The challenge of ergonomic risk and production bottlenecks
In industrial pipe fabrication, efficiency and safety drive profitability. Hansen Mechanical fabricates pipe for large construction projects. They faced a bottleneck on their production floor. Moving heavy pipe assemblies weighing more than 3,800 lbs was difficult because of their awkward shapes.
Before using a dedicated lifting solution, Hansen Mechanical used forklifts to move assemblies between work cells. This method caused problems. Maneuvering 2-ton loads with a forklift in tight areas created a high-risk environment for floor workers. Production slowed because technicians waited for forklifts and drivers to move pieces between stages like rolling and final welding. The company initially thought about using a jib crane. However, a single-point pivot only covers a small workspace. This would still require forklifts to move product through the rest of the process.
Free standing workstation bridge crane solution
Fred Volkmann of Precision Crane and Hoist advised Hansen Mechanical on the best product for the job. They chose the Gorbel Free Standing Workstation Bridge Crane. This system provides rectangular coverage for movement across the whole production line. They installed a 2-ton system with two bridges to meet capacity needs. This setup allows multiple teams to work on different parts of the 118-foot system at once.
Project execution and specifications
The system fits the vertical and horizontal limits of the facility. It has a length of 118 feet. The bridge span is 26 feet and the lifting height is 16 feet. The crane uses blue support steel and yellow bridges. Workers move heavy piping from rolling stations to welding teams and finally to the loading area. The cold-rolled track design makes it easier to move the bridges.
Results for productivity and safety
Hansen Mechanical saw better worker morale and throughput after the installation. They removed forklifts from the fabrication cells. Production speed increased because transitions between cells happen immediately. The ergonomic design reduced physical strain on workers. The system has worked without problems for over a year. The company plans to add more Gorbel systems later.