Large base
Large base
Large base
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I. Introduction to the Large Base

The large base is a rigid structural platform that supports ultra-heavy equipment, such as 10,000-ton presses, steam turbine sets, and mining crushers. It bears static loads (including the equipment's own weight—up to several thousand tons)—as well as dynamic loads (such as impacts, vibrations, and torques—for example, the impact force of forging hammers can exceed 10,000 kN)—and environmental loads (including seismic forces, wind loads, and thermal deformations).

Core function: Supporting the equipment's own weight (ranging from hundreds to thousands of tons) and dynamic working loads (impact/vibration).

Maintain equipment installation accuracy (levelness ≤ 0.1 mm/m, parallelism ≤ 0.2 mm/m)

Distribute the load to the foundation to prevent settlement and deformation.

II. Common Materials for Large Bases

Component

Commonly Used Materials

Standard/Performance Requirements

Primary Board Material

Q355D/E (Chinese National Standard)

Low-alloy high-strength steel, with an impact energy ≥47 J at -20°C

 

A572 Gr.50 (U.S. Standard)

Yield strength ≥ 345 MPa

Critical weld zone

Q355ND

Anti-laminar tearing steel (Z-directional performance ≥ Z25)

Foundation anchor bolts

40CrNiMoA

Alloy structural steel (tensile strength ≥980 MPa)

III. Selection of Welding Methods

Weld Type

Recommended Process

Advantages

Primary Board Splicing

Submerged Arc Welding (SAW)

Large penetration depth, high efficiency (plate thickness ≥30mm)

Gusset Plate Fillet Weld

Flux-Cored Arc Welding with Gas Shielding (FCAW)

Flexible welding in all positions

High-Requirement Sealed Welds

Narrow-Gap GMAW

Low heat input, controllable deformation

4. Key Processes in Welding Technology

Pre-weld preparation: material cutting, forming, and beveling (with precision control).

Strict cleaning: Remove oil, rust, water, oxide scale, and other contaminants from the bevel and surrounding areas on both sides.

Assembly tack welding: Use the same welding materials and processes as for the final welds, ensuring high-quality tack welds with appropriate length and spacing. Also, inspect assembly gaps and misalignment.

Preheating (if required): Heat evenly to the specified temperature and monitor and record accordingly.

Welding process:

Weld strictly according to the WPS and welding sequence.

Control interlayer temperature (monitor and record).

When performing multi-pass, multi-arc welding, carefully clean away interlayer slag and spatter. Ensure proper fusion of the weld beads to prevent defects.

Monitor key parameters (current, voltage, speed, gas flow rate, etc.).

Key Process Control

Bevel Design: Thick Plate Butt Joint: Double-U Bevel (Reduces Weld Material by 30% and Minimizes Residual Stress)

Rib plate welding: Deep-penetration fillet welds (weld throat ≥ 0.7 × plate thickness)

Preheating and Interpass Temperature: Q355D (plate thickness ≥40mm): Preheat to 80–120°C, with an interpass temperature ≤250°C.

Welding sequence: Symmetrical skip welding method: First weld the vertical rib-to-bottom plate seam → then weld the vertical rib-to-top plate seam

Weld outward from the center to reduce concentrated shrinkage stress.

Post-weld treatment: Vibration Stress Relief (VSR): 30%–50% residual stress reduction (as an alternative to thermal stress relief)

Localized annealing: 600°C stress treatment in the anchor bolt area (preventing fatigue cracks)

Welding Process

Application Scenarios

Material preparation process

Flame cutting (CNC cutting), plasma cutting, laser cutting, shearing, and sawing. High-precision bevel machining (such as edge milling and bevel cutting machines).

Forming process adopted

Rolling (cylindrical and conical shapes), bending (using a bending machine), pressure forming (with large-scale presses), and roll forming.

Assembly and Alignment

Using large-scale tooling fixtures and platforms—such as welding positioners and roller stands—ensures the precise positioning and dimensions of each component. This is a critical step in quality control.

Common Welding Methods

Application Scenarios

Submerged Arc Welding

Suitable for long straight welds and circumferential seams (such as longitudinal and circumferential seams of cylindrical shells).

Gas-shielded welding

MAG (CO2 or mixed gas), MIG (inert gas). Widely used and highly versatile (manual, semi-automatic, automatic), suitable for various positions and joint types.

Shielded Metal Arc Welding

Suitable for positions that are difficult to automate, short welds, and repair welding. It is less efficient and relies heavily on the welder's skill.

Electroslag Welding

Vertical welding for extra-thick plates (such as box-beam diaphragms).

Narrow-Gap Welding

Designed for butt joints of ultra-thick plates, it offers high efficiency with minimal deformation.

Post-weld treatment

 

Stress

Large components generally require post-weld heat treatment—either overall or localized (typically stress relief annealing)—to remove weld slag and spatter, followed by grinding of the weld seam and its surrounding areas. This process helps relieve residual welding stresses, preventing deformation, cracking, and improving the material's toughness.

Orthopedic

Flame straightening, mechanical straightening (using a press), to control welding deformation.

Mechanical Processing

Perform precision machining operations such as milling, boring, and drilling on critical mating surfaces and hole locations.

 

We will conduct non-destructive testing, inspection, and testing on the products:

Project Content

Visual Inspection

Surface defects (cracks, undercut appearance inspection (VT), porosity, arc craters, etc.).

Ultrasonic Testing (UT)

Detecting internal defects (such as lack of fusion, incomplete penetration, slag inclusions, and cracks) is especially critical for thick plates.

Radiographic Testing (RT)

Intuitively displays internal defects and is commonly used for critical butt joints.

Magnetic Particle Testing (MT)

Detection of Surface and Near-Surface Defects (Ferromagnetic Materials)

Penetrant Testing (PT)

Detecting surface opening defects (non-magnetic materials).

Destructive Testing (Sampling)

Such as tensile, bending, impact, hardness, and metallography tests (typically conducted during process qualification or random inspections).

Dimensional Inspection

Check whether the overall structural dimensions and dimensions of key components meet the drawing requirements.

Pressure/Leak Test (if required)

Such as hydraulic tests, pneumatic tests, and air-tightness tests.

V. Specification Range

Typical scenario weight reference

Device Type

Equipment self-weight

Base weight

Structural Features

2000-ton press

300t

350–450 tons

Box-type integral casting + welding

300MW Steam Turbine Generator Unit

450t

550–700 tons

Modular Steel Plate Welding (Modules ≤50 tons)

Mining crusher

80t

100–120 tons

Thick base plate + heavy-duty ribbed plate

Ship Propeller Base

-

200–300 tons

Double-layer grid structure (torsion-resistant design)

Weight Composition Ratio

Component

Weight Percentage

Explanation

Baseplate

40% to 50%

The thickest plate (often reaching 100mm+)

Top cover plate

20% to 25%

Precision-finished surface (flatness ≤1 mm/m)

Ribbed Plate

25% to 35%

Grid spacing ≤ 1.5 m

Attachment

5% to 10%

Anchor bolt boxes, lifting lugs, and more

Keywords

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Large base
Large base
Large base
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  • Large base
  • Large base
  • Large base

Large base

The large base is a rigid structural platform that supports ultra-heavy equipment such as 10,000-ton presses, steam turbine units, and mining crushers, bearing static loads. Commonly used materials include Q355D/E (national standard), Q355ND, 40CrNiMoA, and others, making it suitable for applications in industries like chemical engineering and mining equipment manufacturing.

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