Scrap Handler Supplement -- Putting Attachments to Work

It always helps to have the right tool when doing a repair job around the house or maintenance on a car. The same is true when choosing the correct attachment for a scrap handler. Today, there are roughly four major categories of attachments designed for scrap handlers, with several variations within each of those categories. And new variations are on the way as manufacturers look to eliminate steps scrap handler operators have to take when moving scrap.

GRAPPLES ARE GREAT

In any scrap yard, one is bound to find several grapples dangling from the booms of scrap handlers. That’s because grapples are the most used and versatile of the attachments. The variations of the grapple include:

• Orange-peel - Grapples that have four or more tines. When the tines are open, the grapple resembles an orange being peeled back. These grapples are ideal for picking up a wide range of loose scrap. They can even be used to pick up auto hulks, but only one at a time. Orange-peel grapples are not best suited for small scrap, like turnings. Options include 360-degree rotation.

• Tulip - Grapples that have wide tines that form a seal when the grapple is closed. These types of grapples are also called full-leaf grapples. Because of its sealing capability, tulip grapples are perfect for handling small stuff. In addition, they can handle a wide range of larger scrap. Like orange-peel grapples, they can have the option of 360-degree rotation.

• Narrow-tine - Grapples that have skinny, fork-like tines. The narrow tines are ideal for picking up soft scrap because the tines can dig into the scrap more easily than orange-peel or tulip grapples. Its uses include handling paper, cardboard, plastics and tires.

• Log - Claw-like grapples that usually have two fingers that fold into three fingers (these are also called two-into-three grapples in the industry). Log grapples were originally designed for the forest industry to move large trees that were cut down. Adapted to the scrap industry, they are used for moving auto hulks and larger pieces of scrap. Because of their grip, log grapples can even move two or three auto hulks at a time, increasing cycle time.

MAGNETS MOVE MATERIAL

Large, circular electromagnet attachments are staples in many ferrous scrap metal operations. That’s because a lifting magnet can be used for several operations that a grapple cannot handle. One is cleaning up areas around the yard, as the magnet can virtually sweep areas. Another is removing ferrous material from railcars, as the magnet can get the scrap left over on the bottom, whereas a grapple cannot.

Lifting magnets come in many sizes, but the most common ones are in the 5- to 8- foot range. Ones that are smaller may not be able to do the job as effectively and have low cycle times, meaning the scrap handler operator has to make more swings of the boom.

Since lifting magnets are electromagnets (they can’t be real earth magnets because the scrap handler operator needs to be able to turn off the field to drop the load at some point in time), a power source is needed to generate the electromagnet field. Therefore, scrap handlers need to be equipped with an onboard generator. Along with the generator is a controller mechanism that allows the operator to manage the current.

Onboard generators are normally powered by the scrap handler’s hydraulic system and most have dedicated pumps. Here’s a quick test to see if a magnet you want to buy can be powered by the generator currently installed in your scrap handler. Use the equation: Power = (Force)(Current). If the force is 230 volts DC (what most magnets operate at), and the magnet’s rated at 80 cold amps (current), then a generator that can produce at least 18.4 kilowatts of power would be needed.   

It is also important to know whether the scrap handler has or does not have an onboard generator when making a purchasing decision. A retrofit later on may cost more. Or if the scrap handler is never going to have a magnet attached to it, then why buy the generator option in the first place?

There are many characteristics to look for when buying a magnet, such as weight, coil temperature rise, cold amps, volts and kilowatts, etc., but probably the one area owners are most interested in is lifting capacity. Can the magnet’s field penetrate far enough to lift the desired material?

Another important area is the durability of the magnet. In the tough arena of the scrap metal yard, a scrap handler operator needs a magnet that is encased in a hard shell - one that has enough thickness to last. While bottom and side thickness is important to protect the coils from getting banged, top thickness is important, too, but for a different reason. The casing on the top needs to be of a proper thickness to force the magnetic field downward where it is needed.

