How Are Cranes Built? Your Guide to Crane Creation

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Cranes are a crucial part of the construction process. Primarily known for lifting and moving heavy objects, these machines have been around since the ancient times.

Let’s take ancient Egypt for example. Back in the day when they wanted to transport water up, and down the Nile River they used a crane called a shaduf.

This crane consisted of a bucket/weight system where the user would pull the bucket down on one side and allow the heavyweight to pull the bucket up on the other side.

Thanks to technology, modern cranes don’t require that much arm work. With a push of a button, heavy objects are now lifted and placed precisely how where you need them.

So the question is: How are cranes built now? How did we evolve? Let’s take a look.

Let’s Talk About The Basics: How Are Cranes Built?

What does it take to construct one of these monstrous machines? How are they able to work so effectively?

Depending on the size, a crane can weigh anywhere from 10 tons to 300 tons and can hold up to 400,000 pounds. So when it comes to the crane structure, clearly every manufactured part is vital to make this move and lift exactly how it’s supposed to.

1. Making Steel Components

When it comes to figuring out how cranes are made, steel is the essential material in the manufacturing process. Melted iron is taken through a furnace where carbon is removed via the oxygen blasted in the liquid.

Much like the welding process, the steel is melted and molded in high temperatures to form flat sheets, rods, and bars that make up the crane material.

2. Assembly

After the components are intricately cut and formed – it is then moved into an assembly line where the welding and bolting process begins.

Different cranes require different types of machine operation. For instance, a mobile crane is usually assembled to the blueprint of a truck or crawler. Contingent upon the size, the cranes may either be assembled in the factory or broken down and put together on site.

3. Quality Check

Every single crane has to go through a quality check inspection. Assuring the security of the crane is one of the most important factors in this process.

From the largest sheet of metal to the smallest cable, these pieces arrive at a crane manufacturer where they go through lathes, drills, and precision machinery where they’re shaped to form mobile crane parts, hoists, and other important parts that make up the crane design.

Let Us Be Your #1 Source For All Your Industrial Needs.

There you have it. Everything you need to know about how cranes are built.

Here at Kor-Pak, we focus on everything industrial. From supplying machine parts to aiding engineers who need to custom solutions for their industrial environment – allow us to help you with your manufacturing needs.

Feel free to contact us to request a quote or if you have any questions! We are here to help.

The Different Types of Oil Drilling Rigs

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Drilling rigs are essential to the oil and gas industries because of their ability to extract petroleum from the earth’s surface. There are many types of drilling rigs, used in both offshore and land-based drilling. The type of oil rig selected for a particular job depends on the specific requirements of the site.

Both offshore and land-based rigs bring in large amounts of oil, though offshore rigs tend to come to mind when you think of an oil rig.

Let’s take a closer look at the different types of drilling rigs, how they are designed, and their uses.

The Different Types of Drilling Rigs

An oil drilling rig extracts petroleum from the earth. But there are different types of drilling rigs. Here’s your guide to know which rig your company needs.

Jackup Rigs

Jackups are the type of drilling structure most often used for offshore operations. The main deck is supported by a series of open-truss legs that extend up to 350 feet to the ocean floor.

Some jackup rigs are known as a keyway or slot-type rigs, which have an opening in the drilling deck, with a derrick positioned over the opening. The second type of jackup is known as a cantilevered jackup, with the drilling derrick mounted to an arm that extends out from the deck.

Floaters

This type of offshore oil drilling rig is semi-submersible units that float on giant pontoons or hollow columns that can submerge the rig to the needed depth when filled with water. Floaters are typically used for drilling new wells because of their ability to withstand rough ocean conditions.

Fixed Platforms

These types of oil platforms are permanent, immobile cement structures, used to house drilling rigs that open new wells. Fixed platforms are connected to the ocean floor, and are large enough to house crew and equipment.

These are mostly found in great depths, up to 1,700 feet, such as on continental shelves, and can use a drilling technique called directional drilling, allowing them to be attached to numerous wells within a five-mile radius.

Complaint Towers

Similar to fixed platforms, complaint towers consist of a narrow tower supported by a piled foundation, and a conventional drilling deck. Because of its narrow and flexible design, a complaint tower can withstand tremendous forces sustaining great lateral deflections in depths from 1,500 to 3,000.

