Producing over one million tons of product per year is an impressive feat for any industry. At Giant Cement in Harleyville, S.C., this annual quantity reflects the effective strategies implemented throughout their lean manufacturing process. Producing and transporting this amount of cement requires a devoted workforce and equipment that never stops. The 24/7 demands can take its toll on equipment and installing durable scales is integral to keep product moving. Giant Cement requires the most durable truck and rail scales to handle its high volume of trucks per day and constant stream of rail cars. They turned to Rice Lake’s SR truck scale and a custom-designed railroad scale to meet their needs.
An existing competitor’s truck scale still resides on its original installation site, inhabiting low ground on the lot and providing a reminder that proper installation is an essential ingredient for optimal weighments. Because of its location, every rainfall washed any nearby debris beneath the scale and would often create pools of standing water. “That scale was a maintenance nightmare,” explains Brad Locker, Industrial Controls Engineer for Giant Cement. “It seemed like we were always calling someone out here to make adjustments or clean the foundation.”
They contacted Nate Keisler, sales manager of Carolina Scales, who recommended a concrete deck SURVIVOR® SR truck scale and a different installation strategy. “Nate really knows his stuff,” remembers Brad. “Because he is a former installer, he gives us a great perspective on our needs for the entire project—not just the scale selection but also what we need for the right installation.”
“Any equipment in this area is going to be put to the test because of the sheer quantity of product they produce,” explains Nate. “I knew they needed the toughest scale possible so I recommended the SURVIVOR SR because of its added strength.” The SR provides increased rigidity and reinforced, easy-access load cell pockets for uncompromising performance and quick maintenance.
Utilizing their experience and knowledge of the site, Carolina Scales installed the SR in an optimal location. The new scale towers above a nearby small drainage pit. This ensures any rainfall is diverted past the truck scale and any debris is carried away in the flow.
Todd Keisler, head of construction for Carolina Scales, is a maestro truck scale installer. He takes every precaution to ensure the scale will last as long as possible. The optimal installation site was a solid foundation for this goal, but Todd went one step further. He ran all conduit along the top of the scale’s prominent siderails, guiding the system’s electronics away from the perils that led to the demise of the competitor’s truck scale.
Carolina Scales’ expertise and the SR’s rugged durability are the perfect combination for the factory’s demanding truck scale needs. One solution was in place, but a more challenging problem resided in the rail car loading area. Here, two 50-year-old rail scales were buried beneath an offset in the track. Once fully mechanical, the scales received an electronic conversion in the 1980s, but the pits were originally built to accommodate the original cantilever system. This required the rails to be slightly off-center and would necessitate a tailor-made scale to match the unusual design.
Carolina Scales worked with Rice Lake to custom-design a massive rail scale that would fit the pit and its existing rail, but installation would not be easy. Once the old rail scale was removed, a half-century’s worth of rail-car residue was revealed. It would need to be removed before installation of the new rail scale could commence. “The pit required a lot of cleanup,” Brad remembers. “There was an incredible amount of buildup after fifty years of rail cars passing over the scale. In places, it was so tough to clean that even a jackhammer got stuck. It took a while, but we were finally able to clear out the pit remarkably well.”
