Manufactured Parts

• Farley Fabricator and Atlas plasma burning machines
• Unique ability to drill with CNC accuracy single or multiple holes while plate is still on cutting bed
• Less material handling creating labor savings passed on to the customer
• UMV brake press
• CNC accuracy to hold tight tolerances
• Adjustable die to handle many different size parts without changing the die resulting in greater productivity and cost savings passed on to the customer
• Your one stop fabrication shop with the ability to handle the smallest to the largest jobs.  Able to produce flame cut only parts, complex formed and machined parts to complex welded assemblies
• JIT warehousing, shot blasting and painting

• Management committed to customer satisfaction and quality products delivered on time at a competitive price
• Free up valuable floor space for assembly of core products and development of new products
• Lower your inventory costs with JIT deliveries
• Minimize capital expenditures with single supplier outsourcing for large and small parts and assemblies

• 1.6 million square feet under roof and 400,000 square feet of open crane yard on 140 acres plot
• Plasma and Oxy fuel burning
• Shot blast and paint
• Plate leveling
• Surface conditioning
• Crane capacity from 10 to 75 tons
• 40 ft hook height
• Active Rail access
• Convenient Midwest location with access to major interstates

Hodgkins Facility

• 160,000 square ft
• Laser cutting
• Forming
• Machining
• Painting
• Welding
• Plate leveling
• Crane capacity from 10 to 40 tons
• 40 ft hook height
• Convenient Midwest location with access to major interstates

• Farley Fabricator – West
• Plasma – HT 4001 Hypertherm
• Single torch
• 30 mm max plate thickness
• Single drill spindle (BT40) with 12 tool carousel
• 124” x 120 ft. drill travel
• 131” x 120 ft. burn and mark
• .030” hole to hole tolerance
• max hole size 2” in 30 mm material
• min hole size 5/16” in 6 mm material

• Plasma – HT4400 Hypertherm
• Two (2) torches
• 63 mm max plate thickness
• Single drill spindle (BT50)with 9 tool carousel
• 150” x 45 ft. burn and mark
• 146” x 45 ft. drill travel
• .030” hole to hole tolerance
• max hole size 2.5” hole in 63 mm material
• min hole size 5/16” hole in 6 mm material

Farley Fabricator - East



Farley Fabricator - East

• Hy Performance Plasma – HPR 260 Hypertherm
• Hy Definition cut quality at speeds up to 145 ipm
• Two (2) torches
• 60 mm max plate thickness
• Single drill spindle (BT 40) with 12 tool carousel
• 129” x 43 ft burn and mark
• 123” x 43 ft drill travel
• .030” hole to hole tolerance
• max hole size 2” hole in 30 mm material
• min hole size 5/16” hole in 6 mm material

• MG East – 4 torches
• 110” x 43.5 ft max plate size and torch travel
• MG West – 8 torches
• 2 separate beds – max 200” x 18 ft max plate size and torch travel
• Burny 5 – 5 torches
• 125” x 100 ft max plate size and torch travel
• Burny 10 – 6 torches
• 125” x 100 ft max plate size and torch travel

• 60” x 120” (10 ft) max plate size
• 58” x 118” max torch travel
• 2000 watts
• 3/8” max plate thickness
• + / - 1 mm hole to hole tolerance
• Material handling package

• 30” max vertical spindle travel
• 40” max width spindle travel
• 120” max length spindle travel
• + / - .001” hole to hole tolerance
• + / - .0003” positioning tolerance
• + / - .0002” repeatability tolerance
• 30 hp spindle motor
• 7500 rpm
• CAT 50 taper spindle
• 4000 lbs. bed limit

• 750 ton capacity
• CNC controlled – with CNC back gauges
• @ 14 ft 11” max bed length – 16” max leg length bend
• @ 12 ft max bed length – unlimited leg length
• + / - 2 degrees production forming tolerance
• + / - .5 degrees close tolerance forming
• Adjustable die opening up to 10”
• Capability to adjust the bending pressure to facilitate uniform bend

• AWS welding procedures and qualifications
• Certified welders to AWS D 1.1
• MIG welding
• Flux core welding
• Stick welding
• 7 – Lincoln Idealarc DC-400
• 1 – Lincoln Idealarc DC-600
• 2 – Miller Dimension 452

• USF, BCP Wheelabrator (Auto Blast)
• Entry and exit tables 13 ft wide x 60 ft long
• Entry table is equipped with a high pressure air knife to remove loose scale, water, etc., from the plate surface prior to blasting
• 270 hp, Nine (9) wheel horizontal center feed at 3,600 RPM
• Three (3) stage blow-off abrasive removal
• Two (2) 30 hp blowers feeding ten (10) 6” diameter air cannons (525 cfm)
• One (1) 25 hp blower feeding eight (8) 4” diameter air cannons (325 cfm)
• Two (2) 15 hp feeding a 6” x 168” Air Knife (4000 cfm)     
• Typical profile – 1.5 to 2.5 mils
• S280 shot
• SSPC – 10
• Size Capability
• 3/16 to 3” thick
• 48” to 154” wide
• 96” to 60 ft long   

• Fast drying water and solvent base paints
• Paint system is specifically designed for Nippe Ceramo and similar type paints
• DFT applied per customer specifications
• Plate Pre heater
• USF, Spencer Halstad
• Hot air
• 34’ long
• 75 degree temperature rise on a 1” thick plate at 10 FPM
• 2.6 MBTUH gas fired
• automatic temperature reduction feature when conveyor is stopped
• Paint System
• USF, Spencer Halstad
• Designed for higher line speeds
• Electrical reciprocators with variable speed drives
• Upper and lower reciprocators common drive for absolute speed synchronization
• Double lap spray pattern capability
• 4 airless and 4 HVLP guns mounted on each reciprocator
• Airless system specifically designed for use with abrasive paints such as Nippe Ceramo
• Separate systems for fast changeover between water and solvent based paints
• Slat conveyor
• Variable speed drive to match with the blast machine and exit conveyor
• Slats are spaced on 16” centers
• Cure Oven
• 44 ft long
• 12,000 cfm, 100F recirculating air
• 1.4 MBTUH

• Carbon plate up to 6” thick
• HSLA plate up to 4” thick
• Widths to 150” (12.5 ft)
• Weights to 40,000 lbs (20 tons)
• 1000 ton capacity

• Birdsboro Roller Leveler (“five over four) originally installed at the Armco Plate Mill in Houston, TX
• 180” (15 ft) wide work roll faces
• 13” diameter work rolls
• 16” diameter back-up rolls
• 6,000 ton total separation force
• Manual and semi-automatic screw positioning
• 375/750 hp drive motors
• 10” x 183” maximum window opening
• 80 ft long powered roller table north of leveler
• 110 ft long powered roller table south of leveler
• Crane capacities: 10 to 40 ton hoist
• Served by four (4) truck doors and one rail siding
• 48” to 180” widths
• 84” to 1200” (100 ft) lengths

• ISO 9002 compliant
• 4 x 6 ft granite layout table
• Faro Arm (up to a 4 ft radius) for dimensional and flatness checking
• Non Destructive testing
• All measuring devices certified and calibrated

Copyright © 2005 Industrial Steel Construction, Inc. All rights reserved.