Industrial conveyor systems for quarries are complex pieces of machinery that need to be able to handle this shifting demands of any worksite. They require a high level of design expertise to ensure maximum safety and reliability under any workload. Many companies choose to have industrial conveyor systems custom made for their projects because they can specify the exact weight, length and width requirements to fit their needs. Swanton Welding can help design a system that will match every one of your needs.
Complex Builds
Industrial conveyor systems are made up of numerous parts all working in conjunction to move bulk material for processing. From the chute to the rollers, and from the drums to the frame itself, each part and piece of your conveyor system must be precision engineered using the best industry standards. This requires multiple drawings utilizing 2D and 3D computer aided drafting software to provide the metal workers with comprehensive details about the structure you are building.
Industrial Conveyor Systems
Industrial conveyor systems present a number of unique challenges to any machine shop. Even when manufactured in sections, the length of each stage exceeds the ability of many shop facilities. The materials used to achieve structural integrity at this length need to be flexible enough to handle shifting weights and winds when the finished conveyor is out in the field.
Most conveyor systems also take a lot of wear and tear during their lifetimes from both rocks and weather. All parts of the system need to be galvanized and painted to protect against corrosion as much as possible, and the whole system needs to have enough support that the chutes will not become damaged by the materials in the process.
Materials
There are a wide range of materials used in the custom fabrication process to achieve a high quality conveyor system. There are a wide range of materials available such as:
- Carbon steel
- Stainless Steel
- Aluminum
- and more
These materials are perfect for maintaining the flexibility and rigidity needed for up to 250 foot lengths and up to 100 tons of bulk weight. The dedicated team of metalworkers will look at your plans and handle all of the:
- Bending
- Cutting
- Rolling
- CNC Machining
- Welding
Rollers
One of the most important parts of any industrial conveyor system for quarries is the rollers. These rollers are machined to work smoothly within a tight space and under tons of pressure. The efficiency of the entire conveyor system relies on well designed rollers that can withstand weights of up to several tons while remaining free to move.
While rollers are generally seen as wearable parts that will need to be replaced at some point, the goal is to protect rollers from corrosion and unnecessary buildup of dust and other clogging debris. A well designed roller can handle between 50 and 70 thousand hours of operation before replacement.
Function
Industrial conveyors serve many different purposes at any quarry. The conveyor system you build will need to work flawlessly with the other components of your system. It is possible to design stationary overland conveyors for moving bulk material over long distances. Loading conveyors for ships, rail cars and other containers depending on what type of machinery you will be using on site. There are also a number of portable conveyors in shorter lengths available which offer more flexibility and functionality in tight spaces or when trying to route your bulk material around obstacles.
Custom Fit Fabrications
An effective conveyor system requires a deep understanding of the quarry’s day to day operations, but also a working knowledge of the specific job site where the conveyor will be set up. The actual application required at each job site will have an impact on the materials and overall design of the conveyor parts built. In some cases this means extra steep conveyors used to excavate a site directly into trucks. In other cases, the quarry could stretch over thousands of feet, allowing plenty of space for horizontal conveyors to carry material away from the dig and over to processing machinery.
No matter what size or type of quarry you will be working in, the need for reliable equipment is a must. You know that you need conveyors to move material out for further processing. The good news is that you can have an entire conveyor system built from the ground up using the most advanced machining and metal fabrication technologies available in the industry. This means that you can get exactly the right size and type of conveyor for your project, and you can customize your design to work with any of the unique factors that could set your project back.
The skilled professionals handling your project will work from any 2D or 3D drawings you have available to help you design a perfect conveyor system that meets all safety and industry regulations while also ensuring that the design has the integrity to withstand the entire weight of the project without issues. They will make recommendations for any changes necessary and recommend materials or finishing projects to maintain the equipment long term.
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Bridge and Boardwalk
Swanton Welding was contracted to build a bridge and boardwalk for a client in Westfield, IN. Our estimation team and project manager worked with the client to make sure we provided an accurate and complete quote and timeline. This project took place from late May through late September of 2024. This bridge and boardwalk, weighing […]
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Stainless Steel Hopper
We custom fabricated this stainless steel hopper and finished it off with a polished interior for food grade application.
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Discharge Hopper, Clarifier, Clarifier Structure, Catwalk & Stairs, Auger
We custom built a large Discharge Hopper, a Clarifier used to remove slurry, the Clarifier Structure, accessible Catwalk & Stairs, and a custom Auger for the Clarifier. The most interesting thing about this project was its overall size and the custom auger we built.
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Steel Stack Fabrication
Swanton Welding & Machining was approached by a client from the clean air industry to fabricate 950,000 lbs. of steel stacks. Eight large stacks were fabricated using a variety of processes including rolling, bending, forming and MIG welding. The stacks were fabricated using a combination of material such as, A36 steel and 304 and 409 […]
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Acid Furnace Fabrication
Swanton Welding & Machining was approached by a chemical industry customer to fabricate a 125,000 lbs. acid furnace. We first drafted complete shop fabrication drawings for the furnace using AutoCAD software. We then used a variety of fabrication methods to complete the A516 grade 70 and A-36 grade steel furnace, including: drilling, rolling, laser cutting, […]
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CE Boiler Stack Replacement
Swanton Welding was responsible to create a drawing based printed CAD drawings to design and fabricate a replacement stack out of A588 material for the refinery
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Ladle Maintenance Carts
Customer needed a way to conveniently transport large ladles to areas where they will be used.
