Case Studies

According to Bob Thurman, Padgett Project Manager, "Planning was everything on this job. The shear was manufactured and shipped from Spain. Coordination was critical. We had to be set and ready to off-load the barge as soon as it arrived. Because there was no working space at the Klempner site each piece of equipment was unloaded, moved and placed sequentially, which meant that the rigging and equipment had to be set for each placement. Technicians came from Spain to oversee the re-assembly and placement of the equipment. In addition to tight spaces, the customer also had a tight schedule for this job which we were able to beat by several days."

The shear arrived at the Port of Louisville via barge where it was off loaded by a tandem crane lift utilizing a 250-ton and a 200-ton crane. The shear had been broken down into 3 large sections and miscellaneous parts for shipment. Each section was loaded onto a 350-ton trailer pulled by our Mack Prime Mover and moved one section at a time to the job site. It took 3 days to off load and move the large sections. In addition to the 3 main sections of the shear there were 3 semi-loads of miscellaneous pieces.

Our work area at the job site was very confined. There was no room to store the equipment until each piece was ready to be set, which meant that each section of the shear was loaded, unloaded and placed. Not only was the space tight, but the yard remained in full production during the move-in and erection.

A 1200-36 gantry system with special rigging was required to remove each section from the 350-ton trailer prior to being placed into position by an 80-ton crane and the gantry. The 120-ton shear stands approximately 28 ft. x 12 ft. x 12 ft. As each section was brought in the rigging was reset to move that piece into position. The piece was set and then the next piece was off-loaded and moved to the job site where the rigging and equipment was reset to move this next section into place. The first section had to

Morrison Knudsen selected Padgett, Inc. for an on-going job, consisting of the removal of 400 machines used at the old Naval Ordinance facility for the manufacture of gun barrels. Before each machine could be moved, it had to first be drained and decontaminated of oil and chemicals. It was then coated with Cosmoline* and wrapped in black plastic to await being transferred to other buildings on site, scrapped, or loaded onto trucks for shipment.

Padgett became responsible for the removal of 28 machines of various sizes, shapes, and weights. Some of the machines were massive. One particular machine, originally installed on July 4, 1942, consisted of 7 pieces, weighing from 19 tons to 64 tons each. This machine was dismantled and loaded onto 16 semi-trailers for transportation.

Each machine was located over a pit that had to be cleaned and mapped, (to insure that any cracks were documented). A typical pit was 30 ft. wide x 60 ft. long x 6 ft. deep. After a pit was cleaned and mapped, it was backfilled with gravel to 15 inches below existing floor level, and then filled with rebar and concrete to bring the pit level with the existing floor.

This particular project required the total expertise of Padgett's rigging experience. Two overhead cranes were linked together to accomplish the 60-70 ton lifts. A 1200-36 Gantry System with special rigging, and 2 large forklifts were used to remove the machinery from the pit areas. Pieces taken from the pit areas were placed onto a 200-ton die cart, (designed and built by Padgett), for removal from the building. Once outside, a 90-ton truck crane was used to transfer the machinery to a semi-trailer.

Under the guidance of Project Estimator Steve Reardon, and Field Superintendent Darrel Herron, this project was finished safely and on schedule.

This project involved the installation of Jeffboat's latest 40-Ton gantry crane #95. The company called for assembly of as much of the crane house and 130 ft. boom as possible prior to positioning it atop a 60 ft. tall gantry base in one pick. This was also challenging because re-arranging the Jeffboat yard for additional space and any loss of production was not allowed by the company. Jeffboat workers would assemble the complete house of the crane and install half of the counterweight. This section would weigh approximately 85 tons. Next, they would assemble the 130 ft. of boom and attach it to the house (another 25 tons ). The total assembly weighing 110 tons would be picked at one time and set on top of the 60 ft. gantry tower. The weight and height of the lift were not the only critical factors involved in this lift. Once the crane house was positioned above the gantry base, the house would need to be lowered slowly and precisely onto a machine shaft approximately 12 in. in diameter by 36 in. long. This shaft would not only hold the crane in position, but would allow it to rotate during actual operation.

A 3-crane lift arrangement was needed for this job because of the weight, lift radius, lifting height, and the precision alignment required. Two Linkbelt truck cranes - a 258 (200-Ton), and a 268 (250-Ton), - would be used for the main hoisting power and attached to lifting lugs on the house. A Linkbelt HTC-11100 hydraulic truck crane would be attached to the head section of the crane boom to assist in keeping that crane level for the precision alignment onto the center shaft. Lifting hardware was also determined at this time. Our fabrication shop would pre-engineer and fabricate a spreader beam.

Five days before the scheduled lift, Padgett began to move in the 18 plus tractor-trailer loads of cranes, booms, counterweights, mats, and rigging needed for the lift. Our cranes had to be assembled completely with 150 ft. of main boom, and all the counterweigh

Phase 1

Working in tandem a 250-ton and a 150-ton crane will off-load equipment from barges at the River Road Terminal (Louisville, KY). This equipment shipped from Japan includes several presses and miscellaneous equipment. The smaller presses and miscellaneous items will be transported to the Padgett warehouse in New Albany and delivered JIT to the Georgetown site. Warehousing will require 5000 sq. ft.

Phase 2

The main press, an Ajax 6,000-ton stamping press, will be discharged from the barge and loaded onto rail car. Once the press arrives in Georgetown, the Padgett crew, using 300-ton slider beams, will off-load the press onto Padgett's new Mack Prime Mover with 350-ton trailer for movement to the job site.

Phase 3

Installation of the #2 line is scheduled to begin March 1st. The line consists of a 6000-ton Ajax press, coin press, pre-form, and trim presses. Like most Padgett machinery moving jobs, this one requires setting a heavy piece of equipment --to exact tolerances-- in a tight space. For instance, the base plates will be leveled and grouted to a 12/10,000 inch per foot tolerance.

Phase 4

Fabricate and install miscellaneous steel including ladders, pit covers, stairs, platforms, etc.