Finally, ask about what type of magnet cabling is used from the generator to the magnet. Is it well insulated and protected against the elements? And is it capable of carrying the current properly?

MOBILE SHEARS SAVE

Because not everyone needs a heavy-duty shredder or stationary shear to process large pieces of scrap, mobile shears are a popular and important addition to a scrap yard operation.

A powerful mobile shear, some with more than 1,800 tons of cutting force, can easily snap metal pipes in half or cut up large steel wheels from trucks, as well as I-beams.

While manual torch cutting may be needed in some areas, having a mobile shear to do the work of a torch can be far faster and safer. In addition, a mobile shear can be taken to a demolition site to tear apart steel structures or other items.

“If you are a small- to mid-size yard,” says one manufacturer, “you need that mobile shear to handle the big stuff, because it’s not feasible to buy a heavy-duty shear or shredder.”

Characteristics to look for when buying a mobile shear include the power source - hydraulic or mechanical. Mechanical-operated shears operate off of the existing hydraulics of the handler, while a hydraulic-powered one has it’s own hydraulic cylinder. Mechanical shears usually have bigger and beefier fronts, and need a larger scrap handler. If buying a mechanical shear, make sure the scrap handler’s hydraulic system can power it effectively.

Other items to look for are blade design and anticipated wear. Most manufacturers use super hard steels and allow for easy blade changeouts. Does the shear have a parrot beak to easily hold material in its jaw prior to shearing? Is there a boom relief device to divert force away from the boom? (Note, some mobile shears may not require one.) Does the mobile shear rotate? The rotation option comes in handy when the operator has to shear scrap at different angles or to better position the mobile shear for a better cut without moving the handler.

Caterpillar’s S-series scrap and demolition shears rotate 180 degrees rather than a full 360 degrees. “Compared with shears with top-mounted 360-degrees rotation, the center of gravity of the 180-degrees side-mounted rotator is much closer to the excavator,” the company claims. “This means a Cat shear of any given size can be operated on a smaller excavator than can competitive shears with 360-degrees rotation.”

THE CRUSHERS

Attachment crushers and pulverizers are another category of boom-mounted devices that are used widely in the recycling industry. Although these attachments work basically in the same fashion with jaw-like movement to crush concrete and rock, variations usually appear only in the shape of the teeth, size and types of steel used in construction of the attachment.

Crushers are used mainly in on-site demolition projects, but can also be used at a yard to free rebar and other metal imbedded in concrete used for construction or roads.

Manufacturers have devised an increasing number of variations of crushers, pulverizers and speciality shears that are tailored to the task of liberating steel reinforcing bar from concrete demolition debris.

Companies such as Genesis  Equipment & Manufacturing Inc., Superior, Wisc.; Caterpillar Attachments, Peoria, Ill.;  Stanley Works/LaBounty, Two Harbors, Minn.;  and Teledyne Specialty Equipment CM Products, Solon, Ohio, offer a variety of attachments designed for cutting steel and rebar, crushing concrete and picking up and sorting materials.

The SH Series hydraulic shears from Teledyne Specialty Equipment rotate a full 360 degrees in order to operate in urban demolition applications where space may be limited.

Pulverizers made by the company include special seals to keep dust and other debris from clogging the pins.

Other features that scrap processors and demolition contractors look for include high peformance cylinders that provide faster jaw opening and closing cycle times, as well as cutters that can endure the rugged environment for the maximum amount of time before requiring replacement.

A pulverizer offered by Caterpillar has 21 crushing teeth and six rebar cutting knives positioned between the teeth in the lower and upper jaw. The teeth are made of a wear-resistant alloy steel.

COMBINATIONS COMING ON

Not that long ago, a combination scrap handling attachment consisted of a separate grapple and a magnet tied to the same boom. Scrap handling operators used to do this (and some still do) in order to save time when changing out attachments. For instance, while the magnet was being used the grapple would be attached above. When the operator’s work with the magnet was all completed then he could set the boom to the ground and detach the magnet without having to reattach the grapple.

