lifting letter - barnhart crane

Vol. 65 2020 | www.barnhartcrane.com 1VOL. 65Copyright 2020A Publication of Barnhart

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19BRANCHPROFILE: Elkhart, Indiana

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www.barnhartcrane.com

LIFTING LETTER

A CULTUREOF TRAINING

Vol. 65 2020 | www.barnhartcrane.com2

TABLE OF CONTENTSA CULTURE OF TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CHEMICAL : SCRUBBER REMOVAL AND REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ELECTR ICAL : TRANSFORMER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MANUFACTUR ING : DAMPER REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . 6

C IV I L : BR IDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

NUCLEAR : TRANSFORMER REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 8

INDUSTR IAL : PRESS SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

REF IN ING : HEAT EXCHANGER REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . . . . 10

NUCLEAR : BR IDGE SHOR ING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GOVERNMENT: HYPERBAR IC CHAMBER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

MANUFACTUR ING : AUTOCLAVE TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C IV I L : BR IDGE INSTALLAT ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

NUCLEAR : F EEDWATER HEATER REMOVAL AND REPLACEMENT . . . . . . . . . . . . . . 15

BRANCH PROF I LE : E LKHART, IND IANA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

EQU IPMENT PROF I LE : POWERED GANTRY BASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19TABL

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Vol. 65 2020 | www.barnhartcrane.com 3

Training is integral to Barnhart’s success as a company.

Every Barnhart employee – from branch administrators to

accountants to crane operators – have to go through it.

“Training is, first and foremost, an introduction to Barnhart’s

culture,” says Barnhart Training and Implementation

Manager Kary Meadows.

All employees are required to take what is called Tactical Self

Preservation (TSP) classes, which help employees become

more aware of conditions that might lead to an accident.

Field employees also have to take a class known as the

Basic 5, which includes topics like company culture, crane

orientation, and basic rigging skills.

Beyond that, there are specialized trainings depending on

your role. The company also has a resource called Barnhart

University, an online library of videos and courses to make

education more accessible.

“In our business, training is one measure of performance,”

Meadows says. “The better our people are trained, the better

job we do and the more value we bring to the customer.”

Training promotes safety in a business that is inherently

dangerous. Properly trained employees operate safely on

job sites and have a knowledge of safety standards.

Employees are also encouraged to say something if they

see a situation that might be potentially unsafe.

The training department is also responsible for keeping

up with what individuals are trained to do and the

certifications they have received. Training is not just a

one-time requirement; it is recurring. After all, continuous

improvement is one of Barnhart’s core values.

While training is ultimately about learning, it also leads to job

and personal satisfaction.

“When someone goes through a specific training and then

goes out and executes their job perfectly, they see the

value of that training almost instantly,” says Meadows.

“That’s very satisfying, which I think also helps with

employee retention.”

A CULTURE OF TRAINING

COVER STORY


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The scrubber needed to be tailed from vertical to

horizontal for hauling. The existing scrubber’s head lugs

were unsuitable due to corrosion and other factors. No tail lug

was present.

To tail the scrubber, shackles were connected to two

anchor bolt chairs and a second crane assisted in bringing

the vessel into a horizontal position. It was then set to cribbing prior

to being loaded onto a trailer.

Barnhart was hired to remove and replace a 20,000-pound scrubber at a chemical plant in Arizona. It was 34’-8” tall and 6’-6”

diameter and inside of a 70’ tall structure. The team used a Liebherr LTM 1220 crane and 75-ton temporary trunnions to lift the

scrubber vertically out of the structure.


PROJECT PROFILES

Barnhart used a 6-Line PST single-wide Goldhofer with

a power pack. Height was an issue as the cargo was 18’

overall with the transformer and Goldhofer. Barnhart had to work

with local utility companies to raise and lower the impacted lines.

The unit was hauled 1.2 miles to the new substation,

offloaded, and set. Barnhart utilized a Link Belt ATC 3275

crane to offload the transformer from the Goldhofer trailer for final

placement. The job was completed in a safe and timely manner.

Coordination with local city authorities and electric company

employees allowed for the successful completion of the job.

The elevation changed drastically on the haul route so

the crew had to ensure that levels of the load could be

maintained throughout the haul. The changes in elevation made

for a challenging job for regular over-the-road trailers, so Barnhart

utilized a shorter Goldhofer option.

An electric company in Arkansas approached Barnhart about

receiving an 111,000-pound transformer from a third party

and hauling it to a new substation. The team’s first challenge was

a short window of time to complete the project because the third

party truck could not make it to the site.

