System and methof for fabricating hot-rolled semi light weight i-form beam

Abstract

The embodiments herein provide a hot-rolled semi light weight, medium I-flange (I-7) beam with strength and more resistance when compared with the existing I-flange beam standards. The flange (I-7) beam comprises a vertical element known as web and two horizontal parallel edges known as flanges. The web connects the two parallel edges and forms the flange (I-7) beam. Due to light weight, the flange (I-7) beam imposes less load on structural elements in the construction and eases the use of beams at the construction site. Light weight of the flange (I-7) beams reduce the transportation costs at the construction site. Also, the flange (I-7) beam is cheaper than existing flange beams and uses less raw materials and energy during the manufacturing process. The manufactured flange (I-7) beams are free from defects such as crack, delamination, tear, non-metallic inclusion, and folds.

What is claimed is: 
     
         1 . A hot-rolled semi light weight, medium flange (I-7) beam comprising:
 an upper flange;   a lower flange; and   a web;   
       wherein the web extends between the lower flange and the upper flange, and wherein the upper flange is perpendicular to the web, and wherein the lower flange is perpendicular to the web and wherein the web separates the upper flange and the lower flange with a height (h), and wherein the web has a thickness (s), and wherein the upper flange and the lower flange has an equal width (b), and wherein the upper flange and the lower flange has an equal thickness (t), and wherein the flange beam is made up of a steel alloy and wherein the steel alloy is selected from a group consisting of steel 275 type alloy, steel 295 type alloy. 
     
     
         2 . The beam according to  claim 1 , wherein the beam is identified using an identifier, and wherein the identifier of the beam comprises an abbreviation, a beam number, and a minimum yield strength of the steel alloy in N/mm 2 . 
     
     
         3 . The beam according to  claim 1 , wherein the steel 275 type alloy comprises a carbon (C) at a quantity of 0.18%, a manganese (Mn) at a quantity of 1.50%, a phosphorus (P) at a quantity of 0.030%, a sulfur (S) at a quantity of 0.030%, a nitrogen (N) at a quantity of 0.012%, a cupper (Cu) at a quantity of 0.55%, and a Carbon equivalent  (C eq ) at a quantity of 0.40%, and wherein the Carbon equivalent  (C eq ) is equal to sum of (Carbon (C)+Manganese (Mn))/6+(Chromium (Cr)+Vanadium (V)+Molybdenum (Mo))/5+Cupper (Cu)+Nickel (Ni))/15. 
     
     
         4 . The beam according to  claim 1 , wherein the steel 295 type alloy comprises a carbon (C) at a quantity of 0.20%, a silicon (Si) at a quantity of 0.50%, a manganese (Mn) at a quantity of 1.50%, a phosphorus (P) at a quantity of 0.025%, a sulfur (S) at a quantity of 0.025%, a nitrogen (N) at a quantity of 0.012%, a cupper (Cu) at a quantity of 0.45%, and a Carbon equivalent  (C eq ) at a quantity of 0.40%, and wherein the Carbon equivalent  (C eq ) is equal to sum of (Carbon (C)+Manganese (Mn))/6+Chromium (Cr)+Vanadium (V)+Molybdenum (Mo))/5+Cupper (Cu)+Nickel (Ni))/15. 
     
     
         5 . The beam according to  claim 1 , wherein a tilt of the upper flange is measured in relation to the web, and wherein the tilt of the upper flange has a maximum allowable flange tilt, and wherein a tilt of the lower flange is measured in relation to the web and wherein the tilt of the lower flange has the maximum allowable flange tilt, and wherein the maximum allowable flange tilt is 1.5 mm when the width (b) of the flange is less than or equal to 110 mm. 
     
     
         6 . The beam according to  claim 1 , wherein the upper flange is symmetrical with respect to the web, and wherein the lower flange is symmetrical with respect to the web. 
     
     
         7 . The beam according to  claim 1 , wherein the thickness (s) of the lower flange is measured at a distance of one fourth of a total width (b) of the lower flange. 
     
