DYNAMICALLY LOADED STRUCTURES
MULTI-DISCIPLINED ENGINEERING
ANALYSIS | TESTING | INSPECTION | DESIGN-BUILD | INTEGRATION

MULTI-DISCIPLINED ENGINEERING COMPANY

At our company, we specialize in providing reliable and safe solutions to clients with unique needs and requirements. We offer a range of services, including design, analysis, simulation, testing, inspection, optimization, fabrication, and turnkey integration of custom purpose-built equipment and dynamically loaded structures.

Our company has a team of skilled engineers specialized in mechanical, structural, civil, controls, automation, electrical, and welding engineering services. Our engineers work collaboratively to design and build custom equipment and structures that are reliable, safe, and efficient. We use advanced computer-aided design (CAD) and simulation tools to ensure that our designs meet specifications, regulations, and standards.

OUR COMPANY ROOTS IN FAILURE ANALYSIS AND FIELD TESTING

With our extensive history in performing failure analysis and field testing of failed equipment, our experienced engineers have valuable insights into the design, analysis, fabrication and commissioning of reliable solutions for our clients. We use our knowledge of equipment failures to design and build solutions that are not prone to failures, providing our clients with greater reliability, safety, and efficiency.

ADVANCED ANALYSIS, TESTING, AND INSPECTION

To validate and optimize new or existing designs, we perform computer analysis and testing, destructive and non-destructive testing, and design optimization. This is to ensure reliability and to enhance the lifetime of capital equipment and structures.

We offer a range of testing and inspection services to ensure that our products meet the highest standards of quality and reliability. Our state-of-the-art fabrication facility enables us to build custom automation equipment and steel structures with precision and efficiency.

EXPERTISE IN SPECIALTY ONE-OF-A-KIND STRUCTURES AND EQUIPMENT

Our advanced analysis, engineering, and turnkey delivery capabilities provide us with a unique position to design, develop, and commission unique or one-of-a-kind structures and equipment. We have designed and built boundary-layered wind tunnels, entertainment rides, edge walks, large overhead moving structures, custom building features for princes, and equipment to perform new or complex tasks in a vast industry spectrum.

REDESIGN, REBUILD, AND REPURPOSE OF EXISTING EQUIPMENT 

We offer redesign, refurbish, and repurposing of existing equipment services. This service is generally used when equipment has failed, is about to fail, or to optimize a piece of equipment for new loads or cycle times. This includes large equipment in manufacturing plants that need to lift or transfer heavy products, Moving Bridges, Gantry Structures, etc. 

WELDING ENGINEERING, DESIGN, OPTIMIZATION, AND INSPECTION

Our CWB welding engineers and inspectors have been providing welding engineering retainer services for over 20 years. We are the CWB Retained Welding Engineers for over 160 weld shops in southwestern Ontario.  We also perform ultrasonic impact treatment for welds to extend the lifetime of welded structures and equipment. Visit: Welding Solutions Page 

REPEAT CLIENTS

We are proud to have worked with several high-profile clients in various industries, including CN Tower, MTO, LiveNation, RWDI, USACE, Parks Canada, Tesla, Toyota, General Motors, Honda, 407 ETR, Daifuku, GK Corp, and OCC.

services

MULTI-DISCIPLINED ENGINEERING & DESIGN-BUILD

ANALYSIS, FATIGUE MODELLING & LIFE-CYCLE ENHANCEMENt

FIELD TESTING (NDT) & INSPECTION 

WELD INSPECTION & CERTIFICATION

SPECIALTIES

SPECIALTY ONE-OF-A-KIND EQUIPMENT & STRUCTURES

CRITICAL HIGH CYCLED EQUIPMENT

DYNAMICALLY LOADED & MOVING STRUCTURES

AFTERMARKET MOBILE EQUIPMENT

PROJECT EXAMPLES

WORK ON EXISTING ASSETS

Proficiency in Failure Analysis, Field Testing, and Weld Inspection: POW brings extensive experience in failure analysis, field testing, and weld inspection, providing valuable insights for designing and building reliable solutions in maintenance, modifications, or refurbishment projects. Our expertise allows us to identify potential failure points, assess weld integrity, and ensure the overall safety, reliability, and efficiency of existing equipment and structures.

