Pre-engineered steel beam processing technology solution

Mainly processed products

• Beams, I, H composite columns for prefabricated factories; variable cross-section beams (A beams), K beams, truss beams, curved beams.
• Columns, box beams for high-rise buildings, heavy industrial buildings; crane beams.
• Accompanying details: code plates, flanges, reinforcing ribs, connecting ears.
• Materials: Q235, Q345/Q355B steel or equivalent

Production problem

In steel structure production, reliance on pre-cut steel sheet sources increases input material costs and limits the ability to actively supply blanks. Additionally, the uneven flatness of steel sheets easily causes deviations when processing webs, beam wings, affecting the accuracy of the assembly stage. The discontinuous supply of blanks also causes subsequent equipment to wait, interrupting the production flow.

Technology solution from Weldcom

Weldcom provides an automatic uncoiling – flattening – sheet cutting line, helping factories actively produce steel sheet blanks directly from hot-rolled Q355B steel coils. The solution meets two thickness ranges 4–16 mm (LCZN-(4-16)×2000) and 6–25 mm (LCZN-(6-25)×2000), width 1,000–2,000 mm, maximum coil weight 35 tons, and sheet length from 1–12 m.

The steel coil is fed through an uncoiling system, continuously flattened by a set of 15 rollers; the double flattening configuration supplements the primary flattening station Φ450 to enhance flatness processing efficiency. Then, the hydraulic shear performs cross-cutting according to pre-set lengths, with the entire cycle controlled by Siemens PLC, achieving final product flatness ≤ ±1 mm.

Value provided

The solution helps businesses actively source steel sheet blanks, reduce reliance on pre-cut materials, and optimize input costs. The processed blanks achieve flatness and size as required, ready to move to the stage of shaping webs, wings, and assembly welding. The active supply of blanks right at the factory also contributes to reducing waiting time between equipment, maintaining continuous production flow and improving the overall operational efficiency of the steel structure line.

Learn about the product: Automatic uncoiling – flattening – sheet cutting line

Production problem

In steel structure processing, traditional methods like CNC Plasma, Oxy-gas, band sawing, and shearing still have limitations in speed, edge quality, and the ability to handle complex shapes, especially with A beams, curved beams. Separate marking, drilling stages also prolong processing time, increase costs, and affect the continuity of the production line.

Technology solution from Weldcom

Weldcom provides a high-power Fiber Laser cutting solution, applied in processing I, H, A, K beam webs, wings, truss beams, curved beams, code plates, and reinforcing ribs; meeting steel sheet thickness up to 50 mm when using compressed air, depending on laser source power.

The system uses compressed air through a nitrogen separation unit as cutting assist gas, replacing bottled oxygen or nitrogen. Combined with nesting software to optimize blank layout, the solution allows detailed shaping, hole processing, inclined lines, curved lines, and beam head shapes in a single cutting program. For thin sheets requiring only straight strip cutting, Weldcom directs the use of hydraulic shearing machines to optimize investment and processing costs.

Value provided

Fiber Laser technology achieves cutting speeds of 5–6.5 m/min with 10–12 mm thick steel, 3.5–4 times faster than Oxy-gas. With 20 mm thick steel, cutting costs are about 700–1,000 VND/m, lower than the 1,400–2,200 VND/m of the Oxy-gas method. Integrating multiple primary operations in one cycle helps reduce intermediate operations, create clean cut edges, limit surface treatment, and be ready to move to the welding stage. Thus, businesses shorten blank processing time, control costs, and improve the overall efficiency of the steel structure production line.

Learn about the product: CNC Laser Cutting Equipment

Production problem

In processing steel pipes, composite steel, and shaped beams, traditional processes often require multiple separate stages such as sawing, marking, drilling, and finishing grinding. Reliance on manual operations not only consumes labor but also prolongs processing time and poses potential position hole deviations, beam head shapes, leading to adjustment and repair work during field assembly.

Technology solution from Weldcom

Weldcom provides a 20 kW power shaped steel laser cutting solution, integrating multiple primary operations on the same system, meeting the processing of round pipes with a diameter of Φ30–500 mm, square pipes with a size of 20–500 mm, rectangular pipes, and H beams with a size below 380 mm, blank length up to 12 m.

