Conici ERW — depliant tecnico in inglese
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from hot rolled steel
CONICAL COLUMNS ERW
AN ITALIAN INNOVATIVE TECHNOLOGY
A NEW ERA
COMPARISON AND ADVANTAGES
The conical columns ERW from hot rolled steel sheet disclose important advantages compared to
the traditional conical columns employed up to now.
TECHNOLOGICAL INNOVATION
COLUMNS EMPLOYED UP TO NOW A NEW ERA
HSP Conical column SAW-MAG conical column ERW conical column
60’s technology 80’s technology new technology
AESTHETIC Comparing the external surface of the finished product we highlight the aesthetic advantage.
Columns that can be seen in public areas
visibile transversal scars due to the
visibile seam of the longitudinal welding smooth surface and absence of visibile welding
rolling process / pressorotation
SAVING OF RESOURCES Comparing the weigh of the colums with similar performances, we highlight that less material is needed.
Example of a columns length 8,8m
kg87 kg91 kg74
(8800x127x3,6x60) (8800x148x60x4) (8800x127x60x3,6)
STRUCTURAL RESISTANCE Comparing the quality of the employed steel we highlight the structural advantage.
Steel quality declared by the manufacturers
S275 S235 S355
snerv. 275 N/mmq snerv. 235 N/mmq snerv. 355 N/mmq
PRODUCTIVE FLEXIBILITY Comparing the materials and the machinery needed to manufacture the product, we highlight our
productive flexibility.
Data from the manufacturer’s catalogue
employing of commercial tubes with standardi- taper ration 10 mm/m; taper ration from 8 up to 15mm
sed measures as per standard thickness 3 or 4mm; thickness for 3 to 4mm and intermediate
steel grade S275JO steel grade S235 steel grade S355, S275, S235
RESPECT FOR ENVIRONMENT Comparing the production processes, we highlight the reduction of the working phases needed to manufacture the
product having consequently a reduction of the CO2 emissions in the environment .
EMPLOYED MATERIAL
HSP CONICAL COLUMN SAW-MAG CONICAL COLUMN ERW CONICAL COLUMN
The three compared processes employ the same basic material: HOT ROLLED STEEL SHEET
In the hot rolling process, the steel sheet is heated to reach the plastic deformation temperature, then is worked out
between rollers couple untill the required thickness is reached. The original structure of the plate molten and coar-
se-grained is disaggregated and replaced by a thinner one having better toughness and ductility. The plastic deforma-
tion due to the crushing, causes the reduction of the thickness and a consequent increasing of the length. The original
plate becomes too long to be handled as a flat item, so it is rolled up into a reel so-called “coils”.
WORK 1
cutting coils with tailor-made measures levelling and cutting of the coils into rectangles levelling and cutting of the coils into rectangles
having tailor-made length having tailor-made length
The coils is opened by means of an unwinder and Coils is opened by means of an unwinder and the material going through some rollers, undergoes
the material going through some rollers, under- some alternate plastic deformations in order to remove the internal stresses until it becomes per-
goes some alternate plastic deformation in order fectly flat. Then it is cross-cut in order to obtain plates of the needed length.
to remove the internal stresses until it becomes
perfectly flat. Then it is longitudinally cut in order
to obtain the plate of the needed width.
slitting
leveling
remove correct reset
uncoiling recoiling memory shape memory STEEL SHEET
cutting of the steel sheet into trapezium
WORK 2
forming of the cylindrical tubular profile cutting of the steel sheet into trapezium
In the molding process of the cylindrical tubular
profile, the plate is arranged on an unwinder, le- The rectangular steel sheet, having needed thickness and length, is cut into
velled and subsequently “U” shaped and then trapezium in order to obtain the conical profile.
closed like an “O” by means of some molding
rollers.
WORK 3
length-wise fusion without filler material
molding of the conical profile molding of the conical profile
ERW method
The welding process of the profiled steel sheet The steel sheet trapezium is bent on a purpose made mold with
consists in heating the two hems up to the mel- conical profile.
ting temperature by means of high frequency
electricity, then the tube is pressed by means of
rollers obtaining the junction of the hems. The
extra metal formed during the pressing welding
process is completely hot removed.
