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Fab Flange

Structures from pre-eng steel buildings pre-eng metal buildings to large skyscrapers require someone to cut, drill, bend and join structural beams, columns, plate and angle. All of this work is done at a structural steel fab shop, because the work is done on a contract-by-contract basis for many different builders.

A structural steel fabrication firm must do the equivalent tasks as a carpenter - sawing and drilling. But the workpiece to be sawed or drilled could weigh close to a ton or more. The workpieces - I beams, H beams, heavy plate, channel, angles, HSS - are transported through the shop using cranes and conveyors. They are moved between different workstations where a number of "shaping" tasks are accomplished - sawing and drilling, grinding (the equivalent of "sanding" structural steel), in addition to "beam coping" for which there isn't an equivalent task in the woodworking world.

Drilling is carried out by a beam drill linebeam drill line. Here, a large strauctural beam or channel is moved into place to line it up with a drilling head. The drill head moves in an up-and-down plane to drill bolt holes into the flange of the I beam or in a side-to-side plane to drill into the web of the beam. The carbide drill bits spin at thousands of rpms to drill holes extremely quickly, but these kinds of high speeds often need coolling fluids to be sprayed on the work area.

A beam coping machine might not be a machine at all. It may be a hand-held cutting torch. The operator follows a design drawn on the workpiece. The actual cut referred to as a cope is a notched out section of an end of a structural steel beam that prevents interference with another structural section when the workpiece is installed in place at the job site. Since coping is so prevalent, the manual coping torch has been automated, moving the workpiece into a panel-walled box and affixing the cutting torch to the arm of an industrial robot.

This concept of the robotic coping torch has been extended to the other structural steel fabrication jobs, producing a line of versatile all-in-one structural fabrication models. These machines do not use any friction metal cutting technologies at all - just the thermal cutting torch. The new all-in-one plasma fabricating machines guide the I beam into an area where the plasma torch-wielding robot arm can produce a complete cross cut and can cut bolt holes in the flange or web. This reproduces the capabilities of the bandsaw and the beam drill line. The plasma cutting machine can then cut notches, slots, circles or any other feature, carrying out the functions of a structural plate workstation.

And, of course, the plasma machine can make all manner of cope cuts.

These versatile plasma cutting systems are an exciting new capability for the structural steel fabricator. But they are getting increasingly popular, as they can replicate the functions of the machine discussed above (plus a couple more highly specialized machines) with one single piece of equipment that achieves all needed structural steel fabrication operations.

Learn more about the new class of plasma cutting structural steel fabrication machines. Visit the PythonX web site and explore.

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