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plate crack

  • 1.  plate crack

    Posted 04-15-2015 00:18
    Hi Folks,

    I'd like to get some advice. I stood up to tune the top section of this Steinway S located in one of our practice rooms. First thing I noticed was this crack. This piano is tuned about every 6 weeks and the last tuning was a tiny pitch lowering of 1-2c to A-440. The area around this crack was 10c flat or so and I thought it was off a bit more than it should be but didn't think too much about it until I saw the crack.This must be brand new in the last week because I would have gotten some complaints. Should I take the tension down immediately and put the piano out of commission until I can get it repaired?

    Oddly enough this piano is slated for an action rebuild and new bass strings this summer. I want to keep the piano, but I want to do this the right way so there is structural integrity. Is welding the strut the only option? I did not explore the crack more than to take pictures though it does look like it goes all the way through. 

    Thanks for your thoughts and advice.

    -------------------------------------------
    Alan McCoy
    Spokane WA
    ahm2352@gmail.com
    -------------------------------------------


  • 2.  RE: plate crack

    Registered Piano Technician
    Posted 04-15-2015 00:26
    Alan

    If, by tomorrow morning the crack is even a .5 mm bigger, I would immediately release tension and lock the room. You don't want to take a chance that the plate will explode with any one near that piano.

    -------------------------------------------
    Willem "Wim" Blees, RPT
    Mililani, HI 96789
    -------------------------------------------




  • 3.  RE: plate crack

    Registered Piano Technician
    Posted 04-15-2015 01:19
    Explode? Really? Like with parts flying around and stuff? A plate can really do that? Yow!

    -------------------------------------------
    Geoff Sykes, RPT
    Los Angeles CA
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  • 4.  RE: plate crack

    Registered Piano Technician
    Posted 04-15-2015 01:30

    I've heard it happening.
    -------------------------------------------
    Willem "Wim" Blees, RPT
    Mililani, HI 96789
    -------------------------------------------




  • 5.  RE: plate crack

    Posted 04-15-2015 06:42
    There are many Bechsteins out there with this type of crack. There is a M&H CC here that had a crack develop like this on the two treble struts. I welder simply drilled for two #12 or #14 self tapping sheet metal screws (ground flush) thru the center of the crack to lock the vertical offset in place. The cracks are on the block side of the capo. It's held fine since the mid '80's with no tuning problems. 
    -------------------------------------------
    Regards,

    Jon Page


  • 6.  RE: plate crack

    Registered Piano Technician
    Posted 04-15-2015 08:10
    I would carefully lower the tension with lid down and eye protection on.  This is not in the same category as other cases with a hairline crack in a plate.  Your example is the third Steinway S from the 40's that I'm aware of with this problem.  Here are photos from my case.  It was a 1947 Steinway S.  There must have been a problem in casting during this time. Not surprising considering retooling after WWII.

    This is something to consider next time you are raising pitch on a Model S from this era.


    -------------------------------------------
    Joyce Meekins
    Greenbelt MD
    -------------------------------------------



  • 7.  RE: plate crack

    Registered Piano Technician
    Posted 04-16-2015 11:54
    Literally, you heard it happen, or have you heard somewhere that it happened?  


    -------------------------------------------
    Virginia Bear
    Seattle WA
    425-765-3514
    -------------------------------------------




  • 8.  RE: plate crack

    Registered Piano Technician
    Posted 04-16-2015 13:29
    I had head somewhere that it happened.

    Wim Blees, RPT
    Mililani, HI 96789
    -------------------------------------------




  • 9.  RE: plate crack

    Posted 04-16-2015 13:44
    Believe it or not, I have actually heard somewhere, that the sky is falling  :-)

    Keith McGavern, RPT
    Shawnee, Oklahoma, USA
    http://www.cokptg.org



  • 10.  RE: plate crack

    Posted 04-17-2015 04:06
    Keith - you heard that from a Dutchman!   Michael  UK

    -------------------------------------------
    Michael Gamble
    semi retired
    Brighton
    01273813612
    -------------------------------------------




  • 11.  RE: plate crack

    Posted 04-16-2015 13:58
    Virginia,

    Moving on, I shall share a plate crack that I actually experienced, first hand. No explosion, however.

    Name of piano make, unimportant.

    Raised this grand piano to pitch, did a second pass. Left feeling good with my efforts.
     ... was called back couple of weeks later to say the piano was no longer in tune.
    Went there, it was out-of-tune as when I first went there, did another pitch raise and second pass, not understanding what happened at all.
     ... was later called back couple of weeks again to say the piano was, once again,  out of tune.

