Category: General

Dewatering Screens

Dewatering screens are steel structures designed to remove and dewater materials in industrial processes, particularly in mineral processing, quarries, and mines. These screens quickly drain water, allowing the materials to dry.

Applications:

• Mining Facilities: Used to dewater materials extracted from mines.
• Quarries: Dewatering of stone and rock materials.
• Sand and Gravel Plants: Used in washing and drying sand and gravel.
• Wastewater Treatment Plants: Dewatering of sludge and wastewater.
• Chemical Industry: Dewatering and drying of chemical products.

Types:

• Vibrating Dewatering Screens: Use high-frequency vibrations to separate water and dry materials.
• Static Dewatering Screens: Remove water through gravity and inclination without vibration.
• Curved Dewatering Screens: Feature specially inclined surfaces to quickly drain water.

Production Stages:

1. Design and Engineering: Design is tailored to requirements and engineering calculations are completed.
2. Material Selection: Durable and long-lasting steel materials are chosen.
3. Cutting and Shaping: Steel plates and profiles are cut and shaped using CNC machines.
4. Welding and Assembly: Cut and shaped parts are joined through welding.
5. Surface Treatment: Screens are treated to be resistant to corrosion (e.g., galvanizing or epoxy coating).
6. Assembly and Testing: Screens are assembled and undergo functional tests to ensure readiness for use.

Metal Materials Used:

• Carbon Steel: Commonly used in general-purpose dewatering screens.
• Stainless Steel: Selected for high corrosion resistance requirements.
• Alloy Steels: Used in applications requiring high wear resistance and strength.

Concrete Plant Bunkers

A bunker is a type of storage and transportation structure used for storing and regularly feeding large volumes of materials. In concrete plants, bunkers are typically used for the storage of cement, sand, aggregate, and other materials.

Applications in Concrete Plants:

• Material Storage: For storing essential materials for concrete mix, particularly cement, sand, and aggregate.
• Material Feeding: Provides regular and continuous feeding of materials to concrete mixing machines.
• Mix Balancing: Used to ensure balanced and accurate mixing of different materials.

Types and Uses of Bunkers:

• Sand and Aggregate Bunkers: Provide organized storage of sand and aggregate. Typically made from large and durable materials.
• Cement Bunkers: Specifically designed for storing fine powders like cement. Cement bunkers may have protective features against moisture and air.
• Mobile Bunkers: Designed for temporary or portable use, often preferred for short-term projects.

Metal Materials Used:

• Carbon Steel: Used for its general durability and cost-effectiveness.
• Stainless Steel: Preferred for its corrosion resistance when in contact with cement and other abrasive materials.
• Abrasion-Resistant Steels: Used in applications involving abrasive materials like aggregate and sand.

Cement silos are large, enclosed tanks used for the storage and protection of cement and other bulk materials. They are employed in construction, concrete production, and various industrial applications. Silos ensure that cement is protected from moisture and external elements.

Materials Used in Cement Silo Manufacturing

Cement silos are typically made from high-strength materials such as carbon steel or stainless steel to ensure durability and longevity. The interior surfaces of silos are usually coated with corrosion-resistant coatings to enhance their lifespan.

Manufacturing Process of Cement Silos

1. Design and Engineering: The manufacturing process begins with design and engineering work tailored to the customer’s requirements. This phase involves determining the silo’s capacity, dimensions, materials, and other technical specifications. Detailed technical drawings are created using CAD software.
2. Material Cutting: Steel plates are cut to the required dimensions using plasma cutting machines.
3. Bending and Shaping: The cut plates are bent into cylindrical or conical shapes to form the main body of the silo.
4. Welding: The bent plates are welded together using MIG/TIG welding methods. The quality and leak-tightness of the welds are carefully inspected.
5. Assembly: The silo’s base, top cover, and other components are assembled. The interior and exterior surfaces are protected with necessary coatings and paints.
6. Testing and Quality Control: The manufactured silos undergo various quality control tests, including pressure tests and leak tests, to ensure their integrity and performance.

Transportation of Cement Silos

Manufactured silos are usually disassembled into modular parts for transportation. These parts are transported to the construction site and assembled there. For large-capacity silos, special transportation methods and equipment are used.

