In various large-scale events, public places and even daily traffic management, we often see a seemingly ordinary but vital facility – crowd control barriers. They are usually made of metal or plastic and are in the form of continuous barriers. Their core function is to guide, restrict and manage the flow of people to ensure public order and safety. As a professional fence manufacturer, our crowd control barriers not only provide an efficient management solution but also ensure the optimization of safety and efficiency through technological integration, and sustainable practices. We will take a deep look at crowd control barriers and the related production process in this article. and innovative design.
Crowd Control Barriers Production Process
Precision machining of frame tubes
- We purchase high-quality hot-dip galvanized steel pipes that meet national standards. The average zinc layer thickness is not less than 60-80g/m², which is much higher than the industry average, and the corrosion resistance is improved by more than 20%.
- Imported high-speed fiber laser cutting machines are used to perform automated, non-contact cutting of pipes. The cutting accuracy is controlled within 0.3mm, which is 40% higher than the traditional sawing efficiency and 5% lower material loss rate.
- High-precision CNC punching equipment is introduced to perform multi-point, high-precision punching of pipes according to preset drawings. The aperture tolerance is controlled at 0.1mm, and the hole spacing error is less than 0.2mm to ensure the accuracy of subsequent welding and assembly.
- Fully automatic pipe bending machines are used to bend and form pipes at precise angles and radii according to design requirements. The bending angle accuracy is controlled at 0.5 degrees, and the maximum bending radius can reach R200mm, effectively avoiding human errors and material waste.
Automated processing of vertical pipes
Similar to frame pipes, vertical pipes are made of high-quality galvanized steel pipes with a wall thickness of 1.0-1.2mm to ensure their load-bearing and pressure resistance. The compressive strength of a single vertical pipe reaches 350 MPa, and its bending resistance is excellent.
Automatic feeding and fixed-length cutting technology are adopted, and the tolerance is controlled within 0.2mm to ensure a perfect fit with the frame pipe.
Robot and manual collaborative welding
Industrial robots automatically weld and work with experienced welders. The robot welding speed is increased by 3 times, and the weld consistency reaches 99%. All welds are required to be fully welded, the weld penetration reaches more than 80%, and the weld tensile strength is increased by 30%.
Sandblasting pretreatment
The guardrail body is sandblasted, and standard quartz sand or steel sand is used for comprehensive sandblasting. This step completely removes impurities such as welding slag, oxide scale, rust and oil. The surface cleanliness reaches more than 95%, and the surface roughness usually reaches Ra 6.3-12.5μm, which significantly improves the adhesion of subsequent coatings by 25%, ensuring the durability of the coating.
Multi-stage immersion phosphating
The guardrail is degreased-washed-pickled-washed-surface-adjusted-phosphating-washed-passivated. This process forms a dense zinc or iron phosphating film on the metal surface. The weight of the phosphating film is controlled at 3-5g/m², which can increase the corrosion resistance of the guardrail by 2-3 times, and significantly enhance the adhesion of the powder coating by more than 50%.
Electrostatic powder spraying
Special polyester powder coating is used for electrostatic spraying and cured in a high-temperature oven. The coating thickness is uniformly controlled at 60-80 microns. The curing temperature reaches 200°C. The fence after spraying passes the salt spray test for more than 1000 hours, ensuring the service life of the guardrail for more than 15 years in harsh outdoor environments.
Comprehensive quality inspection and packaging
Each guardrail undergoes a strict quality inspection process before leaving the factory. 100% visual inspection of the appearance: Ensure no scratches, no spray leakage, and uniform color. Conduct coating thickness detection, adhesion test, weld strength test and structural stability test. Ensure that each product meets or exceeds customer expectations.
For packaging, environmentally friendly PE film wrapping and pallet packaging are used to ensure that the product is intact during long-distance transportation.
Vertical Tubes Production
- Tube Procurement: Similar to frame tubes, vertical tubes are made from high-quality galvanized steel, chosen for their load-bearing capacity and durability.
- Cutting: Each tube is cut to precise dimensions using advanced cutting technology to ensure all components fit together perfectly.
- Welding: Skilled technicians weld the frame and vertical tubes together. We use automated and manual welding techniques to enhance the structural integrity of our barriers.
- Sandblasting: Post-welding, the barriers are sandblasted to remove any impurities, rust, or scale from the surface, providing a clean base for further treatments.
