1、IMPROVING STEEL DISTRIBUTION EFFICIENCYTABLE OF CONTENTS3 /MORE EFFICIENT STEEL DISTRIBUTION UNLOCKED BY VERSATILE REACH STACKERS4 /RE-EVALUATING THE WORKFLOW FOR LOADING RAIL CARS6 /COIL HANDLING GETS HUGE7 /GETTING A HANDLE ON STEEL SLABS8 /STRENGTH AND STABILITY FOR BILLET HANDLING9 /KEEPING LONG
2、-LOAD HANDLING STRAIGHTHyster and are registered trademarks in the United States and certain other jurisdictions.Hyster products are subject to change without notice.Trucks may be shown with optional equipment.2022 Hyster Company.All rights reserved.10017HGC5WP001_E_EN_US_V2R0_100422 3 ith automatio
3、n,increased connectivity and evolving labor demographics reshaping industrial landscapes,change is constant,and the steel industry is no exception.Today,mills must serve demand for steel in a variety of shapes and sizes,and face expectations for greater speed and efficiency when moving steel from pr
4、oduction to distribution and ultimately,to end users.Mills face significant financial commitments,with demand for larger and wider coils driving major investments to widen coil production lines and produce steel in larger depth and diameter coils.The material handling equipment and labor necessary t
5、o move steel products also accounts for significant costs.But steel mills cannot afford to cut corners doing so risks unsafe and ineffective coil and slab handling,which can cause extremely costly lost-time accidents and mill shutdowns.WSteel mills can lose an average$150,000 per hour when the mill
6、is not operationalTo stay competitive in such a challenging market,steel producers must re-examine not only the equipment they use,but how they use it.Instead of using multi-step,multi-machine workflows,what if they could shift to a streamlined approach,unlocking greater performance and efficiency t
7、o thrive in todays market?Thanks to material handling equipment innovations that provide unprecedented flexibility,this streamlined approach is a growing reality for steel-handling operations.A single reach stacker can now handle tasks traditionally divided between equipment like gantry systems and
8、coil-ram lift trucks.This enables a consolidated workflow that avoids non-value-added steps like dropping loads at mid-points and changing equipment,while reducing overall equipment inventory and associated training time.MORE EFFICIENT STEEL DISTRIBUTION UNLOCKED BY VERSATILE REACH STACKERS 4 RE-EVA
9、LUATING THE WORKFLOW FOR LOADING RAIL CARShe established process to move steel from production to rail cars is a lengthy one,involving multiple steps and pieces of equipment.Reach stackers have traditionally handled cargo containers and moved heavy loads around the yard.Often,other forklifts and sla
10、b carriers are dedicated to a single task,such as handling coils or slabs and bringing them to staging areas.Then,gantry systems use cranes to lift and load them into rail cars.With steel mills facing competitive pressure to become more efficient,this workflow falls short when it comes to speed and
11、cost.Cranes travel slowly,yet they must traverse long rows of rail cars to pick and place each load,and waiting for rail cars to shuttle in and out of buildings extends the process further.From a financial standpoint,investing in so many different pieces of equipment means greater capital expenditur
12、e,while labor efficiency suffers with operators requiring adequate training and shuffling between equipment dedicated only to a single task.TBy using a reach stacker,steel handling operations can engage in a more efficient,simple loading process,using a single piece of equipment to pick up finished
13、pieces of steel and move them to staging and storage areas or load them directly into rail cars.Reach stackers can optimize the process by:Reaching far enough to load two rail cars deep without having to drive to a new loading position Side-load rail cars and be equipped with gondola car lid lifters
14、 Driving and lifting up to four times faster than overhead cranes Enabling more precise load placement and thus avoiding time-consuming adjustments,due to an elevated cab that offers better visibility to get it right the first time Operating without the need for an outside spotter,freeing scarce lab
15、or for more valuable tasks Eliminating the need for extra rail spurs,opening up more yard spaceThe average fully burdened labor rate for a steel mill forklift operator is approaching$100/hour.What could your operation do with a reduction in labor costs?5 RE-EVALUATING THE WORKFLOW FOR LOADING RAIL C
16、ARSOVERHEAD/GANTRY CRANE:Located at end of production line;pick up finished coils,place on railcars or transfer cartsBut a reach stacker appropriately equipped for coil handling can safely and effectively execute all of the coil picking,transportation and loading functions handled by fixed or moving
