Modular Steel Construction
Modular steel construction
Usually, the steel construction for elevated conveyor systems such as
APM accumulating conveyors is considered to be a special design.
While it is true that the steel construction is not only guided by the length
and width of the conveyor technology, its superstructure and support
must be in line with the plant layout, too.
This is why the steel construction is always a special solution specifically
designed for the individual application.
However, special solutions may also include standard ones, as
evidenced by the popularity of the Euro gripper system.
Here, the modular approach is key to standardization.
This presentation shows how our colleagues from Tünkers Iberica APM
have implemented this approach to complex steel constructions.
29.03.2016 Kapitel 2
The modular steel construction
“Concept“
The accumulating conveyor belt is
positioned on both sides of the
cross member with horizontal
connection
Support for maintenance bridge
Accessible workpiece guard
Pillars are assembled on site in
line with plant layout
3
The modular steel construction
“Concept“
Bridge design with lateral laggings positioned on pillars.
The supports of the pillars may be positioned individually as specified
by the plant manufacturer.
4
The modular steel construction
“Concept“
The maintenance bridges may be
placed laterally on the pillars as
self-supporting units.
5
The modular steel construction
“Concept“
Turning
Optional access to the workpiece
engine
guard via the longitudinal girders.
hooks
(depending on the belt distance).
6
The modular steel construction
“Concept“
LADDER in modular design: STAIRWAY in modular design:
7
The modular steel construction
“Components“
Structure
SUPPORTS and BEAMS
are adapted on assembled on site
Beams to enhance rigidity
8
The modular steel construction
“Components“
Standard modules
Application example of a connecting disc 9
The modular steel construction
“Components“
Standard modules
Beam and
tension rod:
10
The modular steel construction
“Components“
Standard modules
Preassembled components
Manufactured with material and quality documentation
Welding certificate to DIN EN ISO 9606-1:2013
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The modular steel construction
“Components“
Standard modules
Mechanical
connections in modular
construction are
manufactured in series
12
The modular steel construction
“Components“
Standard modules
Mechanical connections
in modular construction
are manufactured in
series
13
The modular steel construction
“Assembly“
• The material is delivered in compact packages. The individual parts may be removed
manually.
• The entire material may be stored in a small area on site.
• Staff can start with any steel construction.
• Large parts like supports or struts are assembled into structural components on site.
• After assembly of the supports in the required position, the steel construction is
assembled without welding, allowing for a very flexible assembly approach on site.
14
The modular steel construction
“Assembly“
• The tips of the fitted supports and struts are provided with series-manufactured
standard
• Together with the bars and brackets, everything is assembled into an entire steel
construction.
• The bars of the steel construction may also be added at the end of the assembly
and adapted to the surrounding conditions such as cable ducts, electric cabinets,
etc.
29.03.2016 Kapitel 15
The modular steel construction
“Quality/Standards“
The following standards are included/met
Eurocode 1: Actions on structures (EN 1991)
Eurocode 3: Design of steel structures (EN
1993)
Eurocode 8: Design of structures for
earthquake resistance (EN 1998)
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The modular steel construction
“Quality/Standards“
SCREW CONNECTIONS
Elements used:
Hexagon head cap screw:
DIN EN 14399-4: M12, M16 Property class10.9
High-strength preload nuts:
DIN EN 14399-4: M12, M16
Conical spring washer:
DIN 6796: M12, M16
17
The modular steel construction
“Quality/Standards“
Elements used: High-strength preload screw
connections
Hexagon head cap screw DIN EN 14399-4: M12, M16
High-strength preload nuts DIN EN 14399-4 : M12, M16
Property class10.9
18
The modular steel construction
“Quality/Standards“
Elements used:
Conical spring washer DIN 6796 M12, M16
19
The modular steel construction
“Quality/Standards“
Instruction for tightening moments
for socket cap screws
verwendete Schraubenqualität 10.9
20
The modular steel construction
“Quality/Standards“
Proof of life and strength
Steels for steel construction: hot-rolled structural steels
St 44-2 to DIN 17100, S 275 JR to EN 10025-2
Mechanical properties:
max. tensile Ductile yield
Material Yield point
strength A
number Rm (N/mm²) Re (N/mm²) [%]
< 3 mm < 16 mm
S 275 JR 1.0044 430 - 580 275 22
• The high-quality materials and the generously dimensioned connections ensure a long
life even when subject to intense dynamic effects (vibrations caused by man or
machine).