The system uses a rotating chuck combined with a laser cutting head moving along 3D shapes, performing length cutting, shape grooving, hole creation, and beam head processing in just one setup. Optional bevel cutting head expands the ability to process bevel edges according to connection and welding requirements.

For larger-sized steel beams beyond the laser machine's processing range, Weldcom provides specialized equipment including AMG gantry CNC drilling machine, DJ500 CNC band saw, and DX3535 beam head milling machine, meeting the diverse processing requirements of steel structure factories.

Value provided

Integrating multiple stages in one setup helps shorten the processing procedure, reduce manual operations, and limit cumulative deviations between primary operations. Position hole accuracy and beam head shapes are controlled right from the processing stage, contributing to improving assembly accuracy, reducing adjustment and repair time at the construction site, and accelerating the steel structure assembly progress.

Learn about the product: Shaped Steel Cutting Machine 

4.1. V-0815N Multi-functional Beam Assembly Machine – positioning, welding, straightening on one machine body

Production problem

Independent positioning – welding – straightening lines occupy a lot of workshop space, require many workers and cranes to transfer beams. The decentralized process increases waiting time, relies on skilled workers, and is difficult to maintain consistent productivity and quality.

Technology solution from Weldcom

Weldcom provides the V-0815N multi-functional beam assembly machine, 3 in 1 integrating positioning, welding, and beam straightening on the same machine body, suitable for steel structure factories with a scale of about 200 tons/month/machine.

The system centers, clamps the vertical web between two wings, fixes the beam head with MIG welding. Two simultaneous wing-web welds are performed in 2F position using SAW S2 technology, using two parallel Φ1.6 mm wires on each weld. The automatic flux feeding and recovery system combined with straightening immediately after welding creates a continuous production cycle.

Equipment processes H, T, A beams (angle between two wings ≤8°), web height 200–1,500 mm, thickness 6–14 mm; wing width 150–800 mm, thickness 6–20 mm; length 4–15 m. Suitable for Q235, Q345 steel and maximum corner weld 8 mm.

Value provided

SAW S2 technology achieves a productivity of 8–10 kg/hour, compared to 6–7 kg/hour of single wire Φ4.0 mm welding; low heat input helps limit warping, especially with thin web beams.

With a productivity of 16–20 beams/machine/shift, requiring only 2 operators, the solution helps reduce crane transfer operations, save space, labor, and investment costs compared to independent lines; at the same time, improve continuity and stability of production quality.

4.2. V-0815F Smart Beam Assembly Line (upgraded version)

Production problem

Independent welding stations require cranes to flip, transfer beams between two welding surfaces, causing production interruptions and increasing waiting time. Manual welding seam adjustment still depends on worker experience, making it difficult to maintain consistent quality.

Technology solution from Weldcom

Weldcom provides an automatic positioning – welding beam line consisting of two A/B stations, connected by a T-shaped flipping and transfer system. The hydraulic mechanism combined with electric magnets performs flipping of the beam web 0–90°. SAW welding technology under flux integrates laser sensors to track the line and servo automatically adjust the welding seam position, along with pre-set digital welding library. The beam processing line has a web height of 200–1,500 mm, thickness 6–14 mm; wing width 150–800 mm, thickness 6–20 mm; length 4–15 m. Welding speed 0.2–2.0 m/min, optional Fly Tack positioning 0.4–3.3 m/min and automatic blank folding system.

Value provided

Automatic flipping, transferring beams between two stations without cranes, reducing transfer time and increasing the continuity of the line. Laser sensors maintain accurate welding seam position, improving weld quality. Welding data and actual welding time for each operator are stored, transmitted to the central computer, supporting productivity monitoring and production management.

Production problem

After welding, the wing plates are prone to angular deformation, beams warp, affecting geometric tolerances and assembly accuracy. Manual straightening methods often take a lot of time, require multiple adjustments, interrupt production progress.

Technology solution from Weldcom

Weldcom provides specialized beam straightening solutions with mechanical, hydraulic, and automatic horizontal straightening technologies, meeting diverse sizes, thicknesses, and beam shapes. The roller system creates pressing force to correct wing plate deformation after welding. Mechanical straightening machines use mechanical transmission, suitable for small beams and thin wings; hydraulic straightening machines use cylinders to create large pressing force for thick wing beams. The horizontal straightening system integrates laser sensors to measure deformation and automatically adjust the straightening process. On the V-0815N upright welding station, the straightening unit is directly integrated, height adjusted by motor and electronic ruler, displaying data on the control screen.

