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Welcome to the

Magnum Companies
Tampa, FL USA

The Magnum Companies are


committed to:
Safety
environmental conservation
The community
Reducing our customers unit cost per ton
Rapid response and service

Magnum Companies:
are dedicated to supply parts and services
in the following sectors:
Mining
Sugar Mills
Paper Mills
Cement
Electric Generation
Industries that require special materials and parts
in their operations with better designs, more
effective and better prices

Magnum Companies:
Magnum Steel
Magnum Slurry
Magnum Engineered Products
RBT Industrial & Electrical Services
Magnum Star Latin America
Unimag S.A.

MINING
SECTOR

Parts for Mining Equipment

Track Pads

The Challenge
Produce Track pads
for bucket wheel
excavators that will
last longer than the
OEM KRUPP and cost
much less.
Some other parts
produced: corner bits,
cone liners, 2 wheel
bogies, upper bogies,
tumblers and cams,
take up tensioner,
drive shafts, bucket
wheel shafts and
much more.

Draw your own conclusion


Krupp-

Magnum

9 months of life

24 months of life

@ 53% avail. = 3434 hrs.

@ 53% avail. = 9158 hrs.

Cost per set: $616,000

Cost per set: $178,000

Delivery time: 17 months


FOB Colon, Germany

Delivery time: 5 months


FOB Tampa, Florida

From 1991 until 2010 Magnum constructed more than 625 different parts
for the KRUPP Bucket Wheel Excavator system, supporting 3 bucket
wheels, 6 MTCs, and more than 10,00 0 ft. of 54 and 72 conveyors
saving PCS Phosphate, Inc. in Aurora millions of dollars in parts cost
and many more millions in down time that was not lost due to improved
design and construction, working with PCS personal.

Mobile Transfer Conveyors at


PCS Aurora

New Challenge
P&H 4100 C Boss
Shovel working in wet
soil conditions. Help
stabilize machine
The best solution will
be to redesign Track
Pads putting 54%
more steel on the
ground, reducing the
ground pressure by
33%
P&H

MAGNUM

$2.1 million per set of 90


Pads

$1.3 million per set of 90


Pads

* Since this is a new project this is Magnums best estimate of cost

P&H Design of Track

Pad

51,104 Sq.In in contact


with the ground

Improved design of Track Pad


MAGNUM Design of

Track Pad

79,104 Sq. In
In contact with the ground

Existing Track Pads &


Undercarriage

Cast and machined pads ready for


shipment
4100 C P&H Boss excavator Pads cast on
alloy steel by P&H

4100Track Pads cast in


manganese steel by
Magnum

Feeder breaker picks with tungsten


Underground mining chain with
carbide inserts
tungsten carbide inserts in potash

Stamler

MAGNUM

Pic $205.00
Holder $590.00

Pic $107.00
Holder $238.00
Chain /Sprockets

The Challenge

Bucyrus Erie 2550 Dragline


Construct a universal walking
cam housing that will not break
in at the foot and can be used on
both sides of the machine by
redesigning lower half of
housing.

Bucyrus Erie

MAGNUM

Cam Housing

Cam Housing

$605,000

$299,000

The Challenge

Larger opening in the shoe box


Reinforcing with T-1 gussets
Design a shoe slide that has larger
Cross sectional thicknesses using
T-1 Alloy steel plate to double the
strength

The Challenge

Mesco shoe slide shown in


Grey.
B.E. slide in black.

Installing new shoe slide

Some parts designed by Magnum for


the draglines and shovels

The Challenge
Construct a tub for
the 8200 that will
not crack under the
soft ground
conditions at PCS
Aurora

Marion 8200 Dragline

The solution was to construct an octagonal center section to


reduce inward point loading stress by half from high
strength low alloy steel

The tub was completely constructed on site at


the mine PCS Aurora

Robotic Welding

Marion 8200 Dragline

Machining with laser the upper roller path


after installing 6 thick alloy plate.

Marion 8200 Dragline

Machining one of the two new forged swing


bosses installed

Photo from top of 8200 looking at completed tub in Magnum work


zone

This was the first


tub built with an
octagonal center
section and high
strength low alloy
steel. As of last
inspection report
2010, no cracking
was found

Machining the base with the laser

Separating the machine from old tub

Removing the old tub

Preparing to
lower the boom

The boom
lowered

Rebuilt machine in operation

Marion (minserco) MAGNUM


base tub cost only base tub cost only
$ 4,900,000
tub only
mild steel

$3,319,000
tub only
alloy steel

Magnums bid to PCS in mild steel was


$2,650,000

Zero time lost, zero incidents, zero


accidents

The Challenge
Bucyrus Erie 1260 Relocalizacion

Dismantle, move and repair


Bucyrus Erie 1260 from Big
Sky Montana to West Beach
Florida

Upgrade electrical system


from analog to digital using
SIEMENS

Drives and controls installed

Bucyrus Erie 1260

Completely automated and mechanically like new, ready to rais th


boom and go to work in West Palm Beach, FL.

