Smart Solutions Category: Welding

Quality & Productivity Soar with Tecnar and Way Engineering

Way Engineering was skeptical that automated welding could deliver the high quality they demanded, but Tecnar’s Rotoweld 3.0 technology proved so effective, the company purchased a second machine just three months later. The Rotoweld is also helping Way Engineering adapt to the industry-wide shortage of skilled welders.

Increasing Quality and Capacity

Way Engineering, a 100-year-old company with over 2,500 employees, faced a clear challenge: how to maintain the craftsmanship that built their reputation while meeting the demands of modern industrial projects. Historically, manual welding had been their gold standard, with skilled welders adept at handling the irregularities inherent in pipe joints. However, as the company scaled up operations, leadership began to question whether manual welding alone could meet growing demand while delivering the same level of consistency. They were also particularly concerned about how automation would cope with real-world conditions, such as gap changes, high-low misalignment (hi-lo), and pipe ovality—issues that seasoned welders had long managed with finesse.

Adding to these concerns was a broader industry trend: the growing scarcity of skilled welders. As experienced professionals retire and fewer young workers enter the trade, the mechanical contracting sector is facing a significant labor shortage. This new reality underscored the urgency for Way Engineering to explore automation not just as a means of enhancing productivity but also as a solution to labor challenges.

Addressing Automation Concerns

The transition to automation was not a decision Way Engineering took lightly. Company leadership was particularly apprehensive about whether a machine could replicate, let alone exceed, the adaptability of their skilled workforce. Automation, they feared, might struggle with the imperfections that are inevitable in pipe fit-up, leading to compromised weld quality and increased rework.

After extensive research and evaluation, Way Engineering chose Tecnar’s Rotoweld 3.0, drawn by its reputation for flexibility and precision. The Rotoweld quickly dispelled their doubts, exceeding expectations with its ability to deliver consistent, high-quality welds, even in the face of irregularities. Unlike traditional automated systems, which often require near-perfect preparation, the Rotoweld adapted seamlessly to changes in gap, hi-lo, and ovality. This adaptability was made possible by the machine’s fully robotic arm and Tecnar’s advanced PerfectPass-iQ technology, which continuously monitors and adjusts welding parameters to ensure optimal results.

In addition to its adaptability, the Rotoweld’s design offered practical advantages for Way Engineering’s operations. The company opted for a face-to-face configuration, which provides twin bay productivity in a compact footprint. This layout allows Way to efficiently handle small and medium spools simultaneously while maintaining the flexibility to produce large spools up to 60” in length when needed. The system’s versatility and space-saving design made it an ideal fit for their facilities, enabling them to maximize output without requiring significant infrastructure changes.

Rapid Adoption and Expansion

Once the Rotoweld was deployed, its impact was immediate. Within weeks, Way Engineering saw dramatic improvements in both quality and productivity. Encouraged by the results, the company committed to purchasing a second machine just three months later, doubling their automated welding capacity. Way Engineering uses their Rotoweld units for carbon steel and stainless steel spools with diameter ranging from 48” to 2-1/2”, for medical, commercial, and light industrial projects.

Watch the Rotoweld in action at Way Engineering: https://www.youtube.com/watch?v=Y7MGYQ4EU74

The success of the Rotoweld was further amplified by its integration with PerfectPass-iQ, Tecnar’s fully automated welding technology. Way Engineering served as the beta tester for this groundbreaking system, providing valuable feedback that helped refine its capabilities. PerfectPass-iQ’s real-time monitoring and parameter adjustments ensured flawless welds, even in challenging conditions. PerfectPass-iQ is not limited to automatic welding. It also automatically provides a report about the quality of the preparation and the performance on each welding pass. All of that information is included in Tecnar’s ProDataLog, the Rotoweld’s operating data system. Future implementations will aim at deploying fully automatic, high-level reporting so that shop operators can have insights about their welding quality at a glance using their mobile devices.

The Rotoweld’s ease of use also addressed another critical challenge: the skilled welder shortage. With a growing demand for skilled welders and fewer entering the industry, Way Engineering sought innovative solutions to ensure they could continue meeting the increasing needs of their projects. The Rotoweld requires minimal operator training. Its automation capabilities allow operators to oversee the machine while performing other tasks, dramatically improving workflow efficiency.

Way Engineering’s partnership with Tecnar has grown beyond that of client and supplier. As the beta tester for PerfectPass-iQ, Way played a pivotal role in refining and enhancing the technology. This collaboration ensured that the Rotoweld continued to evolve, addressing new challenges and opportunities as they arose. The relationship between the two companies underscores the importance of innovation and adaptability in the face of industry challenges.

Embracing Automation

Corey Gill, vice president and director of construction at Way Engineering, is now a vocal advocate for embracing automation. When asked about the impact of the Rotoweld on operations, he was unequivocal in his advice to other contractors: “Don’t wait, and stop trying to calculate ROI—just do it.” For Gill, the value of automation extends far beyond immediate financial returns. It offers a long-term solution to the challenges of scalability, quality assurance, and labor shortages, positioning companies for sustained success in a competitive market.

Today, Way Engineering is reaping the rewards of its investment in welding automation. With two Rotoweld machines already in operation, the company is exploring additional applications and considering further investments to expand its capabilities.

For more information, visit https://tecnar.com.

Doubling Shop Productivity with Novarc Technologies Inc. & W.W. Gay Mechanical Contractor, Inc.

W.W. Gay Mechanical Contractor, Inc. saw a 200-percent increase in shop productivity and a 12-fold increase in weld productivity by implementing Novarc Technologies Inc.’s collaborative Spool Welding Robot (SWR). They are also realizing a 100-percent pass rate on radiography tests (RTs). The SWR has reduced W.W. Gay’s dependence on highly skilled welders, of whom there is a global shortage.

Based in Florida, W.W. Gay provides a variety of commercial and industrial contracting services, and has the experience, equipment, facilities, and professional licensures and certifications to meet even the largest project requirements. To maintain their competitive edge, they needed to increase their productivity and efficiency to keep up with the fast-track projects in their market while ensuring high quality. W.W. Gay sought an automated welding solution that would allow them to use junior welders for simpler work and deploy their more experienced welders on other key projects.

Collaborative Solution

David Ray, W.W. Gay’s pipe fabrication shop foreman, explained, “We looked extensively to find a solution, and we narrowed our search to several companies. After putting all our choices under the microscope, it was an easy choice. Only the Novarc SWR has the capabilities to do what we do on a daily basis in our shop.” The SWR is designed specifically for pipe, small-pressure vessel, and other types of roll welding.

The company implemented the SWR at their facility and trained their operators to use it. Using the SWR combats the shortage of highly qualified welders because it can be operated by less-experienced workers and produce high-quality welds every time.

Ray continued, “My first impression was that the SWR was a really good investment. My impression now is that my first impression was 100-percent accurate.”

Ray also appreciated Novarc’s responsiveness. “To date, any question or suggestion I have made has been met with a quick response, and we are 100-percent happy that we chose the Novarc SWR,” he said. “The SWR was the only solution out there that fit our needs, it was a perfect fit.”

