Scrap Handler Supplement -- An Appropriate Platform

That adage, often applied to essay questions, is also appropriate when looking at which scrap handler platform is best within a scrap processing facility.

While certain situations cry out for the use of one platform over another, in many other instances, more than one platform can produce good results and admirable productivity rates.

ON THE GO

They may not log highway miles, but a certain amount of mobility in a hydraulic scrap handler can still be valued by a scrap processor.

Of the several scrap handler platforms available, wheeled scrap handlers have probably moved into the number one market share position. In North America, larger yards with more ground to cover have been one factor leading to the popularity of hydraulic handlers on wheels. In general, wheeled handlers can move around the yard more quickly than those on treads, and if needed can even be used off-site if such a situation arises.

Operators of paved yards also have a strong incentive to switch to equipment with wheels. Environmental standards have resulted in a great deal of paving at scrap processing facilities throughout North America. As concrete is poured at more and more yards, wheels become a platform option that can make sense. “The trend toward wheeled handlers is really gaining momentum,” says one dealer of scrap handlers. “I would say that nearly every yard today has at least one wheeled handler, and those that have completed a lot of paving have numerous wheeled handlers.”

In Europe, as many as 90% of the scrap handlers are estimated to be of the wheeled configuration, according to manufacturers who sell equipment there. Concrete at facilities in Europe proliferated earlier this decade due to strict environmental regulations adopted to bring member nations in line with European Union standards.

European equipment makers have geared many of their product lines to include wheeled platforms as standard. Fuchs introduced its 50-ton MHL 360 scrap handler to North America at the ISRI Annual Convention in Orlando.

Fuchs engineers say maneuverability was a key design criteria when designing the MHL 360, which is available in both55-feet and 59-feet reach options. The 68-ton Fuchs MHL 380 is the largest wheeled scrap handler manufactured by the German company.

American companies have kept pace with the demand for wheeled material handlers, not only to retain access to European markets but also to be ready should the North American market continue to move toward paved yards.

Storm water runoff standards outlined by the U.S. Environmental Protection Agency (EPA) are in fact steering many scrap processors to pour concrete over areas of their yard that were formerly unpaved. (A decrease in the generation of dust has been an added benefit of paved surfaces, many yard operators have found.) Paving is among the nearly 200 “best management practices” for scrap yards to control storm water runoff recommended by the EPA.

“Yards are finding that it is in their best interest to stay ahead of the regulations,” says one scrap processor. “We have our entire nonferrous operation under roof, and our ferrous operation outside is entirely paved. That portion of the yard is on a gradual slope, so any runoff is collected at a drain at the end and goes through a separation process that removes any major contaminants.”

Even with “clean” scrap, there are residual metals present in storm water runoff that can be considered hazardous, and the EPA is concerned about what affect, if any, that may have on the environment.

After the decision to pave comes the attention to maintenance. Scrap processors have to keep an eye out to treating the pavement with care. “You don’t want to be dropping large, heavy pieces of scrap on the pavement, and you don’t want to tear it up with crawlers,” says one processor. “So, we have turned to tired handlers to work on the pavement, and if a crawler needs to work on the pavement we instruct the operator to be extra careful when moving and turning.”

Non-standard tires such as solid tires or foam-filled ones are almost necessary in the scrap environment. One crane conversion specialist strongly recommends solid tires to his scrap-handling customers, most of whom operate in non-paved settings. “I recommend solid in most cases,” he says. He recounts the story of one customer who decided against solid tires initially, but “60 days later he called to say the tires had fallen apart, and he asked for some solid tire manufacturer recommendations.”

Paved yards, by most accounts, have proven to be ideal working environments for scrap handlers with tires. A paved surface is one that lets the wheeled handler take full advantage of its mobility. Some handlers are being designed to offer more maneuverability in tight spaces than their predecessors did. These newer models have smaller footprints and features such as dual-axle steering that enable them to move quickly around the yard.

WHERE TIRES FEAR TO TREAD

Stability and the knack for proceeding through the sloppiest of terrain scenarios have made scrap handlers mounted on treads the favorite of many scrap facility operators.

The trend toward paving may well be long-lasting, but there are still many yards in operation with an exposed soil surface at part or all of their site. And even in the face of a trend toward paving, companies that offer treaded models are introducing innovations to make sure crawlers retain a place in the scrap processing facilities of the next century.

“It’s still the most durable design on the market,” says one manufacturer regarding tracked platforms, “and scrap processors like that.”

OmniSource Corp., Fort Wayne, Ind., operates several scrap yards throughout the Great Lakes region. The company has been updating its crane and material handler fleet and has purchased several Komatsu hydraulic handlers mounted on treads.

Dave Kaminski, the operational manager at one of OmniSource’s largest ferrous yards, believes the tread-mounted Komatsu machines have offered good operator comfort, helping lead to increased productivity. “All of our operators love the PC400LC-6’s cab,” says Kaminski. “If they are going to be in the machine all day long, they want the best operator comfort features available,” he adds. Kaminski cited reduced cab vibration as another plus.

A practical consideration for operators of smaller yards involves versatility. One crane conversion specialist notes that yard conditions often make treads the most sensible platform for small and medium-sized processors. “If they’re in a do-all market, but can only afford one crane, they tend toward track,” he notes. “Even a lot of larger processors who may have two or three yards—and they like the mobility of wheels—can find that conditions don’t favor tires. If they’re near a river in alluvial conditions, it can be muddy a great deal of the time.”