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Catalytic Converter
Fabricated stainless steel Catalytic Converter w/ Pipe Bundle. A customer approached us about doing this job out of stainless steel with the stainless pipe bundle being made out of a special seamless tubing. The timeline was critical as the customer had a two day plant outage scheduled and they needed this unit installed during that […]
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Clarifier Tank Project
At Swanton Welding, we have the expertise and resources to meet all your large scale project requirements at our state-of-the-art facility. As your trusted partner in welding and fabrication projects, we are committed to providing exceptional craftsmanship, reliable service, and timely project completion. An example of our capabilities is the recent construction of a sizable […]
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Tire Separator and Hopper
The project involved making a hopper & separator for a tire recycling plant. The hopper was designed to dump truckloads of used tires. It has a motor and sliding floor system that was sloped to feed the tires to the separator, which would separate the tires based on size and feed them to additional equipment […]
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Vertical Clarifiers with Thickeners
These were vertical clarifier tanks used to separate certain materials from water.
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4100 Grillage Fabrication
Barge Stabilizer Swanton Welding took on a project with a simple goal: support a 1500 tons crane with two barges. The heavy duty steel frame binding the two barges together, and the crane would be used to drive in bridge pilings.
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CVG Airport Canopy
Fabrication of two large canopies out of steel tubing to be installed at an airport. The canopies were fully assembled in shop prior to shipping. Both canopies were hot dip galvanized to withstand the corrosive installation environment.
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Accumulator Tower for Metal Coating Process
Structural Steel Tower This project consisted of constructing two similar towers. The entry side is pictured and the exit side can be seen in the distance. This new customer to Swanton Welding requested the project to be finish painted before it was delivered. These structural steel towers were assembled in the field and required very […]
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Replacement Boom
It is basically the structural arm for a heavy duty conveyor ship loader.
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Lamella Style Inclined Plate Clarifier
Swanton Welding was contracted to fabricate a Lamella Style Inclined Plate Clarifier that will ship to Mt. Holly, NC, when completed. This fabrication will serve as a wastewater clarifier for the facility in North Carolina. Swanton began this project in June of 2024, and it is currently ongoing. When completed, we expect the fully assembled […]
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125 Ton Steam Car
We built a 125 Ton Steam Car. We fabricated it, blasted and painted it, did the assembly, electrical work, and shop tested it.
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Purification System Filter
Waste Water Separator This project’s client needed a water tight clarifier tank fabricated. We had to build, weld, leak test, shop assembly, blast, caulk, and paint the tank. In the end, we delivered a completed clarifier tank assembly. Completion Date March 7, 2017 Materials All materials were carbon steel Fabrication Methods This project utilized […]
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Double Drop Trailer
Swanton Welding Company was contracted to construct a double drop trailer for a client in Ottawa, OH. The project took under two months after a mid-July 2024 start, with completion in early September 2024. A double drop trailer, also known as a lowboy trailer, transports oversized loads considered too large for a standard trailer on […]
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Bottom Casing for Glass Furnace
This custom fabrication project was for approximately 30 Bottom Casings for a Glass Furnace. Each section had to have pads custom machined to ensure it was within 1 mm of flatness. After the individual casings were completed, we had to shop assemble the entire length of them and use a transit to ensure their critical […]
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Industrial Conveyor Fabrication
An agricultural industry client approached Swanton Welding & Machining to fabricate twelve, 5,000 lbs conveyor components. Utilizing AutoCAD 2009, we first drafted complete shop fabrication drawings of the component. We then fabricated the 20′ long, 3’6″ high and 8′ wide conveyor section using a CNC beam line, saws, and drills. After fabrication, during which we […]
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Fulton County Hospital Office Addition
Swanton Welding was tasked with fabricating the steel framework for the new Fulton County Hospital addition in Wauseon, Ohio. We appreciated the opportunity to support Rupp/Rosebrock, Inc. and their construction crews as they constructed a four-story medical building that will attach to Fulton County Hospital. The team at Swanton Welding used our beam line to […]
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Support Structure
Swanton Welding is fully equipped to meet all your large-scale structural steel project requirements in-house at our cutting-edge USA facility. We take pride in being a dedicated partner in the success of every fabrication project we complete. Recently, we collaborated with a client based in South Carolina to construct a support structure. Given its critical […]
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Mixing Tank Fabrication
A customer from the water treatment industry approached Swanton Welding & Machining to fabricate a mixing tank assembly. The 50,000 lbs. tank assembly was made up of many different parts and systems including rapid mix, reactor and clarifier tanks, a 16′-8″ long platform, and a 15′ high draft tube. To fabricate these components and many […]
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Stainless Steel Platform
Custom fabricated stainless structural steel platform with carbon steel columns and handrails.
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Truck Dump Project
Swanton Welding fabricated two truck dump platforms. These are used in various industries where semi or other large trucks are driven onto a platform for unloading. After securing the truck, the platform is raised high into the air, and the load on the truck is transferred via gravity into a bin or hopper. Our client builds […]
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Steel Thrustframe Fabrication
A customer from the gas exploration industry approached Swanton Welding & Machining to fabricate an A36 and A-514 steel thrustframe weldment. The 225,000 lbs weldment was fabricated using a variety of processes, including CNC milling, MIG welding, drilling, laser cutting, bending, tapping and forming. The 54′ long and 8′ wide thrustframe was skillfully fabricated using […]
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Glass Furnace Rebuild – Support Steel
A client proposed and drew the initial design of this support steel project. It will encase and support a glass melting furnace for the engineered reinforcements industry. Swanton Welding supplied materials such as tie rods, platform steel, stairs, and ladders for the 20 ft tool glass melting furnace. Fabrication, blasting, and painting were customized to […]