17、 cranes,conventional counterbalance lift trucks and ram tractors in a traditional application.Reduced product touches Reduced labor and training requirements Fewer pieces of equipment to purchase and maintain Tool changing technology enables equipment to switch attachments to handle different tasks
18、in simple,plug-and-play workflow See videoTERMINAL TRACTORS:Pull coils on transfer carts to storage and staging areas/A TRADITIONAL COIL HANDLING APPLICATION REQUIRES MULTIPLE,VERY COSTLY,DEDICATED-TASK MACHINES AND TRAINED OPERATORS.COIL-HANDLING LIFT TRUCK:Picks coil from storage yard and transfer
19、 to loading areaOVERHEAD/GANTRY CRANE:Pick and load coils for shipment 6 o keep production lines running longer and reduce coil change-out time,customers that manufacture products from steel are asking producers to provide larger coils.These new coils are as large as 96,000 pounds and 96 inches wide
20、 up to 16,000 pounds heavier and 16 inches wider than the previous standard.But for steel producers,creating much less distributing these larger coils is no small task.Mills are making significant investments to widen production lines,but they must also modify material handling and transportation in
21、frastructure.This means higher capacity lift trucks and a transition to rail and barge travel instead of over-the-road semi-trucks./MAKE LIGHT WORK OF HEAVIER LOADSTo handle heavier,wider coils,a reach stacker offers the right combination of size,heavy duty features and most importantly,greater payl
22、oad.In addition to heavier booms,larger tires and axles,and right-sized coil handling attachments,reach stackers can lift up to 120,000 pounds and offer an extended load center of up to 252 inches,not only accommodating wider coils,but providing the extended reach necessary to place them on a double
23、 deep rail car,or a widely staged semi-trailer flatbed.TCOIL HANDLING GETS HUGEOperations can also utilize attachments designed specifically for coil handling,like coil hooks and grabs.Coil hooks,similar to those used by overhead cranes,allow operators great flexibility when positioning coils on fla
24、t rail cars with coil cores placed perpendicular to the railroad tracks.They can even include an integrated rail lid lifter for quick,integrated access to loading targets.Coil grabs are an effective choice to load walled gondola cars.The grab arms need a minimal distance to release the coil,fitting
25、inside the walls of the rail car for maximum precision.7 ith end users demanding steel coils and slabs alike,mills must be prepared to produce,handle and load both types.Flat slabs possess key differences from coils and lift trucks require different attachments to effectively handle them./SLAB HANDL
26、ING ATTACHMENTS Slab magnets are used for stacking ambient temperature slabs in a storage yard and dropping them into place.Unlike clamps,magnets are well-suited for loading rail cars with side walls,and they avoid the extra step of placing spacers between loads,expediting processes and enabling rea
27、l productivity gains.Slab tongs,on the other hand,are typically used to grab and transport hot slabs around the yard and to load flat rail cars without walls.They enable more precise handling than forks.WGETTING A HANDLE ON STEEL SLABSQUICK AND EASY ATTACHMENT CHANGESIf a mill uses some lift trucks
28、to handle coils and other equipment to handle slabs,they are most likely paying for a bloated fleet.The coil handling trucks will sit idle and take up yard space when slabs are handled and vice versa,simply due to an inability to easily switch between the proper tooling.A new tool changing technolog
29、y eliminates the cumbersome,arduous process of manually changing attachments and the need for excess lift trucks.For non-powered attachments such as coil hooks or mechanical slab tongs,operators can change them without even leaving their seat!For items that require power,such as electricity for slab
30、 magnets or hydraulic power for clamping or rotating attachments,operators will need to briefly leave the cab,but the process is simple.A plug-and-play workflow means operators just need to use quick-connecting fittings to connect the power supply for the attachment.Ultimately,this ability to more e
31、asily and quickly switch between different attachments can enable a leaner,more productive fleet.8 T he round,cylindrical shape of billet steel pieces makes them susceptible to rolling on forks.When billets roll back toward the cab,they strike the forklift carriage,stressing components with great fo
32、rce.And if forks are tilted forward,billets can roll ahead and abruptly fall off,risking damage to the environment and other objects.Billets rolling in either direction creates scenarios where excessive forces are continually placed on the lift truck,causing machine and product damage.Successfully h