Multi-Disciplined Engineering Expertise: POW’s team possesses a wide range of engineering expertise, covering various disciplines from building systems to capital equipment. This diverse skill set enables us to approach existing equipment and structural projects holistically, considering all relevant aspects to deliver comprehensive and effective solutions.

Advanced Design, Measurement, and Fabrication Technologies: At POW, we leverage advanced design, measurement, and fabrication technologies and tools specifically tailored for working on or with existing equipment. These state-of-the-art resources enable us to accurately assess the condition of equipment and structures, identify areas for improvement, interference considerations, , and develop efficient solutions that meet the unique challenges of maintenance, modifications, or refurbishment projects.

By combining our proficiency in failure analysis and field testing, multi-disciplined engineering expertise, and advanced design, measurement, and fabrication technologies, POW excels in working on existing equipment and structural projects. Our focus on safety, reliability, and efficiency drives our ability to deliver successful outcomes while ensuring the optimal performance and longevity of the assets involved.

Background: POW was approached by a customer who had been experiencing fatigue cracking on a high-cycled welded component of their vertical vehicle lifter. The failures were detrimental to the overall functionality and reliability of the lifter, potentially com

promising the safety of lifting operations and production. The lifter was subjected to a million load cycles during its lifespan lifting a 2000 kg vehicle. The customer sought POW’s expertise to investigate the failures, determine the cause, and provide a reliable solution:

  • Weld Inspection and Field Testing: POW began by conducting a detailed weld inspection and performed field testing on the vertical vehicle lifter. This allowed them to closely examine the welds and identify any structural weaknesses or potential failure points. The results obtained from the field testing provided valuable data for further analysis.
  • ­Finite Element Analysis (FEA): Using the data gathered from the field testing, POW employed Finite Element Analysis to simulate the lifter’s performance under measured loads and forces. This enabled them to analyze the stress distribution and identify critical areas prone to fatigue cracking. The FEA provided insights into the root cause of the failures and guided the subsequent design modifications.
  • ­Redesign for Optimal Reliability: Based on the findings from the FEA, POW proceeded to redesign the vertical vehicle lifter to eliminate the failure points and enhance its reliability. The design modifications focused on reinforcing vulnerable areas, optimizing weld geometries, and incorporating improved materials and structural elements to withstand the dynamic loading conditions.
  • ­Fabrication and Ultrasonic Impact Treatment (UIT): After finalizing the redesigned lifter, POW carried out the fabrication process, ensuring precise adherence to the revised design specifications. Additionally, Ultrasonic Impact Treatment (UIT) was employed to further enhance the welds’ fatigue resistance. UIT is a process that subjects the welds to high-frequency mechanical impacts, inducing compressive stresses that help extend their lifecycle.
  • ­Weld Certification and Supply: POW ensured that the newly fabricated and treated welds met the necessary standards and certifications for quality and reliability. Stringent weld inspection and testing procedures were performed to validate the weld integrity and certify their suitability for the lifter’s demanding operational conditions. Finally, POW provided the customer with the newly designed and certified vertical vehicle lifter.

Results: POW’s comprehensive approach successfully resolved the fatigue cracking issues faced by the customer. By investigating the failures, performing weld inspection and field testing, conducting Finite Element Analysis, and redesigning the lifter, POW effectively eliminated the failure points and enhanced the overall reliability of the equipment. The application of UIT further extended the welds’ fatigue life, ensuring long-term durability.

refurbishment and analysis of a vertical drop lifter

Overview: This case study focuses on the evaluation and redesign of an existing conveyance system for the transition to hybrid vehicle assembly. Various components were studied, including carriers, body contact pads, rail supports, roof trusses, and more. The objective was to assess the system, perform stress analysis, estimate fatigue life, and develop repair details for improved performance and efficiency.

Challenges: The transition to hybrid vehicles introduced new loading conditions and changes in the center of gravity, requiring the review and redesign of key elements within the conveyance system.

Solutions:

  • Carrier Concept Review and Design: POW optimized the carrier design to accommodate hybrid vehicle requirements, considering loading conditions and center of gravity changes.
  • Determination of Carrier Weldments for Replacement: Critical weldments were identified and replaced to ensure structural integrity during the transition.
  • Finite Element Analysis and Fatigue Life Estimation: FEA was conducted to assess stress distribution, deflection, and estimate fatigue life, identifying components needing reinforcement or replacement.
  • Review of Vehicle Contact Pads: Contact pads were redesigned to provide stable support for hybrid vehicles during assembly and painting.
  • Conveyor Rail Support Spacing: The spacing of rail supports was adjusted to accommodate increased loading requirements, optimizing the support system.
  • Development of Roof Truss Loading and Analysis: Roof trusses were analyzed and optimized to handle the added loads from hybrid vehicle assembly and painting processes.
  • Development of Repair Details: POW developed practical repair solutions to address deficiencies and improve the longevity of the conveyance system.