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All components were outfitted with swivels to allow the

damper to move in any direction and bend completely

around a corner for both extraction and installation. Barnhart’s crew

carefully guided the double cantilever system into position using

remote controls, tag lines, and radios. They navigated the system

between two buildings, under a slanted wall, over the ductwork,

and around the corner to hook onto the damper.

The old damper was removed and lifted above the existing

ductwork avoiding all obstacles and was safely brought to

the ground. The process was reversed to install the new damper.

Barnhart’s work on the complex project was awarded a Specialized

Carriers and Rigging Association (SC&RA) 2020 Rigging Job of the

Year under $150,000.

Removal required an approach that could bend around a

corner 180 degrees, safely lift the damper, and remove and

replace it. Barnhart’s engineers settled on a unique solution – a

double cantilever approach. A multi-pick beam was attached to the

primary beam. Counterweights were attached to this secondary

cantilever. The unit was lifted by a GMK 275-ton all-terrain crane.

Management at a cement plant challenged Barnhart to solve

a project they believed was impossible – the removal and

replacement of a 9,600-pound. Bellowseal damper, which was

buried behind steel and handrails and hidden around a corner.

Slanted sidewalls wouldn’t allow for a conventional crane boom or

even the ability to drop a hook from above. There were numerous

overhead obstructions and over 40 feet of 8-foot. diameter, double

wall, stainless ductwork, which could not be removed.


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The challenges of the project included an accelerated

schedule, bridge weights in excess of one million pounds, tight

working quarters, offset CG’s on the sections, and tight tolerances.

Working two shifts, the northbound bridges were installed

in three days and the southbound in four days.

Each phase of the project was accomplished during an extended closure separated by a 10-day period. Still, the crew had to deal

with heavy traffic.

Barnhart was hired to replace six total bridge sections on I-95 in Warwick, Rhode Island. There were three northbound sections and

three southbound sections, which each weighed over 500 tons. The team mobilized equipment, including two 16-line PSTe series

trailers, 5’ “Marino Girders”, (2) 40’ long and (2) 100’ long girders along with assorted wood crane mats and cribbing.


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Barnhart also avoided overhead clearance issues using an

old school plate on plate spinner design. The on-site team

had over 1,000 pieces of lumber to maneuver to reduce ground

bearing pressure. Manipulation to the transformers was required

while sliding, which included changing the height on the plates.

The project took 1,000+ hours of Barnhart engineering time

to execute. Even so, the on-site team finished five shifts

ahead of schedule. The client was impressed with the move, which

was the first stage of an eventual 22 transformer R & R contract.

A standard 500-ton slide system and hydraulic turntables

would not work to maneuver the pieces because the

transformers were two feet taller than expected. The engineering

team developed a new slide system with a 4” deep slide track to

minimize overall height. The team utilized pull-up gantries to lower

the transformer to the track.

Barnhart was hired to remove and replace two

200,000-pound auxiliary transformers at a nuclear plant

in Illinois during an outage. The route to the transformers was

circuitous and located inside the facility which would require using

a slide track system.


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Floor loading was an issue, so Barnhart used a 6 line PSTe

to help distribute the load. One inch steel plates were also

laid on the floor to further distribute the weight. Clearance was also

a factor, as the Goldhofer only had a foot of clearance between the

two building columns. The press was attached to header beams.

The team used 400-ton gantries to lower and set the press

to its foundation. Once the press was set, the Goldhofer

was removed. Though the project was scheduled for three shifts,

Barnhart was able to complete it in two.

An industrial site in Wisconsin needed a 185,000-pound press set inside one of its buildings. The press had been hauled to the site

and set on a trailer. After the press was offloaded from the trailer, Barnhart transported it inside using a Goldhofer PSTe.

THE TEAM USED 400-TON GANTRIES TO LOWER AND SET THE PRESS TO ITS FOUNDATION. ONCE THE PRESS WAS SET, THE GOLDHOFER WAS REMOVED.


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The MOCCS configuration had to be changed from single

to double beam during the removal of the exchangers.

Portions of the existing concrete saddle structure had to be

demoed due to the diameter of the exchanger head.

Once the exchangers were removed, they were placed

onto a trailer. Barnhart had provided the client with a five-

day schedule but the team was able to complete the project within

two days.

Barnhart used the MOCCS system with two riggers. With

the MOCCS, the counterweight moves along the beam

to balance the load. The gear box and counterweight are remote

controlled, which reduces crane operator risk.