Productivity Soars

Before purchasing the SWR, the team at W.W. Gay was welding between 80 and 100 diameter-inches on average per shift using welding positioners with the gas metal arc welding and flux core arc welding processes. The company wanted to increase the welding bays’ inch count to the maximum amount that they could imagine.

“With the SWR, we have seen a tremendous increase of weld inches per shift from 6” and bigger,” Ray noted. “Depending on pipe size, we can hit inch counts anywhere from 200” to 275” on a regular basis with the SWR.

“The fact that we can weld slip on flanges is probably one of the most impressive tasks that the Novarc SWR is capable of,” Ray continued. “Also, we have gotten really efficient at welding stainless steel fabrication with the SWR, and this is helping tremendously with our efficiency. Our old way of welding stainless would be to TIG [tungsten inert gas] weld with using an ID [inner diameter] purge. A 16” schedule-10 weld would take two-and-a-half hours or so to get a purge set up and then weld out. We now can do a 16” schedule-10 weld in 12 minutes that will pass RT.” said Ray.

Quality Improves

The SWR minimizes human error and therefore reduces the failure rate from the industry average of 3–5 percent to less than 1 percent. Ray noted, “The thing about the SWR is that it is a start-to-finish weld—once you hit the ‘go’ button, it welds the root, fills, and cap without stopping, which makes doing a weld that has to be RT’d a bit of a cakewalk, since there is no in-between pass clean up and prep. We currently have a 100-percent pass rate with our RTs on the SWR. To put this into perspective, a 10” standard-weight weld can be achieved in 12 minutes or so, which is highly remarkable.”

Managing the Welder Labor Shortage

With the SWR, W.W. Gay can assign their highly skilled welders where they are most needed. The company currently has three trained SWR operators, including a third-year apprentice, who are all equally efficient with running the SWR.

“[The SWR] is head-and-shoulders better and more efficient, and the quality is amazing,” observed Jason Craven, welder at W.W. Gay. “I’m completely comfortable using it, there are no problems at all. Once you get the hang of it, it is easy to use. … [Novarc] provided excellent training.”

Ray pointed out that the SWR opens up opportunities for W.W. Gay. “We do our shop tours for any specific general contractor that we may be working for,” said Ray. “They are really impressed when they see the speed and precision of the SWR. And when I explain how the SWR has improved our efficiency, it is a major eye-opener at our capabilities to keep up with job flow needs and expectations.”

Novarc’s podcast series tackles topics such as the impact of automation on manufacturing. Listen here: https://www.novarctech.com/resources/podcasts/

For more information, visit www.novarctech.com.

Increasing Weld Speed with Novarc Technologies & Kleeberg

Despite an industry-wide shortage of skilled welders, Kleeberg has increased productivity by partnering with Novarc Technologies and adopting the Spool Welding Robot (SWR™). The SWR is a welding cobot designed specifically for pipe, small-pressure vessels, and other types of roll welding. With the cobot, Kleeberg has increased welding speed by three to four times on larger pipes.

Kleeberg excels in a wide array of services ranging from sheet metal and mechanical services to design-build projects and custom industrial fabrication. However, they confronted challenges in sustaining uniform welding quality and efficiency, particularly in welding pipes ranging from 4” to 24”. These dimensions were critical in their diverse array of projects, involving complex systems like steam, chilled water, and hot water. Kleeberg aimed to enhance the consistency of their welds and amplify overall welding productivity while maintaining low repair rates.

Novarc’s robust support system, characterized by prompt responsiveness and comprehensive training, facilitated a smooth transition for Kleeberg’s operators, enabling them to master the SWR within a week. With 95% of their welding now conducted using the SWR, Kleeberg has experienced a transformative shift in their welding processes. This advancement not only resolved their immediate challenges but also positioned them as a frontrunner in industrial efficiency and technological adoption. Kleeberg quickly realized a number of benefits from using Novarc’s SWR.

  • Accelerated project completion: Kleeberg achieved a substantial reduction in project completion times. Specifically, they can complete welding tasks on 12” pipe joints in just 10 minutes, a significant improvement from their previous timelines.
  • Increased welding productivity: The implementation of the SWR resulted in a remarkable increase in productivity, with over 250 factored diameter inches per shift, enhancing the speed by three to four times for pipes ranging from 8” to 14”.
  • Significant weld cost savings: Kleeberg achieved substantial cost savings per weld, amounting to approximately $25 for smaller pipes (6–8”) and around $45 for larger pipes (12–14”), exclusive of the Novarc system’s cost.
  • Time savings: Overall, the SWR contributed to a 12–15-percent decrease in time in Kleeberg’s operations.

Other companies that have invested in the SWR have not only increased their pipe welding productivity but also dropped their repair rates to less than 1 percent, making them more competitive when bidding on jobs and increasing margins on contracts already won. The collaboration with Novarc Technologies enabled Kleeberg to successfully address key challenges and set new benchmarks in welding productivity and quality.

For more information, visit www.novarctech.com.

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Ramping Up Welding Capacity

Metropolitan Mechanical Contractors, Inc. (MMC) put Novarc Technologies Inc.’s Spool Welding Robot™ (SWR) to work and dramatically increased their welding capacity, achieving consistent, high-quality welds every single time. Corey Hagerty, pipefitting shop foreman at MMC, described the impact: “Before implementing the SWR, we typically had three to four guys welding (depending on the project) and we averaged from 60 to 80 factored diameter inches (FDI) a day. Currently, we’re doing 200 to 250 FDI a day on the SWR; we even achieved 290” in one day.”

MMC has an impressive portfolio of completed projects including the Mall of America, Target Center, Target Field, and the Xcel Energy Center. “The SWR has helped with our capacity on the larger projects, and that’s definitely where we have shined,” said Hagerty.

Aiming for Quality and Consistency

When evaluating pipe welding automation systems for their fabrication shop, MMC was looking for a solution that would help them achieve consistent, high-quality welds. “The projects that we work on vary a lot,” said Hagerty. “Specific jobs typically require a percentage for X-ray and ultrasound testing. Sometimes we run into jobs where it is 100% X-ray and sometimes 10%. What was important to us was to improve the quality and consistency of our welds.”

Novarc’s SWR is a welding cobot designed specifically for pipe, small pressure vessels, and other types of roll welding. Since implementing the SWR, MMC has increased their pipe welding capacity dramatically, with no failures or repairs needed to date. In North America, repair rates at pipe fabrication shops are typically around 3 to 5 percent. A shop producing 6,000 welds per year with a 5-percent repair rate is likely spending around $300,000 each year on repairs. At MMC, Hagerty noted, “The cost of repairs is typically between $800 and  $1,000 per test, and with Novarc we’ve achieved a 0-percent failure rate.”

Tackling the Welder Shortage

The SWR has reduced MMC’s dependence on highly skilled welders, of whom there is a global shortage. With the SWR, MMC has been able to leverage the skills of its current workforce. Hagerty explained, “We actually have an individual that was a pretty skilled welder in the field of stick welding, and he didn’t have a significant amount of experience in wire, but he just obtained certification with wire, and we’ve been able to put him on the SWR. It’s been pretty seamless to be able to put a junior-level welder on the SWR and achieve high-quality welds.”

