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6-9-05
Todd-Ford
Murphy Co., a mechanical contractor based in St. Louis Missouri,
was hired by Toyota USA to install seven large Chiller units weighing
30-tons each in their new plant in San Antonio Texas; due to begin manufacturing
operations in late 2006.
In
his 20+ years as a project manager, Don Billington had observed on past
projects other contractors using Fluid Film Technology to move extremely
heavy loads with virtual ease and at a cost that undercuts other forms
of load moving that he had looked into. As Don pursued his search for
the correct mix of Air Caster equipment for his application he quickly
concluded that ASE’s Load Module System would indeed allow his personnel
to install the mammoth chillers on time and under budget.
Each
of the 30-ton chiller units stood 13’ high x 9’ wide x 16’ long.
The
“27-Heavy”, one of ASE’s most versatile rigging & machinery moving
Air Caster systems, was chosen to move the 30-ton chillers. Rated at a
total capacity of 96,000-lbs, the 27-Heavy #4K27NHDL can not only move
loads “easily” at full capacity but also lite and delicate loads weighing
just 5% of total capacity. The 27-Heavy’s versatility would allow Todd-Ford
Murphy to enjoy a myriad of future load moving projects.
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Toy
1:
In the absence of a suitable dock facility due to the early stages
of construction at the Toyota plant, Todd-Ford Murphy (TFM) constructed
a temporary platform where the chillers could start their 150’ to
200’ trek to their final resting positions.
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Toy
2:
The 27-Heavy’s load modules and interconnect hoses were laid out
so that the load bearing surfaces of each chiller would set directly
over the middle of each load module. In this application, the chiller’s
load bearing frame was extremely narrow thus ½” thick metal
plates were placed over the top of each load module to help distribute
the load evenly over each module.
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Toy
3:
As each of the chillers was delivered by the transportation company
a local crane service would lift them from the Low-Boy trailers
and place them on the adjacent platform with the Load Module System.
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Toy
4:
Pull Cords were used to precisely position the “York” Chillers onto
the load modules and also keep the workers at a safe distance.
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Toy
5:
The Control Console and Interconnect Hoses were placed on top and
draped over the chillers where ever possible; it is important to
have the pathway free of any and all obstructions which could cause
the Air Casters to loose flight and also reduces a trip hazard for
the team members.
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Toy
6:
Pryor to moving the chillers a forklift was attached to the leading
end of the load thus giving the rigging team complete control of
the moving process. No floor is absolutely level, if the slop of
the floor is in the opposite direction then your intended direction
of travel, a forklift is ideally suited to provide complete control
of the load and extra boost when faced with a up hill slope.
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Toy
7:
The outside metal platform was built to a height to coincide with
the floor surface of the building’s interior. A 22 gage strip of
sheet metal with it’s leading edged taped with standard carton sealing
tape allowed the load module system to pass over the small gap between
the platform and the building’s concrete floor.
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Toy
8:
Due to the ease at which the Load Module system moves a heavy load,
it is important to move at a very slow speed- ¼ to ½
walking speed is recommended; a slow speed will allow the rigging
team to effectively manage any unexpected issues that may present
themselves during a move.
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Toy
9:
Once the chillers were inside the building they were immediately
side shifted onto the special concrete foundation where they will
remain throughout their useful life cycle. TFM used a Polystyrene
overlay to negotiate the gap between the special foundation and
the temporary interior metal deck.
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Toy
10:
With the forklift reattached to the load to maintain control, and
spotters at the ready, the first chiller was effortlessly moved
to the far end of the special foundation.
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Toy
11:
TFM’s rigging team used ASE System’s Air Jack System to remove the
air caster load modules out from underneath the chillers. A convenient
place under the chiller that was determined to be structurally sound
was chosen as the interface point. 4 x 4 & 6x 6 blocks of wood
were used to crib up to the bottom of the chiller unit. A #2J2424L
air jack system with a total capacity of 64-tons and a lowered height
of 7/8” is ideally suited for lifting duties of this nature.
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Toy
12:
Maximum capacity of each Air Jack System is achieved at low lift
height. Maximum lift height is achieved at reduced capacity which
is why cribbing materials are used in conjunction with the Air Jack
System when lifting extremely heavy loads. Utilizing the hand held
controller a TFM team member inflated the air jack system thus lifting
one end of the chiller and allowing other team members to remove
the air caster load modules on that end. The air jack system was
deflated and moved to the opposite end of the chiller along with
the cribbing materials and the process was repeated.
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Total
time to move the Chillers into place: 25 minutes each.
Total
time to remove the air caster system utilizing the air jack system:
8 minutes each.
At the end of the day Don Billing was beside himself with glee and joy
over doing business with ASE Systems because for the first time in his
long career he had rubbed shoulders with a devoted, enthusiastic and honest
organization that will always have its customer’s “best interest at heart”.
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