Mason Responses to Customer Quality Audit Questions
(Compiled from completed customer questionnaires)
We have custom fabricated over 7,000 shell & tube heat exchangers, ASME pressure vessels and a variety of tanks in over 5,500 unique jobs.
Each year, 67% of our production is dedicated to the fabrication of custom shell & tube heat exchangers. The remaining production is primarily in ASME Pressure Vessels with tanks filling out the remainder of our capacity.
Common fabrication materials include 316, 304, 2205, C276, 904, 200 Nickel, and Carbon Steel.
50,000 sq. ft. in two fabrication buildings
3,200 sq. ft. office building
5 acres fenced and secure
(1) 25 ton, (1) 20 ton, (3) 10 ton, (5) 5 ton, (2) 2 ton
42 feet under crane
26’ wide X 30’ tall
Maximum length – 120 ft.
Maximum diameter – 24 ft. 4 in.
Maximum weight – 160 tons
(30) Sets (10 ton to 150 ton)
Road – Limitation 120’, Diameter 15’-6”, Weight 135 Tons
Rail – Adjacent to rail yard, within 5 miles of Midwest Inland Port Railway Hub
Plate Roll – 1.25” x 10’ Bertsch; 3/8” x 5’ Webb; Subcontract to 3” thick
Press Brake – 600 ton 14’ bed
Burn Table – CNC BurnTable 10’ x 50’ MG
Shear – ½” x 12’ Niagra
Flame cutters (9) to 6” CS
Plasma cutters (6) to 2” SS
Alloys are received, stored and segregated from iron steels through fabrication process. Fabrication work stations are segregated and partitioned with segregation screens. Tools, especially grinding wheels, are coded and dedicated to specific type of steel. Shared equipment, like plate rolls, are brushed and cleaned with zylene between each material change over. Completed stainless vessels are passivated.
Yes. We provide SA, SB & SFA materials with MTR’s
Yes. Conformance to ASME Sec. VIII, Division 1
Yes. R stamp.
Yes. Engineering is staffed with degreed mechanical and chemical engineers
Mechanical Engineering – PV Elite, API 620/650; TEMA, ASME SEC VIII, Div. 1 Thermal Sizing – Aspen Tech.,
Yes. Per ASME Code, our formal Quality Control System is documented in our Quality Control Manual and is independently audited every three years.
Yes. Our Quality Control Manager reports directly to the Company President.
Yes. Copies are available under controlled distribution.
Yes. Projects are tracked from inception with receipt of an RFQ through receipt of purchase order, design & drawing approval, long lead materials ordering, machining, bundle insertion, hydro-test, inspection points, complete fabrication, paint if required, shipping. Delivery dates are quoted in “weeks after receipt of approved drawings” – (ARAD). Customers and/or their quality inspector agents are notified in advance of dates for requested hold points. Logistics coordinates shipping and delivery with customer needs and timing. Communication is ongoing throughout entire process through our Inside Sales single point of contact or directly with specific company staff. Customers and their agents are welcome to visit our facility to inspect or discuss their projects.
Yes. Material is tracked and recorded through entire process. Information is filed in permanent job files.
Yes. Procurement is managed by an experienced Purchasing Manager utilizing purchasing management tools within an integrated software system.
Our material receiving manager confirms and documents receipt of purchased materials including receipt of supporting MTR documentation for formal tracking of all materials used in a project.
Yes. Designated parking, desk, phone, computer with access to Wi-Fi and conference room available.
Due to the almost limitless machining capabilities available locally, we subcontract most our machining resulting in accelerated deliveries and very competitive pricing for our final products.
Painting is done in a partitioned area in our shop normally during our 2nd shift.
We have demonstrated ability to handle 320,000 lbs, although this is beyond our cranes.
We use up to 500 ton auxiliary lift capability when needed.
As a custom fabricator, this time will vary based on each individual job quoted and customer needs. Typical lead times range from 8-16 weeks after receipt of approved drawings.
Heads, 5 weeks
Plate, 1 week
Pipe, 1 week
Flanges, 1 week
Tubes, 5 weeks
Tube Sheet Material, 1 week
14,000 to 16,000 hours per quarter with ability to increase second shift by an incremental 5,200 hours.
Yes. Mason does repair heat exchangers and pressure vessels in house. Mason requires that customers ship units that are clean and dry with Safety Data Sheets (formerly MSDS sheets).