Structural Fabrication 1st Quarter 2012

Structural Fabrication for the Department of Water and Fish and Game

The structure in the background of this picture is a completed frame with catwalk.

These frames hold culverts in the Delta near Stockton.  We built 4 total frames.

The dimensions are 5 feet tall, 11 feet wide, 60 feet long, and weighed approx. 16,000 lbs.

The frames where made mostly using 4″x8″x1/4″ rectangular tubing and 4″x6″x1/4″ rectangular tubing.

The majority of the project was welded using NR232.  This welding wire is approved for all structural applications.

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Certified Welding at Cell Phone Tower

We were awarded the contract to do the cell phone tower modifications at a site in LA.

First I had to become an LA Certified Welder.  That was not a problem but very involved – I had to make a special trip to LA, do a welding test I had already completed for my AWS welding certification, and a 50 question test.

The contract required us to install 12 – 1-3/4″ x8′ anchor rods and weld 6 large gussets equally around the tower 20′ high.

To install the anchor rods we had to remove the grout from under the base plate.

The rods needed to be epoxied 7′ into the existing foundation with is 22′ deep.

Before we installed the rods I cut a bevel on the end of the rod so it would go into the epoxy easier without leaving any air bubbles in the epoxy.

Rods epoxied into the foundation

Before installing the gussets I needed to remove all the galvanizing from the plates and the tower  in the weld area so the galvanizing would not contaminate the weld.

I then used a crane to “fly” the gussets in to place.  It took only about 1 1/2 hours to fly all the gussets in.

Welding the gussets in.  I bounced around the tower as I welded so the tower would not get too hot in any one area.

Welding completed and painted.  I also caulked the areas with silicone which were not welded where water could get between the gusset and the tower to keep the rust out.

All told this was a nice project and I enjoyed doing the work.  From coordinating the equipment, subcontractors, and materials to installing the anchors, welding the gussets, and getting final inspections everything what quite well.

Certified Pipe Welding in Sacramento

Dan and I installed this valve assembly Thursday, 2/3/11.

From start to finish we completed it in about 12 total man hours.

We supplied and installed 3 – 6″ flanges, 2 – 90 deg. elbows,  and about 11′ of 6″ pipe.

Dan cut into the existing pipe for the valve assembly and 6″ pipe, then we worked together to fit the pieces in.

Dan completed the project by welding everything up.

Both of us enjoy this type of work and were satisfied with the finished product.

Excavator bucket repair in Santa Cruz

I repaired this “Remu” type excavator bucket for BlueIron, Inc.  They had a job in Santa Cruz so I traveled there to work on the bucket.

The blade was obviously worn,

I cut it off and replaced with a new one.

The grinders were also worn and I hardfaced using tungsten powder.

Hardfacing is the overlaying of a harder material than the parent metal to help the existing metal last longer.  There are several types of hardfacing.  Some are designed to withstand abrasion which you would use in an application where the piece was subject to constant wear from dirt, sand, or gravel, etc.  Others are designed for impact resistance which would be used in applications where the piece is used in crushing or chipping.  The product I used is designed for high wear applications, it is a very specialized type of hardfacing and provides for excellent wearability.

Gate Repair in Sacramento

I was called out to an apartment complex on the north side of  Sacramento, they stated their drive thru gate had been damaged.

This gate had apparently been damaged because someone backed into it.

The only piece that was damaged was the 2×2 frame.

I cut out the full vertical piece of the frame and replaced it.

Then sprayed primer so it did not rust and made it ready for their maintenance to paint to match the existing.

I was on site no more than 45 minutes.  A nice little job.

Cell Phone Tower Modification

I received a call I was hoping to receive, this company needed a certified welder to modify a cell tower here in Fair Oaks, CA.  I believe this is a great fit for my company and am hoping to be able to take care of all the cell tower modifications for this company.

There are several critical elements to modifying a Cell Tower.  Safety is of utmost concern.  The threat that fire is to the cables is always in the front of our mind.  It is critical there be  a fire watch and we had to provide a 500 gallon water trailer on site.  Next the galvanizing must be removed at every weld location.

The galvanizing on this pole was approximately 1/16″ thick.  We had to grind approximately 400 lineal inches by 2″ wide on this pole for the plates that needed to be welded on.

Two of the six gussets we welded on.

The vertical plate shown here with the holes in it is typical of 3 plates on this pole.  They are 10′ tall by 9″ wide.  We drilled 17 1-1/4″ holes in each then mounted them and drilled thru the tower at each location.   Also you can see how close the cables are to the weld locations.

Four of the six fire extinguishers required to be on site.

Modified Gate for Security

 

I was called out to Amtrak here in Sacramento, CA to modify luggage enclosure gate so folks could not reach through or around to open the door.  I used 1/2″ x #13 flat expanded metal for the screen and 1/4″ round bar on the top of the screen so there is a smooth surface on top of the screen.

The gate on the right is a rolling gate and the one on the left is a man gate.  We have been out to the Amtrak station several times to modify things and they have always been nice and good to work with.

This modification is similar to those we have done on pool gates for Apartment complexes, Hotels, and Motels.