Fabrication & Installation of a Material Handling and Conveyor System for a Foundry Finishing Line

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A customer in the foundry industry needed a company with the professional experience and broad manufacturing capabilities to design and fabricate a large material handling and conveyor system. WickFab was contracted to do all the work profiled here, which included the project management, and the engineering and manufacturing of the foundry finishing line system that would convey and maneuver large castings to reach each grinding station. After finalizing the design and developing the production schedule, mild steel was sourced and a multitude of fabrication processes were employed to realize the exacting configurations. Laser cutting, press brake forming, piping, and welding were carried out on mild steel to construct the system, achieving a tight tolerance of ± 0.010" throughout production. The components were subjected to a powder coating treatment and finished with a coating of paint. Comprehensive functionality testing and dimensional inspections were applied to ensure the highest accuracy and quality standards were met.

Final dimensions of the system were 52’ in length, 41’ in width, with a height of 14’. The fabrication was completed in 8 weeks and installed over a 4 week period in Warsaw, Indiana. For more information about this roller conveyor construction, or the other large scale engineering and manufacturing capabilities available, please see the table below or contact us directly.

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Highlights of this Large Equipment Fabrication Project

Product Description
To convey and maneuver large castings to reach each grinding station.

Fabrication Capabilities Applied/Processes
Primary:
Project Management
  • Material Procurement
  • Scheduling
Engineering
  • Design Changes
Fabrication
  • Laser Cutting
  • Press Brake Forming
  • Piping
  • Welding
  • Painting
Secondary:
Installation and Assembly
Equipment Used to Manufacture Part
Plasma Cutter, Akyapak Plate Roller, Mitsubishi ML 3015 LVP 4000 Watt CO2 Laser, Akyapak Angle & Profile Roller, LVD 250 Ton Press Brake, Pipe & Tube Bender, 452 Delta Welder, Round Rod Iron Worker, Clausing Automatic Saw, Batch Powder Coat System and Wet Spray

Overall Part Dimensions
Length: 52’
Width: 41’
Height: 14’
Tightest Tolerances
± 0.010"

Material Used
Mild Steel

In Process Testing / Inspection Performed
Dimensional Inspection, Functionality Testing

Industry for Use
Foundry

Delivery/Turnaround Time
8 week Fabrication
4 week Installation
Delivery Location
Warsaw, IN

Standards Met
Customer Specifications, 2D CAD Drawing

Product Name
Roller Conveyor

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