World Trade Center Hub

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Hi all going to post some work pics. First is the east box truss 25 ft deep 187 ft long 602 tons. Next is a diagonal the weld is a horizontal 4" full pen field welded. The third is a hand squirt weld on a stiffener on a 96 ton piece . All for the World Trade Center Transportation Hub !!!   John Attached Images
Reply:Impressive stuff John!That last picture, what kind of 'gun' is that you're using?Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Lincoln K113 sub arc 5/64 LA-75  860 flux DC-600 power supply LN-9 feeder   WPS 385 amps  +37-0  29 volts -+2 - 11ipm travel speed  production 60lbs 10 hrs
Reply:now thats what u call  some heavy  duty  steel  welding  !>Innovations are what i leave behind for History
Reply:so when are you going to start the big stuff?
Reply:Hey John are those the 60 ton cranes you where telling me about?  I need to borrow one of those babies for the new shop.  Thats really tiny iron compared to some of the bridge stuff you guys have made.Lincoln 300 Vantage 2008300 Commander 1999SA250 1999SA200 1968Miller Syncrowave 200XMT350MPA/S-52E/xr-15Xtreme 12vs Millermatic 251 w/30A  Millermatic 251 Dialarc 250 Hypertherm 1250 GEKA & Bantom Ironwokers
Reply:Originally Posted by Rick VImpressive stuff John!That last picture, what kind of 'gun' is that you're using?
Reply:I live in SP!  I'm glad our town is making those beams etc for the WTC.  btw, you all hiring there?www.thefusionsolution.com
Reply:awesome work,keep the pictures coming please.
Reply:What is the backing material (h,w,l) on that brace weld?
Reply:Nice! that is a very cool project to be a part of!72 Chevy Cummins Project94 3500HD Welding Rig build Sold NOV 2011
Reply:Originally Posted by MrBeastNice! that is a very cool project to be a part of!
Reply:Originally Posted by Xtreme FabricationHey nick, Johns already tried to hire me to come up there and work on it.  He can make it happen if you want to work on it.
Reply:Originally Posted by MrBeastas a Rig Welder? or a Single hand?
Reply:so random question that thing looks 30+ feet wide how the hell they going to transport it out the shop?Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by Dualieso random question that thing looks 30+ feet wide how the hell they going to transport it out the shop?
Reply:Pieces are 40 ft x 40" x 8-10 ft /  20 to 114 tons  Harris Camden Terminal takes most on 5 axel  oil field single drops , 4 axel high flats . Supor hauled some on his 8-axel or 3+4+3  Niclolas dollys . The pics are a butt welder Lincoln Tiny Twin  2-5/64 LA-75/ 860 flux 900 amps , DC-1000 power supply NA-5 controls . The bearing is being matched to a sole plate in a subs shop. Attached Images
Reply:Welds are on 1x3/8 back up bar or backgouged and welded up 100 UT or x-ray we gouge 5/8 dia 900 amps . A piece from Spain on the truck . A connection weldment from ADF in Canada 132KO1 finishes out 72 tons we are adding 20 tons of plate 3 tons of weld material . John Attached Images
Reply:We have built 200 ft long pieces ,176 ton pieces, hauled 27 ft wide to McKees Rocks PA  Buith the Isod Arena , Betsy Ross Bridge , Gerater New Orleans #-2 , Brooklyn Tower of The Verrazano Bridge  , Kingston Rhinecliff Bridge , Rip Van Winkle Bridge , Port Authority Bus Terminal , the list goes on and on . John
Reply:The sheer scale of all this is mind-bogling! About the only thing I can relate to is that big C-clamp in one of the pictures - busted, then weld repaired/reinforced.  Pavinsteelman these posts of yours are awe-inspiring views inside 'Heavy' industry.Thanks for sharing...Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Very impressive.  And I absolutely respect that you were chosen for this project.(Retired) Professional firefighter, amateur everything else I try to do...Oh yeah:  Go Big Red!   (You know: one of the 12 members of the Big 10 cuz we left the 10 members of the Big 12...)
Reply:Doggone Pavinsteel, I missed the LA-75 the first time around! The E80-1Ni is gonna test around 90ksi so I guess they want the WTC to stay put this time around! That may be my all time favorite wire/rod of all time to work with,The prep work all looks first class to me, really good torch work.Do you guys still use the old lincoln guns with the little hopper on top & a coffee can of flux for small work? I don't even know if you can get those anymore.Also looking at the millman standing next to the weldment makes me glad I don't fiddle with the big things anymore... Customers often expect to pay the same for a hole in a 90ton part the same as a hole in 100lb part.Matt
Reply:The K-113 can have a cone but ours are attached to a flux tank with a LN-8 or 9 feeder and run a 5/64 or 3/32 wire LA-75 or LA-85 for HPS -70W with Mill 800-HPNi flux. The bearingn is at Freiri Machine in South Plainfield and that is the owner ,a closer look you can see the thru bolts holding it to the angle plate on a Collet HBM , he  has a 72"x 65.5 ft Niles Lathe too !!! White Marine in Perth Amboy is also doing work for us bearings and field milling the 237 ton super columns .. And the torch work is done with natural gas and we have cut 17 inches with it .
Reply:Do you work for Weirs?  Charlie Weirs?Some Blue , Some Red & Some GreyProverbs 16:2-3.2 "All a person’s ways seem pure to them, but motives are weighed by the Lord. 3 Commit to the Lord whatever you do, and he will establish your plans."