Learn more about MMC’s experience with Novarc during this online chat with Corey Hagerty: https://www.novarctech.com/videos/

In addition, Novarc has helped MMC get the most out of their SWR. “Novarc’s support team has been very helpful, and they ensured that we were up and running all the time,” said Hagerty. “I really like the platform that the team has in the background; basically, if there is an important issue, they see it and they take care of it right away. They have a gauge on who takes care of it, how, and why.”

Hagerty also praised Novarc’s training opportunities. “The Novarc Academy was also a great help. I had walked through the training sessions myself, and I think that it took out a lot of the unknown and the pessimistic views that a lot of welders can have towards it. The fact that you can override it, interact with it, and make adjustments on the fly is a huge benefit. I fully believe that’s the benefit to Novarc over the other semi-automatic processes,” Hagerty concluded.

For more information, visit www.novarctech.com.

Hermanson Employs Miller Electric Welder for Innovative Approach

Compact System Fits in Tight Space for Successful Tunnel Welding

Faced with a tight working space, Hermanson Company took advantage of Miller Electric’s new XMT® 350 FieldPro System welder along with a custom-built pipe turner so the mechanical contractor could make hundreds of high-quality welds in a fraction of the time that hand-turning would have required. The innovative approach not only increased productivity but also contributed to a safer, healthier work environment.

Tackling a Tunnel Project

In 2017, the Port of Seattle broke ground on the North Satellite Modernization Project at Seattle-Tacoma International Airport. The project involved expansion and renovation of a 45-year-old facility to enhance the passenger traveling experience. As part of the mechanical upgrades, Hermanson Company, a mechanical and plumbing contractor located south of Seattle, was awarded a contract to install 3,400 lineal feet of 16” welded steel chilled water piping in an existing utility tunnel located under the main terminal leading to the North Satellite.

The tunnel measured only 7′ high by 6′ wide and was already fitted with multiple building infrastructure services, including existing chiller piping and electrical conduit. Available space to route new piping was at a premium, and existing infrastructure had to be removed from service and demolished to complete the upgrade. Hermanson shop foremen, engineers, and field techs began working out the most efficient methods of phasing, fabricating, transporting, installing, and joining to successfully and safely install infrastructure chilled water piping in such a constricted space.

Paul McLain, Hermanson’s pipe shop foreman (who has more than two decades of industry experience, including 17 years as a welding instructor for United Association of Plumbers & Pipefitters (UA) Local 32 and an American Welding Society inspector), developed a fabrication plan. “Based on past experience working in tight spaces, I knew that rotating the pipe in place was the best way to achieve the highest performing, quality welds,” recalled McLain. “We had just never done it on this scale before.”

Employing pipe turners when fabricating pipe assemblies is standard practice for Hermanson Company welders. Rotating the pipe allows for use of pulse spray or regulated metal deposition (RMD) welds rather than stick welding and creates a better deposition rate. Welds on rounded surfaces like pipe can create “weld puddle”—the result of gravity pulling on the weld material. Additionally, pulse spray welds reduce weld smoke, which is an important health consideration when working in constricted spaces. Overall, rotating pipe as it is welded is much easier on the welder and provides a more consistent, better quality weld.

Hermanson Company’s staff paired a space-saving Miller Electric welder with a novel mechanism to rotate pipe in place, making welding easier in a confined space for Gary Lockram, UA Local 32, and
coworkers, which increased productivity.
Glen Lee, UA Local 32, of Hermanson Company helped install 3,400 lineal feet of 16” welded steel chilled water piping in an utility tunnel only 7’ high by 6’ wide, relying on a Miller Electric welder to connect the pipes in such a tight space.

Building to Scale

McLain knew a pipe turner was the answer and consulted with Hermanson engineering staff to calculate the torque value needed to rotate a series of 13′ pieces of 16” standard-weight pipe at lengths up to 200′ long. Once the values were determined, McLain worked with a fixed welding automation fabricator to build a pipe turner that could handle cumulative weights up to 12,500 pounds while welding. The pipe turner consisted of a motor, sprockets, a variable speed foot peddle, and a heavy gauge chain that attached to a sprocket bolted to the end pipe section. “Think of a bicycle assembly—just on a massive scale,” said McLain.

Once the pipe turner was fabricated, it was shipped to Hermanson’s pipe shop in Kent, WA, where McLain began simulated field testing. Working with project-specified materials, tests allowed welders to simulate the same wire-feed welding process currently used in the Hermanson shop. Amperage tests were also completed, and it was determined that the pipe turner was only running at two thirds of its maximum capacity, thereby ensuring adequate amperage for the field operation.

Success Onsite

Meanwhile, at the jobsite, preparations were being made to stage the chilled water pipe in the utility tunnel for installation. An access point was cut into the tunnel from the ground level of the North Satellite, the existing piping was removed, and a crane was set to lower hundreds of 13′ pieces of pipe onto custom-built rolling carts. The pipe sections were then positioned in the tunnel, where workers reloaded them onto carts and moved them into place. Electricians installed three-phase, 110-volt power every 100′ along the tunnel for lights, tools, and welding equipment. Traditional welding wire feeders would have been too large for the space, but Miller Electric’s new XMT 350 FieldPro System welder was a good fit. Measuring just 24” x 11” x 17“, the FieldPro and its power supply took up less than half the space of traditional welders and was positioned on a cart for easy mobility.

Once all the pipe was in place, a team of three welders and pipefitters began the process of making over 340 welds to connect the stacked supply and return chilled water piping in the tunnel. In addition to creating a superior weld, the pipe turner saved the crew valuable time that would have otherwise been spent hand-turning the pipe with a series of chains and come-alongs. The simple and effective approach achieved with the pipe turner allowed the project team to accurately forecast labor and meet schedule deadlines with no recordable injuries.

For more information, visit www.millerwelds.com.

Editor’s Note: Sadly, just prior to publication, Paul McLain, 43, passed away. Paul’s take-charge and lead-by-example management style will be sorely missed by his fellow Local 32 union members, his two sons, and friends and coworkers at Hermanson Company, where he worked and innovated for more than eight years.

Tips for Increasing Productivity in Today’s Construction Environment

The construction industry continues to feel the ripple effects of the COVID-19 pandemic. 

Many jobsites fell quiet in 2020 as projects were delayed or cancelled due to uncertainty in the immediate aftermath of the pandemic. And while things are rebounding, ongoing supply chain and project timeline issues continue to be challenges for many companies. 

This makes it more important than ever for contractors to find ways to improve efficiency and make up for lost time on projects. While that has always been a priority, it’s especially critical in today’s construction industry. Read more about ways to improve productivity and save time on projects. 