WORK 4
cutting of the tube to tailor-made length external longitudinal welding with filler material SAW length-wise fusion without filler material ERW
or MAG method method
After welding, the tube is tailor-made cut to the The bent conical profile is closed joining the lon- The bent conical profile is closed joining the lon-
requested length. gitudinal edge with electric longitudinal welding gitudinal edge with ERW method which consists
submerged arc with filler support material SAW in heating the two hems up to the melting tem-
o MAG method. perature by means of high frequency electrici-
ty, then the tube is pressed by means of rollers
obtaining the junction of the hems. The extra me-
tal formed during the pressing welding process is
completely hot removed.
WORK 5
conical shaping of the tube by means of hot possible smoothing of the longitudinal welding if
pressorotation any
The tube having diameter, thickness and length Removal of the external welding seam by
needed, is heated to a temperature of 700° by grinding.
means of electric induction, then it is slowly de-
formed by hot pressorotation, carrying the ma-
terial inside the column to modify the geometry
and obtain the conical profile.
DESCRIPTION
Conical columns with circular section made of hot rolled steel sheet obtained by molding of a steel plate trapezium
on purpose made mold in order to give a perfect circular shape. The bent conical profile is closed joining the lon-
gitudinal hem by die casting; the hems to be joined are heated up to the melting temperature, by means of high
frequency electricity passage, then the profile is pressed by means of rollers obtaining the fusion of the hems. The
extra metal generated during the pressure welding process is completely hot removed, obtaining a smooth profile.
The die casting process ERW (electrical resistance welding), consists in autogenous wedling where the material
composes the part to be joined, guaranteeing the total continuity on the material characteristics.
MATERIAL
The steel that can be employed can be steel grade S355, S275 or S235 having characteristics as per standard
EN10025 according to the structural needs.
S355 S275 S235
breaking point from 470 to 630 N/sqmm breaking point from 410 to 560 N/sqmm breaking point from 360 to 510 N/sqmm
yield strength: 355 N/sqmm yield strength: 275 N/sqmm yield strength: 235 N/sqmm
WORKS
Works can be customised according to the drawing, such as, base plate, opening with flush type door obtained by cutting, dril-
ling, threading, welded details, bending, etc.
PROTECTION
Protection against corrosion by means of hot dip galvanization obtained with the following cycle: degreasing, pickling,
washing, fluxing, pre heating, hot dip galvanization in melted zinc bath at 440÷450°, with minimum percentage of zinc
into the bath 98.5%.
Coating obtained according to UNI EN ISO 1461 with minimum thickness 55 microns and average 70 microns.
External painting, if any, with colour from our colour card, rough effect, obtained with thermosetting powders cycle
including: cleaning from zinc coating burs; smoothing of the surfaces by means of a light mechanic device; cleaning of
the surfaces in order to eliminate grease or dirty and create a good adherence base; application by means of electro-
static spray of polyester powder suitable for galvanized surfaces for outside installation, polymerization into oven at
constant temperature of approx. 200°, package for each column, by banding with tissue 100% polyester, (no pluriball),
in order to avoid damages during the handling phase.
Characteristics of the obtained coat:
Cycle C4DUPLEX = cathodic protection double coat, average film thickness 130 microns (70 galv+60 top coat)
Cycle C5 Plus = cathodic protection + barrier effect average film thickness 190 micron, (70 galv+ 60+60 primer and
top coat)
Restistance to mechanical test ISO1519, ISO2409, ISO1520, STM D2794, ISO2815
Resistance to chemical test ISO9227, ISO6270, ISO3231, EN2260-1, ISO2810, ISO11341-1; ISO11507
MARKING
The columns will be CE marked according to the standard in force (DPR246/93, 89/106/CEE; 93/68/CEE).
