Field System Machining Onsite Machining!
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40,000 Pound Shafts with Broken Splines?
Field System Machining recently repaired two massive work rolls, which are used to roll out heavy steel plate into storage tank components.  Although we are known for field machining repairs, FSM's shop repair solutions provide an affordable alternative.  When your machinery will fit on a flat bed and the down time can be scheduled, the results are a repair completed at a lower cost. Of course, when down time is the key driver, field machining is the only way to go. In this instance, the above ground storage tank manufacturer was able to schedule an outage with a duration long enough to allow them to part with these two massive shafts and send them here. FSM has relationships with numerous flatbed haulers so that we can get you the single drop, double drop, or double drop lowboy needed to get your machinery here safely and 
affordably. Large Shaft Repair On Site In Situ Shaft Machinery Repair
In this photograph you can see how the shaft arrived.  The drive spline has broken of the work roll shaft. 
Large Shaft Repair Services - Here or There 
In the photograph, above, you can see where the pre-machining has occurred, and preliminary NDE reveals indications of discontinuity remaining near the work roll edge.
Large Shaft Repair - 40,000 Pound Shaft Repair Portable Lathe
Large Shaft Repair - 40,000 Pound Shaft Repair Portable Lathe
 In the video above, you can see Field System Machining's 225 Ton Portable Lathe, and the single point machining of the spline fit, in progress.
Work Roll On Site Machining Heat Treating Welding Repair 40,000 Pound Shaft Portable Lathe
Work Roll On Site Machining Heat Treating Welding Repair 40,000 Pound Shaft Portable Lathe
In this video you can see the custom heat treating box we made to maintain shaft temperature during welding.  Also visible is the heat transfer sink we made to dissipate heat away from the shaft, beyond the necessarily heated zone.  The customer reports that this pair of work rolls are back to rolling out high quality plate radii and everyone in plant management is happy with the decision to hire Field System Machining.
Die Pocket Machining - New Setup with Massive Rigidity
Field System Machining loves forges - ring forges, open die forges, closed die forges, hammer forges - we love a good metal compaction of any kind.  We are also adept at the in field machining of forging machinery.  FSM has repaired forge machinery in situ since our inception.  
Field System Machining Custom X - Y - Z Milling Machine with Numeric Controls

Although we machine certain die pockets every year for a faithful customer, and we could have done it yet again this year using the same machine as always, we decided to make an entirely new machine.  This milling machine allows us to trim out faster, meaning setup time is reduced, resulting in a smoother on-site performance.  We are not contented and are always on the lookout to machine faster, stronger and straighter.  CONTACT US if you have a quote request.
Steel Mill Table Roll Bearing Seats
 
Steel Mill Table Roll Bearing Seat In Situ Machining
Table Roll Bearing Seat Machining in Progress

Table roll bearing seat repairs are one of those steel mill machinery repair
items that comes up, regularly.  The seats are subject to heavy loads and wear. Welding and machining become necessary to repair the bearing seats. Steel Mill Machinery repairs are one of FSM's core 
competencies. We have never met a steel mill machine we didn't like. 
Steel Mill In Situ Machining On Site Machining In Situ Guru Field System Machining
Table Roll Bearing Seat Machining In Progress 
In the photograph above you can see the milling of the bearing seats, in progress.  The pockets were badly worn, requiring welding then machining to put the seats back to size.
Steel Mill On Site Machining and Welding - You Call, We Haul, That's All
Milling the Sides of the Welded, Restored Table Roll Bearing Seat Blocks
This customer, for whom we work a half dozen times or more per year, was delighted with our results.  
Machining a Forty Food Diameter?  Why Not? 
Do you have a project that your not sure can be done, or perhaps has never been done, in situ?  Would it save your plant money if it could be repaired in situ? Please send us your ideas-we will be the first, not the last, to tell you the feasibility of machining your project in situ.  Likewise, if it is cheaper to do the work in our shop, we will be the first to tell you that, as well.  Please visit CONTACT US, to tell us more.


Ron Reschke Ron@fieldsystems.com 
Peter Radakovic Peter.radakovic@fieldsystems.com
Field System Machining, Inc.
Since 1978!
1-800-789-2814 United States
+1-847-468-1313 International