Improving Productivity 

As contractors look for ways to improve efficiency and productivity on projects, investing in new technology or making a change to processes or techniques can deliver results. Here are three factors to consider that can help your operation save time and money: 

Invest in new technology to save time. When operators have the ability to make welding adjustments remotely, it can deliver significant time savings, not to mention reduce safety risks. The time spent walking between the weld joint and the welding power source to change parameters and processes can add up—resulting in hours wasted every day. This is especially true on large jobsites where the operator may be hundreds of yards or several stories away from the machine and needs to make frequent adjustments. If an operator makes the trip to the power source four times a day and takes an average of 15 minutes each time, that’s 250 wasted hours per year—totaling $11,250 in lost productivity. With ArcReach® technology from Miller Electric Mfg. LLC, operators have complete control at the weld joint using a wire feeder or stick/TIG remote. This allows them to reduce or eliminate the time wasted by walking back to the power source. Wireless Interface Control on Trailblazer® and Big Blue® welder/generators is another technology from Miller that provides full front panel access from wherever operators are working on the jobsite, so they don’t have to go back to the welder/ generator to adjust parameters, change welding processes, or turn the machine on and off. 

Streamline steps in the process. When contractors can complete parts of the construction or welding process with the workers they already have on the jobsite—rather than hiring a third party for those tasks—it helps them reduce costs and gain better control over the schedule. One example of this is welding preheat, which is required in many welding applications on construction jobsites. If the contractor pays a subcontractor to come to the site and use resistance heating for this work, it can add significant time and cost to the process. Setup time can be up to three hours per weld joint, and preheating contractors may charge up to $2,000 per joint. With the new ArcReach Heating Systems from Miller, contractors can do the preheating work in-house, with the operators they have—and often using the welding power sources they already have onsite. This eliminates the need to bring in more subcontractors by enabling welders to do the welding preheat quickly and easily. 

Consider making a process change. Converting to wire welding processes is another change that contractors can make to improve productivity and efficiency. More companies are transitioning from stick welding to wire welding on construction jobsites, due in part to the significantly higher deposition rates and travel speeds that wire processes can deliver. These gains can be realized while still meeting high weld-quality requirements and also improving jobsite safety. 

Efficiency Gains Through Technology 

As the construction industry deals with many challenges—from supply chain issues to labor shortages and strict timelines—contractors are looking for more efficient ways to do business. There are solutions available to make up lost time and keep ahead of schedule. New welding technologies and more productive processes can help deliver results to improve efficiency and quality. 

For more information, visit www.millerwelds.com. 

Western Allied Mechanical Saves Time, Expands Reach With Novarc’s Spool Welding Robot

Like every contractor, Western Allied Mechanical is always looking for innovative ways to get ahead in their market and deliver projects better, faster, and cheaper for their clients. Also like every contractor, Western Allied is facing the nationwide shortage of qualified welders. By adopting Novarc’s spool welding robot (SWR), they have not only increased productivity dramatically, they also increased capacity and are taking on bigger jobs.

Opening Up to Automation

Western Allied operates in the highly competitive market of California’s San Francisco Bay area. Cyrus Patel, piping superintendent at Western Allied, explained that the company has been trying to automate more of its production processes to improve efficiency and productivity. “Robotics is the way of the future,” he said. “We have been looking at it for a long time from the sideline.” About two years ago, Western Allied decided to move forward, to “see where robotics would help us as a team to achieve some better results,” said Patel.

The company focused on areas in the fabrication process where fatigue had the most impact. Jim Jeffrey, operations manager, explained, “We learned that we were having fatigued welders, and that was the bottleneck in our fabrication process. When we compared the productivity at the start of the day to the end, we noticed that we were kind of dragging. So that’s why we looked at automating our pipe welding and choosing the SWR, because it doesn’t call in sick, it doesn’t get fatigued, and it takes a lot for it to beg for mercy.”

Finding the Perfect Fit

When they came across Novarc at FABTECH Expo, Western Allied knew that they had found the right automated solution to speed up welding and increase productivity. They also needed a solution that would meet the requirements of ASME B31.1 and B31.3 codes.

“We were looking for a custom, tailored product at the FABTECH Expo when we came across the Novarc machine. The SWR had the lead on the other solutions, so we took that and ran with it,”, said Patel. “I really liked the SWR; it was a well-manufactured product.”

Novarc’s SWR is a collaborative welding robot designed specifically for pipes, small-pressure vessels, and other types of roll welding. As a collaborative robot, the SWR enables less-experienced operators to significantly improve shop productivity and produce high-quality welds every single time.

“Novarc did some testing for us, and we fell in love. The first project we did we cut off four-and-a-half man-weeks of shop welding, so we saved around $114,000 on that project, and it made us competitive and added value to the end user,” said Jeffrey. “Also, with the SWR we could take the video of each weld and give it to the inspector if he’s not there, and that basically was the driver.”

See the Novarc SWR in action on the shop floor: https://www.youtube.com/watch?v=tAbEbFWUrQw

Scaling Up

With the SWR, Patel said, “We’re now going after projects that we were shying away from because of the size. Since we have implemented the SWR, we have been spooling a lot more, and we are also taking on bigger projects, knowing that we have the capabilities of the welding in place. So it’s actually helped us go after some projects that we were not going after before.”

Jeffrey added, “We’ve reduced our dependence on hybrid systems and embraced flanges and bolting it up because the net effect is that it is cheaper and faster, and the quality is there.” Moreover, the SWR is helping Western Allied manage the shortage of highly-qualified welders. “We are getting repeatability and productivity so we can compete head-to-head with non-union shops. And I’m not worried about having a qualified welder that I have to have all the time,” said Jeffrey.

Check out Novarc’s podcast series, which covers topics like robotics, artificial intelligence in welding, and estimating the return on investment with collaborative robots:

https://www.novarctech.com/podcast/

Filling a Gap

The American Welding Society anticipates that the current labor crisis will very quickly escalate to a shortage of about 400,000 welders by 2024. “The labor shortage has been coming for years,” said Jeffrey. “We had been experiencing it before the pandemic as well, so we had to innovate to keep up with the demand.”

Western Allied also appreciated the simplicity of the training for Novarc’s SWR. “Once you get it up and running, to feel happy with it and to feel comfortable with it, you are not talking months and you are not talking about getting another university degree,” Jeffrey observed. “It’s very intuitive, and in three days, you are good at it. In five days, you are really good at it. So that’s what really more than anything else made me pleased. I can train people, and I’m not dependent on people who have changing commitments.”

For more information, visit www.novarctech.com.

PULL QUOTE

“Novarc did some testing for us, and we fell in love. The first project we did we cut off four-and-a-half man-weeks of shop welding, so we saved around $114,000 on that project.”

—Jim Jeffrey, Operations Manager, Western Allied Mechanical

Miller Electric Illustrates Benefits of Induction for Welding Preheating

Welding preheating is used to ensure weld quality and reduce the chance of cracking and other defects that can result in costly rework. Preheating is commonly used in field and shop applications when welding steel or steel alloy pipes or plates that are 1” thick or more. Applications that often use preheating include power plant and structural construction, as well as pipe fabrication. Here, Miller Electric outlines four common methods for welding preheating and how to choose the best option for your application.