Conveyors, Pulleys, Rollers

The Challenge
Construct rollers and pulleys that would last in a 72 belt
conveyor carrying 3600 TPH moving with a belt speed of
over 1100 fpm

The solution was to bolster the structural


modules of the KRUPP design with heavier cross
sectional materials and changing the rollers to
CEMA F with vulcanized rubber covers that
would except one of the most severe conditions
working in the U.S.

The Challenge
Caterpillar D10 track links were used in the great Canadian tar sands
projects carrying oil and sand to the separation plants. The problem
was they were unable to accept the extreme forces of this application.
In this case when the plant broke a link in the chain it caused more
than $500,000 in damaged equipment and more than $1,000,000 of
down time. (Based on oil being $65 a barrel

The solution was the design a new side link increasing the
cross-sectional thickness across the link and still have
interchangeability with Caterpillar components i.e. rollers,
guides, sprockets and tumblers. Also, Magnum would
change the metallurgical composition of the link from
Caterpillars 1070 carbon steel to AISI 4340 ultra high
strength alloy steel after hardening links to 400 Brinell, the
links would go through a process of nitrating to close the
grain structure on the surface to help prevent stress
corrosion cracking.

MAGNUM D-10 forged in 4340 ultra


high strength steel.

Caterpillar D-10 link forged


in 1070 carbon steel

The final Solution

Slurry Pumps

Magnum manufactures its


own brand of pumps
(Magnum SPP) and is an
alternative source for
dimensionally
interchangeable parts
with:

WARMAN
GIW

Magnums pump parts are completely


interchangeable with GIW pumps

Magnums pump parts are completely


interchangeable with Warman pumps

-Large Inventory
-Immediate Shipment
-Perfect Fit

-Completely Interchangeability
-Bellenite High-Chrome White
Iron
-Bearing Housings Available in
most sizes

Magnum SPP 20 x 20 working with Magnum suction


plate. GIW frame plate and pedestal

Magnum has millions of


dollars of pup parts in our
inventory ready for shipment

Dredge pump
which uses a
103
diameter
impeller

Magnum 8 x 6 being installed in


an Alumina Plant (retro fits with
Goulds)

Magnum wet in parts for GIW interchange

chrome white
iron ASTM-A532
III
manganese A128grade-A
Ni-hard 4

Gate Valves

CEMENT
PLANTS

The Challenge
A kiln ring that can be
changed without
cutting the kiln in half
eliminating over
$1,000,000 in labor
and 3-4 weeks of
down time.

Shown above, a 2 piece kiln ring


228 OD with a 34 face that can
be changed without cutting the
kiln in half

Machining ring and completed tyre shown

Complete parts for


Ball mills

Medium chrome white iron liners


with forged grade 8 bolts, nuts, and
washers

HK Stainless Steel Kiln Nose


Ring for 2100 degrees F.

HK Stainlees Steel Tipping


Seat Vortex

HH or HK regular or
pocket style cooler grates

A few of the critical parts that Magnum manufactures for the


cement industry.

Undercarriage and digging equipment for the


construction and mining sectors for most
makes and models

Teeth and adapters for backhoes, loaders, excavators


and dragline buckets for most makes and models
(Caterpillar, Komatsu, John Deer, and many others)

Sugar Mills
& Co-generation Plants

-Complete Sugar Mills


-Refinery
-Ethanol
-Cogeneration
-Parts & Services

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Turnkey Projects
Design, Manufacture, Erection & Commissioning

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MEPCO & HI-TECH are suppliers of complete engineering


solutions for Sugar, Power & Cogeneration Industries.

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Cogeneration
-Turbines
-Generators
-Boilers
Design
Engineering
Construction
-Switchgear
-Control Panels
-Automation
-Electrical Maintenance
& Services
-Inspections
-Complete Mills/ Drives
-Mechanical & Civil
Engineering

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We have gained vast experience from previous turn-key co-generation projects as well as our
ongoing research and development program. MEPCO and HI-TECH have joined together to offer
complete services of design, engineering and constructions of projects involving turn-key sugar mills
and co-generation facilities. We have the expertise to take you from the fuel, to the boiler, to the
power grid and every step in between.
Facilities for electrical work:
-In-house capability of MCC panel building.
-In-house capability of VFD panel building.
-In-house capability of panel fabrication.
-In-house capability of electrical project execution.

