Next week, people across the United States will be celebrating July 4th with fireworks, festivities and backyard barbecues galore. For most people, it’s a day off from work to celebrate America’s 241st birthday.

It’s also a chance to reflect upon what’s great about America. Among the many gifts our country gives us, we are grateful for opportunity, freedom, and the ability to succeed through hard work.

our branches

Our branches (red dots) from sea to shining sea.

Barnhart is a proudly American company. We were founded in 1969 in Memphis with a single location – a kitchen table. In the beginning, our current president Alan Barnhart’s parents started and ran the family business from their home.

Today, Barnhart has 45 branches and 1300 employees. Our employees come from all regions of the country. They are engineers, project managers, salespeople, crane operators, mechanics, ironworkers, and truck drivers, just to name a few roles that are indispensible to the success of our company.

Our employees represent all political persuasions, cultures and ethnicities. It’s a melting pot that works together to get the job done for our customers. It’s a picture of America.

This 4th of July we salute our employees and the country that has given us so much.

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Cool Tools and Planning Make Dryer Installation Successful

Barnhart specializes in remove and replace projects. We enjoy the challenge involved in safely extricating a component, which is often buried in a tight, congested space with limited access, and replacing it while causing minimal plant disruptions and downtime.

These kinds of projects get our engineering team’s creative juices flowing as they devise a plan of action using our cool tools and specialized rigging techniques to get the job done.

Sometimes we handle just the replacement portion of the project, which doesn’t necessarily require any less innovative engineering or tools. For a project at a wood and pulp mill in Maine, Barnhart’s job was to haul and set two Yankee dryers weighing 141 tons each. They started in onsite staging and were hauled a half mile utilizing six lines of PST to a raised building opening.

The dryers were then hoisted 20’ in the air to reach the building opening using 44A gantries with a rigging tray arrangement that incorporated a 16” slide track. Once at the elevation, Barnhart slid the dryers along the track and handed them off to a 450 J/R gantry.

Floor loading issues were a problem, and Barnhart had to use transverse beams to support our track system on load bearing points. In tight working conditions, Barnhart had to rig, lift and rotate the dryer using a spreader with a swivel hook in order to rough set the dryer on its support steel.

Despite these challenges, which also included tight tolerances, an accelerated schedule and logistical considerations, the dryer was installed safely and on schedule.

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On Memorial Day, we will remember those in the armed forces who gave their lives for our country. We are grateful to them and to our military veterans for their service and sacrifice.

Veterans are part of the Barnhart team. They’ve found the culture and values of military life in many ways reflect what we’ve built within our company.

Take Sabrina who was a member of the U.S. Army. When she got out of the service she admits to being a little lost. Not content with flipping burgers, she was looking for a job with a purpose. At Barnhart she found her mission in logistics, a position she considers not your “typical 9 to 5 job.”

Barnhart’s approach to training and development was familiar. In the army, she had received extensive training, hands-on learning and developed leadership skills, all core components of the culture at Barnhart.

For Jim, a former Navy officer and current Barnhart engineer, the most important lesson he took away from the military service was how to be a servant leader, one who helps his troops do their jobs better. As a servant leader, he says, “We serve. We teach. We help our team be safe.”

Safety, service and continuous improvement are three of Barnhart’s company values. We are constantly training our teams, helping them develop new skills. Whether it’s an apprentice, a project manager or a crane operator, every member has an important role and is reliant on others to successfully complete the project.

“A military veteran is trained in the field to complete any tasks to the best of your ability,” Sabrina says. “…You’re trained to never give up and to give it your all.”

We admire that spirit and invite all veterans to consider Barnhart as your next post.

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Creative thinking and extensive planning resulted in two 2017 Job of the Year awards for Barnhart from the Specialized Crane and Rigging Association (SC&RA). Barnhart was recognized in the categories of “Rigging Job of the Year Under $150,000” and “Hauling Job of the Year 160,000-500,000 lbs.”

In the Rigging Job of the Year, Barnhart tackled an emergency project that involved the removal and replacement of a ground-level exchanger shell at a refinery. But due to restricted access to the shell, it wasn’t going to be easy.

Directly above the 17-foot-long shell was a tangle of live piping within two inches of the shell. It was also surrounded by instrumentation and structural steel. The alleyway to the exchanger was less than 30 feet wide and at 15 feet above grade elevation there was a 10-foot-wide overhang. The unit was also operational.

Barnhart determined that the solution for removing the shell would need to be “mobile, modular and maneuverable.” The team had five days to come up with an answer.