Results: POW’s comprehensive assessment and redesign resulted in an enhanced conveyance system that met the new loading demands of hybrid vehicle assembly. The implementation of repair solutions ensured increased structural integrity and improved performance.

Project Description: The King George VI Lift Bridge is a critical transportation link for the community of Port Stanley, Ontario, Canada. The bridge spans the Kettle Creek and allows for marine traffic to pass through to Lake Erie. The lift bridge was due for a mechanical overhaul, including the replacement of the high-speed custom gearboxes and refurbishment of a low-speed gear set. Pow was chosen as the mechanical engineering and site services provider for this project, working in partnership with LCI and Sharp Industrial.

Scope of Work: Pow’s scope of work for this project included detailed mechanical engineering for the design of new high-speed custom gearboxes, refurbishment of a low-speed gear set, 3D laser scanning of the existing bridge components, FARO Tracker measurement, and bridge balancing. Pow also provided on-site services for installation and commissioning of the new gearboxes.

Solution: Pow’s team of expert engineers designed custom high-speed gearboxes that could be installed in the limited space available. The refurbishment of the low-speed gear set was also done with precision to ensure optimal performance. The 3D laser scanning and FARO Tracker measurement helped the team to accurately measure the existing components and design the new gearboxes accordingly. The bridge balancing was done with great care to ensure smooth operation of the lift mechanism.

Results: Pow successfully completed the mechanical overhaul of the King George VI Lift Bridge, ensuring that it can continue to serve as a critical transportation link for the community. The new high-speed custom gearboxes and refurbished low-speed gear set have improved the reliability and performance of the lift mechanism. The 3D laser scanning and FARO Tracker measurement helped to ensure accuracy and precision in the design and installation of the gearboxes. The bridge balancing ensured smooth operation of the lift mechanism.

mechanical and structural modifications for a swing bridge

Background: POW was approached by an automotive plant in Michigan to address fatigue cracking issues on a vertical curve section of a power-and-free conveyor rail. The current rail designs were cracking frequently, and the client was in dire need of a durable and reliable solution.

Challenge: The dynamic loading profiles of the rail made it challenging to design and fabricate a solution that would be up to specific tolerances. Additionally, there was a need to ensure that the fatigue life of the weldments was enhanced to prevent future cracking.


Solution:

  • POW provided an extensive analysis, design, and fabrication process to address the issue. The team used a FARO Laser Tracker to ensure fabrication tolerances up to 2 thousands of an inch. This process helped ensure that the design and fabrication were executed to specific tolerances, which would enhance the durability and reliability of the rail.
  • To further enhance the fatigue life of the weldments, the team also performed Ultrasonic Impact Treatment on the entire rail section. This process helped improve the fatigue life of the weldments up to 10 times more than what it would have been without the process.
  • The team also performed 3D laser scanning of the existing area to eliminate potential interferences on-site and ensure proper measurements of the replaced section.

Result: POW’s solution provided the client with a durable and reliable power-and-free conveyor rail that would be able to withstand dynamic loading profiles. The Ultrasonic Impact Treatment also helped improve the fatigue life of the weldments, ensuring that future failure was prevented.

Problem: A client’s battery marriage lift system was experiencing structural fatigue, leading to reliability and performance concerns. The failures disrupted their production process and increased the risk of damaging valuable battery components. A reliable solution was needed to eliminate the fatigue-related issues.