Installation and Setup of Cement Silos

The installation process begins with site preparation. After preparing the foundation and placing the anchors, the silo parts are assembled using cranes. All connections and welds are checked, and the silo is made ready for use.

Maintenance and Repair of Cement Silos

Regular inspection and maintenance of cement silos are essential. Maintenance activities include renewing surface coatings, conducting leak tests, checking mechanical connections, and cleaning procedures. Damaged or worn parts are repaired or replaced as needed.

Advantages of Cement Silos

Cement silos offer several benefits:

• Safe Storage: Provides secure and long-term storage for cement.
• Protection: Shields cement from moisture and external factors, preserving product quality.
• Efficiency: Facilitates material management and logistics, improving operational efficiency.

Cement silos are crucial for ensuring the safe and efficient storage of cement, enhancing product quality, and streamlining material handling processes.

Steel construction formwork consists of temporary structural elements used in concrete casting to ensure that the concrete achieves a specific shape and structure. These formworks offer superior durability and reusability compared to other formwork materials.

Applications Steel construction formwork is used in a wide range of construction projects, including:

• Bridge and Viaduct Formworks: Used for casting large and heavy concrete elements.
• High-Rise Building Formworks: Preferred for casting columns, beams, and walls.
• Infrastructure Formworks: Employed in tunnels, metro systems, sewage systems, and similar projects.
• Industrial Formworks: Used in the construction of large-scale industrial buildings such as factories and warehouses.
• Dams and Water Formworks: Utilized for the casting of large-scale water infrastructure.

Types Steel construction formwork is categorized based on its purpose and the characteristics of the structural elements:

• Beam Formwork: Used for casting concrete beams.
• Column Formwork: Designed for the casting of concrete columns.
• Wall Formwork: Employed in the construction of concrete walls.
• Foundation Formwork: Used for pouring concrete foundations.
• Custom Formwork: Specially designed formwork for specific project requirements.

Production Stages The production stages for steel construction formwork generally include:

1. Design and Planning: Designing the formwork according to project requirements.
2. Material Selection: Choosing high-quality steel materials.
3. Cutting and Shaping: Cutting and shaping steel plates and profiles to the required dimensions.
4. Welding and Assembly: Welding the cut pieces together.
5. Surface Treatment: Cleaning and applying protective coatings to the formwork surfaces.
6. Inspection and Testing: Conducting quality control and durability testing of the produced formworks.

Metal Materials Used The following metal materials are commonly used in the production of steel construction formwork:

• High-Strength Steel: Steel types resistant to heavy loads and deformation.
• Galvanized Steel: Steel with enhanced corrosion resistance.
• Stainless Steel: High-corrosion-resistance steel for specialized applications.

Advantages Steel construction formwork offers several benefits:

• High Durability: Reusable and long-lasting.
• Easy Assembly and Disassembly: Modular design allows for quick assembly and disassembly.
• Precise and Smooth Shapes: Ensures the desired shape and surface quality of concrete.
• High Load Capacity: Suitable for casting heavy concrete elements safely.
• Time and Cost Savings: Provides efficiency, saving both time and costs.

Steel construction formwork plays a critical role in accelerating construction projects, enhancing quality, and ensuring safety. They can be customized to meet project requirements and are designed to withstand various climatic and environmental conditions.

Tunnel support steel is a specialized type of steel used in tunnel construction. This steel is employed to provide support during tunnel excavation, maintain the stability of the structure, and enhance safety. Tunnel support steel typically possesses high strength and durability, and it is used in various tunnel construction methods.

What is Tunnel Support Steel?

Tunnel support steel is a structural element used to prevent ground movement during tunnel excavation and to enhance the tunnel’s stability. The steel can be shaped and installed according to soil conditions and generally has a high load-bearing capacity. Tunnel support steel is used to support the ground surrounding the tunnel during construction and to ensure structural stability.

Applications

1. Tunnel Construction: Tunnel support steel is used to support, stabilize, and protect the ground in underground tunnels. It is especially preferred for metro, railway, and highway tunnels.
2. Mining: In underground mines, tunnel support steel is used to ensure the safety of mining galleries and to enhance ground support.
3. Infrastructure Projects: It is used in infrastructure projects such as water channels, pipelines, and other construction works to provide ground support and structural stability.