When To Use Preheating

The process of preheating involves heating the area around the weld joint or the entire part to a specified temperature before welding. This reduces the weld cooling rate and drives out moisture, which helps prevent hydrogen buildup and the potential for cracking.

Determining whether an application requires preheating depends on several factors, including the type and thickness of the base material. Often, use of preheating is dictated by the welding procedure specification (WPS), which outlines the minimum and maximum preheating temperatures as well as the necessary duration of preheating. Welders typically must monitor and document the base material temperature between weld passes to ensure the metal remains within the required temperature range.

Weld Preheating Methods

Several methods can be used for preheating, and each option offers benefits and drawbacks. Determining the best method for a specific application often depends on the material thickness, weldment size, project timeline and budget, and available personnel and expertise.

  • Induction creates a magnetic field that generates eddy currents within the base metal, heating it internally from within. Accessories such as cables or blankets are placed on or near the part to generate the magnetic field. Induction provides quick setup time—often less than five minutes—and a fast time to reach the desired temperature. This method also produces a uniform heating area, making it easy to achieve and stay within the necessary temperature window. In addition, because the output coils do not get hot or create an uncomfortably hot environment for welders, induction can be safer than other methods. It also delivers flexibility to heat parts of many sizes and shapes. Induction can have a higher initial cost and require some operator training to ensure proper wrapping techniques.
  • Open flame involves operators using a fuel gas and compressed air torch (sometimes called rosebuds) to apply flame directly to the metal part. Flame preheating requires little operator training, but it does have several drawbacks. Flame often provides inconsistent temperature uniformity, has a slower time to reach desired temperature because of its inefficient process, and also compromises comfort and safety for operators working near the soot, smoke, and gases produced. This method also includes the extra expense of gas storage and distribution.
  • Resistance heating uses electrically heated ceramic pads placed on the base metal. The tiles transfer heat to the part through radiant and conductive heat, specifically where the pads are in contact with the part. This method can offer temperature consistency as long as no heating pads are broken. Downsides of resistance heating include cost and inefficiency. This method is often contracted out to a third party, increasing the cost. It can also sometimes take an hour or more to arrange and secure the heating pads on the part; the required cool-down time also adds significant time to the process. Broken heating pads can cause hot and cold spots in the part and add repair and replacement costs to your heating process. Also, resistance heating elements get extremely hot and can pose a safety hazard.
  • Ovens use convection heating, and the entire part is placed inside the oven, resulting in uniform heating. This method allows for heating many parts at once. However, ovens can be quite large and must be connected to an electrical outlet or gas supply, so they lack mobility. When large parts are involved, you may have to transport hot parts through your facility. In addition, the oven may need to be preheated for several hours before it is used, adding time to the process.

Induction Provides Many Benefits

Many critical welding applications require preheating. Understanding the differences between the preheating methods can help you choose the one that optimizes efficiency, reduces costs, and minimizes safety hazards for operators. Contractors in numerous industries have seen significant time savings with a move to induction heating—reducing cycle time by several hours per weld in some cases. Compared with other methods, induction heating is an efficient, consistent method for preheating, bakeout, and stress relieving for a wide range of part shapes and welding applications, helping you save time and money.

For more information, visit www.millerwelds.com.

Harder Mechanical Tackles Welder Shortage, Amps Up Productivity With Novarc’s Spool Welding Robot

By implementing Novarc’s Spool Welding Robot (SWR), Harder Mechanical Contractors has minimized their need for highly skilled welders and increased productivity from an average of 120 factored diameter inches (FDI) per shift to more than 200 FDI, while also achieving a repair rate of 0 percent and maximizing arc-on time. Moreover, because the SWR is a collaborative robot—or cobot—Harder Mechanical can assign less experienced welders to operate the machine, significantly improving shop productivity and resulting in high-quality welds every single time.

See the Novarc SWR cobot in action! https://www.novarctech.com/spool-welding-robot/

Weathering the Welder Shortage

The welder shortage, caused by the combination of an aging welder workforce and the lack of uptake of the welding trade, is affecting many industries, and it is one of the main reasons why Harder Mechanical decided to look into welding automation solutions. With over eight decades of experience, Harder Mechanical is a large, nationally recognized contractor with an outstanding reputation, based in Portland, OR.

“Our biggest priority was to get qualified welders,” said Mark Nastari, corporate quality director at Harder Mechanical. “Like everybody else in construction, we’re seeing a lot of skilled labor retiring and the new generation of workers not choosing blue-collar union jobs. So we were getting pretty nervous about finding specifically hard wire welders for our shop.”

Nastari noted that the shortage of highly skilled welders is a particular concern. “To find guys who have the skill to weld hard wire with a gun and be able to pass X-ray was getting pretty flimsy,” he said. “Our biggest concern was buying equipment that we can train people on easily and get them up and running and making X-ray quality welds.”

Harder Mechanical found that even junior welders using the Novarc SWR can produce excellent welds, none of which have required repairs.

Harder Mechanical was looking at pipe welding automation solutions that would help them combat the shortage of skilled welders when they came across Novarc’s SWR, a cobot designed specifically for pipes, small pressure vessels, and other types of roll welding.

“We’re very tech savvy at Harder Mechanical, and we’re always looking for better tools, better means and methods.” said Nastari. “So we looked at a variety of mechanized and automatic weld equipment. It came down to a decision between Novarc and another pipe welding machine that we had seen at FABTECH. What made the Novarc machine stand out was the quality of the root pass, the laser, and the technology.”

Dramatically Increasing Productivity

Nastari noted, “In our wheelhouse piping, which I call 2”–16” diameter pipe, a good welder would average about 120 diameter inches [per shift]. With the SWR, we have already exceeded 200 diameter inches, and we are not even at full throttle.” In fact, he predicted substantial advances for the future. “It will be easy for us to get to 300 diameter inches on our wheelhouse piping with the SWR.” The significant productivity improvements provided by the SWR can help contractors become more competitive when bidding on jobs and increase their profit margins on current jobs.

Robot Boosts Safety, Efficiency, Accuracy

Nastari pointed out other upsides of the new technology. “Another benefit of the Novarc machine is the safety factor. You don’t have welders hunched over, breathing fumes; they are standing back behind a weld screen, looking at the HMI [human machine interface], recording it. They really don’t need to get near the weld except for when they start it and when they stop it,” said Nastari.

Nastari continued, “The robot really kicks butt because we do not need to stop and clean in between passes. We’ve had a lot of clients come to see our shop during the bid process, and they go crazy when they see the robot. They love it! They love the videotape capability. We play back the welds for them and they are absolutely gorgeous welds.”

Prior to purchasing [Novarc’s] SWR, we were experiencing failure rates of 2–3 percent, which is better than industry average. But on the current job with the robot, we are doing X-rays, and we haven’t had any repairs,”

—Mark Nastari, Corporate Quality Director, Harder Mechanical

The ability to train junior welders to use the robot has also proved to be a substantial boon to Harder Mechanical. “Currently we have three people trained. We are a union contractor, and two of the people trained are apprentices. The third guy is a journeyman, and all three of them are about the same as far as competence. We’ve never had apprentices who could wire a weld and pass X-rays before. That’s a huge benefit to us, and it’s fantastic!” said Nastari.