Solution:

  • Inspection, Field Testing, and Structural Analysis: POW began by conducting a thorough inspection of the battery marriage lift system’s structure. They performed field testing to gather real-world data on system performance, load profiles, and stress distribution. Structural analysis techniques were used to identify the root causes of fatigue and understand failure mechanisms.
  • Redesign for Better Reliability: Based on the findings from the inspection, field testing, and structural analysis, POW proceeded with a redesign of the battery marriage lift system using our expertise in lightweighting. The objective was to eliminate fatigue sources and enhance overall reliability. Structural components, welds, and connections were reevaluated to ensure optimal performance and durability.
  • Finite Element Analysis (FEA) and Design Validation: To validate the redesigned system, POW employed Finite Element Analysis (FEA) techniques. FEA simulations were conducted to assess the system’s behavior under various loading conditions and ensure structural integrity. This step ensured that the new design could withstand operating conditions and address the previous fatigue-related issues.
  • Fabrication of Replacement Component: Once the redesigned system was validated through FEA, POW proceeded with the fabrication of the replacement component. Specialized materials were selected to enhance structural strength while maintaining lightweight characteristics. The lightweight design aimed to minimize overall weight without compromising reliability, essential for efficient operations and energy consumption in electric vehicles.

Result: POW successfully resolved the structural fatigue issues in the EV manufacturer’s battery marriage lift system through thorough inspection, testing, and analysis. The redesign eliminated fatigue sources, resulting in improved reliability. Rigorous FEA and design validation ensured that the system met performance standards. The use of specialized materials and lightweight design minimized weight without compromising reliability.

picture of a battery marriage gantry system

Overview: POW completed and shipped a ROPS for a large mobile watering truck mine in Northern Canada. The project was undertaken to ensure the safety of the operators working in the mine and to comply with safety regulations. It is a Komatsu 830E-AC truck with the 48,000 gallon water tank in place of the dump box. The maximum loaded weight of the truck w/ water tank and ROPS weldment is approx. 846,000 lbs. The ROPS weldment by itself weighs approx. 26,350 lbs. The ROPS is a classified as a “One of a Kind” certified by calculation to CSA B352.0-09 Clause 5, done by Pow

Objective: POW was responsible for the design, analysis, simulation, fabrication, ultrasonic impact treatment, and delivery of the ROPS. The primary objective of the project was to create a ROPS that could withstand any potential rollover incident and protect the operator from serious injury or death.

Challenges: The project presented several challenges, including the weight and size of the mobile watering truck and the extreme weather conditions in Northern Canada. The ROPS also needed to meet the mine’s safety standards and comply with Canadian regulations.

Process: POW started the project with a detailed analysis of the requirements and specifications provided by the client. POW’s experienced team of engineers and designers then created a design that met the specific needs of the mobile watering truck. Once the design was finalized, POW used advanced simulation and analysis software to test the ROPS’s strength and durability under different conditions. The results of the simulation were then used to optimize the design, ensuring that the ROPS would withstand any potential rollover incident. After the design was validated, the fabrication process began. The ROPS was built using high-quality materials and cutting-edge technology, ensuring that it met the highest safety and tolerance standards. The ROPS was also subjected to ultrasonic impact treatment, a process that improves the material’s strength and durability after installation to the truck. 

Outcome: POW successfully designed, fabricated, and delivered a ROPS that met the client’s specifications and Canadian safety regulations. The ROPS provided the necessary protection to the operator in the event of a rollover incident, ensuring their safety and complying with safety regulations.

Conclusion: POW’s experience in designing and fabricating custom ROPS systems for large off-highway mobile equipment helped the company deliver a high-quality product that met the client’s needs and complied with safety regulations. The ROPS’s advanced analysis and simulation techniques and physical roll tests ensured that the ROPS was effective in providing protection in the event of a rollover incident.

PROJECT EXAMPLES

NEW DESIGN-BUILD

Proficiency in Failure Analysis and Field Testing: With extensive experience in failure analysis and field testing, POW brings valuable insights to the design and construction of reliable solutions for clients. This expertise allows us to identify potential weaknesses and design robust structures and equipment that prioritize safety, reliability, and operation.

Advanced Analysis and Engineering Capabilities: POW’s advanced analysis and engineering capabilities enable us to tackle complex design-build projects with confidence. We leverage our expertise to develop innovative and customized solutions, tailored to the specific requirements of each project. This approach ensures that our designs meet or exceed industry standards, leading to successful, reliable, and predictable project outcomes.

Turnkey Delivery and Project Management: As a turnkey solutions provider, POW offers comprehensive project management from concept to completion. Our multi-disciplined team seamlessly integrates various project deliverables in-house, streamlining the design-build process. This cohesive approach ensures efficient communication, collaboration, and timely project execution.

