CONCRETE PIPES AND MANHOLES

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1 Concrete Plant International AUGUST CONCRETE PIPES AND MANHOLES Automated flagship concrete pipe plant in Winter Haven, Florida SPECIAL PRINT CPI 08/04

Hanson Pipe & Precast, Winter Haven, FL 33881, U.S.A. Automated flagship concrete pipe plant in Winter Haven, Florida Hanson Pipe & Precast has over 100 facilities in North America.

Hanson consolidated three existing plants to form the largest pipe production plant in North America. Fig.

one of the largest companies in the concrete industry.

consolidation. This new facility produces products for ASTM C-76 storm drainage. ACT supplied the batching equipment and Hawkeye the automated pipe production equipment.

The state-of-the-art planetary mixers create a high sheer environment that ensures optimum cement dispersion, thoroughly coating the aggregate particles resulting in a high quality mix.

2 Hanson Pipe & Precast, Winter Haven, FL 33881, U.S.A. Automated flagship concrete pipe plant in Winter Haven, Florida Hanson Pipe & Precast has over 100 facilities in North America. Hanson, a division of Lehigh Hanson, is owned by HeidelbergCement, the fourth largest cement producer in the world. Hanson consolidated three existing plants to form the largest pipe production plant in North America. Fig. 1: The new pipe plant in Winter Haven, Florida, is the flagship in the Southeast region of Hanson Pipe & Precast With more than 8,000 employees in North America, Hanson Pipe and Precast represents one of the largest companies in the concrete industry. When planning for the new plant began in 2004, the size and automation of the plant was designed to address the issues of the decreasing labor force, improved quality and cost efficiency of the consolidation. This new facility produces products for ASTM C-76 storm drainage. ACT supplied the batching equipment and Hawkeye the automated pipe production equipment. Two HPGM 3750 Wiggert Planetary Countercurrent mixers each produce 3 cubic yards every 2.5 minutes continuously. The maximum output is 252 tons per hour. The state-of-the-art planetary mixers create a high sheer environment that ensures optimum cement dispersion, thoroughly coating the aggregate particles resulting in a high quality mix. The skip hoist is very efficient and works well in the space constraints. It also allows the next batch to be pre-weighted for maximum plant output efficiency. The PCS Control System communicated with the Hawkeye machine. When the Hawkeye hopper is low, concrete is automatically batch, mixed and delivered! At the end of the day, the mixer are cleaned with the automatic high-pressure mixer cleaning system, thereby further reducing labor and money. The cement silos are pneumatically charged from the cement bulker trucks; an environmentally friendly ground mounted dust collector captures dust particles and reclaims them into a hopper for dispersion into the silo. Batching and mixing plant ACT's aggregate star bunker storage system of the Winter Haven plant is the first of its kind in North America. This type of system allows for significant aggregate storage on a very small footprint, and the atomization minimizing labor. This type is system is common Europe. Inside, the four-bin aggregate compartments have a total capacity of 375 tons. Fig. 3a: Two HPGM 3750 Planetary Countercurrent mixers from ACT are serving two PipePro 96 machines from Hawkeye Fig. 2: The dual aggregate scraper aggregate material handling system will automatically recharge the inside aggregate bins at approximately 450 tons/hour. 2 CPI Concrete Plant International

3 Fig. 3b: For the Hanson crew, house keeping is a priority Fig. 4: Hawkeye PipePro 96 producing 6 at-a-time 24, 4 at-a-time 30 and 2 at-a-time 48 CPI Concrete Plant International

Fig. 5: Automatic offbearing 24 SixPak Fig. 7: Cured pipes are automatically removed from the moving floor system. Pallets and headers are removed simultaneously.

Precise load cell technology is employed to ensure accurate batching of the coarse and fine aggregates. The mix accuracy is critical in the production of superior quality pipe.

all completely handsfree. Each PipePro 96 machine produces 3 different pipe sizes or shapes at the same time. Up to 6 pipes at-a-time are produced in one multiform module.

The pipes are moved through two tunnel kilns using a steam curing system supplied by Kraft Engineering.