The SWR minimizes human error and therefore reduces the failure rates from the North America industry average of 3–5 percent to less than 1 percent, resulting in massive cost savings for fabrication shops. “Prior to purchasing the SWR, we were experiencing failure rates of 2–3 percent, which is better than industry average. But on the current job with the robot, we are doing X-rays, and we haven’t had any repairs,” said Nastari.

Harder Mechanical has also been pleased with Novarc’s support as they put the SWR into practice. “The support was fantastic; we were always able to get ahold of the Novarc support team. They were always able to work on the screen in real time, and they always showed up when they said they were going to show up,” said Nastari.

For more information, visit www.novarctech.com.

Explore the Latest Welding Technologies to Improve the Bottom Line

Wasted time and lost productivity are enemies in any welding operation. Many companies have seen significant productivity increases, without sacrificing quality, by converting from traditional welding processes such as stick or TIG to advanced wire processes, such as pulsed MIG and Regulated Metal Deposition (RMD®), a modified short-circuit MIG process from Miller Electric Mfg. LLC. These processes offer consistent weld quality and travel speeds that are three to four times those of stick or TIG.

A modified short-circuit MIG process such as RMD offers easy weld pool control thanks to more forgiveness to variations in stickout and gun angle. This helps reduce operator training time, along with delivering quality arc performance that helps boosts productivity. This process also produces less spatter and eliminates the need for backing gas, saving time and money.

Pulsed MIG offers better fusion and fill at the toes of the weld, higher travel speeds and deposition rates, and shorter changeover time, because the same wire and gas can be used with modified short-circuit MIG processes.

Improve Efficiency and Quality

Using newer welding approaches and directing the arc energy where it is needed allows novice and experienced welders to improve their skills. A more consistent arc is also easier to manipulate to ensure good fusion, resulting in better weld quality and less rework.

Advances in remote control welding technologies, such as also ArcReach® technology from Miller, gives welders complete control of parameters at the weld joint using the wire feeder or remote—eliminating the need to walk back to the power source to make changes. These technologies also reduce the likelihood of trips and falls.

Benefits of Advanced Technology

Many financial and business benefits can be realized by converting from traditional welding techniques and processes to more advanced solutions.

  • Increased productivity. New machines can pay off quickly in increased productivity and other factors. For operations struggling to find and retain skilled welders, productivity improvements can help meet demands while making the most of the current workforce. If you source fabricated components from regions where labor costs are high, productivity improvements provide a significant cost reduction.
  • Reduced scrap loss. With stick welding, a common goal for welders is to achieve stub loss (the portion of the electrode not deposited in the weld) of 2–3”, which translates to “planned scrap” of 16 to 25 percent of each electrode. Converting from stick to a wire process eliminates stub loss costs and produces labor savings because it is a more productive process.
  • Fewer failures and rework. Consistent arc performance and filler metal selection are key to achieving higher first-time weld pass rates. Processes and technologies that offer more consistent arc performance can help reduce the time and money spent on weld failures and rework. A high level of rework impacts quality and can lead to delays, disrupting the entire flow of the construction process. (For more about the cost of rework and how to avoid it, see “Four Ways Specialty Contractors Can Reduce Construction Rework.”)

The Bottom Line

Understanding the potential productivity gains offered by advanced processes and new technologies can help ensure that jobs are completed on time and on budget. Change can be difficult, but companies willing to accept some level of risk might be rewarded with faster project completion, potential cost reductions, and better utilization of assets. Proper training is key to mitigating the risk.

For more information, visit www.millerwelds.com.

Team Industries Decreases Training Time, Increases Efficiency with Miller PipeWorx Welding System

With Miller’s PipeWorx 400 welding system, “we have seen a decrease in X-ray failure. The consistency of the arc definitely plays a role in that,” said Jim VanZeeland, shop superintendent of Team.

Since they started using the Miller® PipeWorx 400 welding system, Team Industries has reduced rework—saving time and money—because of the system’s ease of use and consistent arc quality. “We have seen a decrease in X-ray failure. The consistency of the arc definitely plays a role in that,” said Jim VanZeeland, shop superintendent. “It’s just been a great machine for us.”

The PipeWorx system offers conventional stick, TIG, MIG, and flux-cored welding processes optimized for pipe welding, in addition to advanced wire processes including pulsed MIG and Regulated Metal Deposition (RMD®) from Miller. The versatile, multiprocess machine has a simplified, single-system design.

“The quicker we can get people to pass X-ray the better it is for us, and the PipeWorx system really helps us do that.”

—Mike Schmidt, Vice President of Manufacturing, Team Industries

Team Industries relies on the PipeWorx welding system to stay on the cutting edge of welding technology and exceed customer expectations. The pipe fabrication company, with three locations in Wisconsin and Texas, has established a one-stop shop process to set themselves apart and to meet customer demands. Team Industries has a reputation for delivering high-quality pipe and tank fabrication on time and within budget, with the capacity at its three shops to produce up to 6,500 spools per month combining large and small bore.

Team appreciates that the PipeWorx system offers easy setup, an intuitive front panel, and push-button process changeover. “Everything about this machine is just easier,” said Dwayne Tremaine, a Team fabricator who also helps with training.

Team has standardized its welding booths with the PipeWorx 400 welding system, which fits the company’s varied welding requirements. The single- system design with one machine footprint helps maximize weld cell space.

Equipment that is easy to use plays an important role in training and retaining skilled welding operators for Team. The PipeWorx system offers easy setup, an intuitive front panel, and push-button process changeover—making it easier and faster for Team to get welders trained and on the job.

Users can simply push a button to indicate the type of welding needed, and the machine automatically selects the welding process along with the correct polarity, cable outputs, and welding parameters. The system also changes the shielding gas required. Eliminating the need to manually switch polarity or cables and hoses between processes helps new welders hit the ground running.

“They have enough things to learn already, like techniques and torch angle,” said Mike Schmidt, vice president of manufacturing. “Having a super machine is one less thing they have to worry about. The quicker we can get people to pass X-ray the better it is for us, and the PipeWorx system really helps us do that.”

Using the Miller PipeWorx 400 welding system, Team Industries has reduced rework—saving time and money—because of the system’s ease of use and consistent arc quality.

That simplicity also provides productivity and efficiency benefits for Team. After a TIG root pass, fabricators can switch to flux-cored for the remaining passes with the push of a button—no need to change cables or gas lines.

“Everything about this machine is just easier,” said Dwayne Tremaine, a Team fabricator who also helps with training. “Simplicity is the key word.”

For more information, visit www.millerwelds.com.

De-Cal Improves Productivity with Miller PipeWorx 400 Welding System

By taking advantage of the multiprocess capabilities of the Miller® PipeWorx 400 welding system, mechanical contractor De-Cal, Inc., was able to change its pipe welding processes to significantly improve productivity—by as much as 30–40 percent—while also growing business. The PipeWorx system offers conventional stick, TIG, MIG, and flux-cored welding processes optimized for pipe welding in addition to advanced wire processes, including pulsed MIG and Regulated Metal Deposition (RMD®) from Miller.