Expertise in Dynamic Loaded and Purpose-Built Structures: POW has a proven track record of delivering reliable engineered solutions for dynamically loaded and purpose-built structures and equipment. We understand the unique challenges associated with such projects and have the technical know-how to design structures and equipment that can withstand demanding operational conditions while meeting safety and performance requirements.

In summary, POW’s extensive experience in failure analysis and field testing, advanced analysis and engineering capabilities, turnkey delivery approach, and expertise in dynamically loaded and purpose-built structures position us as a reliable partner for successful new design-build projects. Our focus on safety, reliability, and operation ensures that clients receive tailored solutions that meet their specific needs.

Overview: POW was contracted to provide a comprehensive turnkey solution for the design, fabrication, and installation of all components for two Boundary Layer Wind Tunnels. The project encompassed multi-disciplinary design-build and turnkey integration, including the implementation of PLC-controlled testing and safety systems, servo rotating/elevating test turntables, servo adjusting flaps and spires, servo-controlled fan testing system, CLT and steel structure, precision formed turning vanes, precision formed contraction/expansions, acoustic baffles, heat exchanger, and civil elements.

Challenges: The project presented several challenges that required specialized expertise. A highly skilled team with experience in wind engineering, PLC systems, structural steel fabrication, precision engineering, and mechanical design was essential. Close collaboration with RWDI and Aiolos was necessary to meet the design specifications, adhere to project timelines, and manage the allocated budget effectively.

Solutions: POW’s team of experts approached the project with meticulous planning and advanced technologies to overcome the challenges and deliver a successful outcome.

  • Comprehensive Project Planning: Working closely with RWDI and Aiolos, POW developed a detailed project plan that included a comprehensive timeline, budget, and clear milestones. This plan served as a roadmap for the entire project, ensuring efficient coordination and management of all aspects.
  • Advanced 3D Modeling and Simulation: Utilizing the latest technology and software, POW created detailed 3D models and conducted simulations of the wind tunnels. This allowed them to visualize the integration of various components, ensuring a perfect fit and optimal functionality. The simulations provided insights into the airflow patterns, enabling design refinements for enhanced performance.
  • PLC-Controlled Testing and Safety System: POW’s team designed a PLC-controlled testing and safety system to monitor and regulate all aspects of the wind tunnels during testing. This system ensured the highest level of safety, precise control, and reliable data acquisition, contributing to the overall success of the project.
  • Precision Engineering and CNC Machining: To ensure the servo rotating/elevating test turntables and servo adjusting flaps and spires met stringent standards, POW’s team employed precision engineering techniques. CNC machining was utilized to fabricate components with exceptional accuracy and quality, ensuring reliable and precise operation of the wind tunnels.
  • CAD to CMM and Virtual Point Clouds: To guarantee fabrication and installation met the required tolerances, POW utilized CAD to CMM (Coordinate Measuring Machine) technology and Virtual Point Clouds. These tools enabled precise measurements and ensured fabrication and installation accuracy within tolerances as small as 2 thousandths of an inch.

Results: POW successfully completed the project within the specified timelines and budget. Both wind tunnels were fully operational and functioned as intended, providing RWDI with essential testing capabilities for a wide range of products and designs. Due to the success of the initial wind tunnels, POW has been contracted to build two additional wind tunnels, further establishing their expertise in the field.

Introduction: In this case study, POW highlights our recent collaboration with Northbank Civil and Marine and Timberland Equipment for the design and supply of the structural and mechanical system (excluding hoist) for a 25 T Gantry Crane at Dexter Dam. The project was performed for the United States Army Corps of Engineers. POW’s role involved the comprehensive design, analysis, simulations, calculations, fabrication, and certifications of the structural and mechanical system, with a focus on adherence to regulations, progress reporting, and operating within the guidelines of the “Buy America Act.”

Project Scope and Challenges:

Collaborative Efforts: POW joined forces with Northbank Civil and Marine and Timberland Equipment to ensure a seamless execution of the project. The collaboration allowed us to leverage each party’s expertise and deliver a comprehensive solution that met the client’s requirements.

Structural Design, Analysis, and Simulation: As POW, we took charge of the structural design, advanced analysis, and simulations for the gantry crane. Our team meticulously designed the main gantry structure, trolley, beams, and supports, ensuring compliance with the specific requirements of Dexter Dam. Through rigorous analysis and simulations, we optimized the design for performance, safety, and longevity.

