Kalup co

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With the development of Kalup factories in 2009 in industrial city of Sagzi located in Esfahan and after 5-6 years of research that led to installation of HSS production line, now this company is capable of stepping into construction industry and improving the construction quality in the country and also promoting the construction industry toward industrialization
Steel Structures Production Process
Coil Processing :
The roll of sheet is flattened by the use of rollers placed in the production line in different distances.

Rolling the edge of sheet
This machine is able to roll the edge of sheets and prepare them for optimal welding conditions based on DIN, ASTM etc. standards.

Forming
This part of production line is responsible for converting different flattened sheets into pipes and it includes:

Preparation before forming:
The flattened rolls of sheets are slightly bent by the rollers and they are prepared for the final formation.

Forming
At this section, the bent roll of sheet is formed by different rollers and it takes the form of pipes.

Sizing
Based on the production size the rollers in this section take the responsibility of sizing sheets that are converted into pipes and the final form of pipes are developed.

Welding the Edges:
With capacity of 500KW this machine is able to weld the prepared edges of sheet together in two CONTACT and INDUCTION modes.

ON-LINE Ultrasonic testing machine:ON-LINE
This machine is able to detect the possible flaws in seam welding area and HAZ immediately after welding; thus it is able to immediately remove the defective pipe out of the production line.

Forming & Sizing:
Forming and sizing the section from pipe into profiles happens in this part by the use of different rollers.

Profile Identification system:
In order to reach the aims of Kalup Co. for producing profiles with the highest quality, a computer system called PIS (profile identification system) is installed in Kalup factories in order to increase the ability of tracing the profiles and having access to their exact production history. In this system the information related to each profile in each production station is registered and the summary and highlights are transferred to the server through an Ethernet network. This machine can specify the information related to each profile even to the specifications of the primary steel coil and its melting number. By the use of this system the customer is able to achieve a summary of production and testing stages of each profile when required and thus the customer could be ensured about the accuracy of production and testing stages.

Cutting & Output Line
At the end the produced profile is cut based on the required length up to 12 meters and it is transferred to the storage for loading.

Laboratory:
An industrial laboratory is equipped with the latest technology and equipment purchased from the leading manufacturers such as Zwick and Clemex in order to conduct several tests on the samples extracted from the profiles based on DIN and ASTM standards. The followings are a few samples of tests conducted in this laboratory:
Mechanical Testing:

Tensile testing
Flexural testing
Impact testing (Izod & Charpy)
Flattening testing
Hardness testing (Macro & Micro)

Control after production :
Based on the aims determined for quality control section which is providing the highest quality, each profile that has not managed to successfully pass the previous quality control stages must be separated from other profiles. Profiles that successfully pass all quality control stages go under the following tests:
1. Initial inspection
2. Flattening testing
3. Central inspection
4. Hydrostatic testing
5. Ultrasonic testing of seam welding of HAZ area and also both ends of profiles
6. Final inspection
During these stages all requirements of DIN and ASTM standards and also every extra need of the customers are considered and in case of least contradiction with the specifications of standards they are immediately removed from the production line and the inspection stages increase.
Customer Inspection
In customer inspection section an appropriate space is provided for customer inspection after all machines and before the loading zone. This space let the customer to control each pipe based on the contract specifications. .

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