Types and Characteristics

• High-Strength Steel: Tunnel support steel includes special alloys with high strength and durability, providing resistance against ground movement.
• Rectangular or Round Profiles: Steel can be produced in various profiles (flat, round, rectangular) depending on the tunnel support needs.
• Protective Coating: Steel can be processed with various coating methods (galvanization, painting) to enhance corrosion resistance.

Installation and Application

• Formwork and Support Systems: Tunnel support steel is used as part of formwork systems and support structures. This ensures safe ground support during concrete pouring and other construction processes.
• Placement and Positioning: Steel is placed appropriately during different stages of tunnel excavation. This is crucial for maintaining ground stability and structural integrity.

Advantages

• High Durability: Tunnel support steel provides effective support against ground movement due to its high load-bearing capacity and durability.
• Safety: It enhances safety in tunnel construction by providing protection against potential collapses and slides.
• Rapid Installation: Steel elements allow for quick installation and ease of processing.

Selection Criteria and Applications

• Soil Conditions: Tunnel support steel is selected based on soil type and tunnel depth. For example, stronger support systems may be required in weak soils.
• Load Conditions: The loads the tunnel will be subjected to affect the choice of support steel. H or I profiles are preferred for situations requiring high load-bearing capacity.
• Tunnel Shape and Size: The shape (round, elliptical, etc.) and size of the tunnel determine the type and placement of support steel.

Stainless Steel Sheets in Industrial Manufacturing

Stainless steel sheets have a wide range of applications in industrial manufacturing. These sheets are preferred due to their advantages, including high strength, corrosion resistance, hygienic properties, and aesthetic appearance.

304 Stainless Steel

• Properties:
  • Corrosion Resistance: Exhibits excellent performance, especially in humid and acidic environments.
  • Strength: Provides high strength and durability.
  • Weldability: Features good weldability.
  • Thermal Resistance: Resistant to high temperatures.
• Surface Types:
  • 2B Surface: Matte, non-reflective surface. Cold-rolled and annealed, finished with a light roll. Used in general industrial applications.
  • No. 4 Surface: Finished with fine sanding, providing a shiny and aesthetic surface. Ideal for decorative purposes and applications requiring hygiene.

430 Stainless Steel

• Properties:
  • Corrosion Resistance: Moderate corrosion resistance, performing well in dry and slightly humid environments.
  • Strength: Offers high strength.
  • Magnetic Properties: 430 stainless steel has magnetic properties.
  • Economical: A more cost-effective option compared to 304.
• Surface Types:
  • No. 4 Surface: Finished with fine sanding, providing a shiny and aesthetic surface. Suitable for decorative purposes.

Processing Stainless Steel Products on Industrial Machines

Stainless steel products are processed using various methods on industrial machines. CNC cutting allows precise cutting of stainless steel sheets and profiles to desired dimensions. This ensures high accuracy in product manufacturing and perfect fit during assembly.

Bending processes shape stainless steel sheets and profiles into desired forms. This allows structural elements to be bent into specific angles and shapes to fit project requirements. Drilling and hole-punching operations create mounting and connection points in stainless steel materials, which is a critical step for assembling structural elements and completing projects.

Stainless Steel Storage Tanks

Stainless steel storage tanks are widely used in various industries. These tanks are preferred in fields such as food and beverage, chemical and petrochemical, pharmaceutical, and water treatment due to their high corrosion resistance and durability.

• Production Process: The production of storage tanks begins with the design and planning phase. The tank is designed according to its intended use, and production is planned. Stainless steel sheets are selected and cut to desired dimensions using CNC cutting machines. The cut sheets are bent into the tank’s shape using specialized bending machines. Stainless steel sheets and other parts are joined using MIG, TIG, or laser welding methods. All parts are assembled, and the tank undergoes a leak test and quality control.
• Applications: Stainless steel storage tanks are used in the food and beverage industry for storing milk, fruit juice, beer, wine, and other beverages. In the chemical and petrochemical industries, they safely store chemical substances. In the pharmaceutical industry, they are used for storing pharmaceutical raw materials and products under sterile conditions. Additionally, they are commonly used in treatment plants for storing clean water and

Drinking water treatment plants are facilities that make water from various sources drinkable and safe by using different purification methods. These facilities treat water from both natural sources (groundwater, lakes, rivers) and reservoirs through physical, chemical, and biological processes.