Mechanical System Design: In addition to the structural components, POW was responsible for designing the mechanical system of the gantry crane, excluding the hoists supplied by Timberland Equipment. This encompassed selecting and sizing motors, gears, brakes, and other essential components. Our goal was to ensure the crane’s load capacity, movement, and control mechanisms aligned with the operational needs.

Fabrication, Inspection, and Certification: POW managed the fabrication process, adhering to industry standards and conducting strict quality control measures. Stringent inspections were carried out to ensure compliance with safety regulations, and necessary certifications were obtained to guarantee the fitness of the components for operation.

Ultrasonic Impact Treatment: To enhance the longevity and durability of critical structural elements, POW implemented Ultrasonic Impact Treatment (UIT). This technique was applied to the gantry crane’s structural components, increasing their resistance to fatigue and wear, thereby ensuring a reliable and long-lasting system.

Fit-Up and Tolerances Adherence: At POW, we assembled the gantry crane’s structure at our facility to ensure precise fit-up and adherence to tolerances. This approach allowed for thorough testing and verification of the crane’s structure, ensuring its readiness for installation at Dexter Dam.

Compliance with Regulations and “Buy America Act”: Working with the Corps required diligent attention to detail, navigating through various certifications and compliance requirements. POW ensured that all calculations and designs adhered to regulations and received the necessary approvals.

Conclusion: POW successfully completed the design, analysis, simulations, calculations, fabrication, and certifications of the structural and mechanical system (excluding hoist) for the 25 T Gantry Crane at Dexter Dam. Through close collaboration with Northbank Civil and Marine and Timberland Equipment, we delivered a comprehensive solution that met the specific requirements of the USACE.

Project Overview: POW was entrusted with a challenging high-profile project for an Indiana-based automotive manufacturer. If proven successfully, this process would be implemented throughout their N.A facilities. The project required the design, build, and installation of a comprehensive solution for selecting, picking, and installing moon roof/panel roof trim options (9) for three vehicle models on the same production line. Our responsibilities included mechanical, structural, and controls design-build services, turnkey installation, and commissioning.

Project Scope: To meet the project requirements, we shipped three full-sized flatbed trucks to the client’s facility in Indiana. Our scope of work encompassed the design and implementation of key equipment such as the Automated Pick Tool, Install Tool, and Backup Tool. Additionally, we provided Mod Racks, Platforms, Overhead System, PLCs, and other components essential for a successful solution.

Challenges and Solutions: Leveraging our increased in-house capabilities, we utilized our mechanical, structural, welding, materials, and controls knowledge to develop an automated and reliable solution for selecting, picking, and installing trim options. Overcoming challenges related to integration and coordination, we conducted site interference detections as well as a planed order of sequential installation, the shipping was arranged to match installation on site due to limited lay-down space.

Benefits and Results: Our turnkey solution delivered significant benefits to the client. By implementing our automated pick, place, and install solution, we streamlined the client’s operations and improved production efficiency. Our versatile design allowed for the selection and installation of various trim options across multiple vehicle models, enhancing the flexibility of their production process. The robust controls and automation technologies ensured safe, precise and consistent trim installation, minimizing errors and rework.

Conclusion: POW  successfully executed a complex project, delivering a turnkey solution for the moon roof/panel roof trim selection and installation needs of our Indiana-based automotive manufacturer client. Our in-house capabilities and expertise in engineering and automation enabled us to seamlessly integrate various components, resulting in improved production efficiency, reliability, and customer satisfaction. This project further established our reputation as a reliable and versatile partner for projects requiring multiple design-build disciplines. After a successful completion of the system, the client has now asked for additional copies for other locations.

POW was tasked with performing the structural and mechanical design and supply of the overhead support system for a major expansion project at a Truck Assembly Plant in Tijuana, Baja California, Mexico. The project was completed for our client, Daifuku America, and involved designing a robust overhead support system to handle the primary loads from a conveyor system moving 2000kg trucks above the production areas of the plant.

Challenges and Considerations:

As-Built Conditions and Existing Building: Working with existing structures and brownfield conditions required careful consideration. We utilized 3D scanning software and CAD-to-BIM integration to create a virtual environment that accurately represented the dimensions of the site, ensuring a precise design.