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Turn plates with replacable alloy


tips
450-500 brinel

Pinion shafts
Cane carrier sprockets

Mill shell flanges

Forged shafts
finished machined in
1040, 4140 & 4340

Offset
square forging

Shredder hammers fabricated


from
MTA 500 plate with
Shark-Bite tungsten carbide tips

The Shark-Bite tips


are easily replaced
using a grade 8 bolt
system

Shredder rotors for hammer mills


and swing back knives
constructed at Magnum using
alloy steel and Magna- Cladd
plate for greater wear life

Shredder rotors fabricated from T-1 alloy steel with 4340 high
strength alloy shafts

MAGNUM WEAR TECHNOLOGY


Shark-Bite tungsten carbide
Magna-Cladd overlay plate
MTA 500 alloy wear plate

Materials commonly cast by


Magnum:
Work-hardening had \field manganese
Alloy steel
High chrome white iron
Gray iron
Ductile iron
Cast steel
High temperature & corrosion resistant Stainless Steel
bronze

Protect you body


MAGNUM MTA 500

For the best resistance to impact and


abrasion Magnum MTA 500 allows the
reduction of thickness to allow greater
loading capacity of transported cargos
Magnum can cut the plates exactly
to the size you require
(installation kits for excavators,
front end loaders, drag line
buckets and articulating trucks

Tensile strength: 250 ksi


Yield strength: 185 ksi
Ellongation: 11.0% in 8
Brunell Hardness: 475 min / 500
nominal

MTA - 500 is an alloy steel quench and


tempered with high pressure water. It is
utilized in applications where severe impact
and abrasion is the principal cause of material
fatigue
Principal Characteristics:
MTA - 500 Can be used in the most sever
abrasion and high impact conditions.
MTA - 500 Can be machined or drilled using
high speed tungsten carbide tooling
MTA 500 Can be easily welded with
electrodes, low carbon E-70XX or E-110XX

MAGNA-CLADD

Easy to install with welding. MagnaCladd is applied to a structural steel


A-36.

Plate of Magna-Cladd hard coating


with an implementation with three
passes and a counter sunk hole

We can cut or form Magna-Cladd


according to any of your plans or
specifications

Chemistry Composition:
Crome - 26-35%
Carbon - 4.0%
Manganese - 2.0%
Silicon - 0.50%

Stock Sizes:
1/8 en 1/4 X 60 x 120
1/4 en 1/4 X 60 x 120
3/8 en 3/8 X 60 x 120
Other sizes and thicknesses
available upon request

Magnum Shark-Bite

Protect your expensive mining


consumables such as buckets,
teeth adapters, lips, corner
shrouds, shouts, crushers, and
high impact areas with SharkBite tungsten carbide inserts.

The wear side of the Shark-Bite


insert is 91 Rockwell A. The alloy
steel around the carbide is 52-55
Rockwell C.

Shark-Bite welded to bucket


adapters and corner shroud

Mechanical lip shroud with more


than 5,000,000 tons of
overburdened mined

Lip shroud lasted 10 times


longer, protected by SharkBite

soldar facilmente

Eletrical Division &


Automation

RBT INDUSTRIAL ELECTRICAL


SERVICES

OVER 27 YEARS EXPERIENCE IN PHOSPHATE


FOOD GRADE JUICE PLANTS
POWER GENERATION AND CO-GENERATION
SUGAR MILLS AND REFINERIES
CHEMICAL PLANTS
PHOSPHORIC AND SULPHURIC AUTOMATION

INSTALL POWER AND


CONTROL FOR
FLORIDA PHOSPHATE

13,000 volt feeder tie between 45


megawatt turbine generator and
main sub station feeding chemical
plant

Pumping
station
Control panels
Install medium
votage starters

BUILD
AUTOMATION
PROGRAM
POWER
DISTRIBUTION
UPGRADE
MAINTAIN
TROUBLESHOOT

MOTOR CONTROL CENTER


POWER AND CONTROL SIDE

500 mcm cable


being pulled

Automating animal feed plant


Allen Bradley controls logix
system.

CT wiring going into terminal box


from the mcc (motor control center)
displaying motor amps

Automating MCC and control


panel with starks stop and
auxiliary contacts

Allen Bradley MCC

start-stop relays, power


supplies and circuit breaker
(Allen Bradley)

Allen Bradley Control


logix processor and I/O
racks

Magnum offers:
Complete design engineering and construction
The best materials to fight against wear
Capacity to cast & finish machine pieces up to 82,000 lbs.
Forgings finish machined up to 33,000 lbs.
15 different licensed foundries and forging houses in the global
market
All foundries have ISO 9001 certification
Engineers readily available to help assist your engineering
department to asses solutions and available designs to prolong
your equipment
More than 150 years of combined experience
Assistance in hydraulic pumping systems
Assistance in electrical design & installation

A few of our clients:


Alcoa
Albian
Suncor
Syncrude
PCS Phosphate
PCS Potash
Mosaic
Texas Utilities
Tampa Electric
Barrick
Consolidated Coal
U.S. Sugar Corp.
Florida Crystals

CEMEX
Southern Peru Copper
Xtrada
BHP Billiton
Titan
Lafarge
Phelps Dodge
Argos Cement
Orlando Utilities
Arch Minerals
C.F. Industries
Okeelanta
Sugar Cane Grows