Equipment list meets various processing scales: JZ40 mechanical straightening for wings 6–40 mm thick (Q235), speed 13 m/min; YJZ-60A/60B/80B hydraulic straightening for wings up to 60/80/100 mm thick (Q235), speed 6–8.5 m/min; WJZ6015 horizontal straightening for straight beams and angular beams below 8°, wings 8–60 mm thick (Q355).

Value provided

The solution helps control deformation, ensure geometric tolerances and assembly accuracy. Diverse straightening technologies allow businesses to choose configurations suitable for beam thickness, optimize investment costs. Especially, the integrated straightening unit on the upright welding station helps reduce transfer stages, eliminating the need for separate straightening stations, improving the overall efficiency of the line.

Learn about the product: Beam Straightening Machine

Production problem

Welding reinforcing ribs, code plates, and finishing details on beams is a labor-intensive stage, directly affecting the overall line productivity. Reliance on highly skilled manual welders not only creates pressure on personnel but also makes it difficult to maintain consistent progress and weld quality.

Technology solution from Weldcom

Weldcom provides a MAG 7-axis welding robot system integrated with sliding rail, 3D camera, and intelligent robot control software. The system automatically scans components, recognizes weld line positions, and creates welding paths without needing manual point programming. The solution is specialized for welding reinforcing ribs, code plates, and repetitive welds on long beams. 3D vision technology helps the robot adapt to various types, component shapes, meeting diverse production requirements of steel structure factories.

Value provided

The system achieves a productivity of up to 120 m beams/shift, compared to 30–40 m beams/shift of manual welding methods. One operator simultaneously operates 2–3 robots, helping reduce reliance on skilled welders, increase productivity, and maintain stable weld quality. The ability to automatically recognize and program also helps reduce setup time when changing products, increasing flexibility in production organization.

Learn about the product: Smart Welding Robot Station

Smart Welding Machine Ehave 2 CM500B connected to SMARC IoT 

Production problem

In steel structure factories, the lack of data on the actual productivity of each machine, each worker makes it difficult to evaluate production efficiency and control electricity, protective gas, welding wire consumption. Besides, moving welding machines along long components increases auxiliary time and reduces operational flexibility.

Technology solution from Weldcom

Weldcom provides a CO₂/MAG Digital 500 A welding solution, integrating RFID tags to identify operators and SMARC module to connect welding data to the Cloud platform in real-time. The system meets the stages of positioning code plates, finishing welding, and repair welding; using Φ0.8–1.6 mm welding wire, supporting continuous welding with Φ1.6 mm flux-cored wire. The wire feeder is arranged 50 m away from the welding source to expand the working range while maintaining stable welding processes.

Value provided

The solution allows monitoring equipment status, welding output, and consumption levels of electricity, protective gas, welding wire, while also ranking productivity by each worker. Centralized data helps businesses control costs, evaluate operational efficiency, and enhance transparency in production management. The ability to arrange the wire feeder far from the welding source helps reduce equipment movement along large beams, while Digital welding technology contributes to saving about 1,000 kWh/machine/year, optimizing long-term operational costs.

Learn about the product: Hand Welding Machine

Production problem

Cleaning steel beam surfaces by manual methods often takes a lot of time, quality is inconsistent and difficult to meet cleanliness, roughness requirements before painting, directly affecting adhesion and durability of the protective coating.

Technology solution from Weldcom

Weldcom provides an automatic shot blasting system with conveyor, including models SBH0816-8, SBH1020-8/10/12 with 8, 10, or 12 blasting heads, along with an automatic cleaning HPG system, meeting the processing of steel beams up to 15 m long. The beam is fed through the shot blasting chamber, where the blasting heads shoot steel shots at high speed to remove rust, scale, weld slag, and create surface roughness. The system integrates shot recovery and dust filtration, ensuring continuous cleaning processes.

Value provided

The system achieves a surface cleanliness of Sa 2.5, creating conditions to enhance adhesion and durability of the protective paint layer. With a processing speed of about 800 mm/min when using round shots, the solution helps shorten cleaning time, maintain consistent surface quality, and improve the efficiency of the steel structure finishing stage.

Learn about the product: Shot Blasting, Beam Cleaning Machine