If employed in public lighting, the label on each column quotes: standard reference EN40-5, manufacturer’s identifi-
cation, certificate number of the authorization to the mark CE CPD P029, year of marking, product code, and contract
reference number.
If employed in other strucutral fields, according to the CE are manufactured according to EN 1090 execution class
ECX2, certificate issued by third party according to European directive UE 305/2011. The marking, on each column
quotes, standard reference EN 1090, manufacturer’s identification, certificate number of the authorisation to mark CE
0475-CPR 15, year of marking, product code, contract number.
DIMENSIONS
Tolerances on dimensions UNI EN 40/2 - UNI EN 10051
weight galva- production on
length diameter on top base diameter thickness painting surface standard pro- standard pro-
nised demand steel
mm mm mm mm smq duction S355JO duction S235JR
kg grade at choice
89 3,2 29 0,94 X X
92 23 0,96 X
60
100 24 1,01 X X
116 26 1,11 X
107 27 1,14 X
4000
75 115 3 29 1,19 X
131 31 1,29 X
122 32 1,33 X
90 130 33 1,38 X
146 36 1,48 X
89 3,2 27 1,05 X X
96 26 1,10 X
60
105 28 1,17 X X
123 31 1,29 X
111 31 1,31 X
4500
75 120 3 33 1,38 X
138 36 1,51 X
126 37 1,53 X
90 135 38 1,59 X
153 41 1,72 X
102 3,2 32 1,27 X X
100 30 1,26 X
60
110 32 1,34 X X
130 36 1,49 X
115 36 1,49 X
5000
75 125 3 38 1,57 X
145 42 1,73 X
130 42 1,73 X
90 140 44 1,81 X
160 47 1,96 X
102 3,2 35 1,40 X X
104 34 1,42 X
60
115 36 1,51 X X
137 41 1,70 X
119 40 1,68 X
5500
75 130 3 43 1,77 X
152 47 1,96 X
134 47 1,94 X
90 145 49 2,03 X
167 54 2,22 X
114 3,4 44 1,64 X X
108 38 1,58 X
60
120 41 1,70 X X
144 46 1,92 X
123 45 1,87 X
6000
75 135 3 48 1,98 X
159 53 2,21 X
138 52 2,15 X
90 150 55 2,26 X
174 60 2,49 X
weight galvani- production on
length diameter on top base diameter thickness painting surface prod.S355JO prod. S235JR
sed kg demand
114 3,4 50 1,86 X X
127 3,6 57 2,00 X X
114 44 1,86 X
128 3 48 2,01 X X
60
155 55 2,30 X
114 59 1,86 X
128 4 63 2,01 X X
155 73 2,30 X
129 52 2,18 X
143 3 56 2,33 X
6800
170 63 2,62 X
75
129 69 2,18 X
143 4 74 2,33 X
170 84 2,62 X
144 60 2,50 X
158 3 64 2,65 X
185 71 2,94 X
90
144 80 2,50 X
158 4 85 2,65 X
185 94 2,94 X
127 3,6 65 2,29 X X
122 53 2,23 X
138 3 58 2,43 X X
60 169 68 2,81 X
122 70 2,23 X
138 4 77 2,43 X X
169 89 2,81 X
137 63 2,60 X
153 3 67 2,79 X
7800 184 77 3,18 X
75
137 83 2,60 X
153 4 89 2,79 X
184 101 3,18 X
152 72 2,97 X
168 3 76 3,16 X
199 86 3,54 X
90
152 95 2,97 X
168 4 101 3,16 X
199 114 3,54 X
127 3,6 74 2,58 X X
139 3,8 83 2,75 X X
130 63 2,63 X
148 3 69 2,88 X X
60
183 81 3,36 X
130 83 2,63 X
148 4 91 2,88 X X
183 107 3,36 X
145 73 3,05 X
163 3 79 3,29 X
8800
198 91 3,78 X
75
145 97 3,05 X
163 4 105 3,29 X
198 121 3,78 X
160 84 3,46 X
178 3 90 3,70 X
213 102 4,19 X