Next on the scene was the grapple-magnet, which has been on the market for several years. The attachment attempts to combine the benefits of both attachments in one operating piece, but so far it has had mixed reviews within the scrap processing industry. Criticism of the combination attachment is mainly targeted toward the smaller than normal size of the magnet that is limited in diameter due to the tines of the grapple. The tines have to reach around the magnet and be able to close correctly for proper operation.

But making the magnet larger would significantly increase the size of the grapple portion and make the combination attachment too heavy.

Benefits of the attachment include time saved in attachment changeouts and giving the scrap handler operator more flexibility.

Another drawback of the magnet-grapple is that it is not ideal for cleaning out the corners of gondolas.

Now, a new design is being tested by a company that promises to revolutionize the scrap handling industry. It’s a unique type of orange-peel grapple that has magnet segments attached to the outside of each tine. The magnets are attached to the spine of each tine and are shaped in such a way that when the grapple is closed the magnets combine to form a rectangular shape.

This innovation could breathe new life into the sales of magnet-grapples as the rectangular shape of the magnet could be used effectively to clean out the corners of railorad gondola cars and barges.

Another recent innovation in combination attachments is the grapple-detector. This grapple has a radiation detector installed directly into the grapple’s tine base frame.

The detector comes with a wireless transmitter and is completely automatic.

The manufacturer that has the patent pending on the new system, says it can provide 25 times more detection capability than detectors mounted on the boom of the handler. In addition, because the detector is closer to the scrap it can sense radiation levels more accurately. And the detector is analyzing every load that is handled, thus saving precious time by allowing the operator to pinpoint the radiated scrap.

So, is anyone thinking about a radiation detection magnet-grapple?

Finally, some manufacturers of crushers for the demolition industry have included shearing blades within the jaws of their crushing attachments to handle stuff like rebar after pulverizing the cement, citing demands from users for more versatile attachments.

An improvement on this design that was recently introduced by one manufacturer enables its crusher to not only shear rebar, but structural steel as well.

Larger shears on the market are touted as being effective for cutting a variety of materials, from large tires, scrap cables and reinforced concrete all the way up to cars, trucks, farm machinery and railroad cars.

“It’s exciting to see these innovations in this market,” says one manufacturer’s representative. “I think we were overdue.”

Sidebar

Magnet Maintenance

Among the maintenance procedures recommended by one magnet manufacturer are the following:

• Check the magnet case for cracks, broken welds, dents, discolored metal and severe wear evidence

• The terminal box should be checked for broken welds and lead clamps as well as compound leakage and wire insulation stress at the clamps

• The stopper of the fill pug should be checked for damage (and to make sure it is in place)

• Using an Ohm meter, test the insulation resistance of the magnet coil. Also, check coil resistance by using a volt meter connected across the coil leads, and compare the findings with nameplate data.

• Use a straight edge to check for bending along the bottom plate

Sidebar

How Do You Know When Your Magnet is Failing

When the electromagnet field is on, is too much scrap falling off the magnet?

Are there numerous cracks in the magnet case?

Are there signs of discolored metal on the magnet case?

When the magnet is resting on a level, flat surface, is it convex or concave?

Are there any broken welds on the magnet?

Are there any signs of large gouges on the magnet?

Is there carbon tracking on the bottom plate?

Sidebar 3

Attachments and Their Uses

Attachment Type                   Lifting Use

Orange Peel Grapple            Metal/non-metal scrap

Tulip/Full-Leaf Grapple          Metal/non-metal scrap including small pieces

Narrow Tine Grapple             Softer scrap, such as cardboard, plastics, tires

Log Type Grapple                  Large metal scrap, including auto hulks

Magnet-Grapple                     Ferrous and other metal/non-metal scrap

Magnet                                    Ferrous scrap; ideal for sweeping areas

Mobile Shear                         Safe ctting; moving long metal scrap pieces

Crusher                                  Pulverize concrete, rock