Using Technology to Address Multiple Challenges
Apex Steel specializes in steel erection, architectural metals, reinforcing steel, and tower crane and construction hoist projects. The welding jobs often include fillet welds and butt welds, with steel thicknesses ranging from 1/4-inch to 6 inches. The company works extensively in Seattle, a seismic region, where many building projects must meet the stringent American Welding Society (AWS) D1.8 structural welding code.
For structural steel contractors such as Apex, finding ways to save time while still meeting quality demands is critical to productivity, scheduling and the bottom line. As such, Apex relies on the Miller ArcReach family of products, including the XMT 350 FieldPro and ArcReach Suitcase 12, to address the numerous challenges that they face in the field. ArcReach technology helps Apex increase productivity, maintain consistent arc quality and improve safety. The solution offers complete control of the power source at the weld joint without a control cable.
Saving At Least An Hour per Welder Every Day
Having the ability to control welding parameters at the point of welding reduces the amount of time that welders need to spend walking to-and-fro the power source. For Apex, this means a savings of an hour or two each day per welder, thereby greatly increasing arc-on time and productivity. When there are a large number of welders on site, the total savings in manhours can add up very quickly.
Because ArcReach technology provides remote control capabilities without a need for special control cables, welders no longer have to spend time laying out and keeping the cables each day. In addition, Apex is also able to eliminate the time and money spent on cable maintenance and repair.
Reducing the Potential for Slips, Trips and Falls
Besides providing significant improvements in productivity, ArcReach technology can also enhance welder’s safety. In the expansive jobsite, Apex’s welders typically need to climb up or down ladders or flights of stairs in order to access the welding power source to make the necessary adjustments. The fewer walks a welder needs to make back and forth to the power source, the fewer opportunities there are for slips, trips and falls.
When a welder needs to work above ground or in hard-to-reach welding locations, remote welding technology can also help reduce operator fatigue significantly because the welder can stay at the same welding location until the job is completed.
Maintaining High-Quality Welds
With ArcReach technology, welders can easily make all adjustments at the point of welding and no longer need to “make do” with less-than-optimal welding parameters. As such, Apex is able to consistently meet AWS D1.8 code requirements and produce high-quality welds.
In addition, when an ArcReach accessory is paired with an ArcReach power source, the power source is locked-out, and all controls are transferred to the accessory that the welder is carrying. This prevents other welders from making accidental changes to the parameters on the welding machine, thereby eliminating unnecessary mistakes and frustrations.
Transition from Stick to Flux-Cored Wire
Similar to many other contractors, Apex has made the transition from stick welding to Self-Shielded Flux-cored Arc Welding (FCAW-S) on the construction site. FCAW-S allows for significantly higher deposition rates as compared to traditional stick welding.
For a recent bridge project, Apex required a FCAW-S wire certified for AWS D1.8 code welding. Apex decided to evaluate and qualify the Hobart Fabshield XLR-8 wire, and it is now the company’s default wire of choice. Because the Fabshield XLR-8 wire has a wide operating window, it is user-friendly and consistently produces high-quality welds. After each welding pass, welders also spend little time on clean-up since the slag releases easily.
Leveraging Technology
In order to complete projects quickly and move on to the next job, Apex is constantly searching for new technology to improve its productivity and safety in the jobsite. The Miller ArcReach remote control technology and Hobart Fabshield XLR-8 wire have proven to save Apex both time and money, without compromising on the stringent quality standards that Apex needs to abide by.