Based in Warren, MI, De-Cal has worked since 1992 to establish itself as a premier mechanical contractor in the mid-Atlantic states, with additional locations in Youngstown, OH, and Pittsburgh, PA. The addition of a fully functional fabrication shop at the Youngstown location allowed the company to add a new element to its business to meet the demand for customers in oil and gas as well as municipal water, chemical, power generation, food and beverage, and institutional applications.

As De-Cal has largely standardized on two processes (RMD and flux-cored), process changeover with the PipeWorx and its dual wire feeder (with solid wire on one spool and flux-cored wire on the other) is as simple as picking up the appropriate gun and hitting the trigger.
As De-Cal has largely standardized on two processes (RMD and flux-cored), process changeover with the PipeWorx and its dual wire feeder (with solid wire on one spool and flux-cored wire on the other) is as simple as picking up the appropriate gun and hitting the trigger.

The fabrication shop used several PipeWorx welding systems along with a series of weld positioners. However, most of the local welding talent had been certified to the ASME codes using only stick and TIG welding processes in fixed positions. To remedy this issue, De-Cal worked with UA Local 396 to certify welders in MIG and fluxcored processes to UA and ASME codes.

The productivity gains that De-Cal realized spurred them to make the switch from the proven-yet-slower stick and TIG processes (in fixed positions) to the faster MIG and flux-cored processes (rolled using a positioner). De-Cal has achieved numerous certifications under ASME Section 9 that included extensive radiographic and bend testing to prove the quality of these processes.

One of the primary contributors to De-Cal’s success has been the conversion of most root pass applications to the RMD process from Miller. RMD is a modified short-circuit MIG process in which the welding system anticipates and controls the short circuit, then reduces available welding current to create a consistent metal transfer. Precisely controlled metal transfer provides uniform droplet deposition, making it easier for the welder to control the puddle. The smooth metal transfer also compensates for high–low misalignment between pipe sections and creates more consistent root reinforcement on the inside of the pipe than other short-circuit MIG processes.

The process also maintains a consistent arc length regardless of electrode stick-out. This compensates for operators who have problems holding a constant stick-out, and it enables a better view of the weld puddle—making the process easier to learn than TIG welding.

De-Cal made similar improvements as the shop transitioned from stick to flux-cored welding for the fill and cap passes. Flux-cored welding provides a number of benefits over stick welding that help improve productivity and quality. These include faster travel speeds, increased deposition rates, and increased deposition efficiency, which ultimately means that less filler metal is wasted in the process.

In addition to the process advancements, the PipeWorx welding system also provides a number of additional benefits in terms of ease of setup and process changeover. For instance, the RMD process is easily set with the touch of a button, and the selection of the wire type, wire diameter, and shielding gas type helps dial the system in to typical weld parameters for pipe welding. The ability to save weld parameters is also helpful to operators. The flux-cored process sets up with voltage and wire feed speed and can also be assigned to a memory location.

One of the primary contributors to De-Cal’s success has been the conversion of most root pass applications to the Miller RMD process. A root pass using the process is shown here.
One of the primary contributors to De-Cal’s success has been the conversion of most root pass applications to the Miller RMD
process. A root pass using the process is shown here.

As De-Cal continues to grow to meet increasing regional demand, the PipeWorx welding system helps shorten the learning curve so the shop can bring welders up to speed faster. The use of advanced welding processes and a system that is optimized for pipe welding helps shops address critical industry challenges such as the shortage of skilled welders, shorter project turnaround times, and the need to increase quality standards.

For more information, visit www.millerwelds.com.

Modern Piping Increases Productivity and Safety in the Field with Miller Electric’s Multiprocess Welding System

Modern Piping Inc. put the PipeWorx 350 FieldPro™ System from Miller Electric Mfg. Co. to work to save time and enhance safety for a job where some welding took place hundreds of feet in the air, far away from the power source. International food and agricultural producer Cargill had purchased an unfinished corn wet-mill ethanol plant in Fort Dodge, IA, in 2011 and contracted with Modern Piping of Cedar Rapids to complete the construction on an aggressive schedule.

The facility has the capacity to grind 150,000 bushels of corn each day and produce 115 million gallons of ethanol per year. Before production could start, however, Cargill needed to finish construction on the facility and bring it up to Cargill standards for quality and safety.

Remote Control Saves Time, Increases Safety

Modern Piping used the PipeWorx 350 FieldPro system at the Cargill site for stick and TIG welding. The FieldPro machine can also be used for MIG and flux-cored welding, as well as the advanced technologies of pulsed MIG and regulated metal deposition (RMD), a modified short-circuit process. The optimized welding performance offered by the system specifically meets the needs of open-root pipe welding and helps reduce training time.

Modern Piping was tasked with laying out, fabricating, and installing the ethanol plant’s piping systems, including multiple process piping systems, compressed air lines, vacuum piping, chemical lines, cooling water supply, and return and steam. Much of the welding involved schedule-10 stainless steel pipe that had to be welded in elevated areas, requiring the use of scaffolds and manlifts. The remote control capabilities of the FieldPro System saved time by allowing process and parameter changes at the weld. The feature also increased jobsite safety by reducing trips up and down stairs and ladders to change welding processes and parameters at the machine.

“It’s good for us because it increases productivity, improves value to the end-user, as well as reduces safety concerns. There is great value to have a system that is very safe,” Modern Piping President Ken Brown said.

Made for the Field

Constructed to withstand the rigors of field use, the simplified cable management of the PipeWorx FieldPro saved Modern Piping journeyman pipefitters time by eliminating the communication cables that cause clutter on jobsites. Journeyman pipefitters using stick and TIG processes were able to change process selection, amperage adjustment, and stick electrode selection remotely, and the push-button process changeover eliminated the need for swapping cables.

In addition, workers were able to reduce the likelihood of weld defects because the correct polarity is automatically set for each welding process. The FieldPro System alerted Modern Piping journeyman pipefitters if the weld cables were connected incorrectly. The machine’s ability to set optimal parameters automatically improved quality control by helping ensure a consistent bead profile and by minimizing defects caused by incorrect welding parameters, such as porosity or lack of fusion. Each setup of a new weld process is done with the touch of a button, so the streamlined system helped avoid downtime and focus on the weld.

“It’s nice to have it within arm’s reach,” said Tony Hensley, a journeyman pipefitter with UA Local 125 in Cedar Rapids who worked on the project. “Every time you have to go up and down on that ladder, that’s another possibility that you could get injured, that you could drop something, and that causes problems. That’s something you don’t want.”

These capabilities are important because many jobsites, like the Cargill plant, are expansive. Modern Piping workers sometimes were 200 feet in the air.

PipeWorx Saves Time, Money

The simplified cable management of Miller Electric’s PipeWorx FieldPro saved Modern Piping journeyman pipefitters time by eliminating the communication cables that cause clutter on jobsites.
The simplified cable management of Miller Electric’s PipeWorx FieldPro saved Modern Piping journeyman pipefitters time by eliminating the communication cables that cause clutter on jobsites.