Another perceived benefit: the weighty crawler configuration can keep the handler’s center of gravity lower, usually eliminating the need for outriggers that are common with wheeled handlers.

The addition of rubber pads on the tracks of crawlers is one way to minimize damage to pavement. “The pads have worked well, and we paved our yard with extra-thick concrete so that it is more durable,” remarks one processor.

The value of the pads may vary regionally, however, with some processors claiming that the pads do not offer maximum traction in harsh winter weather. “It is certainly fine in warmer climates, but if the pavement is slick or icy, the crawler can loose traction and slip, and you don’t want that happening when you are handling scrap,” says one manufacturer.

Among the features to note when comparison shopping for crawlers is the design of the undercarriage. “You want the underneath of the handler to be free of obstructions and dangling hydraulic lines,” says one manufacturer.

RIDING THE RAILS

Many scrap consumers, as well as quite a few processors, use scrap handling equipment mounted on rails.

While wheels, treads and stationary pedestal-mounted cranes are the most common platforms for scrap handling machines, the rail-mounted crane there is another noteworthy option available. The use of rail-mounted material handlers, of course, is limited to those with on-site rail capabilities. But the market for such cranes, whether of the hydraulic or lattice-boom configuration, still exists.

Ohio Locomotive Crane Co., Bucyrus, Ohio, touts rail cranes as a dependable material handling method: “For over 90 years, the world has depended on the strength and durability of the locomotive crane to provide a dependable and economical solution to their material handling problems.”

Among the products made by Ohio Locomotive is its 480 Scrap Grab’r material handler. (Despite the company’s name, it also offers the Scrap Grab’r on non-rail platforms, including rubber tires, treads and pedestal-mounted.) The product is believed to be one of the first scrap-specific machines to be offered by a rail crane company.

Rail-mounted cranes are chosen as an efficient option by many steel mini-mill scrap consumers and large scrap yards that do a lot of rail shipping. Having the benefits of the faster, newer hydraulic material handler in particular, while still being able to operate on rail, is seen as an advantage by these users.

Many rail-mounted cranes used in scrap applications have been refurbished after having worked in a more general cargo setting. Often, the main frame of the lower part of the unit has passed a full inspection to ensure that any cracks have been repaired. For scrap purposes, the rail unit  should not have had excessive ballast or counterweight added in an attempt to maximize over-the-side lift capacity. Any additional weight can lead to frame fatigue and possible axle failures.

On hydraulic models, it is also important to have the proper size rail lower match the size of the hydraulic material handling upper. Rail-mounted cranes can now be purchased using newly-manufactured rail lowers. The benefits of buying a new unit include having a factory warranty, having access to original manufacturers’ spare parts, and having accompanying reliable lift charts.

At one time, locomotive cranes had a major presence in the scrap handling market. But the popularity of hydraulic handlers with crawling and wheeled platforms often came at the expense of rail-mounted machines. The availability of crawler models—combined with the growth of shipping scrap by truck—lessened the demand for rail-mounted handlers.

“Before hydraulic material handlers were made and marketed in the 1970s, if you needed mobility, you got a locomotive crane,” says one seller of new and pre-owned cranes. The hydraulic material handlers quickly put the rail cranes at a competitive disadvantage, he notes. “They had new models available for $250,000. A new locomotive crane was $400,000, plus you needed an experienced and highly-skilled operator to run the lattice boom configuration.”

Makers of rail-mounted cranes have subsequently taken steps to address the price inequities that put them on the defensive. Some new models—such as the Scrap Grab’r—feature the hydraulic configuration instead of the lattice boom set-up. Many manufacturers are hopeful that interest from steel mini-mills, in particular, will spark a renewal in their market.

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Protecting the Investment

After making the decision to purchase a mobile material handler, one of the first considerations upon taking possession of the machine is setting up a comprehensive maintenance program.

A hydraulic material handler is right behind large tonnage processing equipment in terms of major capital expenditure items. Maximizing the operating hours and length of ownership thus becomes a critical bottom line issue.

According to both equipment makers and processors, a planned and detailed maintenance program for material handlers has the following benefits and features:

• Prevents small problems from turning into larger ones

• Increases resale value of equipment

• Saves money by managing the costs of repairs

• Tracks all maintenance, ensuring correct intervals are established

• Schedules checks to minimize equipment downtime

• Uses the right tools and trained personnel to safely and accurately conduct maintenance

• Involves regular inspection.

While efficiency-minded scrap processors have established meticulous maintenance programs without the aid of computers, for those who desire  computer systems involvement, help is available.

One way is through computer-based software programs that help owners better manage their maintenance programs. Another way computers are being used is to help maintenance personnel in diagnosis routines. Some scrap handlers have recently been designed with an on-board microchip that tracks the complete history of the handler. By reading the data from the chip, a service technician can find out when the machine was running hot, and for how long; when the oil level dropped below the recommended amount; or any other of a wide range of parameters.

“The chip can track these parameters from day one, and continue for the life of the handler, or the chip can be wiped clean, such as after a major overhaul,” says one dealer of scrap handlers.