Chiller base modification

Modified the base attachments on two Chillers in Milpitas.

We drilled 12 inches into the concrete and epoxied a 5/8″ stainless steel all thread using Simpson Set XP epoxy.

The initials CEL where written by the inspector indicating the welds passed inspections.

There were 8 total locations

I used E7018 welding rod, a rod which can be used in all Structural applications were mild steel is being welded.

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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.

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.

Broken Fork on Forklift

A Front Loader Fork lift had a broken fork.  Some folks say they don’t have much luck with welding the fork on  a forklift back together.  I do my best to not depend on “luck” to determine what I can or cannot do.  There is a specific procedure to weld these together.  First you must make certain the forks are parellel and they are lined up right.

Then preheat the forks to ensure the weld does not cool down too quickly as the forks are being welded.  It is critical that the filler rod is tougher than E7018 because the forks are typically a medium carbon steel and tougher than mild steel, I used E10018.

Here I used the back of my truck to align the forks, as if the truck needed the additional weight on it, it held up alright.