21
The modular steel construction
“Quality/Standards“
Fatigue strength of screw connections
• The high-strength prestress screw connections used in modular steel construction
provide for low-slippage and low-ductility screw connections which are used mainly in
designs where undesired deformation within the connections would limit the properties of
the structures. The key parameters of connections of this kind are the static friction
coefficient and the preload in the screws.
• The screws are manufactured with a lower thread dimension of tolerance class 6az
(thread play) before adding the surface protection (DIN EN ISO 10684). After
galvanization, the screws are “ISO compliant”.
22
The modular steel construction
“Quality/Standards“
Play of holes
Detail: laser-cut elongated holes 23
The modular steel construction
“Quality/Standards“
Play of holes
In order to check whether the spring preload of the
washers (spring washers) is sufficient, a restraint was
removed. It was fastened with three M12 screws. A paint
coat thickness of 0.2 mm was measured at the component.
With a travel of 0.4 mm, the spring washer was in line with
the reference value in the table. In the area of the screw
pressure, the paint coat was compressed to 0.05 to 0.1
mm.
From this finding, we can derive that a residual preload of
0.4 mm corresponding to 9000N preload remains when
two spring washers are added with M12 screws and a total
travel of 0.8 mm after deduction of 4* paint thickness
0.1=0.4, if the paint dissolves completely.
When the number of screws is adapated to the load,
the connection may be regarded as fatigue endurable.
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The modular steel construction
“Quality/Standards“
Assembly certificates
• All screws tightened are marked with red sealing wax.
• Parts in Poka Yoke design in order to avoid mixing up modules.
Certificate of qualification of assembling staff
• All components are checked and approved by a head mechanical engineer on site.
• No welders required, as no welding is done on site.
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The modular steel construction
“Quality/Standards“
Levelling of belt
Levelling screw
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The modular steel construction
“Quality/Standards“
Levelling of steel construction
Levelling screw
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The modular steel construction
“Logistics“
Dispatch in 40´containers,
Irrespective of the size of the steel structures
Modules, beams, screws
Workpiece guard
Ladders, longitudinal members, cross members
Ca. 5 containers are required for 15
medium-sized steel structures
29.03.2016 Kapitel 28
The modular steel construction
“Benefits“
• The benefits at a glance
– Planning of all standard parts irrespective of the specific design
– Complete final assembly on site
– High flexibility with regard to modifications
– Low transport costs thanks to modules
– “Space-saving” assembly thanks to low number of lifting devices required
• As compared to conventional steel construction
– Individual special design
– Pre-assembly of complete complex welding modules
– A lot of transportation required
– Final assembly of large components on site requires lifting devices
– It is not possible to modify the basic design on site
– All modifications on site are very difficult to handle
29.03.2016 29
Contact
Your contacts
TÜNKERS Iberica SL TÜNKERS Maschinenbau GmbH
Mr Jose Pac Mr Kai Mönkediek
Head of technical design Product management
C/ Enric Prat de la Riba 14, Am Rosenkothen 4-12
E-08830 Sant Boi Llobregat D-40880 Ratingen
Phone +34 933 952 207 Phone +49 (0) 2102-45 17-0
Mobile +34 607 309 873 Mobile +49 (0) 162-1311896
Fax +34 933 953 097 Fax +49 (0) 2102-45 17-9999
E-Mail jpac@tunkersiberica.com E-Mail kai.moenkediek@tuenkers.de
Internet www.tuenkers.de Internet www.tuenkers.de
© 2016 TÜNKERS Maschinenbau GmbH 30
