Transmission Tower Production Process

In modern society, transmission towers, as a crucial component of power transmission, bear the heavy responsibility of ensuring a stable power supply. JOISYNC, as a leading transmission tower manufacturer, is committed to providing our customers with high-quality transmission tower products.

In this article, JOISYNC uses its own transmission tower production process as an example to provide a detailed introduction to the entire production process of transmission towers, helping you better understand the entire process from raw materials to final delivery.

1. Transmission Tower Materials

The production of transmission towers begins with the selection of raw materials. High-strength steel is the primary raw material for manufacturing transmission towers. We typically choose high-quality hot-rolled or cold-rolled steel, which possesses excellent tensile strength, corrosion resistance, and good machinability. Selecting high-quality raw materials is a crucial step in ensuring the structural safety and durability of the transmission tower.

2. Flattening Steel Plates

After the raw materials arrive at the factory, the steel plates first undergo surface treatment. Steel plates are often slightly curved or uneven, therefore, they need to be flattened using hydraulic equipment. The purpose of this step is to ensure that the steel plates can be accurately cut and processed in subsequent steps, avoiding any impact on the overall structural strength of the tower due to unevenness.

3. Steel Plate Cutting

After being flattened, the steel plates undergo a shearing process, typically using automated shearing equipment to cut them into the required dimensions. According to the design drawings, the steel plates are divided into different shapes, ready for subsequent bending and welding processes. The precision of this step directly affects the overall structure of the transmission tower, and dimensional tolerances must be strictly controlled.

4. Bending

Bending the steel plates is one of the key steps in manufacturing transmission towers. Based on the tower's design requirements, the steel plates need to be bent at specific angles. We use CNC bending machines for high-precision bending, ensuring that the angle and degree of bending of each component meet design specifications. This process requires not only high-precision equipment but also highly experienced operators.

5. Cutting Flanges and Bases

Flanges and bases are indispensable parts of the transmission tower structure. Steel plates are cut into circular flanges and bases using laser cutting machines or CNC cutting machines. The cut flanges are usually ground to remove burrs generated during the cutting process, ensuring a smooth and tight connection.

6. Welding

Welding is one of the most critical processes in transmission tower production, involving the connection of various parts of the tower body. During the welding process, we use advanced automated welding equipment to ensure the quality and strength of the welds. Welding requires not only precise techniques but also special attention to heat treatment during the welding process to avoid excessive thermal deformation of the materials.

7. Assembly

After welding, the assembly stage begins. In this stage, the various components of the transmission tower (such as the tower body, crossarms, and support arms) are pre-assembled according to design requirements. Workers on the production line use cranes and other equipment to assemble the components. All components must be precisely aligned to ensure structural stability.

8. Welding By Hand

After preliminary assembly, workers perform manual spot welding to fix the components in place. This process is carried out in small areas inaccessible to mechanized equipment, making the tower body more stable. The spot welds must be precise to avoid affecting subsequent welding and structural stability.

9. Polishing the Transmission Tower

Polishing removes weld marks, burrs, and any other defects from the tower surface that could affect its appearance and structural stability. Through manual or mechanical polishing, the surface of the transmission tower is made smoother. This not only improves its appearance but also enhances its corrosion resistance.

10. Shaping and Finishing

After grinding, the tower enters the shaping and finishing stage. At this point, workers make final adjustments to ensure the tower's straightness and flatness. During this stage, all components of the tower are fully assembled, and all connections are secured.

11. Galvanizing

Zinc plating is a crucial step in the corrosion protection process. To ensure the transmission towers can withstand harsh environmental conditions, we use hot-dip galvanizing technology to completely cover the surface of the towers with a layer of zinc. This zinc film effectively prevents external corrosive substances from eroding the tower body, extending its service life.

12. Checking the Zinc Plating Thickness

After galvanizing, we rigorously check the thickness of the zinc plating layer. The uniformity of the zinc plating thickness is key to ensuring the long-term corrosion resistance of the transmission tower. If the zinc plating thickness is substandard, it may lead to a decrease in the corrosion resistance of the tower body, thereby shortening its service life.

13. Tensile Testing

Tensile testing verifies the load-bearing capacity of the transmission tower. During this process, we conduct simulated load tests on the tower body to ensure its stability under extreme weather conditions. Through tensile testing, we can verify the structural safety of the tower body and make appropriate adjustments based on the test results.

14. Packaging

After all production stages are completed, the transmission tower enters the packaging stage. To prevent damage during transportation, we use professional packaging for the transmission tower. Typically, we use materials such as wooden crates and steel frames for protection to ensure the safety of the transmission tower during transportation.

15. Delivery

Delivery is the final step in the entire production process. Before delivery, all transmission towers undergo a final quality inspection to ensure they are free of defects. After passing a rigorous inspection process, the transmission towers are delivered to the location designated by the customer. We ensure on-time delivery and provide installation guidance and support according to customer needs.

Conclusion

From raw material selection to final delivery, the production of transmission towers is a complex and meticulous process. Every step is crucial to the quality and reliability of the product. As a professional transmission tower manufacturer, JOISYNC adheres to high-quality production standards and strict quality control to provide customers with superior products and services. Through these rigorous production processes, we ensure that every transmission tower can operate stably in various environments, guaranteeing efficient power transmission.