Seismic and Fatigue Design Criteria: Operating in a Category D seismic zone, we had to account for substantial seismic and fatigue-related design criteria. Our design underwent rigorous lateral load testing and optimization to ensure reliability during earthquakes.

Bracing Design: We designed bracing off the existing structure to accommodate large high-cycle vehicle lifts and transfers that operate above an active automotive manufacturing floor. The design had to adhere to stringent safety and reliability requirements.

JIT Fabrication and Delivery: To optimize material handling costs and available layout space on-site, we coordinated closely with the site and fabricators to ensure just-in-time (JIT) fabrication and delivery of parts. Effective communication among all stakeholders was crucial to maintain uninterrupted construction and installation progress.

3D Point Cloud and CAD Models: We utilized 3D point cloud and integrated CAD models to virtually check the fit-up of fabricated assemblies and identify potential interferences with the existing structure. This approach ensured the accuracy and compatibility of fabricated assemblies.

Budget and Project Management: To effectively manage the project budget, we established fixed pricing agreements with the client and sub-consultants. Key project management strategies included:

  • Weekly meetings with the client, trades, designers, and fabricators to ensure project milestones were being met.
  • Coordination with site progress to provide JIT delivery of fabricated assemblies, involving the transportation of 60 truckloads of steel (45,000 lbs/load) from South-Western Ontario, Canada to Tijuana, Mexico.
  • Constantly adjusting the fabrication schedule and delegations between shops to align with installation priorities, progress, and changes.

Key Takeaway:  POW was specifically requested by the OEM to be the preferred supplier of critical lifting and structural reliant structures. The structure was required to transport 2000 kg vehicles above automotive production workers in an area that is prone to earthquakes. The overhead vehicle conveyance system experiences millions of repetitive loading/unloading cycles.

Project Overview: The Taipei 101 is a 101-story skyscraper located in Taipei, Taiwan, known for its height and unique architecture. Due to its height, the building is vulnerable to wind and seismic forces. To address this, the building features a massive tuned mass damper (TMD) system that helps to reduce the effects of these forces.

Responsibility: Pow was involved in the project by assisting the Canadian engineering firm RWDI, with the structural connection design and fatigue modeling of the steel structure that connects the 1,000,000 lbs damper to Taipei 101’s building structure.

Challenges/Solutions:

  • Structural Modeling: Pow’s primary task was to create a structural model of the steel structure that connects the TMD to the building. The model needed to take into account the forces exerted on the structure due to the damper’s weight and motion. The team used advanced software and analytical tools to create an accurate structural model.
  • Fatigue Analysis: In addition to the structural modeling, Pow also performed a fatigue analysis of the steel structure. Due to the building’s height and unique design, the damper is subject to high-frequency oscillations, which can cause fatigue in the steel structure over time. Pow used advanced analytical tools to accurately model the fatigue life of the steel structure and ensure that it would withstand the forces exerted on it over the long term.

Results: Pow’s work was critical to the success of the TMD system, which has been credited with improving the quality of life for residents and saving the building from damage during typhoons and earthquakes. The team’s accurate modeling and fatigue analysis ensured that the steel structure connecting the damper to the building could withstand the forces exerted on it over the long term. Today, the Taipei 101 is recognized as one of the most innovative and resilient buildings in the world, due in no small part to the TMD system.

Project Overview: POW collaborated with Daifuku America and FM Sylvan to provide a new Assembly Shop for a Michigan Automotive OEM, and also upgraded an existing production line located nearby. POW was responsible for providing all the structural supports, screen guarding, drive decks, rail supports, header grid, inclines and declines while supporting the Daifuku designed steel.

Responsibility: POW provided the design, detailing, fabrication, and delivery of support steel and associated hardware to site in a sequential method that was discussed with the installers. POW was also responsible for finding potential interferences through scanning of the existing conditions and working directly with the OEM and DAC to resolve these solutions from an engineering perspective.