Drillships

Typically built on tanker hulls, these merchant’s vessels are designed for use at great depths for scientific drilling purposes. These vessels look similar to tankers or cargo vessels, but drillships are equipped with a drilling derrick and a helipad for receiving supplies and transporting staff.

Drillships are mobile, able to propel themselves from location to location.

The Importance of Oil Rigs

Each of these types of drilling rigs is vital to the production of oil and gas. Crews work around the clock, every day of the year, pumping petroleum from the earth for countless purposes, for both industrial and consumer uses.

It’s a complex, fascinating industry that impacts your life in more ways than you could imagine.

Contact us to learn more about Kor-Pak’s products and services.

Your Guide to Overhead Crane Safety

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Overhead crane safety is of paramount importance. The statistics speak for themselves. For example, the U.S Bureau of Labor Statistics, reports that between 1992 and 2006, 632 deaths occurred because of crane accidents.

Although safety measures have improved over the last decade, the fact remains that health and safety standards in this arena need maintaining.

In light of this, we’ve compiled a mini guide to overhead crane safety. Hopefully, this will help minimize the likelihood of you and your employees experiencing any accidents on the construction site.

Complete a Safety Checklist Before Operating Cranes

If you don’t have a safety checklist in place, then we recommend drawing one up and completing it before operating a crane.

Here are a few things to include:

  1. Check for any loose materials (packaging, parts, etc.) and remove them before operating the crane.
  2. Always check the load’s maximum capacity weight and ensure the amount doesn’t exceed this limit. This information is usually marked on the outside of the crane, so it’s pretty easy to familiarize yourself with this.
  3. Always remove visible slack from the hoist or sling before lifting.
  4. Ensure the space between the equipment and the loading destination is clear of any hazards or dangerous components that could obstruct the lift.
  5. If you’re working alongside colleagues, let them know when you’ll use the crane, what you’re moving and where you’re planning on using it.
  6. If you’re helping to load the transfer, make sure you and your coworkers position yourselves so you can see the load without putting yourselves in harm’s way.

By executing these preliminary safety measures you drastically increase the likelihood of having an accident-free transfer.

Things to Avoid While Operating an Overhead Crane

We recommend always avoiding the following while operating an overhead crane:

  • Never use a crane if the limit switches are either down or out of order.
  • Never allow yourself to become distracted during the move. You should watch the load at all times; focus is of paramount importance.
  • Never lift a load from a sideways angle. Always aim to center the weight before hoisting. This helps to reduce swinging during the transfer and makes the process safer and easier to control.
  • Don’t under any circumstances allow people to ride on the load during the transfer.

Be sure to follow all of the above advice, stick to these pointers and hopefully you shouldn’t go too far wrong.

Was This Article on Overhead Crane Safety Useful?

If you found this article on overhead crane safety useful, then we’re confident you’ll love our blog. Over there we discuss everything from new crane parts to machine maintenance. Enjoy!

Or, if you have any questions about the content of this blog post, please feel free to reach out and contact us.

One of our professionals will be more than happy to steer you in the right direction.

Your Guide to the Industrial Disc Brake Caliper

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Without the invention of the industrial disc brake caliper, many industries just wouldn’t be what they are today.

Industrial disc brakes are essential to the operation of a number of industrial applications.

Their function governs the operation of many sectors, including the agricultural, mining, energy, oil and marine, and manufacturing industries.

Industrial disc brakes are manufactured in many forms, each suited to their own application and industry.

To learn more about the various industrial disc brake calipers on the market today, this blog highlights it all.

Industrial Disc Brake Caliper Applications

No matter the industry or application, all caliper disc brakes work to achieve the same end goal: to slow, hold, or stop fast moving or heavy loads.

Some caliper disc brakes are designed to achieve this very quickly, while others work in slower motion.

Caliper disc brakes offer the ultimate safety solution and are designed to withstand extreme tension associated with dynamic braking.

Industrial disc calipers are capable of withstanding the most aggressive of conditions, extreme temperatures, locations, and volatile environments.

Some of the most common industrial applications for caliper disc brakes include:

  • Industrial manufacturing
  • Mining
  • Oil and gas extraction
  • Energy production
  • Entertainment
  • Shipping and transportation

As we mentioned, there are various different types of industrial disc brakes, some of the most commonly used include:

Mechanical Disc Brake Caliper

Mechanical disc brake calipers work at the most simple level of the braking system. They are generally operated by a lever, and require no external power source.

