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Sports Stadium Steel Fabrication for World Cup'18 I HGG 3D Profiling

From fabricating bridges to major sports stadiums

Kurganstalmost JSC (Russia), a market leader in metal superstructures, has some time ago shifted its focus from fabricating bridges to major sport stadiums. Becoming a key player in providing tubular steel structures for the World Cup sport stadiums in 2018 was an opportunity not to be missed. Not long ago the company was granted the order of the 1st of a series of stadiums they will fabricate for the world cup in 2018 – the Samara stadium. Its rooftop structure, a unique construction made of 13,500 tubular structures, has one of a kind dome-shaped roof design covering both the calotte and the seats.

Up to that moment Kurganstalmost was relying on dated traditional fabrication processes. Not being able to face any longer these huge volumes and complex design with technology imposing limitations, Kurganstalmost started exploring process automation solutions.

“When we got the order for the Samara stadium we realized that we cannot manage with the tools we’ve used so far. This was a new task which required dealing with much more complex objects than before.”
Konstantin Raznoglyadov, Senior Engineer at Mostproject LLC

Fabrication Glory: Tubular structures large volumes and complex design no longer a problem

For taking this extra step towards process automation Kurganstalmost opted for the advanced technology solutions of two market leaders – Tekla/Trimble and HGG. The integration of BIM software – Tekla Structures, with the HGG pipe cutting machine SPC 1200 PT, resulted in numerous productivity gains for Kurganstalmost.

All data from the information-rich Tekla models, including much more than just geometry, were seamlessly transferred to the HGG pipe cutting machine via HGG’s postprocessor ProCAM software. The connection between Tekla Structures and HGG pipe cutting machine results in ready-to-weld parts of complex tubular structures as predefined in the model. “As a result we have now parts exactly according to the geometry in the 3D model. It is also very easy and simple to use: all actions in 1 click only.” confirms Sergey Medvedev, responsible for work preparation.

By using BIM quick changes can be made at the design stage which further eliminates defects during fabrication. Once the cutting file is transferred from Tekla to HGG’s ProCAM, fine tuning of the cuts is also easily achieved, e.g. changes in the cutting angle.

Vyacheslav Kurlov, welder and assembler at Kurganstalmost highlights the benefits for assembly and welding: “The assembly process is much faster. It’s easier, the sizes are much more accurately cut. We can now guarantee consistent root opening at the weld joint, which in turn has a positive effect on the quality of welding and reduces the workload because we do not need any improvements or adjustments. “. As a result from Kurganstalmost witnessing those productivity gains, the company purchased a 2nd HGG pipe profiling machine – a SPC 660 – 1200RB pipe cutting line, roller bed type with floating chuck.

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