5. MANUFACTURING AND PURCHASING
Once the design has been defined, the drawings are sent to the supplier for the manufacturing. To reduce construction times, we have abandoned the welded construction, which requires a lot of skilled labour, in favour of the bolted construction whose components are produced by automatic machines to which it is enough to send a file “step” format to produce the piece of the drawing. Also, for the Panama plant, two thousand and five hundred tons of hot galvanized carpentry were produced in forty days. At the same time orders are issued for commercial parts: belts, bearings, bolts etc.
6. PACKAGING AND SHIPPING
The shipment of the plant usually takes place by container for overseas countries or loaded on trucks by land. All the components are marked and we prepare a layout of the stands where to store the loads and, thanks to a computerized identification system, the search for the pieces necessary for assembly is practically immediate. The sending of bolted carpentry allows considerable savings on transport as it is possible to exploit the full capacity of the vehicle. In Panama, the cost of transport was half that of the competition.
7. PREASSEMBLY ON SITE
The carpentry must be pre-assembled to have the pylons, the columns, the bases of the machines and the conveyors lattices. With some well-educated teams and some organization, assembly times are comparable with welded structures. Above all, there are no mounting problems due to the deformation caused by the welds and the torch is not needed to proceed with the assembly. The 3D design is so strict that, once the drawing is done, no preassembly is needed and the parts will fit without any need of adjustment.
8. ERECTION ON SITE
After the pre-assembly the structures are transported and installed on the previously prepared concrete foundation. As the erection progresses, the power and control electrical system is installed, followed, if present, by a plant for washing the aggregates and the treatment of water and sludge.
9. COMMISSIONING AND HAND OVER
Once assembled, the machines are adjusted and tuned, the conveyor belts are tensioned before moving on to the blank tests. Then the plant is gradually loaded until the contractual productions are reached. During the test we intervene to fix any problems: direction of the flow of the material to be corrected, chutes that overflow, etc.