Clamping Devices

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First post, so please excuse if it is in the wrong area.Does anyone have a recommendation for clamping the top and bottom pieces of a manufactured I beam?  The beam is constructed of a 1/4" web and will be up to 23" deep.  The top and bottom flanges are between 1/2" and 3/4" thick and up to 6" wide.  The beams range from 20 feet to 60 feet in length.  We currently use a Irwin pipe clamp, but the amount of torque applied in order to get the flange square to the web is substantial and results in premature wear of the pipe clamp.  We've also tried a larger bessy clamp with no greater luck.Thanks.
Reply:Portapower C clamp.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:If you are assembling welded wide flanges make up a giant frame so that you can clamp both flanges using portapower jacks.   I prefer to assemble smaller beams with the web vertical while larger beams with the web horizontal.  Be a bit creative and you can make the frame travel down the beam on wheels.  You can have the pump units mounted directly on the frame with one person one each side.  That way you can pump the flanges tight and square then tack both sides.  Release the pressure and move down a bit to repeat the process.   It takes time to tool up.  You have to decide on the amount of beams you are doing.  I worked in one shop where they had a permanent frame and the flanges were clamped tight full length using a series of truck air brake pots.
Reply:What about tacking on some dogs and driving in some steel wedges ?
Reply:Here a quick drawing I made of a clamp I made years ago for something similar. Adustable depth and size to whatever size beam you have. Just basic dimensions as you'll have to adjust depending on what you have on hand. It worked like a dream clamping the beams and plate together. Arms are 2x2 solid, everything else is 1/2 plate with 7/8 grade 8 bolts. Adjust dimensions to match jack and material your clamping. We had powerjacks but you can use bottle jacks too. Attached ImagesLast edited by WolfmanJack13; 06-05-2007 at 11:38 AM.Latest Toys Miller 180 Mig and Elite Mask!!Wright Welder 225ACShop OutFitters 20/20 Bending SystemHypertherm 380 Plasma30 Years of Sparking (Electrical & Welding)