- Phosphating: The barriers undergo a phosphating process, which involves applying a phosphate layer to protect against corrosion and enhance paint adhesion.
- Painting: We apply a high-quality, weather-resistant electrostatic paint, thus ensuring a long-lasting finish that withstands various environmental conditions.
- Quality Inspection: Each barrier is subjected to a comprehensive quality check. This includes structural integrity tests and finish inspections to ensure they meet our stringent standards.
Crowd Control Barriers Base Production Process
Iron Plates:
– Cutting and Punching: precisely cut plates and punch holes for assembly.
Galvanized Rods:
– Cutting: Cut the rods to the exact lengths needed for the base structure.
Welding:
welding all components together, focusing on points that bear the most stress.
Surface Treatment:
Using a protective coating to prevent corrosion and enhance durability.
Quality Inspection:
The base undergoes its own set of rigorous inspections to ensure stability and longevity.
Advantages of Our Crowd Control Barriers Production Process
Precision and Consistency:
Our use of advanced laser cutting and CNC technology ensures that each component of the crowd control barrier with high precision. This consistency is crucial for the structural integrity and aesthetic uniformity of our products.
Durability:
From the selection of high-grade steel to the application of protective coatings, each step in our process is to enhance the durability of our barriers. This ensures they can withstand harsh environmental conditions without degrading.
Efficiency:
Our streamlined production process allows us to meet large orders without compromising on the quality of each unit produced.
Key Considerations in Our Production Process
Material Quality:
We strictly use materials that meet international standards for strength and durability. Regular audits and supplier evaluations ensure that only the best raw materials enter our production line.
Environmental Compliance:
All stages of our production process comply with environmental regulations. We use eco-friendly materials and processes wherever possible, particularly in our coating and waste management practices.
Worker Safety:
Safety is paramount in our facilities. We adhere to all safety guidelines and regularly train our staff on new safety practices and equipment.
Our Competitive Advantage
– Customization:
We offer customized solutions to meet diverse client needs.
– Technology:
Our use of cutting-edge technology in production leads to superior product quality.
– Expertise:
With years of experience, our team provides insights and solutions unmatched by competitors.
Detailed Advantages of Our Crowd Control Barriers
Robust Construction:
- Focus on high-traffic durability and stability, thus making them ideal for managing large crowds in various settings.
- Reinforce welding points, and inspect each joint to ensure maximum strength.
Advanced Coating Technology:
- The phosphating and electrostatic painting processes not only enhance the aesthetic appeal of our barriers but also provide a weather-resistant finish that protects against rust and corrosion.
- This treatment ensures that our barriers maintain their appearance and functionality over time, even in outdoor environments.
Customizable Design:
- We offer customization options in terms of size, color, and features (such as gates or locking mechanisms), allowing our barriers to meet the specific needs of different venues and events.
- This flexibility makes our products highly sought after for both permanent installations and temporary events.
Ease of Use:
- Our barriers are quick to deploy and easy to operate. They are lightweight yet stable, thus making them easy to transport and set up.
- The interlocking system is user-friendly, thus ensuring that barriers can connecting or reconfigured without requiring tools.
Cost-Effectiveness:
- Despite the high quality of materials and technology used, we maintain competitive pricing. Our efficient production process reduces waste and lowers costs, benefits that we pass on to our customers.
- The longevity and low maintenance requirements of our barriers also provide long-term cost savings to users.
Versatility:
- Our barriers are suitable for all types of events and venues, from concerts to political rallies, thus ensuring effective crowd management in different scenarios.
- The modular design allows for various configurations, adapting to the specific layout and size requirements of each event.
Safety Features:
- Safety is our top priority. Our barriers feature smooth edges and sufficient weight to prevent toppling, thus reducing the risk of injury to attendees.
- We also offer barriers with enhanced features for high-security events, including reinforced panels and anti-tamper connections.
Aesthetic Options:
- We understand the importance of maintaining the visual appeal of event spaces.
- Our barriers come in various colors and can custom with logos or advertising, making them an integral part of the event’s branding.
Conclusion:
Through continuous technological innovation and strict quality control, our crowd control barriers have become leaders in the market. We focus not only on the functionality and safety of our products but also on enhancing the efficiency of use and production through various education and training programs for clients and staff. Additionally, our environmental measures and community engagement activities reflect our sense of responsibility as corporate citizens. In summary, our goal is to provide the highest quality products and services to our clients through ongoing innovation and responsible practices, while also contributing to sustainable societal development.