    It wasn't any different as the first visit, or second time visit. Looking closer to the plate, I did discover a crack. 

    Determined that the crack was gradually becoming larger.
    Advised customer that the piano was no longer useable.

    End of story. Looking back, I do appreciate that no explosion took place, as you can well imagine  :-)

    Keith McGavern, RPT
    Shawnee, Oklahoma, USA
    http://www.cokptg.org



  • 12.  RE: plate crack

    Posted 04-15-2015 13:45
    It's certainly possible, and has been reported, but...

    Yes, there is 18-20 tons, give or take, of string tension in modern
    pianos. Enough to lift the corner of your house, less than a quarter of
    an inch. The distance is the thing. It's the "power stroke", and the
    tension of the string goes down rapidly as it's end terminations move
    closer together. A loud BANG, and a substantial pitch drop accompanies a
    plate break that doesn't visibly move anything other than the crack you
    can see. There is now less stress on the crack, so further spontaneous
    demolition stops there unless a tech does repeated pitch raises
    wondering why the pitch remains low. Run away! That will eventually
    break something else, or extend the first break(s).

    So the plate implosion is unlikely, but it's possible for something to
    break loose and fly out of the piano doing damage elsewhere. Strings are
    another matter. Kids like to hang on the tail of the piano watching you
    tune. Don't let them do that. I've had bass strings break and fly out of
    the piano a good ten feet. But bass strings have the most mass and the
    highest elongation at tension of any other section in the piano.
    Ron N




  • 13.  RE: plate crack

    Registered Piano Technician
    Posted 04-15-2015 14:11
    Ron -
    I'd be interested in your or anyone else's opinion about why three Model S Steinways between 1946-47 would have the same pattern of cracks in plates.  I have never had this issue with any other Steinway, and wonder if it's an issue with casting or installation, and why does it take 60 years or more for it to break?  Your thoughts?

    Would you attempt to reinforce or weld, then continue to use such a plate?

    -------------------------------------------
    Joyce Meekins
    Greenbelt MD
    -------------------------------------------









  • 14.  RE: plate crack

    Posted 04-15-2015 14:47
    > Ron - I'd be interested in your or anyone else's opinion about why
    > three Model S Steinways between 1946-47 would have the same pattern
    > of cracks in plates. I have never had this issue with any other
    > Steinway, and wonder if it's an issue with casting or installation,
    > and why does it take 60 years or more for it to break? Your
    > thoughts?

    The scale alone indicates design problems with this piano, and since
    other models coming out of the same foundry through that period aren't
    showing the same plate breakage problems, I'd call it a design flaw,
    like the Bechstein. It could also be a build problem, but again, other
    models built under the same protocols don't to this. So I can't say with
    certainty precisely why it happens. In the end, it doesn't really
    matter, we'll never really know, there's no realistic way to avoid it
    happening, and the pianos for the most part did last through a realistic
    service lifetime before breaking plates, so it was a successful design
    in that regard.


    > Would you attempt to reinforce or weld, then continue to use such a
    > plate?

    I don't see why not. The failure isn't catastrophic, and I haven't heard
    that it progresses with time once it's broken. Appropriate disclaimers
    issued, and care in not abusing it in assembly, I think it's reasonable.
    Ron N




  • 15.  RE: plate crack

    Posted 04-15-2015 16:57
      |   view attached
    Thanks for the replies. I will be talking to a few more people who responded off list but at this point it seems likely that I will be destringing this puppy sooner rather than later. Then I will find a good welder and go the reinforcement/welding route.

    It is interesting that several other S's from this era exhibit the same problem in the same strut. The question though is what is it about the design of this model that is faulty, assuming that is the case. The string tensions and break points are high. See attached photo. A speaking length of 59 mm at C8 is 93 pounds tension, 280 pounds unison tension, and a ridiculous break %.  Pretty long. Maybe time to move the bridge to get the string length down to the 52-54 mm range.

    Should I add a brace in that area between rim and belly rail as well as plate work to remedy the issue? It would stiffen the belly rail, but would it help give structural support?

    Interesting problem.
    -------------------------------------------
    Alan McCoy
    Spokane WA
    ahm2352@gmail.com
    -------------------------------------------




  • 16.  RE: plate crack

    Posted 04-15-2015 18:28
      |   view attached
    >
    > It is interesting that several other S's from this era exhibit the
    > same problem in the same strut.

    A very good indication of a design fault, I'd say.


    > The question though is what is it
    > about the design of this model that is faulty, assuming that is the
    > case.

