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- Industrial Fabrication
- Quebecor Printing, Inc.,
Mt. Morris, IL
- Maxwell Graphics Printing,
Dallas, TX
- Sethness Company, Water
Storage Tank, Clinton, IA
- BUSCH International,
Chent, KY
- BUSCH International,
Alcoa Davenport Works, IA
- Badger State Ethanol,
Monroe, WI
- Mueller Brass Foundry,
Decator, IL
- John Deere Harvester Works,
East Moline, IL
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Recent and Notable Fabrication Projects |
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With
nearly 90 years of experience to
back JCC service capabilities,
you can be confident in our well
earned reputation for solving even
the largest and most difficult
industrial fabrication challenges.
Our sheet metal expertise, coupled with design and engineering experience, can handle complex assignments including dust and fume collection systems that meet EPA and OSHA regulations. Material handling and ventilation systems for manufacturing plants are also a fabricating specialty. |
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As proof, we invite you to inspect our project galleries, including the dust and fume collection systems already hard at work at facilities of John Deere, Caterpillar, Link-Belt, Kelloggs, Maxwell Graphics and Quebecor Printing.
Browse these projects. Then call JCC to discuss the challenges that we can help you solve. |
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Quebecor Printing, Inc., Mt. Morris, IL |
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| Large
industrial fabrication
can be handled
easily by Johnson's
welding experts.
Three absorber
tanks – each
weighing 26,000
lbs. and measuring
13 feet in
diameter were
fabricated in
Johnson's shop
and then shipped
to the job site. |
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Project |
Quebecor
Printing, Inc. |
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Dimensions |
13'
-0 diameter x 45'
long |
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Customer |
Three
absorber tanks |
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Scope |
In-Shop
Fabrication |
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Material |
mild
steel |
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Man Hours |
1,300 |
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Maxwell Graphics Printing, Dallas, TX |
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| Typical of Johnson industrial systems is this solvent reclamation system installed on Maxwell's plant roof. |
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Project |
Maxwell
Graphics Printing |
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Customer |
Barnsby
& Satcliffe |
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Scope |
Fabrication
& Installation |
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Material |
110,000
galvanized steel |
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Man Hours |
6,900 |
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Sethness
Company Water Storage Tank, Clinton, IA |
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| Designed to hold potable water, this enormous tank measures a whopping 45-feet in length and 13-feet in diameter. Epoxy-coated on the interior and polyurethane on the exterior, both coatings could be applied within our temperature, dust and quality controlled environment. |
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Project |
45,000 gallon capacity potable water storage tank |
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Dimensions |
13’ -0” diameter x 45’ -0” long |
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Weight |
40,000# |
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Material |
3/8” A-36 mild steel plate |
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Coatings |
Epoxy interior, polyurethane exterior |
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Man Hours |
Over 500 |
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| Designed to hold potable water, this enormous tank measures a whopping 45-feet in length and 13-feet in diameter. Epoxy-coated on the interior and polyurethane on the exterior, both coatings could be applied within our temperature, dust and quality controlled environment. |
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Busch
International, Chent, KY |
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Project |
Four Section 120” / 78” Diameter Fume Exhaust Stack x 136’ -0” high |
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Customer |
BUSCH International |
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Dimensions |
Four sections 120” / 79” diameter x 34’- 0” long each |
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Material |
1/2”, 3/8” & 5/16” A-36 HR Plate |
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Total Weight |
76,000# |
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Coatings |
Two
part epoxy systems
with a urethane
finish coating |
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Man Hours |
Over 1,700 |
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ALCOA
Davenport Works, Bettendof, IA |
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| Imagine
shooting
free
throws
across
a section
of this
132-inch
Fume
Exhaust
Stack
and you’d
still
be more
than
a foot
short!
Each
section
was constructed
from
A-36
HR Plate
steel
and when
combined
with
the duct,
totals
over
230,000
pounds. |
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The
entire
system
was finished
with two-part
epoxy with
a urethane
outer coating
for durability.
In total
7,600 man-hours
were required
to finish
this job
for delivery. |
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Project |
Rolling
Mill
Fume
Exhaust
System
with 132” Diameter
x 120'
Stack |
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Customer |
BUSCH International |
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Dimensions |
132” in
diameter
x 120’ tall |
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Material |
3/8” & 5/16” A-36 HR Plate |
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Total Weight |
230,000# |
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Coatings |
Two part epoxy system with a urethane finish coat |
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Man Hours |
7,600 |
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Badger State Ethanol, Monroe WI |
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While the use of ethanol fuel is definitely a positive contribution to the environment, producers must be ever mindful that the production process do no harm.
For that reason, Badger State Ethanol selected the experts at JCC to design, fabricate and install dust collection ductwork that would protect their best interests, as well as the environment. |
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In total, more than 4,000 man-hours were expended to create a complex system from a combined 16,000 pounds of stainless (T-304) and galvanized steel.
Badger Ethanol
reports that the
system exceeds
EPA requirements
by successfully
filtering more
than (99.9%)
of all manufacturing
by-products. |
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Project |
Dust Collection System |
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Customer |
Badger State Ethanol, Monroe, WI |
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Scope |
Design, fabricate and install dust collection ductwork |
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Material |
4,000# T-304 stainless steel and 12,000# galvanized steel |
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Man Hours |
Over 4,000 |
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Mueller Brass Foundry, Decator, IL |
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| Entirely
fabricated from
galvanized and
carbon steel
within the 55,000
square-foot JCC
facilities, this
35,000 pound
Dust Collection
System of ductwork
and supports
was created and
installed at
Mueller Brass
in an efficient
1,400 man hours. |
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Project |
Dust Collection System |
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Customer |
Mueller Brass Foundry, Decatur, IL |
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Scope |
Design, fabricate and install dust collection ductwork and supports |
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Material |
35,000# galvanized and carbon steel |
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Man Hours |
Over 1,400 |
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John Deere Harvester Works, East Moline, IL |
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Few companies in the Midwest can match JCC’s ability to fabricate and efficiently install a discharge stack of this magnitude.
Measuring 90-feet long and 9-feet in diameter, this monster weighs more than 45,000 pounds.
Constructed from GR 50 steel plate that is 3/8-inch thick, the stack was carefully lined with vinyl ester selected for its ability to withstand acids at elevated temperatures. |
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After JCC crews removed and scrapped the existing Powerhouse stack at the massive John Deere manufacturing facility, this replacement stack was transported in a single piece, craned into place and installed by JCC tradesmen in a single day.
In total, over 1,500 man-hours of labor were invested in the job. |
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Project |
Powerhouse Discharge Stack |
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Customer |
John Deere Harvester Works, East Moline, IL |
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Scope |
Take down and scrap existing stack. Fabricate and install a replacement stack. |
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Dimensions |
9’ -0” diameter x 90’ -0” long |
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Weight |
45,000# 3/8” A572 GR 50 steel plate |
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Coatings |
Vinyl Ester lining used for its ability to withstand acids at elevated temperature |
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Man Hours |
Over 1,500 |
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After JCC crews removed and scrapped the existing Powerhouse stack at the massive John Deere manufacturing facility, this replacement stack was transported in a single piece, craned into place and installed by JCC tradesmen in a single day.
Measuring 90-feet long and 9-feet in diameter, this monster weighs more than 45,000 pounds. |
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In total, over 1,500 man-hours of labor were invested in the job. |
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