Reply:Some shop pics a assembly shot some field assembly welds and a LT-7 tractor welder . Attached ImagesA wall welder NA-5 / moggy guidence /weld eng flux recovery /DC-1000 power supply , a 37 ton diagonal made with 4"+8"+17" plate and a few tons of LA-75 , a 30 ton pot bearing. Attached Images
Reply:Loads to the Hub the diagonal is 74 tons all that bevel is field weld ESAB coreshield 8 .072 .  John Attached Images
Reply:We have 3 sizes.....  wee, not so wee, and FREAKIN' HUGE    The Lord has declared, "This is my work and my glory--to bring to pass the immortality and eternal life of man"  Moses 1:39Link: My name is John, and I am a member of The Church of Jesus Christ of Latter-Day Saints.-- ColdCreekWorks.com --
Reply:Those pics just replaced my p0rn collection!Very cool.
Reply:It's awesome seeing the new WTC going out of that plant.www.thefusionsolution.com
Reply:pavinsteelman   I was born in plainfield NJ are yiu off of oak tree rd or randolfville rd  JOKERVET
Reply:Big Load  113 tons 11 ft high 41 ft long around 10 tons weld material 5/64 LA-75/860   & 1/16 Outershield 71 Elite Attached Images
Reply:Amazing, impressive - Great Photos!Thanks for sharring...Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Big stuff gone now rush job welds one piece contains  4000 plus pounds to go. The basic squirt  welder LN-9 Flux tank , K113 gun 5/64 LA-75/ 860 flux. Hand and machine work our portable drill  11" col. 5 " arm Carolton Radial drill . Attached Images
Reply:Originally Posted by PavinsteelmanWelds are on 1x3/8 back up bar or backgouged and welded up 100 UT or x-ray we gouge 5/8 dia 900 amps . A piece from Spain on the truck . A connection weldment from ADF in Canada 132KO1 finishes out 72 tons we are adding 20 tons of plate 3 tons of weld material . John
Reply:The 113 ton piece had 20000 lb of weld material in it. A TC-U4 S takes 31.18 lbs per lf at 4 inches we have miles of them !!!   John PS this little piece needs 15 tons more plate and 3 tons more weld on it. Attached Images
Reply:I just completed a project that I bid based on the amount of the material + time. In the material quote was 1.5 tons of welding electrode and 28.5 tons of steel.
Reply:Well it all came to a end Trade Center almost done , City Island Bridge delayed and DCM shut down MRP ,Harris down to 40 hrs . They have laid off over 600 people .Thank Port Authority and NYCMTA for sending work to Spain,Italy and China . God Bless America .  John
Reply:Originally Posted by PavinsteelmanWell it all came to a end Trade Center almost done , City Island Bridge delayed and DCM shut down MRP ,Harris down to 40 hrs . They have laid off over 600 people .Thank Port Authority and NYCMTA for sending work to Spain,Italy and China . God Bless America .  John
Reply:Had to fill you in City Island Bridge changed to plate girder 3000 tons of steel in yard owned by NYC waiting for drawings. Trade Center almost done,owe us 31 million still. Canam/Structal has all the work Tappan Zee and Goethals cable stayed, Pulaski and Rt-21 NJDOT US Tennis Center. We are bidding Wittpenn Lift bridge 6000 tons biggest piece 15'x124' x 29'-4" wide 206 tons. At least buy American.
Reply:Good luck I hope you get the work.  Thank you for sharing the pictures.  It is mind-boggling and awesome in the truest sense of the word.I can't believe nobody said anything about your "portable drill" !!!   That is unbelievable.  I can't really tell from the pictures, but do you have it mounted a heavy flat steel plate so you can put it down anywhere?  I'm guessing you just pick it up with one of the many overhead cranes?  I'll never be able to look at my "heavy duty" 1/2" Milwaukee holeshooter "portable drill" the same again.
Reply:We would not do it this way in California.  We would have a cheap Chinese company do cracked welds and change the weld procedures to fit the job.  Did this for the new bay bridge mess.  Many of the welds were cracked before it was even shipped to California.  A lot of corruption on the job.  Should have done the job in LA or seattle/brittish Columbia area.
Reply:Yup put a plate on a 11" col 5' arm Carlton radial we have 3 Kaukana side drills too they weigh 7 tons each. 60 ton cranes make it easy. Welding with 900 amps tiny twin wire,30 lbs a hr helps too.Auto Arcair 1000 amp gougers leave a milled like grove. We have a Farrel Newton mill 16 ' high x 24 ' long left over from the Narrows bridge 1960.
Reply:WOW!  To a learning hobby welder like me...this stuff is...incredible.
Reply:john; i've worked on some large projects like the port authority bus terminal in the early 80's and the javits convention center along with the first day's after the wtc disaster. those are some great pictures that bring back lot's of memories of shop and field. thanks for posting them.i.u.o.e. # 15queens, ny and sunny fla
Reply:An update just like to show what a real bridge shop looks like !  Subarc welding is king with some fluxcore and no metal core .
Reply:Originally Posted by PavinsteelmanAn update just like to show what a real bridge shop looks like !  Subarc welding is king with some fluxcore and no metal core .
Reply:All of this work was to be done by ADF in Canada and Ursa in Spain all came back to NJ to get done !
Reply:Originally Posted by PavinsteelmanWell it all came to a end Trade Center almost done , City Island Bridge delayed and DCM shut down MRP ,Harris down to 40 hrs . They have laid off over 600 people .Thank Port Authority and NYCMTA for sending work to Spain,Italy and China . God Bless America .  John
Reply:Thanks for the pictures --  I drive by your plant daily -- Had no idea the immensity of the work going on in there -- see the trucks loaded all the time --the pictures of the "inside" gives those loaded trucks a whole new meaning --  Years ago I used to take the kids to see the stryker combat vehicle frames loaded up on the trucks in the lot off lakeview