4 Fig. 5: Automatic offbearing 24 SixPak Fig. 7: Cured pipes are automatically removed from the moving floor system. Pallets and headers are removed simultaneously. Each of the five silos have a capacity of 189 tons. This is enough cement storage for approximately 4500 tones of pipe production. Precise load cell technology is employed to ensure accurate batching of the coarse and fine aggregates. The mix accuracy is critical in the production of superior quality pipe. Hydromat microwave technology is employed in both mixers to accurately and quickly determine moisture content in the raw materials, which allows for accurate dosing of water to hit the required mix consistency. Automated pipe production The factory is equipped with the latest Hawkeye state of the art technology including two (2) PipePro 96 machines producing from round pipe and elliptical pipe all completely handsfree. Each PipePro 96 machine produces 3 different pipe sizes or shapes at the same time. Up to 6 pipes at-a-time are produced in one multiform module. Each PipePro 96 is setup with an automatic off bearing machine to demold the pipe unto a fully automatically operated moving floor system. The pipes are moved through two tunnel kilns using a steam curing system supplied by Kraft Engineering. The automatic kiln car system moves the pipe from the curing kiln and positions the pipe to be automatically removed from the moving floor with a manipulator. The pipes are then positioned at a station where the pallet and header are automatically removed. This system uses headers that stay on the pipe through the curing process to insure perfectly round pipe joints for trouble free pipe assembly. The pipes are then automatically tipped to the horizontal position and deburred, vacuum tested and labeled with an inkjet printer. The pipes are then sorted by size as three different diameters of pipe are produced simultaneously. The pipes are then handled by a fork lift to be carried to the storage yard. Fig. 6: Automatic demolding of 4 30 pipes onto automatic moving floor system that transports pipes to curing chambers After the pallets and headers are removed from the pipe, they are automatically cleaned and placed into pallet and header inventory areas. They are then automatically taken from the storage area and fed to the PipePro 96 machines. The same automatic system produces and processes both round and elliptical pipes at 4 CPI Concrete Plant International

The location of the Winter Haven plant is central to 60 % of the total Florida population, which allows for economical shipping to most of Florida. Total plant investment was about $50 million.

We are proud of having the new flagship plant in this area and we are sure that Hanson Pipe & Precast will continue their growth constantly. FURTHER INFORMATION Fig.

The reinforcing cages are produced using automatic cage machines from MBK. The cages are placed onto the pallets by the PipePro 96 machine monitor and the fully automatic production of pipe commences.

Graces Mark 5 admixture are used. Hanson Pipe & Precast 1285 Lucerne Loop Road Winter Haven, FL 33881, USA T +1 863 2934549 info@hansonpipeandprecast.com www.hansonpipeandprecast.com Advanced ConcreteTechnologies, Inc.

5 The location of the Winter Haven plant is central to 60 % of the total Florida population, which allows for economical shipping to most of Florida. Total plant investment was about $50 million. Joan Blecha, president of Hanson Pipe & Precast s Southeast region, stated: The Winter Haven plant definitively provides a positive economic impact for the area. We are proud of having the new flagship plant in this area and we are sure that Hanson Pipe & Precast will continue their growth constantly. FURTHER INFORMATION Fig. 8: Automatic pipe tipping for all pipe sizes produced the same time. The system is capable of 24 hour per day production if desired. The reinforcing cages are produced using automatic cage machines from MBK. The cages are placed onto the pallets by the PipePro 96 machine monitor and the fully automatic production of pipe commences. Summary The Winter Haven plant used 45,000 tons of cement (is this daily weekly or what I don t know). The Number 89 limestone used in the production of the pipe is supplied by Rinker Materials. Graces Mark 5 admixture are used. Hanson Pipe & Precast 1285 Lucerne Loop Road Winter Haven, FL 33881, USA T info@hansonpipeandprecast.com Advanced ConcreteTechnologies, Inc. 300 Portsmouth Avenue Greenland, NH 03840, USA T F info@concretebiz.com The Hawkeye Group 506 S. Wapello St. Mediapolis, Iowa, USA T F info@hawkeye-pipe.com Fig. 9: Pallets sprayed with release agent and handled by robotics to transport them from cleaners to the inventory areas and to the PipePro 96 machine Fig. 10: Round and Elliptical pipe at Hanson are used for ASTM C-76 storm drainage CPI Concrete Plant International

CONCRETE PIPES AND MANHOLES

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