During an outage at a Texas refinery, Barnhart was asked

to provide rigging systems and crew to remove and replace

four heat exchangers. The exchangers ranged in weight from

11,000-12,500 pounds and were up to 19 feet long. Barnhart

proposed using their Moving Counterweight Cantilever System

(MOCCS), which is designed to make cantilevered operations more

efficient and easier to perform.


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Barnhart’s engineering team developed a solution using

the Barnhart pull-up gantries, which also included a steel

and wood crane matting to minimize the ground bearing so that

it would not exceed the 2,700 psf site requirements. A custom

header beam had to be designed and fabricated to allow two

gantries to equally share the load while having proper bearing on

the riveted support girder.

The biggest challenge on the project was that the creek bed had continuous flowing water when it was time to shore the

bridge. In order to manage the water, Barnhart built a temporary creek diversion to divert the water around the gantry shoring at

each span. Barnhart also performed site grading to allow for access in the creek bed and to establish a level, compacted surface for the

setup of the gantries.

In the end, the RPV traveled safely over the structure as the pull-up gantries worked as planned to assure the bridge

maintained structural integrity. The creek bed was returned to its previous water flow, satisfying all environmental concerns.

The job was completed on schedule without incident.

Barnhart was hired by a nuclear client in California to come

up with a solution to move a Reactor Pressure Vessel (RPV)

from a decommissioned nuclear plant. The RPV weighed 1,365,000

pounds and needed to be transported via railroad out of Southern

California. However, extensive railroad bridge analysis of the route

found that the triple span bridge over San Juan Creek would be

overstressed when the RPV traveled over it. Barnhart was enlisted

to help solve the problem.


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There was limited space in the alley, so the 150-ton

hydraulic crane was carefully maneuvered into place. The

chamber was successfully lifted using the crane.

The chamber was loaded onto an over-the-road trailer

provided by the manufacturer for transport. The process will

be repeated in reverse for the reinstallation of the chamber.

Using those skates and a steerable dolly, they moved the

chamber to the door, which faced a narrow alleyway.

At a naval station in Connecticut, Barnhart was hired to

remove a 20,000-pound hyperbaric chamber, which would

be refurbished and eventually replaced. The crew used toe jacks to

raise the chamber, then slid skates underneath.


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The autoclaves were hauled approximately two miles to a

manufacturing site. All utilities showed up several hours

before the haul was scheduled to begin prepping the haul route.

The 31’ tall convoy required moving numerous electrical and

communication lines along the route. Most of the electrical

lines had to be de-energized and dropped. Two sets of electrical

transmission lines also had to be de-energized and grounded due to

the load’s height. A railroad cantilever signal also had to be removed.

Due to a well-coordinated effort, the haul was completed in a little

over an hour.

The two autoclaves were unloaded with two 500-ton

cranes via a two crane lift in one day. They were loaded

onto two 12 Line PST Goldhofers for transport.

Barnhart was hired to receive two 397,000-pound autoclaves

from a ship in New Orleans. The equipment was then barged

to its final destination in Memphis, Tennessee.

THE TWO AUTOCLAVES WERE UNLOADED WITH TWO 500-TON CRANES VIA A TWO CRANE LIFT IN ONE DAY. THEY WERE LOADED ONTO TWO 12 LINE PST GOLDHOFERS FOR TRANSPORT.


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The prefabricated bridge sections were removed from a waiting truck. Barnhart’s operator controlled the MOCCS remotely. The

counterweight system on the MOCCS moved along the beam to balance the load.

Barnhart’s MOCCS operator worked in conjunction

with the project superintendent and crane operator to

position the girders in place. The steel will be part of a hinged

side walk that will become a new pedestrian and bicycle pathway

connecting the Lake Front Trail over the Chicago River.

The project involved several parties and planning went

smoothly. It was the first time that any of Barnhart’s

cantilever systems were used in the city limits of Chicago.

Barnhart was hired to provide its Mini MOCCS for the installation of prefabricated bridge sections to create a pedestrian sidewalk

under the Link Bridge in Chicago. The MOCCS was set up and suspended from a crane that was set up on the upper level of the

bridge. Traffic was diverted to allow for the operation.


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Once the critical lift method was confirmed, the crew got

started at the site. Barnhart crews used 50-ton jacks to

raise each heater to install a 100T Lite Slide Track System. The

heaters were skidded about four feet and jacked up to transition

from the slide track to the powered saddle rollers equipped

with custom bolster plates for transport to the equipment

hatch. Then the heaters were lifted through the floor opening

of the equipment hatch to the turbine deck. Inclinometers were

monitored closely to confirm that the tipping angles did not

exceed 69 degrees.

