Category: Industrial Maintenance


Transformer Removal

For this project the costumer needed to remove 3 transformers for service and maintenance.   The job called for 2 transformers removed from the second floor and one located outside.  For obvious reason the two from the second floor presented the most challenges.

Transformer Platform

First challenge in removal was the fact that the door for was 25 feet in the air and no ledge or platform to place the transformers for the crane to pick up.  For this we created a costume built steel platform to fit inside the doorway.  This was anchored down through the concrete floor and also the legs were anchored below into the concrete.

Hilman Rollers

Second challenge was moving the transformers.  Their weight was 1800 lbs and 28500 lbs each.  But this challenge was easily met by the use of Hilman Rollers.  With the KRS-30-SLD kit.  each roller having the capacity of 7.5 tons, Swivel Locking Diamond grip top.  Moving the transformer was only a matter of cable winch and pulleys.  You can find more about the Hilman Rollers on their web site, and also see a short video of our rollers in action below.

18000 lbs Transformer

Each transformer presented it's own challenge but the process was the same.   This required us to first rise the transformer high enough to place the roller under on each of the corners.  Then moving the transformer off the pad and over the containment curb.  Once located in the main hallway we had to perform a 90 degree turn and pull the transformer towards the loading platform.  Once on the platform we removed the cable winch and used come-along winch for more precise motion control.  Then it was just a matter of connecting the transformer to the waiting crane cables as the transformer exited the door onto the platform.

28600 lbs Transformer

24300 lbs Transformer

 The Third and final transformer was much easier.  Able to get the crane parked right beside the transformer, pick up and place directly onto the transportation truck.  Of course safety being the most important, we had power line in the area and this was discussed and documented on proper JSA forms.


Demo & Installation


Due to poor water conditions and maintenance this cooling tower condition quickly deteriorated.  In less than 5 years all galvanized steel was corroded, rusting and literally falling apart.  Customer has purchased a new stainless steel tower and called us to Demo the old structure before delivery and Install the new structure.  We had already helped the customer in decommissioning the tower due to safety concerns.

The challenge of this Demo was that the plant, and there for the other tower, was to remain in operation.   We had to be extremely careful and work around and under the existing return water return lines.  We started work by removing the central components such as fan shroud, fan with motor and gear box and internal fan frame works. Next was to remove the Counterflow Film Fill material and supporting frame work.   Working under the water return lines we couldn’t just lift and carry away.  We cut the frame from the bottom basin,  attached to the top pulled down and inward.  The first frame pulled away and remained intact.  With the second frame the fill material separated from the frame upon lifting.  Finally the solid stainless steel basin was remaining and that was easily separated from the base support beams and removed.


Installation presented additional challenges.  Due to the width of the tower and lifting location we had to create our own custom spreader beam.   First the delivery truck was unable to drive around and park near the location.  This required an additional lift to move the new tower near the site.  Second with the  water return lines still in place we had to lift the new tower in one, place it on the base support beams and slide it into place.

The following week we returned to ready to tower for operation.  Installed the water fill lines, attached the water suction and return lines,  and wired the fan motor for operation.  After a short time to trial the new tower we will return to demo the second old tower.

Hot Flue Gas Project

Customer asked us to replace existing 48″ fiberglass duct with a stainless steel duct.  The installation also included a new working platform and replacing the fiberglass transition duct.  Work site required MSHA certification by all working crew.

removal of excising ductnew platforminstallation of new stainless steel duct


Recondition composite shaft puller

Customer asked us to recondition the composite shaft puller.  We received the unit with broken guide rods, bent frame work and control box dissembled. Unit left our shop fully functional and as a complete assemble. The hydraulic pump and control box were mounted to the machine and with a fresh coat of paint.

Custom Drain Installation

From design to reality...

Here is an example of a customer asking us to cut into an existing concrete floor.  They gave us the desired lay out and suggested a pre-sloped fabricated drain system.

Our job was to make it happen.  From cutting the floor, digging the trench, installing the drain and refinishing the floor.  All within a budget they could afford.

Work was done on weekends and during normal business hours.  Safety was key!