Mechanical brakes are most commonly found in common vehicles, such as your car, operated by a handbrake.

They are best-suited as a safe stopping mechanism within most industries.

Pneumatic Disc Brake Caliper

These caliper disc brakes are powered by compressed air, making it a highly popular braking system across many industries.

The source of power is readily available due to the fact that many industries make use of pneumatic compressors throughout their business.

This braking system is used to slow or bring rotating parts to a complete stop, operating at 70-120 PSI.

Hydraulic Disc Brake Caliper

The hydraulic disc braking system is powered by compressed fluid, known as hydraulic oil across many industries.

Hydraulic brakes operate under immense pressure and are best-suited to holding, stopping or tensioning extremely heavy or fast-moving machinery.

This is also known as high torque braking, and is most commonly used in the mining, oil and gas industries.

Spring Applied Disc Brake Caliper

Unlike a hydraulic braking system which uses direct pressure, this system uses a spring to apply direct pressure onto a moving part.

This system is also known as a ”fail-safe” braking and is highly common in industrial settings.

Stopping, slowing and braking is maintained by the braking system, until the spring is released and parts begin moving once again.

Dual Function Disc Brake Caliper

This dual function braking system combines both mechanical and hydraulic braking force onto a moving or rotating object.

Essentially, this system offers double the amount of braking torque.

However, some pieces of equipment will include separate bores for either the mechanical brake system or hydraulic brake system.

Looking For the Best Spare Parts in the Industry?

Whether you’re looking for a mechanical disc brake caliper or clutch and brake accessories, Kor-Pak supplies it all.

At Kor-Pak our goal is to minimize your downtime as a business, helping you repair, replace or refurbish equipment parts as and when needed.

Looking for a specific spare part for your machinery? Contact Kor-Pak for assistance.

Tips for Every New Crane Operator

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After extensive studying and hands-on training, you’re now officially a crane operator. Congratulations! You’re entering a promising new career.

Here’s why.

Research shows that jobs for material moving machine operators, such as the operators of cranes, will grow by 6% between 2016 and 2026.

Of course, even after training, operating a crane can be intimidating. If you’re a new crane operator, here are some tips to prepare you for your brand-new career.

Let’s get started!

Your Crane Operator Environment

When it comes to operating a crane, safety is your number-one priority. Always.

Therefore, for starters, make sure that your job site can support your crane and future loads before you get set up.

Also, be cognizant of any overhead hazards present in the area where you’re working. Specifically, make sure that power lines and nearby buildings are not in the way within your operating zone.

Along the same lines, continually survey your surroundings to see if your job site’s conditions have changed. Even a slight change may require you to change how you operate your crane. These changes may have to do with personnel at the site or even weather conditions.

Also, just as with cars on the road, avoid using your cell phone while you’re operating a crane. It’s a dangerous distraction that has no place in your crane’s cab.

Your Planning

Before you turn your crane’s key, take time to review your equipment’s load chart. This chart essentially specifies how your crane’s lift capacity differs based on factors such as a certain angle and distance. By planning, you ascertain that you have enough capacity to complete your job.

Also, be flexible. Your plans could change from time to time. In fact, they probably will.

For instance, in some situations, you’ll have to stop and evaluate your lifting situation. If the situation calls for it, you’ll need to develop a safer lifting plan before proceeding with your job.

Your Equipment

One of the biggest mistakes you can make as a crane operator is to overload your crane. Overloading your crane may lead to serious problems, particularly if your machine’s line is strained. In the end, the line may break.

Also, make sure that you’re using the proper cribbing and pads. Otherwise, an outrigger may sink or fail while you’re trying to make a lift.

Finally, before you embark on a job, don’t overlook the basics of crane maintenance. For instance, check your machine’s fluid levels, including the oil and gas levels, to make sure that you are not low.

Also, regularly inspect your crane equipment. You just may end up spotting hydraulic, structural, electrical or mechanical issues that could spell significant problems down the road if not resolved right away.

How We Can Help

We offer high-quality services that every crane operator will need at some point, ranging from crane modernizations/upgrades to overhead crane inspections.