Stainless Steel Manufacturing Process for Treatment Plants

1. Material Selection
   • 304 Stainless Steel: Commonly used, corrosion-resistant, durable, and cost-effective.
   • 316 Stainless Steel: Provides higher corrosion resistance, ideal for harsh conditions such as chemical processes and seawater.

1. Design and Planning

1. • Engineering Design: Technical drawings of stainless steel equipment and structures are prepared. This stage determines the sizes, capacities, and uses of the equipment.
   • CAD/CAM Software: Computer-aided design and manufacturing software are used to create precise and accurate designs.

1. Cutting and Shaping

1. • CNC Cutting: Stainless steel plates are precisely cut with computer-controlled machines. This method ensures high accuracy and repeatability.
   • Bending: Cut stainless steel plates are shaped into the desired form using specialized bending machines. This process shapes tanks and pipes.

1. Welding and Assembly

1. • MIG/TIG Welding: Stainless steel parts are joined using high-quality and durable welding methods. MIG (Metal Inert Gas) and TIG (Tungsten Inert Gas) welding methods are commonly used.
   • Welding Inspection: The quality and durability of weld seams are checked with various tests during and after welding.

1. Surface Treatments

1. • Cleaning and Polishing: Stainless steel surfaces are made more resistant to corrosion and given an aesthetic finish.
   • Passivation: Chemical treatments make stainless steel surfaces more resistant to rust.

1. Assembly and Installation

1. • Field Assembly: Stainless steel equipment prepared in the manufacturing facility is assembled at the treatment plant.
   • Connections and Testing: All pipelines, tanks, and other equipment are connected, and leak tests are conducted.

1. Quality Control and Certification

1. • Testing and Inspection: Produced stainless steel equipment undergoes quality control tests, including pressure tests, leak tests, and structural durability tests.
   • Certification: Equipment compliance with international standards is certified by independent organizations.

Applications of Stainless Steel Manufacturing in Treatment Plants

• Storage Tanks: Used for storing chemicals, clean water, and wastewater.
• Pipelines: Durable and leak-proof pipelines are created for transporting water and chemicals.
• Filter Systems: The bodies and frames of filter systems used in the water treatment process are made from stainless steel.
• Reactors and Mixers: Reactors and mixers used in chemical processes and biological treatment processes are made from stainless steel.
• Pump and Valve Systems: Stainless steel pumps and valves are preferred for their durability and corrosion resistance.

Production and Use Process of Stainless Steel Storage Tanks

Production Process:

1. Design: The size and capacity of the storage tank are determined. Technical drawings and engineering calculations are performed.
2. Cutting and Bending: Stainless steel plates are cut and bent to form the cylindrical or rectangular shape of the tank.
3. Welding: Plates are joined, and sealing is achieved through welding. Internal and external weld seams must be smooth and durable.
4. Surface Treatment: The tank’s interior and exterior surfaces are cleaned, polished, and passivated.
5. Testing and Inspection: The produced tank is subjected to pressure and leak tests. Interior coatings and insulation are applied if necessary.

Wear plates are high-strength steel plates used in challenging working conditions that require high wear and impact resistance. These plates offer significantly higher hardness and wear resistance compared to standard black sheets, extending the lifespan of equipment and reducing maintenance costs.

What Are Wear Plates and What Are They Used For? Wear plates are commonly used in various industrial applications such as mining, construction, agriculture, waste and recycling, energy, heavy haulage, and steel production. For instance, they are frequently chosen for use in crushers, excavator buckets, truck bodies, conveyor belts, concrete mixers, asphalt pavers, harvesters, shredders, and coal processing equipment.

What Are the Types of Wear Plates? The main types of wear plates include Hardox, Miilux, and XAR. These plates are measured on the Brinell Hardness (HB) scale and generally have hardness levels ranging from 400 HB to 600 HB. Their thickness varies from 0.7 mm to 160 mm.

What Do Hardox Materials Represent and What Applications Are They Used For? Hardox steels are a special type of steel known for their high wear and impact resistance. The combination of hardness and thickness determines the steel’s strength and durability. For example, Hardox 400 is suitable for general wear and impact resistance applications, Hardox 450 is used in applications requiring high wear resistance and durability, while Hardox 500 and above are preferred for the most demanding conditions that require extremely high wear resistance.