33、andling billet steel means reducing product damage and handling costs with equipment that is tough enough for the job and designed to prioritize load stability./LOAD STABILITY AND EQUIPMENT DURABILITYWhether billets roll forward or backward,product and equipment damage is a real possibility.Key enha
34、ncements to traditional lift truck forks and carriage components can promote load stability and equipment durability.Heavy-duty radius forks feature a curved fork shank designed to help disperse shock created when billets roll rearward and strike the lift truck carriage.The fork heel radius enables
35、the billets to roll slightly upward,greatly reducing the shock force on the lift truck carriage and related components.Heavy-duty poly blocking is designed to stand up to the shock created by rolling billets.Roller bearings are the traditional means to enable the sideshifter and fork positioner to m
36、ove along the carriage.When billets roll backward,roller bearings are commonly damaged leading to costly replacement.Hyster has replaced traditional carriage roller bearings with poly blocking installed behind the forks and remains intact even when the carriage is shocked by heavy rolling billets.In
37、 addition to radius forks and poly blocking,heavy-duty fork carriers,specially designed carriages with protection plates and increased under clearance are features billet mills should look for to keep equipment moving reliably and keep handling costs under control.EQUIPMENT DAMAGE FROM BILLETS CAN A
38、DD UP FASTPreparing for billets rolling backward is essential because they can lead to costly equipment damage,specifically for roller bearings.Traditional forklift systems use bearings located behind the forks to enable the sideshift and fork positioner to move along the carriage.But not only are t
39、hose bearings fragile and expensive theyre easy targets for billets rolling backward.Replacing broken bearings not only costs money,but the resulting equipment downtime disrupts normal work and costs productivity.For one billet mill operation,broken roller bearings had become an exceptionally common
40、 occurrence up to five incidents each day.With replacement bearings costing as much as$1,000 each,the costs added up quickly and the mill risked material handling costs spiraling out of control.But heavy-duty radius forks and poly blocking proved to be effective solutions.Once implemented,the mill n
41、o longer experienced any equipment damage or workflow disruptions.STRENGTH AND STABILITY FOR BILLET HANDLING 9 /STRENGTHKey enhancements can equip lift trucks to stand up to the demanding duty cycle of steel operations and the stresses specific to handling long loads.H andling long steel loads,like
42、beams and rebar,places unique stress on equipment.Effective long-load handling requires consideration of several variables,including road conditions,yard layout and equipment design.Long loads extend well beyond the sides of the lift truck acting as a huge lever that generates high amounts of torque
43、 that twists the mast and related components.This excess torque is especially powerful when the mast is elevated and operators travel through turns and over bumps and potholes,risking cracks and other damage to the mast,carriage and tilt cylinders.KEEPING LONG-LOAD HANDLING STRAIGHT Mast overlap:The
44、 more overlap between the inner and outer mast channels,the more surface area to disperse the shock and torsion created when handling elevated loads over rough terrain.Additional overlap can help counteract the mast twist and boost durability.Cross bracing:To further strengthen the mast for heavy-du
45、ty applications,cross bracing between the mast pillars along with oversized mast channel brackets can help further improve mast solidity and stability carrying wide loads.Super-duty mast mountings:Enhanced mast mounting brackets,mast mounting pins and bearings can also serve to counteract the stress
46、es of long load handling.Carriage valve protection:The hydraulic control valve is the meeting point for all hydraulic lines that configure and control forks,masts and other elements of carriages.To protect this critical point from costly damage in harsh conditions,manufacturers can place heavy-duty
47、steel plates over the carriage valve./VISIBILITYMoving long loads requires navigating steel yards with limited space and maneuvering around obstacles,often while the load is elevated.Not only does equipment need to be tough enough to withstand the stresses of such movements,but operators must have a clear view of their surroundings to properly position laden equipment.Camera systems are a useful tool to supplement operator views through and around the mast,to the side and behind the operator compartment.
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