The heaters were leveled back to a horizontal position

and the overhead crane transported each one to the truck

bay opening and lowered them to a Goldhofer trailer. The larger

replacement heaters were installed in reverse order. Barnhart

was recognized for their work on this complex project with the

Specialized Carriers and Rigging Association (SC&RA) Rigging Job

of the Year $750,000 to $2 million.

Due to the complexity of the project, the client required

a test mockup lift of Barnhart’s solution featuring the

custom designed 150-ton Tipstick with a moveable lifting point.

The mockup was performed at the Port of Memphis utilizing

Barnhart’s 1,250-ton derrick crane. A concrete-filled vessel with

additional counterweight weighing 125% of the load weight served

as a suitable component for the functional/load test of the Tipstick.

Then a 70’ scaffolding structure was erected to replicate the hatch

opening. Using the actual replacement Feedwater Heater, Barnhart

successfully executed the mockup lift through the hatch opening.

A nuclear power plant client in Georgia needed to remove

and replace its Alpha and Bravo 8th Stage Feedwater

Heaters that were located in the basement of a turbine generator

building. Although hidden in this picture, the circles represented

the heater’s location on the 112-foot elevation floor level. The area

was congested with columns, piping, conduit, and drains. The

heaters would need to travel in the direction of the arrow in order

to be lifted up through the equipment hatch opening to the 164-foot

elevation turbine deck. There, they would need to be tipped at an

angle to clear the hatch opening. This angle could not exceed 69

degrees due to OEM warranty restrictions.


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Barnhart’s newest branch is the result of a purchase of

Days Machinery Movers from a respected and established

Midwest company, Days Corporation. This includes all

associated personnel and equipment of that business unit.

The company will be rebranded and will be added to the

roster of Barnhart’s Midwest branches.

“For Barnhart, this branch fills the gap between our Canton,

Monroe, and Chicago branches,” said Barnhart Regional

Director Jim Chapman. “For current Days Machinery Movers

customers, this acquisition will bring an expansion of

services and equipment to help better meet their needs.”

Barnhart’s new Elkhart branch offers rigging, including machine

installation and leveling, as well as equipment storage.

ELKHART, INDIANABARNHART ’S NEW ELKHART BRANCH OFFERS R IGG ING , INCLUD ING MACH INE INSTALLAT ION AND LEVEL ING AS

WELL AS EQU IPMENT STORAGE .

Equipment setting, which includes anchoring, alignment

and grouting, and millwright work, is offered. Fabrication,

ironworking, and plant reorganization and relocation are also

among its services.

The branch’s stable of equipment includes flat bed, step

deck, and double-drop trailers and a 450-ton gantry system.

Forklifts of up to 80,000-pound capacity, and Versa-Lift and

TriLifter specialty lifts are also a part of the inventory.

The acquisition will further enhance Barnhart’s presence in

the Midwest, where the company already operates several

branches in Indiana, Illinois, Iowa, Nebraska, Michigan, and Ohio.

Barnhart has a network of more than 50 branches across the

United States.


BRANCH PROFILE

The Elkhart team uses a J&R Engineering 450-ton Lift and Lock hydraulic gantry to move a transformer from a trailer to a foundation.

An 80,000 pound Rigger Special lift truck and 75-ton TriLifter move bridge beams to a temporary storage site.


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Combined with Barnhart’s 200TN Jack housing and cylinder, the Powered Gantry Base is an ideal solution for setting electrical control buildings.

Barnhart used pull-up gantries and powered bases to provide a compact solution to lift and set two railroad bridge pieces in New York.


EQUIPMENT PROFILE

One of Barnhart’s most innovative tools is one of its

smallest. Standing at just 1’ tall and measuring a compact 4’

wide by 7’ long, Barnhart’s Powered Gantry Bases provide a

high capacity option when minimum headroom is required.

The Powered Gantry Bases are comprised of a rigid steel

box exterior that houses four high-strength steel wheels.

Each base is equipped with a hydraulic motor and drive

shaft that provide the needed power for fluid and efficient

movement. Each base is then set to a wheelbase dimension

that allows it to run on all standard Barnhart gantry tracks or

leveled steel plates.

This versatile tool can be used in conjunction with several

other Barnhart tools to provide a custom solution for our

clients’ lifting and transport needs. With a capacity of 200

tons per base, this system can be combined with many of

Barnhart’s custom jacking tools to provide both vertical and

longitudinal movement. At a width of four feet, the system

can fit between building columns, down narrow corridors,

and minimize the overall impact to a worksite. Its internal

hydraulic motor is powered via a standard Barnhart pump

and requires no connection to the site’s electrical grid.