Considerations: POW used 3D and 2D reference files and 3D point cloud of the conveyor system to support the rails, drives, feeders, etc. The company also used Navisworks to create a collaborative model and designed the steelwork through Tekla Structures

Challenges and Solutions:

  • One of the significant challenges faced by POW was incomplete layout while designing support steel. To overcome this issue, the company reworked rail layouts with scanned site conditions and proposed solutions to interferences to push the schedule along and meet the project requirements.
  • POW also faced a quick turnaround requirement, which was addressed by working directly with the fabrication shops and the installers to balance design, installation, and fabrication constraints to optimize efficiency of all three.
  • The existing steel posed another challenge for POW, and the company used 3D scans to eliminate interferences by avoiding bridging between trusses, HVAC, conduit, etc. when required and did not impact structural integrity/cleanliness of design.
  • Organization of fabricated steel was also a critical aspect of the project, and POW arranged trucking and completed a Bill of Materials (BOM) referring to every support member sent to the site, which truck it belonged to, # of similar locations, and their approximate location through the plant. The company also provided support steel and naming conventions in a manner that if misplaced and found on site would indicate the area of the plant that it belonged to.

Results: POW delivered over 7,000 assemblies to the site, approximately 1,250 tons of steel over 6 months, with 6 months to design. The project was completed within the timeframe and budget constraints, meeting all the requirements of the Michigan Automotive OEM.

SPECIALTY ONE-OF-A-KIND STRUCTURES and EQUIPMENT

Our advanced analysis, engineering, and turnkey delivery capabilities provides us with a unique position to design, develop, and commission unique or one-of-a-kind structures and equipment. Some examples have included boundary layered wind tunnels, entertainment rides, edge walks, large, overhead moving structures, custom building features for princes, and equipment to perform new or complex tasks in a vast industry spectrum. 

DESIGN OPTIMIZATION, ADVANCED ANALYSIS, SIMULATION, & TESTING

In order to validate and optimize new or existing deisgns, we perform computer analysis and testing, destructive and non-destructive testing, and design optimization. This is to ensure reliability and to enhance the lifetime of capital equipment and structures.

DYNAMICALLY LOADED STRUCTURE DESIGN

Ranging from Automotive Carriers, Large Concert Stages, to Super Structures, POW has been using our core competencies to ensure reliability, safety, and function. We perform engineering and analysis services for all industries that experience dynamic loads on their equipment or structures.

REDESIGN, REBUILD & REPURPOSE OF EXISTING EQUIPMENT

Redesign, Re-Furbish, Re-Purpose of existing equipment. This service is generally used for when capital equipment has failed, about to fail,  a new model line, or to optimize a piece of equipment for new loads or cycle times. This includes large equipment in Manufacturing Plants that need to lift or transfer heavy products.

WELDING ENGINEERING, DESIGN, OPTIMIZATION & INSPECTION

POW’s Welding Engineers and Inspectors  have been providing Welding Engineering Retainer Services for over 20 years. This is done with our Retainer Services for Fabrication Shops. We also perform Ultrasonic Impact Treatment for welds to extend the lifetime of welded structures and equipment.

Wind Tunnel
Design-Build / Turnkey

Overhead Vehicle Conveyor -
Structural Support Steel
Design-Supply

25 Ton Intake Gantry Crane
Structural Design-Build

Lift Bridge
Mechanical Design-Build

Tuned Mass Dampers
Advanced ANalysis

Tow Plow
Advanced Analysis/Design

Finite Element Analysis (FEA)

Finite element analysis (F.E.A.) uses the geometry, material and loading information to determine stress levels and deflections. It can be applied on small components to large complex frames. Our engineers use F.E.A. on a continuous basis and can efficiently use it a variety of projects.

F.E.A. reduces the approximations which occur in many manual calculations while providing an excellent visual representation of both stresses and deflections. The 3D visual animation of the structure under various loadings provides an improved understanding of how the structure responds by amplifying the real deflections. Automatic optimization can be run on structures to determine the cost/weight efficient solutions based on either stress or deflection criteria.

F.E.A. can be used in conceptual design work, redesign, comparisons of designs, troubleshooting failures and as a tool to identify critical locations for field testing strain gauges.

Fatigue Life Predictions

Life estimate software is used to evaluate the fatigue damage which accumulates during equipment operation. The predictions are based on strain life (SAE), S-N curves, fracture mechanics or S-N weld design curves (8S5400). The software is seamlessly interfaced to the field test data but can be used to evaluate other design loading specifications.

Dynamic Motion Simulation

Motion simulation can be performed in either 2D or 3D to estimate the kinematic and dynamic response of equipment during operation. For example, a piece of moving equipment’s motion can be simulated by inputting the geometry and actuating forces/velocities. The resulting component loading, and time cycles can be reviewed for changes in geometry or actuation.