They devised a custom movable counterweight cantilever system called the M1A1, stacked components that resembled a tank. The M1A1 had 30 kips of counterweight secured to a 750-ton hydraulic turntable, which was attached to six lines of Goldhofer PSTe.

The M1A1 allowed Barnhart to maneuver and rotate 360 degrees in the 30 feet wide alleyway. The system was able to stab inside the exchanger, lift the shell in a very tight area, and rotate it 90 degrees for removal from the unit. The process was reversed for the replacement of the shell.

In the Hauling Job of the Year, Barnhart was hired to haul a new heat recovery system generator (HRSG) from Tulsa to Los Angeles, a 2,343-mile journey that crossed six states. The HRSG was roughly 43 feet long, 16 feet wide, 16 feet tall and it weighed 225,000 lbs. The center of gravity was not centered longitudinally, it was offset by 3.5’, so it would be a challenge getting the axle lines loaded evenly.

Barnhart designed a trailer configuration that utilized two Goldhofer six-line California style dual lane trailers with 7’ dollies, 9’1” axle spacings at 20’ wide.  The permitted dimensions of the trailer were 260’ long, 21’ wide, and 17’11” tall with axle loadings of 38,000 lbs. per line. Barnhart also used a gooseneck on the front trailer to maintain equal axle loadings on all axle lines.

The route required permitting in Oklahoma, Kansas, Texas, New Mexico, Arizona and California, 21 local and county permits and approval from 18 different local, county, and district Department of Transportation (DOT) supervisors. Barnhart enlisted and coordinated the help of bucket trucks and police escorts and obtained utility clearances from approximately a dozen different utility companies.

The haul route involved a variety of roadways: interstate, state highways, local, county, and farm roads. The route included dense city travel in LA, mountainous climbs in the desert, and tight gravel roads.

The project took approximately 11 weeks from start to finish, which included seven weeks for permitting, trailer mobilization and loading. The actual 2,343 haul took three weeks, a trek that was completed without a safety incident or any DOT citations.

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While Barnhart performs and documents jobs of all sizes, the massive projects involving large equipment and oversize components are often hard to capture. Words and photos can’t always do a project justice.

An example was a lift of a towering column at a refinery in Illinois, which involved a bit of ingenuity. Instead of using a second crane to tail up the column we used the Goldhofer tailing device. Luckily, Barnhart captured it on video, so you can truly appreciate the scale of the project.

That’s just one of the many videos from our library where you can see our work and equipment in all their glory: videos on the GS800 girder transport system, modular lift towers, or the lift of a colossal jumbotron. While they may not be Hollywood blockbuster material, we think they’re pretty compelling. Check them out.

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Barnhart’s 32 branches are located all across the country. They include a string of Midwest locations stretching from Chicago to Lincoln, Nebraska and north into South Dakota.

This Midwest presence was established in 2014, when Barnhart acquired Crane Rental and Rigging. They inherited a fleet of more than 40 cranes and eight branches located in Omaha, Lincoln and South Sioux City, Neb.; Des Moines, Cedar Rapids, Davenport and Ames, Iowa; and Sioux Falls, S.D. Their service area also extends into southern Minnesota and northern Missouri.

The branches’ capabilities have grown far beyond the exceptional crane service – with up to a 500 ton crane – for which Crane Rental was known. Through Barnhart’s extensive nationwide network, they can tap into an arsenal of specialty equipment, innovative rigging systems, and the expertise of more than 40 engineers.

Services also include wind turbine up-tower services, project cargo logistics, customized industrial machinery moving and transportation solutions, including bridge crossing systems and dolly combinations.

Agriculture, ethanol, nuclear, chemical plants, petroleum refining, wind maintenance, and civil construction are just a few of the industries served by the Midwest branches.

According to Ted Hickson, regional director for Barnhart, “The advantage of being part of the Barnhart family for our customers is that we can meet their needs better with a much larger pool of equipment and manpower. We’re more of a one-stop shop for a variety of needs.”

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R & R projects, the remove and replace variety, are often challenging, time-sensitive jobs performed during turnarounds and outages. These are the kinds of projects we relish.

During a turnaround at a refinery in California, Barnhart was given little notice on a complicated project to remove and replace four air grids. The grids, weighing 28,000 lbs. each, were located inside the regenerator of the fluid catalytic cracking (FCC) unit.

Barnhart was notified of the project on a Thursday. The team arrived on site on Friday and met with the customer. Then they got to work figuring out an efficient solution. Engineering was finalized and equipment and personnel were mobilized on Saturday. By Sunday, the team was ready to make the first pick.

The grids had to be navigated through some tight and congested spaces. Barnhart utilized their Moveable Counterweight Cantilever System due to its maneuverability on lifts needing lateral movement to avoid obstructions.

