Process

To start and finish each new project in the group of Dena Sanat factories, a process is followed, the most important activities of which are as follows:

Feasibility

۱- Checking the plans sent by the employer
۲- Concluding a contract
۳- Meeting with the consultant, supervisor and employer to review the plans and provide suggestions for improving the quantitative and qualitative process of production with the best quality
۴- Presenting the schedule and obtaining the approval of the employer

Preparation and production

۵- Import of materials - quality testing and sheet depot
۶- Preparing shop drawing plans by the latest software in the world and obtaining the approval of the employer and consultant
۷- Cutting
۸- Belt making

Installation and presentation

۹- Radial work
۱۰- Assembly of columns and beams and installation of hardeners
۱۱- Installation of accessories
۱۲- Delivery of work to the monitoring device

Collect approvals

۱۳- Preparation, painting and obtaining approval from the factory QC unit and supervision for product exit
۱۴- Install barcode
۱۵- Product exit according to the request of the installation site
۱۶- Preparing the technical booklet of the structure

Import of materials - quality testing and sheet depot

With the arrival of the required material and compliance of its specifications with the standards set by the laboratory, the construction and production operations begin in the group of Dena Sanat factories.
The group of Dena Sanat factories is equipped with an advanced coding system and tracking of parts using labeling operations. For each piece, labels are prepared according to the progressive processes, and after passing the piece through each step, its code is recorded in the system by a barcode reader. This system can provide users with information such as the number of parts in the production line, the volume of parts made, painted, ready to ship, as well as the details of the parts shipped to the project site, separately for each project.

Preparation of workshop plans

Technical office engineers translate structural designer drawings into the language of construction and execution. Considering the consumption of materials and conditions of construction and installation of the skeleton, an optimal workshop executive plan is drawn for each product. After preparing shop drawings, preparation of welding instructions (wps), approval of welding instructions (PQR) according to Iranian welding regulations (publication 228) and international standard AWS D.1.1 and obtaining approval from the employer and manufacturing operations consultant begins.

Cutting

First, the cutting plan of the sheets is prepared by experienced engineers using the latest software in the world and the sheets are sent to the cutting department. Sheet cutting is done in two ways, hot and cold. One of the machines used for hot cutting is CNC, which has the ability of straightening and modeling for all sheets with different thicknesses. The high technology of automatic cutting machines used in the group of Dena Sanatfactories, causes maximum accuracy in cutting parts and also makes it possible to cut parts with special shapes that are designed and drawn in the software environment.
The hot cutting machines are fed from the oxygen and city gas tank, which are run by pipelines along the production halls and connected to the tank. Sheets with a thickness of 6 to 12 mm are cut by 3 and 6 meter guillotine machines.
After cutting, in parts that need to be edged according to WPS using edging machines (BEVELING) and rail cutting machine, edging will be done cold or hot. The cut sheets are completely flattened by a rolling machine and then sent to the assembly section.

Belt construction

To assemble a column or beam, the sheets are first belted according to the workshop drawings according to the GMAW welding process, which consumes a mixture of very high purity argon and carbon dioxide gas and is modified from the respective tanks, according to workshop drawings.
Welding of seams between the belts, which are responsible for connecting the belts to each other, must be done according to the WPS certification by penetration and by a skilled welder who has a welding certificate from a technical and professional organization so that the whole part and members are integrated. To act.
All welds according to the type and degree of importance by experienced experts of welding inspection companies using tests and non-destructive testing (NDT) including eye test (VT), penetrant test (PT), magnetic particle test (MT) and Ultrasonic ultrasound (UT) test is performed.

Radial work

In buildings with bolt and nut connections, holes are installed on the parts according to the type and size of bolts according to the approved workshop drawings and are executed by radial device. Radial work unit is one of the very precise units with the program of the organization that each device performs drilling with columns and beams according to the specified agenda.
The connecting flanges are prepared in separate halls with advanced machines, including the DRAIL CNC machine, which plays an important role in the speed and production of parts, and are packed for shipment to the installation site.

Assembly of columns and beams and installation of hardeners

The straps are ready to be assembled and accepted as columns or beams. The four-sided assembly of the boxes is done by using semi-automatic box making and etching machines or by the most skilled assembly workers in special fixtures. The use of semi-automatic box assembly machines increases the quality, reduces manufacturing errors, observes the permissible tolerances of the regulations, increases the production speed and reduces the cost of manpower. In the next step, transverse stiffeners are installed on the part. These stiffeners prevent cross-section deformation and shrinkage of the limb.
After installing the hardeners, three new faces of the boxes are welded and the fourth face is welded to the internal hardener of the column after assembly by ELECTROSLAG machine. For longitudinal welding of high thickness parts, which have a large welding volume, submerged arc welding method (by automatic gate machine) is used, which is one of the new processes in the welding industry.

Installation of accessories

This step includes the installation of accessories for the columns, including gripping joints, waiting joints for joints, cutters, and so on. The initial accessories of the columns and beams are twisted with the help of STRAIGHTER device and it is ready to enter the installation unit of the accessories. The installation unit of the accessories on the products is very sensitive because in case of an error, its correction is at the cost of losing the mechanism of the member structures.

Delivery to the monitoring device

At the end of the construction phase and after the approval of the employer and consultant supervisors, as well as obtaining the approval of the welded welds from the competent welding inspection companies, the finished part is sandblasted and painted.

Preparation and coloring

Cleaning and preparation of the part for painting by sandblasting or shotblasting methods is done at different levels with two purposes:
۱- Elimination of surface contaminants such as soil, oil, rust and external decontamination
۲- Roughening and preparing the surface to improve the adhesion of the paint
In sand blasting using abrasive pressure of special compressors, abrasive sands such as lubricants, silica sand, metal oxide powder are sprayed from the outlet nozzle on the metal surface. The use of each abrasive material offers its own roughness with varying degrees.
The degree of cleaning (sandblasting) of the type and thickness of the paint is carried out according to the instructions of the structural consultant and in accordance with international regulations.
In the shot blasting method, steel balls with a certain speed and angle at different angles (inside the machine chamber) are thrown towards the part and the cleaning operation of the part is performed completely automatically without the intervention of manpower.
Then the surface prepared with the device (AIRLESS) is painted, which using this method reduces paint losses, painting speed and the possibility of applying a uniform coating of high thickness. The painted parts are thickened in the spraying steps of the primer and the top layer and are controlled by the observers. At this stage, quality control inspectors inspect the product that has been inspected during the production process and installed control barcodes as a seal of approval for the product and issue a product exit permit.

Barcode and towards installation ...

For each product, when sent to the installation site, a barcode with QR technology is issued and installed on the part. This barcode is used as a product ID in which information such as dimensions, type and type of product is stored.
By removing this barcode, the engineers located at the installation site can view the product specifications and install it according to the approved orders of the consultant and supervisor.
Now the structure is ready to leave the company and send it to the installation site to raise the name of this industrial group on the tallest towers and skyscrapers in the country.
With the acquisition of the best technology in the world and by employing the most experienced engineers and consultants in the country and obtaining valid international certificates in the field of management and product quality, the group of Dena Sanatfactories has been able to establish its name as one of the most reputable brands in the country. Hopefully, with the increasing progress, we can raise the name of Iran at the international level more than before.

+98(51)46139016-23

info@denasanat.co

Khorasan Razavi - Chenaran - Sanat 20

Iran, Mashhad