Easy way to break down boiler.

FriendlyFred

Recently, I had to break down an "Ideal" 1928 American Radiator Co. steam boiler for replacement. After thinking about how to tackle the job, I came up with a technique that ended up being fast, (relatively) quiet, and something I've not seen anywhere else. I used a 4 ton portable hydraulic ram kit.

Often are referred to as "Porta Power" packs. Although there are many other manufacturers, I got mine from Northern Tool for ~$80. The most useful combination of attachments for me was the 'fork' on one end of the ram and 'spiky square' on the other. The 'threaded shelf' included in the kit let me put the ram between and inside the sections with minimal clearance. The 'spreader wedge' also was useful, but is unable to apply as much force as the ram.

First, I used the ram to separate each individual section - it split sections apart easily without a hammer and chisel. With the section on the ground, I used the ram to break it apart further. This requires a bit more creativity to find angles that can put opposite pressure on the section in a linear manner. I found that breaking down even large pieces was quiet using the ram. When it finally does break, it makes a 'crack' but doesn't shatter in an extreme or violent way.

Although I used a sledge in some cases, the ram made sure I didn't have to swing it as often. All in all, it let me from start-to-scrapyard in less than 4 manhours. If I had to do it again, I would have chosen the 10 Ton ram kit. There were a couple times when it seemed like I was putting too much force on the handpump - but was able to manage.

delta T

I am getting one. That is awesome, thanks for sharing!

I just last week had to break down an old Delco boiler using a sledge and a splitting wedge. 0/10 would not repeat. I've been doing it that way for years, but most of the boilers I have to break apart have small sections that are relatively easy to handle, not this old Delco. 200,000 btu with 4 sections. They were HEAVY! had to break them apart further with a sledge and that old cast iron is tough stuff and it took 20+ swings to even start to crack the end sections. Slept very well that night....

EBEBRATT-Ed

That's a good idea and low dollars for what it does.

I usually use threaded rod with nuts on the inside to force the sections apart.....that usually works pretty good.

If you can break up the sections with the ram that's a home run!!

I'm too old for much sledge hammer pounding.

I usually make a few cuts in the cast iron with a cutting disk on an angle grinder...then hit it with the sledge

GW

Wow time for me to get a new tool

How does that long ram separate the inner sections?

gerry gill

Excellent. Beats beating spitting wedges to death!

GW

Just ordered a 10 ton, can't wait to tackle our next beast

I'm curious to see the 'spreader' work.

Steve_35

We use a light Makita electric jack hammer. I think we paid about $300 for a reconditioned one. Rented one the first couple times. It usually takes about 30 seconds to split sections apart. It is definitely noisy tho. Hearing protection is a must.

TMcGroy

From a homeowner who literally loves her 1938 steam boiler, why would you destroy one? I know it's inefficient; but mine still works, so it's not going anywhere until it cracks of its own accord.

FriendlyFred

Splitting the inner sections took a touch more creativity. Essentially, anywhere you can get a good 'bite' to apply linear and opposite forces will work.

The first inner section, I pushed against the cutoff stub of the supply riser. The second inner section, I added the threaded shelf included in the kit, and put the ram through the top of the steam chest, pushing against the back wall of the final section. (illustrated in image, as attached). It was also useful to push between the stickouts for the coal grate.

Once on the ground, I popped the 'legs' apart, and used different lengths of ram extensions to break it to something I could lift and move.

I found limited use of the 'spreader'. Although I used it once to separate the bottom nipples, a small pry bar worked just as well for that task. The best use of it I had was on the rear section of the boiler, to put pressure between the double wall construction.

However, that brings a word of caution - although the ram itself isn't violent when it breaks the cast, hitting cast under pressure with a hammer can result in violent and spectacular flying shards. As always, common sense and learning from experience applies.

re: TMcGroy - This one was leaking water into the fire, and steam into the flue.

GW

Thanks Fred, yes we are turning our mugs sideways and down when the cast is flying. Stuff flies like a rocket

ChrisandJenny

Hey Fred thanks a lot for the info very helpful I just picked up a side job getting one of these boilers out for someone do you have any idea what that boiler you did weighed? Also I'm a bit worried about when using the spreader the boiler will lay down and crack the concrete floor any ideas? I saw the picture of the pallet I was thinking about using a engine hoist to hold it up while splitting not sure if the hoist will be able to hold it up. Any insight would be greatly appreciated thanks again 

Mad Dog_2

Very cool.  I've used a Medium sized Demo Hammer (Chopping gun).  Mad Dog 🐕 

retiredguy

I had one of those boilers yeas ago. I got it for free, it was a 9 section. I got all the coal grates and missing parts and sold it as a complete coal boiler for many dollars. It was a great project. Oh, the tools I don't need them anymore.

clammy

I ve removed many ideals ,burmhams and u name it old steam coal to oil to gas steam boilers and as much as guys complain I never though I need more then what I’ve always carried in just a 5 lb lump hammer and decent chisel cut the rods and if your skill at slamming a chisel is excellent then blast between the section w ur lump and chisel and done . Now this may not be for those who cannot swing a hammer and lack hammer to chisel coordination and might blast your hand but personally I don’t think anything is as easy and I won’t spend a cent or do anything different plus this is the same way the boiler demo guys have done it for as long as I can remember . When I was younger I had a 7.5 lump hammer and it would only be a few shots and usually nothing could stay together ,lost that bad boy so now it’s a 5 lb but most of those old bears of a boilers are already done and as I get older I ll pay the demo guys a couple of bucks and there done in a blink of a eye why destroy your back especially when your at a age where you got 40 years of time in already breaking down and carrying out sections and new boilers down ,my days of that are winding down on that end ,plus every one wants cheap these days which w me it ain’t gonna happen been there done that and didn’t get a bumper sticker or tee shirt for it .
Peace and good luck clammy
Ps do yourself a real favor and find a good boiler demo guy and pay them to remove and set your boilers in place cause you’re not doing anything including the boiler if you strain and hurt your back you ll be sitting on the side lines on the bench if your lucky . In the words of one of the all time worlds best mech don’t be a hero