With the PipeWorx 350 FieldPro, the ability to make adjustments quickly from the weld site also helped save time and money. “It’s speed more than anything else—the efficiency that you get from this machine and this equipment, especially the FieldPro Remote, being able to turn up and down your amperage when you need that done,” said Hensley. “It’s right there, it’s right next to you. It’s a tool in your toolbox that makes you that much better.”

That ability to make finite adjustments at a rapid pace without interrupting the work for long stretches resulted in improved job quality and productivity. “It does give us the ability to provide a higher quality weld because we can make those adjustments when we need to, in the right location,” Brown says.

According to Brown, the PipeWorx 350 FieldPro System provided many benefits for Modern Piping. “One of the goals of Modern Piping is to be so good that we don’t have competition, and the FieldPro System is another step in that direction,” Brown said.

Thanks to the system, Modern Piping more efficiently completed several months of work to ready the Cargill plant for grinding corn to produce ethanol and other bio-based products. The PipeWorx 350 FieldPro kept Cargill on schedule to open the facility, and continues to make Modern Piping more competitive.

For more information, visit www.millerwelds.com.

With Miller’s PipeWorx System, De-Cal Welders Work Twice as Fast as Stick Welders

To meet growing demand, Michigan based De-Cal, Inc., opened its own fabrication shop with four multiprocess pipe welding systems (the PipeWorx Welding System from Miller Electric Mfg. Co.), along with a series of weld positioners. The speed and ease of use of the PipeWorx welding process has helped De-Cal refine its pipe welding processes to significantly improve productivity by as much as 30–40 percent and grow business.

Located in Warren, MI, De-Cal has worked since 1992 to establish itself as one of the premier mechanical contractors in the Mid-Atlantic states. With additional locations in Youngstown, OH, and Pittsburgh, PA, De-Cal finds itself in the heart of steel country, as well as the region’s burgeoning oil and gas industry.

The company added a new element to its business in 2011 when it built a fully functional fabrication shop at its Youngstown location. The expansion was designed initially to support the needs of their own mechanical contracting business but quickly grew to take in work from other companies as their capabilities fit a regional demand for welding and fabrication services.

When the fabrication shop opened, most of the local welding talent had been certified to the ASME codes using only the stick and TIG welding processes in fixed positions. De-Cal worked with UA Local 396 (plumbers, pipefitters, steamfitters, HVAC) to begin certifying welders in MIG and flux-cored processes to UA and ASME codes.

“The guys have bought into that real well,” said Ray Montgomery, manufacturing project manager for De-Cal. “Once I got one guy qualified, and I could have him work a job right next to a guy welding stick, I could show that he’s doing twice as much welding.”

The great bulk of material that comes through the De-Cal fab shop is carbon steel and stainless steel. One recent project—an extensive piping system for coke production—featured both. The first phase involved schedule-80 carbon steel pipe from 6” to 16” in diameter, while the second phase involved 10” to 16” schedule-80 stainless steel pipe. De-Cal has standardized, for the most part, on .035” solid wire for the root pass and .045” flux-cored wire for the hot and cover passes in both applications.

A few customers still prefer TIG and stick and are reluctant to consider change, but De-Cal has achieved numerous certifications under ASME Section 9 that included extensive radiographic and bend testing to prove the quality of these processes.

“We’ve had instances where a customer has given us a job to quote and given us a spec that says, ‘no MIG, no flux-cored,’ and I’ve been able to go back to them and say, ‘We want to perform welding using the same procedures that are approved under our ASME code program,’” said Montgomery. “And just about in every instance, I’ve got approval to do that.”

One of the primary contributors to this success has been the conversion of most root pass applications to the regulated metal deposition (RMD®) process. RMD is a modified short-circuit MIG process in which the welding system anticipates and controls the short circuit, then reduces available welding current to create a consistent metal transfer. Precisely controlled metal transfer provides uniform droplet deposition, making it easier for the welder to control the puddle. The smooth metal transfer also compensates for high-low misalignment between pipe sections and creates more consistent root reinforcement on the inside of the pipe than other short-circuit MIG processes. The process also maintains a consistent arc length regardless of electrode stick-out. It compensates for operators that have problems holding a constant stickout, and it enables a better view of the weld puddle—making the process much easier to learn than TIG welding.

“The RMD process is by far the biggest advancement that I see,” said Montgomery. “Being able to easily do a root weld, get full penetration, have a nice appearance on either side without the welder having to struggle is, to me, the biggest thing.”

Similar improvements in productivity occurred as the shop transitioned over from stick to flux-cored welding for the fill and cap passes. Fluxcored welding provides a number of benefits over stick welding that help improve productivity and quality, including faster travel speeds, increased deposition rates, and increased deposition efficiency— which ultimately means that less filler metal is wasted in the process.

“By using this process and utilizing weld positioners, a welder can routinely weld a continuous pass without stopping,” said Montgomery. “It’s much more efficient, the welders like doing it, and the weld appearance is very uniform.”

For more information, visit www.millerwelds.com.

Weld Positioners Improve Productivity and Quality

The Team Industries positioner includes steel-hardened insert jaws with small-bore adapters to eliminate the need for modified C-clamps.

While most weld positioners will improve the productivity of a pipe welder, a positioner designed specifically for the pipe welding industry to reduce welder fatigue increases the quality of the welder’s work.

“Having a good positioner in a fabrication shop is a must regardless of shop size,” said Ned T. Hawkins of Michigan’s W. Soule. “A good positioner is like adding another fitter to your project without the added expense.”

Positioners designed for a broad market base do not meet the productivity and ergonomic needs of the pipe welder. Pipe welding requires a wide range of rotational speeds to suit the range of pipe diameters and welding processes involved with each project.

Team Industries, Inc., began building weld positioners designed exclusively for welding pipe in 1997. Their products include features that provide ergonomic advantages, such as programmable acceleration and deceleration, a bi-directional foot controller, air tool quick disconnects, variable rotation, and up to 135° tilt capacity. Several accessories can also be supplied with the positioner, including a universal gripper, self-centering quick disconnect jaws, thru-hole purge assemblies, and even a fan for welder comfort. Infinitely variable rotational speed control (.36 to 3.69 RPM) and a gear reduction option permit welding of piping of all sizes (small bore through large bore heavy wall). Thru-hole purging systems save welder time and reduce the cost of inert gasses.

The Team Industries positioner includes steel-hardened insert jaws with small-bore adapters to eliminate the need for modified C-clamps.

Team has also designed a variable height welding positioner that incorporates additional ergonomic features, such as a push-button hydraulically actuated system for smooth height adjustment and a self-leveling system. These features offer a huge advantage over manual height adjustment positioners, which require considerably more time and effort at each height change.

The workstation concept incorporated into Team’s positioners improves the safety of the working environment for the welder. For example, positioners are equipped with 120V power outlets and air inlet filter/lubricator for air tool quick disconnects, reducing the propensity for trip hazards when using the positioner.

For more information, visit www.weldpositioner.com.