Get in touch with us to find out more about how we can ensure that your crane equipment is in tip-top shape this year.

A Guide to Custom Brake Shoes and Pads for High-Speed Rail Applications

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Newer braking systems are in place to ensure the safety of people and freight with the advent of high-speed rail.

A strict policy of systems maintenance and replacement is necessary. Passenger and freight safety require it at the higher speeds. Regenerative braking is added to the standard automated pneumatic brake. This results in shorter braking distances.

When speeds are high, the energy of pneumatic braking is dissipated as heat. High heat applications require specialized custom brake shoes and parts. Read on for a quick rundown.

High-Speed Train Braking Systems

The high energy values of braking at high traffic speeds wear brake linings and discs far more than conventional rail speeds. High-speed trains use dynamic brakes. They don’t rely on direct friction force in combination with automated pneumatic brakes.

The electric brakes redirect high braking forces into the rail or stored for regenerative use. This includes dynamic and recuperative braking, eddy-current brakes, or hydro-dynamic brakes, etc. The high energy values of braking at high traffic speeds wear brake linings and discs far more than conventional rail speeds.

Remaining energy is absorbed by the conventional friction braking system and dissipated as heat. Technical specifications for different rail cars require brake shoes adjusted to each car. Custom brake shoes appropriate to the type of wear, speed, and conditions of use reduce the need to disassemble and change brakes frequently.

Custom Brake Shoes and Pads

Specifications for passenger cars detail the amount of air gap and brake pad that must remain. The technical documents also detail certain brands or their equivalent. Performance of brake disc pads must be suitable for the speeds,

duty, and performance.

Brake shoes must also be suitable for the speed, duty, and performance expected. Composition brake shoes 2 inches thick and of a size and type in general use are specified. Custom brake shoes of the appropriate thermal resistance will improve wear.

Freight and passenger applications require different types of shoes. Let one of our representatives walk you through low and high friction applications as well as tread conditioning shoes.

Right Products for Your Application

Kor-Pak has a large selection of friction materials to meet the requirements of almost any rail application. Kor-Pak meets the requirements of several major rail companies worldwide. High-performance parts such as equalizer seats, vertical liners, center plates, and various wear pads are part of the portfolio.

Kor-Pak carries Rigid Molded Friction Products and Phenolic Laminate Materials. We can make parts to meet almost all specifications and dimensions, including

  • Stainless steel wear plates
  • Custom brake shoes/pads for both high-speed and light rail applications
  • Snubbers for both new and old locomotives.
  • Wear pads for freight and passenger cars

We have experts on light rail and high-speed rail applications to assist you in choosing the right materials and meeting the right specs for your custom brake shoes and pads. Contact us today for more information.

OSHA Requirements for Overhead Crane Inspections

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Approximately 2.9 million non-fatal injuries and illnesses; that’s how many U.S. workers suffered from workplace health and safety problems in 2016. This number shows a decrease from previous years.

But three million is still a significant number. And unfortunately, it could’ve been lower through proper workplace safety policies.

This is especially true on job sites that use heavy equipment, such as cranes and hoists. Their incorrect use and maintenance have led to a yearly average of 71 fatalities.

This is why your facility should follow industry-standard overhead crane inspections. And this means complying with Occupational Safety and Health Administration (OSHA) standards.

Compliance ensures your people remain safe. It also keeps your operations at top efficiency, while bringing down equipment risks.

Here’s what you need to know about OSHA-mandated inspections for overhead cranes.

The Governing Authorities on Safe Overhead Crane Use

OSHA isn’t the only governing body on safe overhead crane use. There’s also the American Society of Mechanical Engineers (ASME). The Crane Manufacturers Association of America (CMAA) also plays a part.

These three developed the standards for overhead crane inspections. They also created the best practice guidelines for maintaining these heavy machines.

As a plant manager, it’s your responsibility to ensure safe overhead crane use. And a big part of your task is to ensure the completion of all necessary inspections before their use.

Many industry standards are surrounding the use and maintenance of overhead cranes. One of these is meeting the required frequency of their inspection.

The Three Frequency Levels of Overhead Crane Inspections

A common mistake involving overhead crane inspections is carrying out a yearly inspection. Many think this is enough to comply with OSHA standards. This is a big mistake that can lead to serious injuries, even fatalities.