    I don't know. I've never had an S apart, and likely wouldn't know
    precisely even if I had. An FEA run would be interesting, to see where
    the stresses are if enough accurate measurements could be made.


    > The string tensions and break points are high. See attached
    > photo. A speaking length of 59 mm at C8 is 93 pounds tension, 280
    > pounds unison tension, and a ridiculous break %. Pretty long. Maybe
    > time to move the bridge to get the string length down to the 52-54 mm
    > range.

    If you intend to be able to pull the top half octave to pitch, moving
    the bridge is a very good plan. In doing this, you'll also reduce the
    overall tensions, and give the plate repair a better chance of long term
    success. Moving the entire bridge 6mm forward to a 53mm C-8, you'll
    decrease overall tension by over 1,000lbs. But then that's enough work
    to consider a board redesign and replacement. Alternately, scab the
    front of the bridge in the top section, trim the rear, and recap the
    section. It would be less work and damage than moving the entire bridge
    on the old board. It also gets the bridge footprint closer to the belly
    bar, which might be why it was put that far back in the first place, as
    an attempt to de-dink the compression crowned soundboard treble. Just
    try to keep the front footprint directly below the front pin row so you
    don't build in a cantilever with it's accompanying torque feature. Less
    desirable than redesign, but quicker, cheaper, and easier.

    Through the years, the Pianotek list(s) have gotten maybe a dozen posts
    asking how to get a restrung S&S S up to pitch in the treble without
    breaking strings. Unless higher tensile strength wire is available than
    we use in stringing pianos, shortening speaking lengths is the only
    answer, however accomplished.


    > Should I add a brace in that area between rim and belly rail as well
    > as plate work to remedy the issue? It would stiffen the belly rail,
    > but would it help give structural support?

    I've been thinking that very thing. The easiest approach there is with a
    socket head bolt in the belly bar, a corresponding socket cut in the
    plate, and a spacer/brace between the two. Samick does this in some of
    their pianos, and some years back, Ron Overs sent me a couple of the
    bolts he made and uses for the retrofit in his rebuilds, with a
    recommendation to try them. I used them in a Knabe player grand that had
    most of the belly bar cut away for a tubing pathway, and it worked
    beautifully to brace the belly bar. The photo is of the trial fit. The
    finished bar was better looking, but I still didn't get it aligned very
    well, as I didn't have a small right angle drill at the time to do it. I
    do now, but it's still an eyeball thing. As for bracing the plate, who
    knows, but it couldn't hoit, and the belly bar most certainly could
    stand bracing, so it's worth doing in any case.


    > Interesting problem.

    It is that, and doable. Keep us posted, please. I could use an
    interesting project, even as a bystander.
    Ron N




  • 17.  RE: plate crack

    Posted 04-16-2015 01:25
    The plot thickens. So does the strut.

    We have another Steinway S in the practice room next door. It was made in 1952. Attached are photos comparing the struts. Speaking lengths are still on the long side. But the 1952 top plate strut is a good bit more stout than the cracked strut in the 1946 piano. The cracked strut is about 10 mm thick at the top and the lower flare is about 30 mm wide. The 1952 strut is 15 mm wide at the top and flared out to 40 mm wide at the bottom.

    -------------------------------------------
    Alan McCoy
    Spokane WA
    ahm2352@gmail.com
    -------------------------------------------




  • 18.  RE: plate crack

    Posted 04-16-2015 17:04
    Appears to be a design thing all right.

    I've thought many times about the problems manufacturers face in
    launching a new product/model, or even a change. The computer analysis
    software available now makes some of the gotchas hopefully less
    disastrous, but there are still plenty of ways to get shot in the foot.
    Suppliers changing formulas or specifications, materials becoming
    unavailable, and less than stellar performance or outright disaster in
    the product. It might show immediately, or years later as the myriad
    commercials of lawyers chasing surgical implant and replacement parts
    victims illustrate daily. They MAY identify and eliminate the problem in
    production, but all those pre-fix units are still out there grinning at
    them and waiting...

    Ron N




  • 19.  RE: plate crack

    Registered Piano Technician
    Posted 04-18-2015 00:03
    I have never felt that welding was a good way to repair any portion of a plate that is under elliptical loading. I would investigate whether an overlay of mild steel could be bolted along the sides of the strut. Make the steel pieces with holes for machine screws and chamfered for flat head screws. Epoxy the pieces in place and after curing drill and tap the grey iron to take the screws. Use fairly small screws and stagger them so the opposing screws don't interfere with each other. You could make the reinforcing pieces taller and weld them together before installing to make a kind of U-shaped structure that covers the strut. That would increase the strength.