90
160 110 3,46 X
178 4 118 3,70 X
213 135 4,19 X
139 3,8 92 3,06 X X
138 73 3,05 X
158 3 81 3,36 X X
60 197 96 3,96 X
138 97 3,05 X
158 4 107 3,36 X X
197 126 3,96 X
153 85 3,52 X
173 3 92 3,82 X
9800 212 107 4,42 X
75
153 112 3,52 X
173 4 122 3,82 X
212 142 4,42 X
168 96 3,98 X
188 3 104 4,28 X
227 118 4,88 X
90
168 127 3,98 X
188 4 137 4,28 X
227 157 4,88 X
weight galvani- production on
length diameter on top base diameter thickness painting surface prod.S355JO prod. S235JR
sed kg demand
152 4 114 3,60 X X
146 84 3,50 X
168 3 93 3,87 X X
60 211 111 4,60 X
146 111 3,50 X
168 4 123 3,87 X X
211 147 4,60 X
161 97 4,01 X
183 3 106 4,38 X
10800 226 124 5,11 X
75
161 128 4,01 X
183 4 140 4,38 X
226 164 5,11 X
176 109 4,52 X
198 3 118 4,89 X
241 136 5,62 X
90
176 145 4,52 X
198 4 157 4,89 X
241 181 5,62 X
152 4 125 3,93 X X
154 96 3,97 X
178 3 106 4,41 X X
60 225 128 5,29 X
154 126 3,97 X
178 4 141 4,41 X X
225 169 5,29 X
169 109 4,53 X
193 3 120 4,97 X
11800 240 142 5,84 X
75
169 144 4,53 X
193 4 159 4,97 X
240 188 5,84 X
184 123 5,09 X
208 3 134 5,52 X
255 155 6,40 X
90
184 163 5,09 X
208 4 177 5,52 X
255 206 6,40 X
168 4 146 4,58 X X
162 108 4,47 X
188 3 120 4,99 X X
60 239 146 6,02 X
162 142 4,47 X
188 4 159 4,99 X X
239 193 6,02 X
177 123 5,07 X
203 3 135 5,59 X
12800 254 161 6,62 X
75
177 162 5,07 X
203 4 179 5,59 X
254 213 6,62 X
192 137 5,68 X
218 3 150 6,19 X
269 176 7,22 X
90
192 182 5,68 X
218 4 199 6,19 X
269 233 7,22 X
164 156 4,8 X
60 190 175 5,4 X
14000 242 4 214 6,5 X
75 260 238 7,2 X
90 270 257 7,8 X
172 173 5,3 X
60 200 195 6,0 X
15000 4
256 239 7,3 X
75 270 262 8,0 X
180 191 5,9 X
16000 60 210 4 216 6,6 X
270 266 8,1 X
Other dimensions can be realised on demand according to the following dimensional restrictions:
maximum length in one section 12,8m; 16m in 2 overlapped sections.
Taper ratio from 8 up to 15 mm/m; Maximum base diameter 280mm; minumum d. on top 60mm
steel thickness from 3 to 4mm.
This innovation is the result of a constant
activity of research and development which
makes Pali Campion a market leader in the
forefront of technology.
Pali Campion boasts of more than 10-year
experience in the steel columns field.
Since the beginning we are linked to resear-
ch and innovation.
We started years ago as “craftsman”, our
commitment is always turned towards the
development.
We believe and invest in technological in-
novation, in order to supply solution having
better performances and grant a constantly
growing quality.
ISO9001 – IT5358IGQ9810
ISO14001 – IT278513 OHSAS18001 – IT278931UK
PALI CAMPION S.r.l.
Via A. De Gasperi, 45
45025 Fratta Polesine (RO) - Italy
Tel. +39 0425 668686
E-mail: mail@palicampion.it
www.palicampion.it
EN1090 – 0475CPR15 EN40 – 1608CPRP029 ISO3834 – IT464 Centro di trasformazione 1836/11