The truth is, there are levels to this frequency. And your organization should meet all of them. Failure to do so means non-compliance with the rigorous standards set by OSHA, ASME, and CMAA.

These three levels include initial, frequent, and periodic inspections.

Initial Inspection

Before you can use a new crane, it first needs to undergo an initial inspection. The same standard applies to repaired, modified, and reinstalled machines. Only an OEM-approved representative can perform the initial inspection of new equipment.

Frequent Inspection

How frequent these inspections depend on several factors. These include the specific applications and environmental conditions it’s used in. This means that you can conduct this visual and operational inspection on a daily or a monthly basis.

Periodic Inspections

These are the most time-consuming examinations. They involve comprehensive inspections of the entire machine. The goal is to examine and check all the parts that go into the crane to assess their structural integrity.

Again, the frequency depends on the same factors above. In general, though, they are often done quarterly, semi-annually, or annually.

According to Manufacturer’s Recommendations

Some overhead crane manufacturers have their own inspection provisions. You’ll typically find these instructions in the equipment’s usage manual. You need to follow these manufacturer’s recommendations too.

Your priority is to keep the workplace as safe and secure for every member of your organization. Ensuring everyone follows these industry standards is crucial to achieving this goal. We can help in making your overhead cranes (and their inspection) OSHA-compliant. Call us now to find out more about our services.

How To Know When It’s Time To Replace Your Oil Rig Disc Brake Systems

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The disc brake systems do the job of controlling the drawworks during operations. Over time, friction to the disc brake systems wears its components, which include the pads & blocks. This wear-and-tear can extend to the caliper, discs, and operating system.

Worn and faulty components aren’t only inefficient, they’re dangerous to personnel and machinery.

Maintenance during the duty cycle will keep the system performing to expected operations. But, there will be a time when it needs replacing. This article shares how to know when the time is right.

Disc Brake Systems: The Tell-Tale Signs They Need Replacing

With on-going maintenance, you will begin to notice signs of issues with your brake system. In fact, many brake systems will last throughout the life/duty cycle of the project; however, this varies. However, the harsh demands in the oil industry typically require regular changes compared to others.

Here are some of the signs the disc brake systems need replacing:

1. Wear Indicators are at Their End

Brake pads and blocks show interval wear from use. Indicators on these items provide signs they’re close to their duty cycle end. Maintenance and regular inspections of these areas will let you know when they are too worn; then the time has come for a replacement.

Brake systems will also need immediate replacing if damage occurs.

2. Modernizing to New Standards and Regulations

Many oil rigs have been in operation for decades. New standards and regulations have passed since their production. Many fleet operators will modernize and retrofit rigs to adapt to these advancements.

Maintenance and installation crews will use this time to replace critical components — including the brakes — with suitable, efficient replacements.

3. Erratic Performance

The braking system should always provide smooth operations with regular contact and usage. Inspections and replacements are essential if sliding speeds and stability become erratic.

Erratic performance may also extend to the torque performance.

4. Savings Positive

Retrofitting, replacing, or upgrading brake systems may provide an operational cost incentive. Large orders and service orders paid in bulk provide steep discounts — an action the company may leverage to cut costs.

A switch from the leg or aux brakes could provide lower maintenance costs efficiently shrinking overall costs. This places operation in a savings positive. The update also drives financial resources to other areas.

5. Reduced Weight and Footprint

Compared to counterparts, disc brake systems are lighter and have a smaller footprint. Space is limited on oil rigs. Swapping the brake system could open space for other components and resources.

6. Indicator Lights are Going Wild

It’s obvious the system needs changing if the indicators light up like the holidays. Maintenance should verify sensor readouts. But, these automatic warnings should provide enough ample evidence to decide.

Save on Costs, Use Kor-Pak Brakes

Oil production doesn’t slow down, nor should your brakes. Kor-Pak provides industry-leading drawworks disc brakes for standard and customized systems.

We are an OEM and distributor for heavy duty industrial braking systems. Our high-quality parts and service will help you meet your business objective. Get in touch to request a quote — or call (888) 256-7725 for all inquiries.

 

Do You Need New Storm Brakes?

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If you were told that replacing the roof on your house would make it safer, would you do it?

If you were told that immediately moving out of your house was the only way to keep your family safe, would you do it?

Yes, you would. You wouldn’t even think twice about it.

