At Industrial Sprockets & Gears, Inc., we not only have a comprehensive range of gear cutting equipment, we maintain a full fabrication shop capable of producing thrust rolls, tires, and trunnion rolls, among other components. Our team can design tooling to accommodate everything from small precision gears to large rolls that weight thousands of pounds.

This 7,500 lbs. 1045 steel tire is used in an industrial kiln used to produce asphalt and cement. The tire has an outer diameter of 96″, an inner diameter of 84″, and an 8″ face. Our team used a split stair step design on the face of the tire to create a strong fit in the moving parts. Milling the stair step design of the tire face required the design and fabrication of specialized tooling that was used in conjunction with a vertical lathe and horizontal boring mill. The stair step design required a precision fit, necessitating dimensional tolerances as tight as ±0.003″ be held at critical locations. A Pi Tape device was used to verify the dimensions of the tire at critical points to ensure the heavy duty tire would perform as desired when installed in the kiln.

We produced a single tire for this customer with delivery to the West Coast with a lead time of 6 to 8 weeks. The customer was not only happy to find a shop capable of cutting the part; they were impressed by the quality and speed with which we were able to complete the project. For additional information about this custom metal fabrication and machining project, see the table below, or contact us directly.


Product Name


Capabilities Applied/Processes

Primary: split tire
Secondary: special design/engineering

Equipment Used to Manufacture Part

VTL turning machine, horizontal boring mill

Overall Part Dimensions

8′ OD, 8″ face 7′ ID

Tightest Tolerances


Material Used


Material Finish

machine finish

In process testing/inspection performed

measurement with a PI tape

Estimated Part Weight

7500 lbs.

Industry for Use

Asphalt/cement kiln

Delivery Location

West coast, usa