     
         8 . The beam according to  claim 1 , the height (h) of the web is equal to an outer distance between the upper flange and the lower flange along a cross axis of the web. 
     
     
         9 . The beam according to  claim 1 , wherein the chemical components of the steel 275 type alloy and the steel 295 type alloy have tolerance in relation to percentage weight, and wherein a tolerance of the carbon (C) in relation to percentage weight is +0.03, and wherein a tolerance of the silicon (Si) in relation to percentage weight is within range of +0.05 to +0.010, and wherein a tolerance of the Manganese (Mn) in relation to percentage weight is +0.10, and wherein a tolerance of the phosphorus (P) in relation to percentage weight is +0.010, and wherein a tolerance of the nitrogen (N) in relation to percentage weight is +0.0020, and wherein a tolerance of the Cupper (Cu) in relation to percentage weight is +0.05. 
     
     
         10 . The beam according to  claim 1 , wherein the beam has a weight (G) with an allowable weight tolerance, and wherein the maximum allowable weight tolerance is equal to ±4% of a nominal weight of the beam. 
     
     
         11 . The beam according to  claim 1 , wherein the beam has an effective length (L) with an allowable length tolerance, and wherein the allowable length tolerance of a normal product with a fixed length up to 12000 mm is ±50 mm, and wherein the allowable length tolerance of a custom built product with a given length up to 15000 mm is ±5 mm or ±10 mm or ±25 mm. 
     
     
         12 . The beam according to  claim 1 , wherein a transverse shear stress produces a tilt in the beam, and wherein the beam has a maximum allowable tilt of transverse shear, and wherein the maximum allowable tilt of transverse shear is measured in relation to the height (h) of the web, and wherein the maximum allowable tilt of transverse shear in relation to the height (h) of the web is 1.6% of the height (h). 
     
     
         13 . The beam according to  claim 1 , wherein the maximum allowable tilt of transverse shear is measured in relation to the width (b) of the flange, and wherein the maximum allowable tilt of transverse shear in relation to the width (b) is 1.0% of the width (b). 
     
     
         14 . The beam according to  claim 1 , wherein the beam has a maximum asymmetry and wherein the maximum asymmetry of the flange beam is 2.5 mm. 
     
     
         15 . The beam according to  claim 1 , wherein the beam has a straightness, and wherein the straightness of the beam is measured using a straight edge as a reference, and wherein the beam has a maximum tolerance of deviation from straightness, and wherein the maximum tolerance of deviation from straightness is 0.0030 mm when the height (h) is within a range of 120 mm to 80 mm, and wherein the maximum tolerance of deviation from straightness is 0.0015 mm when the height (h) is 200 mm. 
     
     
         16 . The beam according to  claim 1 , wherein the beam has a maximum web curvature (f), and wherein the maximum curvature (f) is 1.0 mm when the beam number is 12, and wherein the maximum curvature (f) is 1.5 mm when the beam number is a range of 14 to 20. 
     
     
         17 . A method for producing a hot-rolled semi light weight, medium flange (I-7) beam, the method comprising steps of:
 cutting a steel ingot into pieces of a preset length, and wherein the steel ingot is made up of a steel alloy;   placing the steel ingot pieces in a heating furnace for melting the steel alloy;   passing the melted steel ingot pieces through a rolling assembly, and wherein the rolling assembly reduces a thickness of the steel ingot pieces to a uniform level along an entire length of the steel ingot pieces;   cutting the rolled steel ingot pieces into custom sizes using a plurality of saws;   passing the steel ingot pieces through a cooling bed and a straightener there by forming a semi light weight, medium flange (I-7) beam.   
     
     
         18 . The method according to  claim 17 , wherein the preset length of the steel ingot pieces is within a range of 3.2 to 4.2 meters. 
     
     
         19 . The method according to  claim 17 , wherein the rolling assembly comprises a plurality of primary rolling stands, a plurality of middle rolling stands, and a plurality of final rolling stands. 
     
     
         20 . The method according to  claim 17 , wherein the furnace is maintained at a preset temperature, and wherein the preset temperature is of 1350 C.