Working together with Linde we helped a local hospital upgrade their medical gas storage and supply. The process involved getting the proper city permits. Understanding the rules and regulations involved with installation of medical gas. We excavated the site and installed the concrete pad and fencing to the storage tank. Linde came in and installed the tank and accessories. Then a professional plumber finished the job by connecting the new system to the existing system.
This was a unique challenge that required special attention and consideration to detail. The floor plan was designed as a architectural dream around key points of interest to the customer. The structural steel fabrication required to accomplish this dream was by far NOT common to industrial standards. No standard steel fabrication shop wanted to be part of this creation. This required us to take it upon our selves to fabricate each component. Using AutoCAD Advance Steel, numerous phone calls and email, file sharing and links to 3D drawings (such as the one below), we were able to come to an agreement between the Architect and Structural Engineer to how this dream would come to life. All together 52,500 lbs. of steel would be required to create the structure.
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.
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.
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, www.hilmanrollers.com 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.
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.
During a remodeling project on a military base two existing joining building walls were removed. This caused the building to shift. We were contracted by the General Contractor (GC) to reinforce/replace sections of the wall with a new Hybrid Steel Frame / Ordinary reinforced concrete shear wall system. GC on the project presented to us the military’s plans. We reviewed the plans and offered changes to help accommodate with the projects current level of completion. Not interfering with current work and to spend as little time and money on the modification. Once all plans were agreed upon, our portion of the remodel only lasted 17 days.
North Shear Wall
North wall was formed between (2) bays with Steel Frame reinforcement consisting of channel iron to contain the ends of the concrete and a horizontal wide flange beam to create a window to accommodate for the existing overhead duct work. The traditional method of wood form work, steal snap ties and reinforcing bars were used when placing the concrete.
South shear Wall
South wall was also formed between (2) bays with Steel Frame reinforcement consisting of channel iron and wide flange beam. Additionally because of the limited space between the walls we used steel plate backing and coil rods with the traditional wood form work on the front.
Both walls were poured with a 4350 psi minimum concrete. On site mixing, precise water control and vibrators placed along the wall form work during pumping insured that concrete flowed and distributed evenly. Each wall was pumped on the weekend and was completed in less than 8 hours each.
SCOPE OF WORK
- Fabrication, deliver and commission an existing charge hopper that is on plant site
- Add top side boards for additional capacity
- Fabricate and install product discharge profile gate
- Fabrication, deliver 2 each 30”x 40’ 150 tph belt conveyors
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.
Customer has asked us to add a table to their bearing beam. The table must be functional but also offer support to lift the shafts when work on the bearing is needed. To guaranty this, we modeled the exciting condition and added a table. Then simulated the situation by adding a 30ton force to the table under the shaft as the point of contact when lifting. The simulation results are below. In conclusion the table will support the necessary load to lift the shaft and work on the bearings.
Displacement shows that we can expect a max deflection of 0.0216 inches
Stress & Strain simulation
Strain shows that we can expect a max of 0.445 ft-bls
Stress shows that we can expect a max of 27kpsi which is below the yield strength of 36kpsi.
The purpose of this truss is to provide a 60 foot wide opening to move stainless steel tubing from the forming bay to the finishing bay of the manufacturing plant.
The truss supports three columns of a building and crane way live loads.
Sam Vacek PE designed the construction of the truss and we designed the method of installation.
Sam envisioned in place welding as the primary method of installation.
We designed and built the truss as 100% bolt-up at ground level, then lifted completed truss to installation height.
This is a typical example of our ability to provide solutions for improving the outcome of non-forgiving scopes of work.
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!