How to produce a climbing wall steel frame structure?
The steel support frame is the most important and complex step in the entire production process of a climbing wall. It is also the largest part of the budget. Current production costs in our factory range from approximately USD $6500 to USD $7500 per ton. This varies depending on the complexity of the welding job. More and more climbing walls are now designed with bolted connections instead of too many welded parts. This design, on the one hand, is a great saving in production costs, on the other hand, makes the subsequent installation, maintenance and other work more flexible, saving time and effort.
The first step is to carefully review the drawings.
Usually, the customer’s drawing package contains the following five parts.
- Material list.
The material list contains the type of each steel required for the project, and commonly used models such as RHS50X3, RHS120X60X3, RSA60X30X5, FL60X6, and so on.
- SP Drawings.
SP refers to Single parts, the factory is based on these drawings to cut and drill the raw materials.
MP refers to Manufacturing production, this set of drawings is the core of the welding work. The welding process revolves around this set of drawings. This set of drawings usually includes the following parts:
1. The attached list means single parts.
- DWGs, or other formats of 3-D drawings. These drawings are required for welding and post-welding quality control processes.
- PDF format drawings. 4.
- Shipping List. This list is very important for the inventory of the goods before shipment. It can prevent missing parts. Each welded assembly should be marked accordingly so that the customer can sort and install them in the climbing gym.
Four: Brackets, hinges. this part of the drawing includes support braces, folded angle, and hinges. we see that nowadays, most of the Boulder wall, and top lead wall will use these products.
overall assembly drawing. Our production team will carefully review these drawings before production and before shipping. In order to have a more comprehensive and accurate understanding of the steel structure of the wall.
Climbing wall steel structure welding is a relatively complex job, which requires the welders to receive and execute the drawing information accurately.
Drawings are the basis and core of all work. Therefore, before undertaking any project, our engineers and production team will carefully review each drawing and communicate with the customer in the first instance if there is any uncertainty. Make sure there is no doubt before starting the follow-up work.
Step 2: CNC laser cutting, holes drilling based single parts drawings.
Based on Single Parts’ drawings, we use CNC laser cutting machines to cut the raw materials. Use the drilling machine to drill holes, etc. Pay attention to the sorting and placement of each part. The quality control department conducts random dimensional checks on each type of part on a two-day basis. QC PASS labels are attached to qualified products. Any error is promptly traced back to all products in the batch.
Step 3: Initial spot welding of assemblies according to Assemblies parts drawing.
Match personnel according to the welding quantity of the project. Take a project with an overall 20 tons including 5 walls as an example. The production cycle is 40-45 working days. We usually arrange 2-3 professional welders to perform the welding work. This step is the most important step of all because this step is the most likely to have quality problems with wrong welding positions and missed welds. The welders who work on this step are the most professional welders in our factory. On the one hand, they have a strong ability to review the drawings, and on the other hand, they have a standard level of welding technology. They have rich experience in welding steel structure products. The idea of our welders in the welding process is to be careful, careful, and careful again. Control the daily welding quantity. After spot welding, that is, QC staff will carry out a re-inspection within the next day. After passing the re-inspection, fill in the QC pass label. Only then can we proceed to the next step of overall welding. If problems are encountered, the problem areas are marked and the welding staff will analyze the problems and change them at the same time.
Step 4: Overall welding.
It should be noted that this step can be done by the same welding personnel, or by another professional welder. Integral welding is done on the basis of electric welding. Pay attention to the quality and quality of the weld seam when welding. When welding, pay attention to the continuity of the weld seam and do not have leakage and over-welding.
Step 5: Quality inspection of the overall welding.
The overall welding quality inspection principle is one-by-one quality inspection, one by one, without missing. Needed by and spot welding quality inspection personnel different personnel for quality inspection. The basic quality requirements for quality inspection personnel are professional drawing review ability.
Step 6: Polishing.
This step is to remove the floating rust on the surface, and also to remove the burr parts.
Step 7: spray paint.
The spraying is epoxy resin paint with good anti-corrosion properties.
Step 8: Shipment
Because these steel structures are of unequal length and irregular shape.
For 20-ton structures, 2X20’GP is usually used.