    I would wait to finish that portion of the plate until the strings are up to tension. Then I would fill and sand everything and then paint it. That way any slight movement will not crack the paint.

    With the S scales I have examined it is only the top 6 or 8 notes that are really too long.

    It is interesting that later S models had taller struts. I have come to the conclusion all the S, L, O and M scales could use a taller capo bar. They are too flexible.

    -------------------------------------------
    Edward McMorrow
    Edmonds WA
    425-299-3431
    -------------------------------------------




  • 20.  RE: plate crack

    Posted 04-18-2015 20:03
    Hey Alan, Here is an alternative to welding that works well. Cast iron welding is pretty tricky though some folks have success with it. http://www.locknstitch.com/ Best, DP ------------------------------------------- Dale Probst Registered Piano Technician Wichita Falls TX dale@wardprobst.com -------------------------------------------


  • 21.  RE: plate crack

    Registered Piano Technician
    Posted 04-18-2015 20:30
    I know of several people who have successfully used "locknstitch," and am considering it myself for a D with a crack at the proximal end of the low bass strut.

    -------------------------------------------
    Alan Eder, RPT
    Herb Alpert School of Music
    California Institute of the Arts
    Valencia, CA
    661.904.6483
    -------------------------------------------




  • 22.  RE: plate crack

    Posted 04-18-2015 20:42
    In a case of a plate that broke because of an apparent under design, I'd
    want something in addition to just locknstitching it back together.
    Ron N




  • 23.  RE: plate crack

    Registered Piano Technician
    Posted 04-18-2015 21:03
    Agreed.

    -------------------------------------------
    Alan Eder, RPT
    Herb Alpert School of Music
    California Institute of the Arts
    Valencia, CA
    661.904.6483
    -------------------------------------------




  • 24.  RE: plate crack

    Registered Piano Technician
    Posted 04-20-2015 00:15
    I would like to add to my description of how to repair a cracked strut with a bolted/epoxy-bonded reinforcement that the screw holes in the reinforcing piece should be sized the same as the portion in the plate. Then tap the holes for the screw threads after bonding the piece to the strut. This will lock the structure together better. It may even be best to use a "thread forming" tap rather than a cutting tap. But I would have to check this out with a machinist before I commit to it. I have recently learned a bit about the difference between cutting taps and thread forming taps. But I can't vouch for their suitability in grey iron.

    -------------------------------------------
    Edward McMorrow
    Edmonds WA
    425-299-3431
    -------------------------------------------




  • 25.  RE: plate crack

    Member
    Posted 03-27-2016 12:41

    The string length for the top note(s) on that "S" is quite long. I have seen that a great many times with the Steinway "S".

    ------------------------------
    Jeff Alterman
    Hastings-on-Hudson NY
    914-478-3454



  • 26.  RE: plate crack

    Registered Piano Technician
    Posted 03-27-2016 13:06
    Alan, I think you're going to find that's closer to 193 lbs of tension per string and just under 600 lbs per unison.

    The longest I've heard of on this model is 62 mm. A tuner called me a few years back -- he was trying to tune a Model S to pitch (from a half-step flat) and the top treble strings kept breaking. He'd replaced several of them twice. He was finding out why the tuner from the store tuned it flat.

    You'll have to recap the thing or move the bridge. You can get by with 55 - 56 mm but 54 is better.
     
    Del


    On Sun, Mar 27, 2016 at 9:41 AM, Jeff Alterman via Piano Technicians Guild



    --
    Delwin D Fandrich
    Piano Design & Manufacturing Consultant
    6939 Foothill Court SW, Olympia, Washington 98512 USA
    Email  ddfandrich@gmail.com
    Tel  360 515 0119  --  Cell  360 388 6525





  • 27.  RE: plate crack

    Member
    Posted 04-22-2015 20:42
    Plate Cracks can occur in almost any piano. There is a design issue in many Steinway "S" grands. The speaking length of the strings for the highest notes is too long. I'm sure many technicians out there have broken the string on the topmost note (or two) quite easily. The excess tension could contribute to a cracked plate. It might be possible to repair the plate in many cases.
     

    -------------------------------------------
    Jeff Alterman
    Hastings-on-Hudson NY
    914-478-3454
    -------------------------------------------




  • 28.  RE: plate crack

    Registered Piano Technician
    Posted 03-28-2016 01:55

    Alan: Have you seen pages 13-15 of the April 1981 PTG Journal for this? Taking it out to weld might be better but obviously more R&R.and maybe could be plan B unless lace spoils the area. 

    ------------------------------
    Paul Klaus