern trend in the anticorrosion treatment of steel. It offers many advantages over other anticorrosion methods.°C Long lasting steel protection Not expensive Steady alloy coating Protective coating on all outer, inner, as well as hard-to-access surfaces, including edges. Possibility of paint application (duplex system) Reliability and resistance Resistance against mechanical damage Environmentally friendly
Galvanization vat dimensions L — 7.000 mm l — 1.500 mm h — 2.400 mm
Monthly production capacity
700 — 1.000 tons
The technology of hot-dip galvanization When immersing a component into zinc melt with a temperature of 450—460°C, not only does there develop a cover of the zinc on the steel, as in other surface treatments, but metallic phases of iron and zinc with high hardness and resistance against abrasion also form. The thickness of the coating created is usually 50—190 microns, depending on the chemical composition and type of material.
Technological Openings Parameters Minimum hole diameter in case of a specific number of holes
Dimensions of the hollow profile
1 15
15
Hot-dip galvanizing of hollow structures cannot be done without technological openings, because of the explosion hazard. It is imperative that the hollow spaces have sufficiently large inlet openings and vents. Their number and size also significantly affects the quality of the surface finish.
20 × 10
8
2
3
20
20
30 × 15
10
30
30
40 × 20
12
10
40
40
50 × 30
14
12
50
50
60 × 40
16
12
10
60
60
80 × 40
20
12
10
80
80
100 × 60
20
16
12
100
100
120 × 80
25
20
12
120
120
160 × 80
30
25
16
160
160
200 × 120
40
25
20
200
200
260 × 140
50
30
25
All dimensions expressed in mm
Individual components must also have holes for hanging. Mounting holes below 8 mm can be flooded after galvanizing. For larger holes it is necessary to add due to the thickness of the material. Threads need to be cleaned or protected from the zinc. You will be noticed about the insufficient quantity of or inappropriately placed openings when we take over the order. You can solve these issues yourself or the technological openings can be made by our staff. This service will be based on an hourly rate and credited to the contract price.
Hot-dip galvanization step-by-step
CAUSTIC CLEANING
RINSING
PICKLING
RINSING
FLUX SOLUTION
ZINC BATH
COOLING & INSPECTION
Technical recommendations The chemical composition, surface, weight, grade, thickness and roughness of the base material will affect the appearance, the deposit and the structure of the zinc coating. We do not recommend assembled structure components. Assembled structure components pose problems both for galvanizing and transportation. The galvanizing of flat structure components is of better quality and is more economical. Prevent deformation. Think about the possibility of the expansion of material and asymmetrical cross-sections. Beware of “dead� corners and angles. Ensure radiuses and holes in the bulkheads. For framed structures of open profiles pay attention to ventilation and drainage openings. Don’t forget about inlet and outlet openings. Because of the danger of an explosion it is necessary that hollow structures be provided with inlet and outlet openings. Their arrangement and size affect the quality of the hot-dip galvanizing. Allow hanging. We recommend placing the inlet and outlet openings in a vertical position to the hanging openings.
before galvanizing your steel Beware! • Improperly designed parts can collect flux residues and zinc ashes. • The diversity of the structure (sheet, section steel – different thicknesses) causes a different surface appearance when cooling down and eventually thermal deformation. Therefore, it is advisable to galvanize sheet materials separately. • Laser fired products must have chamfered edges and grinded burnt surfaces. This allows for a better grip of the zinc on the edges of the product. • Cold formed profiles can result in a reinforcement of zinc coating in stripes in the direction of the drawing. The anticorrosion qualities of the coating are not restricted in any way.
Not suitable for galvanizing • Colour on the structure • Extremely greasy material • Deep corrosion • Slag, gaps, pores and inflammation in welds • Inadequate structural design, for example, combining materials with very different thicknesses. • When welding it is not appropriate to use substances containing silicone – we recommend release agents for silicone-free welding processes. • Paint handlers are not ideal for hot-dip galvanizing – we recommend alcohol or water-based handlers.
• The galvanizing of steel parts which have a size approaching or exceeding the size of the zinc bath needs to be consulted in advance with the production manager. • Tell us also about the subsequent surface treatment of the material (e.g. painting, powder coating, duplex coating) or the need to preserve functional surfaces of the construction.
Material composition
We recommend galvanizing steel which contains silicon in the range of 0,12 % – 0,20 % and below 0,03 %.
The material composition is important for hot-dip galvanizing (in particular the content of silicon, phosphorus and sulphur). It may in fact cause some side efects which we cannot prevent – for example, a ash reaction be- tween iron and zinc, during which a thicker zinc layer or more alloy layers are created.
We do not recommend galvanizing steel which contains silicon in the range of 0,03 – 0,12 % of the mass (threat of the socalled Sandelin effect) and with a content of over 0,20 %. Also, a higher content of phosphorus added to the content of silicon can lead to a reinforced reaction of the iron with zinc.
EN 1090-1:2009+A1:2011
EN 1090-2:2008+A1:2011
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
DIN EN ISO 3834-2
FLEXIBLE COMPETITIVE RELIABLE
SC Orion SRL Viilor street, no. 96 Orion street, no. 5 Slobozia, IL 920081, ROU +0040.749.140.026 +0040.243.230.056 fax: +0040.243.230.835 office@orionslobozia.ro sales@orionslobozia.ro