POWERED GANTRY BASESBARNHART ’S H IGH CAPAC ITY MODULAR GANTRY (HCMG) I S A UN IQUE L I FT ING SYSTEM DEVELOPED AS AN

ALTERNAT IVE TO TRAD IT IONAL HEAVY L I FT CRANES .

• DECATUR, AL | FULL SERVICE

• GADSDEN, AL | FULL SERVICE

• MOBILE, AL | FULL SERVICE

• BLYTHEVILLE, AR | FULL SERVICE

• LITTLE ROCK, AR | FULL SERVICE

• PHOENIX, AZ | RIGGING & TRANSPORT

• LONG BEACH, CA | RIGGING & TRANSPORT

• MIDDLETOWN, CT | FULL SERVICE

• AMES, IA | FULL SERVICE

• CEDAR RAPIDS, IA | FULL SERVICE

• DES MOINES, IA | FULL SERVICE

• MASON CITY, IA | FULL SERVICE

• CHICAGO, IL | RIGGING & TRANSPORT

• EAST MOLINE, IL | FULL SERVICE

• LADD, IL | FULL SERVICE

• ELKHART, IN | FULL SERVICE

• FOWLER, IN | FULL SERVICE

• CALVERT CITY, KY | FULL SERVICE

• OWENSBORO, KY | RIGGING & TRANSPORT

• BATON ROUGE, LA | FULL SERVICE

• SHREVEPORT, LA | FULL SERVICE

• WEST MONROE, LA | FULL SERVICE

• MONROE, MI | RIGGING & TRANSPORT

• JACKSON, MS | FULL SERVICE

• LINCOLN, NE | FULL SERVICE

• OMAHA, NE | FULL SERVICE

• SOUTH SIOUX CITY, NE | FULL SERVICE

• OKLAHOMA CITY, OK | FULL SERVICE

• CANTON, OH | FULL SERVICE

• PORTLAND, OR | FULL SERVICE

• PHILADELPHIA, PA | RIGGING & TRANSPORT

• CHARLESTON, SC | RIGGING & TRANSPORT

• SIOUX FALLS, SD | FULL SERVICE

• CHATTANOOGA, TN | FULL SERVICE

• KINGSPORT, TN | FULL SERVICE

• KNOXVILLE, TN | FULL SERVICE

• MEMPHIS, TN | FULL SERVICE, SERVICE

CENTER, HEAVY LIFT TERMINAL

• HOUSTON, TX | RIGGING & TRANSPORT

• HAMPTON, VA | FULL SERVICE

• KENT, WA | FULL SERVICE

• MT. VERNON, WA | FULL SERVICE

• RICHLAND, WA | RIGGING & TRANSPORT

• SPOKANE VALLEY, WA | FULL SERVICE

ALTERNATIVE HEAVY LIFT• MODULAR LIFTING TOWER

• PULL-UP GANTRY

• HYDRAULIC SLIDE SYSTEM

• JACKS & RAMS

• 4-POINT GANTRY SYSTEM

• STRAND JACKS

• MODULAR HOISTS

TRANSPORTATION SYSTEMS• DUAL LANE TRANSPORTERS

• GOLDHOFER PSTE

• HYDRAULIC DOLLY SYSTEMS

• BARGING

• RAMPS AND TEMPORARY BRIDGES

MARINE HEAVY LIFT• DERRICK CRANE – MISSISSIPPI RIVER

• BARGE CRANE – GULF COAST

• BARGE CRANE – GREAT LAKES

• HEAVY LIFT TERMINAL – GREAT LAKES

• HEAVY LIFT CRANE – HOUSTON

TELESCOPIC BOOM CRANES• FROM 7 TONS TO 650 TONS

LATTICE BOOM CRANES• CRAWLERS FROM 100 TO 1800 TONS

• TRUCK CRANES FROM 115 TO 800 TONS

• RINGER CRANES FROM 360 TO 1,800 TONS

OPERATED CRANE SERVICE• OVER 450 CRANES

• LATTICE BOOM TO 1,760 TONS

• TELESCOPIC BOOM TO 600 TONS

• FULL TURNAROUND SERVICES

• NATIONWIDE NETWORK OF CRANE

BRANCHES

2163 Airways Blvd.Memphis, TN 38114

[email protected]

NATIONWIDE OFFICE LOCATIONS & FACILITIES

BARNHART EQUIPMENT

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