Engineering Reliability for Real-World Challenges
At Ransford Engineering, we specialize in solving complex mechanical engineering problems, ensuring that our clients receive innovative, safe, and efficient solutions tailored to their industry needs. When a client approached us with concerns about the structural integrity and commercial construction site compliance of their concrete washout tubs, our team took on the challenge with a methodical and calculated approach. Through rigorous stress analysis, engineering calculations, and below-the-hook design expertise, we provided a solution that not only met industry safety standards but opened new business opportunities for our customer to expand their product line.
Relieving Stress
Our client’s primary concern was ensuring their concrete washout tubs could safely handle wet concrete loads while remaining compliant with ASME BTH-1-2017 and ASME B30.20-2018 standards so they could be used on commercial job sites. Our final deliverables offered multiple advantages:
- Improved Efficiency – The refined design ensures safer and smoother lifting operations, minimizing downtime on construction sites.
- Reduce Costs – With structurally optimized lift lugs and validated load capacities, the risk of costly failures or OSHA violations is significantly lowered.
- Expanded Market Opportunities – The new compliance certifications and reinforced design open doors to larger construction projects requiring verified lifting solutions.
- Enhanced Safety – Structural validation minimizes risk for field workers, providing peace of mind during lifting and transport operations.
- Stack-ability – We designed the washout tubs to be stack-able on the job site to reduce space requirements.
Customer Testimonials
One of the biggest affirmations of our work came directly from the client:
John with Ransford engineering helped us get our product line of concrete washout tubs rated for lifting with a crane. He did a very detailed, in-depth analysis on the strength of the existing design, and provided revisions to improve strength. His methodology and approach to product development is very streamlined and accurate. John completed the work on time and on budget. John came to witness the load testing of the products and they performed just how he expected them to when we loaded the products with weight. John made sure that we did the load tests in the safest manner possible. I found John to be a very intelligent individual who can provide great insight into manufacturing operations and new product development. The shop drawings he produced were condensed, easy to read, and detailed.
– Roggen Frick, Bear Iron Works
Project Overview
The client, Bear Iron Works, a manufacturer of concrete washout tubs, required a structural assessment and certification to ensure their products were safe for lifting via crane. These tubs, essential for concrete waste management on construction sites, needed validation for various sizes and configurations to meet industry safety standards. Ransford Engineering was contracted to perform an in-depth engineering analysis, including:
Stamped Fabrication Drawings – Creating detailed, stamped shop drawings for weldments and components of the validated designs.
Product Design – We improved an existing concrete washout tub design to make lifting tasks easier.
Design Validation – Engineering calculations and finite element analysis (FEA) for three sizes of washout tubs (1 CY, 2 CY, and 3 CY) with tube-style variations.
Engineering Report – A comprehensive document summarizing the finite element analysis (FEA) performed.
Load Testing Supervision – On-site professional engineer (PE) verification of calculations through physical load testing.
User Manual Update – Enhancing the existing manual with best practices for lifting and compliance.
Key Engineering Challenges and Solutions
Structural Reliability and Compliance
The primary challenge was ensuring that the washout tubs met ASME BTH-1:2017 and ASME B30.20:2018 standards. Our approach:
- Confirmed safety factors for lift lug design to prevent tensile and shear failures.
- Performed FEA and hand calculations to validate load-bearing capacity.
- Ensured compliance with Design Categories for unpredictable, high-stress conditions.
Load Capacity Validation and Risk Mitigation
Each tub needed to safely handle wet concrete loads. Our solution:
- Recommended rigging hardware and lift plans for safe operation.
- Conducted worst-case scenario analyses to validate lift lug strength.
- Ensured minimal deflections for stability and durability.
- Classified lifting safety per shackle reaction force calculations.
Enhanced Safety Through Testing
To validate our calculations, we supervised load tests:
- Ensured controlled testing environments with real-world weight conditions that meet ASME 125% load tests.
- Verified structural integrity under maximum load scenarios.
Innovative Features & Design Improvements
Ransford Engineering implemented the following enhancements:
Durability for Harsh Conditions – Designed to withstand rugged job site environments while ensuring compliance with Storm Water Pollution Prevention Plans (SWPPP).
Reinforced Lift Lugs – Preventing tensile, single-plane, and double-plane shear failures.
Optimized Weight Distribution – Reducing deflection and maintaining balance during lifting.
Enhanced Fabrication Drawings – Condensed, easy-to-read shop drawings for seamless manufacturing.
Updated User Manual – Providing clear OSHA-compliant lifting procedures and inspection guidelines.
Client Links
If you or someone you love is looking for excellent concrete washout tubs, grizzly rock screens, bedding boxes, or construction tracking pads, we highly recommend Bear Iron Works in Grand Junction, Colorado. Links to some of their products are below:
Conclusion
Through detailed engineering calculations, advanced stress analysis, and comprehensive below-the-hook design expertise, Ransford Engineering provided a safer, more reliable solution for concrete washout tub lifting. The improvements not only ensured regulatory compliance but also enhanced efficiency, reduced risk, and offered a more robust product for demanding construction environments.
If your company needs custom engineering solutions—whether for design validation, compliance certification, or structural improvements—Ransford Engineering is ready to help. Contact us today to discuss your next project and experience our commitment to precision engineering and problem-solving firsthand.