Which Machines Process Hardox Materials? Hardox steels are processed in various industrial machines such as CNC cutting machines, plasma cutting machines, laser cutting machines, press brakes, and hydraulic bending machines. These machines ensure the processing of Hardox steels in applications that require high precision and durability.

How Should Welding Processes Be Performed? Welding processes for Hardox steels require special attention. Preheating thick and hard materials, using appropriate welding electrodes and filler metals, controlling heat input, and performing slow cooling after welding are crucial to prevent cracking. Additionally, ensuring that the surfaces to be welded are clean and free of oil enhances welding quality.

What Are the Advantages of Wear Plates? Wear plates play a significant role in industrial applications by providing high performance and long life under harsh working conditions. Choosing the correct combination of hardness and thickness depends on specific application requirements. Proper welding practices maximize the performance and lifespan of the materials.

Advantages and Disadvantages of Hardox Steels Compared to Other Wear Steels

Advantages:

1. High Durability: Hardox steels are highly resistant to wear, making them long-lasting and reliable.
2. Various Hardness Grades: Hardox steels are available in different hardness levels, making them suitable for various applications.
3. Good Machinability: Despite their hardness, Hardox steels are suitable for cutting, welding, and bending processes.
4. Wide Application Range: Used in construction, mining, agricultural machinery, heavy industry, and recycling.

Disadvantages:

1. High Cost: The production cost of Hardox steels is higher compared to other wear steels.
2. Special Processing Requirements: Working with Hardox steels requires specialized equipment and expertise, which can increase processing costs.

In conclusion, wear plates offer effective solutions in various industrial applications requiring high wear resistance and durability. Selecting the appropriate combination of hardness and thickness among brands like Hardox, Miilux, and XAR depends on specific application requirements. Careful and accurate welding practices maximize the performance and lifespan of these materials. These plates provide effective solutions for industrial applications demanding high wear resistance and durability.

A sediment trap is a structure built to control sediment transport in rivers and regulate water flow. These structures slow down the water speed, allowing sediment to accumulate and thereby helping stabilize riverbeds.

Manufacturing Features

1. Material Use:
   • Steel: Steel construction provides high strength and durability. Corrosion-resistant coatings extend the lifespan of steel structures.
   • Concrete: Concrete can be used in conjunction with steel. Concrete enhances the robustness of the steel structure and provides resistance to water pressure.
   • Geosynthetic Materials: Geosynthetic materials can also be used for erosion control.

1. Design and Construction:

1. • Engineering Design: Hydraulic and structural engineering calculations determine the water flow rate, volume, and sediment carrying capacity.
   • Modular Structures: Steel construction can be designed as modular structures, making assembly and disassembly easier.
   • Foundation Work: Ground improvement and reinforcement work are carried out to create a solid foundation.

1. Installation:

1. • Site Preparation: Necessary adjustments are made in the riverbed, and the structure’s foundations are excavated.
   • Steel Assembly: Steel parts are assembled according to the predetermined design, using welding and bolted connections.
   • Concrete Pouring: Concrete is poured in necessary areas to increase the durability of the steel construction.

Application Areas and Advantages

• Erosion Control: Sediment traps are used to prevent erosion along riverbanks.
• Sediment Management: They control sediment accumulation and maintain the depth of riverbeds.
• Flood Prevention: By regulating water flow, they reduce the risk of flooding.
• Protection of Wildlife: They protect river ecosystems and improve water quality.

Other Names and Known Applications

• Flood Dike: A term used for structures with similar purposes and structural features.
• Flood Rake: The name given to smaller-scale sediment traps, especially used in stream beds.

Example Applications

• River and Stream Rehabilitation: Sediment traps are used for erosion control and sediment management.
• Water Management in Urban Areas: Used in urban streams to reduce flood risks.
• Protection of Agricultural Lands: Sediment traps are built to protect agricultural lands from flooding.

Conclusion
Tekmetsan has added a new one to its works with the Sediment Traps application completed in Kastamonu, Turkey. Sediment Traps are essential structures for water management and environmental protection, and steel constructions enhance their durability and longevity. When proper design and manufacturing techniques are employed, these structures effectively provide erosion control, sediment management, and flood prevention. Although these structures may have various names, they all serve similar functions and contribute significantly to water management and environmental protection.