Why isn’t it the same for your employees and storm brakes?

Storm brakes are used to lock something into place to prevent it from breaking. This prevents weather from damaging outdoor equipment. Without a storm brake, you could be negatively affecting the safety of your employees and your equipment.

Why Do I Need New Storm Brakes?

Great question. There are many theories on when you should replace your storm brakes, and it all depends on what kind of storm brakes you are talking about.

We can discuss the timeline of how often you should replace them, but here are the two most important reasons why you need new storm brakes in the first place.

1. Storm Brakes Protect Your Employees and Consumers

Being safe in the mining and construction industry is the number one goal. It doesn’t matter if you build a beautiful building if it isn’t safe to live in. Having these brakes as tools against seismic movements, retractable roofs, and weather threats is essential.

The brakes are used during the building process. They allow for bursts of wind to come in and not halt the building or mining. Updating the storm brakes often will ensure safety with the employees.

When you were questioned as to whether or not you were willing to risk your families safety, you immediately said no. These brakes allow for you to ensure your employees are safe while at work as well.

Risking their lives by not being cautious with your equipment is a mistake even if the likelihood of them getting insured is small.

2. To Protect Your Equipment

In 2017, the construction equipment market was estimated at 192 billion dollars. Equipment costs vary between industries, but with the construction industry using a lot of storm brakes, the maintenance of their equipment is crucial. A storm brake is meant not only to keep those using it safely but to keep the equipment from braking as well.

When playing the “What-If” scenario, what if you choose not replace the brakes after several years and a huge storm comes in. Not only are you putting your employees in danger, but you can damage all of your equipment in a matter of seconds.

Halting production each time a storm comes in so that you do not have to replace a storm brake is also not the answer (although it may sound easier). Just a small burst of wind that is unpredictable could break a thousand dollar piece of equipment.

Preventing Future Heartache

These are two fundamental reasons why replacing your storm brakes should be a yearly investment. It may seem like a pain, but you are preventing yourself from a lot of heartache in the future.

To learn more about how to spot a maintenance problem with your equipment, check out this article.

Why You Need Caliper Disc Brakes for Emergency Applications

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You have worked hard to prevent workplace injuries. All your employees are well trained and equipment maintained according to specifications.

Then out of the blue, an emergency brake failure occurs. Not only was someone injured, but could have died!

It is imperative to make sure your brakes are the best on the market so you can keep your equipment, and your employees, safe.

Read on to find out why you need to get caliper disc brakes for all your industrial equipment today!

What Kinds of Brakes Are There?

There are three main kinds of brake systems, which include frictional, electromagnetic, and pumping. The most common, by far, is frictional brake systems.

A frictional brake is a system that uses a shoe or pad to put pressure on a moving object to reduce the object’s motion.

One of the most common types of frictional brake used on rotating wheels is the disc brake.

Disk brakes are effective because the brake pads depress onto both sides of the rotating disc and the resulting friction slows the motion of the wheel or axle where the disc sits.

What Is a Caliper Brake?

A caliper brake is a specific type of disc brake that uses calipers; which sit on top of the disc like a clamp.

When you activate the brake, hydraulic actions cause pistons inside the calipers to force the brake pads against the disc which slows the rotation of the axle/ wheels to a stop.

This is more effective than the older drum brake systems because gases and heat do not get trapped in the system and cause brake fade.

Brake fade describes when the brake becomes less successful at slowing the machine due to retained heat and gases.

Brake fade is especially dangerous in an industrial setting where heavy machinery may need immediate halting in case of an emergency.

Two Kinds of Caliper Disc Brakes?

There are two main kinds of caliper disc brakes floating calipers and fixed calipers.

Fixed calipers are useful because they do not move. Instead, they have pistons on both sides that force the brake pads onto the disc. The downside is that they can be expensive.

The floating calipers slide closer to the disc when the brake is applied and only have pistons on one side of the calipers.

One of the best kinds of fixed caliper brake systems is the SIBRE SHI system which has a quick response time and is inexpensive to maintain.

They are the perfect combination of reliability and cost efficiency. That is why they are especially recommended for industrial emergency brake situations.

Where Can You Buy Them?

If you have more questions about which kind of caliper disc brakes would be best for your needs or to have new brakes installed in your equipment, please contact us for more information today!