Some of the obstacles Barnhart encountered were platforms that interfered with the crane’s boom and additional structures that had to be avoided. The operation was also happening in a heavy traffic area, so safety was critical.

Despite these challenges, Barnhart removed the grids in one and a half shifts, a fraction of the estimated 14 shifts and seven days the customer had estimated the job would need. That quick turnaround during a turnaround, saved the customer considerable time and money.

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Barnhart Crane & Rigging has been selected by space agency NASA to transport components for its Space Launch System (SLS). SLS will be the world’s most powerful rocket for deep-space missions.

The project will involve delivery of a steel mock-up of a pathfinder vehicle, designed by engineers at NASA’s Marshall Space Flight Center in Huntsville, Ala., which will be used to demonstrate core stage operations for the SLS rocket. This core stage reproduction is essentially a shell with no engines or avionics that will measure 213-feet long and weigh 230,000 lbs.

“We don’t want the first time we transport the core stage to be with flight hardware,” said Shane Carpenter, engineering lead at NASA.

Final welding and assembly will take place at the G & G Steel plant in Cordova, Ala. An overhead crane will be employed at G & G to load the mock-up onto Barnhart’s 200 ft. x 35 ft. deck barge used in conjunction with a 250 ft. x 50 ft. canal deck barge on the Black Warrior River. Barnhart will transport the mock-up to NASA’s Michoud Assembly Facility in New Orleans where it will be offloaded onto Goldhofer transporters.

The cargo is scheduled for load-out and transport in March, with the inaugural flight of the SLS anticipated in late 2018.

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Barnhart was hired to devise an innovative lift system for a rigging project at a nuclear plant in Louisiana. The process was outlined in a recent article in Cranes Today.

One of the plant’s two 35-year-old clarifiers was taken offline because several of its 16 lateral supports were damaged from normal use. This compromised the structural stability of the 600,000 lbs. clarifier, creating an overhead fall hazard which prohibited anyone from being allowed inside the unit. The clarifier had to be supported from above to allow for the safe removal of the supports.

Barnhart designed a rigging system that spanned the 178’ inside diameter tank utilizing both a heavy lift crawler crane and a telescoping hydraulic crane to assemble the lift system. The backbone of this system featured Barnhart’s 8’ girder sections that were connected on the ground for a total length of 180’. Once assembled, these girders, weighing up to 225,000 lbs., were set to the clarifier walls with tandem lifts.

Barnhart custom fabricated stability kickers for the 8’ girders on the wall, deflection load spreading rockers for the girder contact points, and various spreader bars to accommodate the complicated rigging design challenges. With all the rigging in place, the clarifier was lifted and held in place.

With the clarifier safely supported, Barnhart positioned pull-up gantries and 5’ girders underneath. The overhead girder and lift system was disassembled and removed so that the replacement of the supports could proceed. Once this process is completed, the gantries and girders will be removed, allowing the clarifier to go back online.

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For most of the game during Super Bowl 51 on Sunday, victory for the Atlanta Falcons seemed assured. Despite having won four previous Super Bowl titles and being three-point favorites, the New England Patriots were behind at halftime 21-3. By the third quarter, with the Falcons leading 28-9, Patriots fans, including stalwart fan Mark Wahlberg, were streaming out of the stadium.

Photo: St. Louis Post-Dispatch

But that’s when Patriots quarterback Tom Brady began to work his magic and engineered the biggest comeback in Super Bowl history, winning the game in overtime. It was an outcome that was unpredictable until the final buzzer.

Unpredictable outcomes are exciting for sports, fans and TV ratings. These kinds of contests keep your heart pounding and your butt on the edge of your seat. Yet for projects that involve heavy lifts, heavy hauls and project cargo logistics –  basically any type of project Barnhart handles – unpredictable outcomes are something to be avoided.

Barnhart takes steps to manage the unpredictability of projects through extensive planning and engineering. After all, unpredictability affects safety, scheduling and the operation of a customer’s facility during a project. While factors beyond our control happen – bad weather, manufacturing or shipping delays – it’s only a speed bump to the eventual planned outcome.

In a project in New Mexico, Barnhart was hired to offload, haul, transload and set four transformers from a rail spur to a substation. The project was originally scheduled for July, but manufacturing delays pushed the project into December. Ice and snow had turned the dirt road at the substation to mush and revealed some serious grade issues. Barnhart had to wait until the weather improved for the power company to address these issues.

Once the weather improved and the road was regraded, Barnhart was able to continue the haul, using a slide system to successfully set the transformers and complete the project.

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