Variation on a Theme. Hydraulic Adjustable Inverted Tee

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1 Winter 2008 Variation on a Theme Over the years, Hamilton Form has built many different Inverted Tee forms. Forms today are being built with more options and adjustability than in the past. An adjustable form improves capability because it allows the precaster to cast several different products with the same form and delivers a better return on investment. In an industry where variation is more the norm than standardization, an adjustable form is a practical solution. Inverted Tees can be built self-stressing or non-self stressing, with roll back or hydraulic sideforms and with or without ledge block-outs. Hamilton Form can help design a Flexible Inverted Tee to allow you to cast a number of different products. With some forethought and planning a highly functional Inverted Tee Form can be designed and built that will increase the value of your investment. Please call us with your specific requirements and options you would like, including: Minimum and maximum base width Overall height Ledge positions Ledge width Overall length Stressing capacity Hydraulic Adjustable Inverted Tee The form pictured has an adjustable ledge height, beam height, beam width, and removable block-outs. The form can be adjusted to cast a wide variety of inverted tee configurations. The bottom flat table is self-stressing with a built-in jacking abutment. Multiple bolting locations are provided so that the 36 straight side forms can be moved to change the width of the base beam from 16 to 48. Hydraulic Adjustable Inverted Tee The package included an 8 x 24 ledge block-out that can be bolted at different heights. Risers can be added to change the overall height of the product; and the form opens hydraulically for stripping. 1. Form bolted for narrow base, with raised block-outs. 2. Form bolted for wide base, ledge block-outs 3. Form in open position. lowered with riser added.

2 Product News MACH External Vibrators Hamilton Form s Mach Series vibrators are pneumatic, high frequency, low amplitude vibrators designed to quickly and efficiently externally vibrate concrete in precast plants. The Mach vibrator has only three movable parts for trouble free performance with minimal maintenance. Three different mounting styles are available for portable or permanent types of application. Several different models are available. Mach vibrators are used with our High Energy vibratory screeds and are mounted on our Vibrotrack vibration system. See our web site: for complete details or call The High Energy vibratory screed provides a simple and economical method of vibrating concrete from the top. 2. Vibrotrack continuous vibration system has continuous tracks welded to the steel form. Vibrators are mounted to a base that rolls along the track. 3. A vibratory screed with Mach vibrators can also be incorporated into one of Hamilton Form s Utility/Casting machines.

3 Technically Speaking The Art of Vibrating Concrete in Steel Forms Vibration is used to consolidate concrete in steel forms to increase the concrete s compressive strength and strengthen the bond between concrete and rebar. Vibrators liquefy the mortar allowing entrapped air to escape and the mix to flow in the form. Removing excessive entrapped air benefits concrete by decreasing its permeability. Two common types of vibrators are used in precast plants: internal and external. Internal vibrators are typically hand-operated while external vibrators attach to the outside of the form. External vibration is designed to get the mechanical oscillations through the form skin and into the concrete. Hamilton Form designs many of its forms with our Vibrotrack Vibration System to provide external vibration. The Vibrotrack System has continuous track sections welded to the form. A vibrator base with Mach vibrator is positioned in the track. The base contains an air-loc air pad diaphragm. When compressed air is turned on, the pad inflates, locking the bracket in place, and simultaneously, starting the vibrator. Double Tee forms typically have Vibrotrack installed on both sides of the form. Steel forms that are tall are typically designed with Vibrotrack placed low on one side of the form and high on the other. Flat casting tables are usually built with 2 or 3 tracks, depending on the width of the table, welded to the underside. Concrete consolidation through vibration is part science and part art. Concrete slump, mix design, form design, concrete shape, mass and environmental factors are some of the variables that determine how much vibration is needed. The following are just a few tips and suggestions when using the Vibrotrack Vibration System. Vibration should follow the placement of the concrete in the form, staying back from the leading edge. Do not use vibrators to move concrete laterally in the form, which can cause flow lines. At a minimum, the concrete should be significantly above the vibration level and a good distance laterally. If more than one lift is being made to place the concrete in the form, vibrate the first lift, then vibrate the next lift to thoroughly blend the lifts together. Remember, when vibrating concrete in a steel form: Vibration should follow the placement of the concrete Do not use vibrators to move concrete laterally in the form Look for visual clues as to when vibration is complete Move the vibrator along the Vibrotrack so that vibration occurs in overlapping areas of influence If placing concrete in lifts, vibrate each pour to thoroughly blend the concrete together When in doubt, continue vibration, under-vibration can cause more harm than over-vibrating Never vibrate an empty form When applying vibration, watch the concrete to determine when it is properly vibrated. A few visual cues are when large air bubbles stop to escape and when the surface of the concrete takes on a gloss or sheen. This often takes 15 to 30 seconds, but may take longer depending on the shape and the mass of the concrete product. If in doubt, continue to vibrate. The dangers that can result from under-vibration are far greater than over-vibrating. When vibration in an area is complete, turn off the air supply to stop the vibrator and deflate the pad. N ow the vibrator is ready to be rolled to the next position on the track. Space the vibration positions so that the areas of influence overlap. You should be able to observe the area of influence, but a simple rule of thumb is every 3 to 4 feet along the form but should be adjusted as needed to achieve good results. Vibrators should not be operated directly across from each other. If so, they could synchronize and cancel out each other. Stagger the locations of the vibrators when vibrating. Never vibrate an empty form. Without concrete to absorb the vibration, the form, including angles and gussets, will absorb the energy causing welds to separate and the form to crack and fracture. Excessive vibration, or continued vibration in one spot can also weaken the form. Revibration is used to further consolidate concrete. Revibration is a second application of vibration after the form is filled, consolidated, and the concrete is given some time to set. Revibrating reliquefies the concrete and helps create a denser product, improving its strength, water tightness and further eliminating bug holes for a better finish. Like many of the processes used to produce precast concrete, vibration is part science and part art. The art is to apply vibration at the proper locations and length of time to produce the best results. Your experience of what works best in your particular plant will ultimately be the best guide. TIP: Ready to Rumble If a product is difficult to strip from the form, vibration can help. Turn the vibrator on for a brief rumble as the crane begins to lift the product to help break the bond between the form and the concrete.

4 Product News Insulated Curing Blankets An insulated curing blanket helps capture the heat of hydration to speed the curing process. There is no energy cost associated with using an insulated blanket. Curing blankets also protect concrete from the environment. Using insulated curing blankets is a good idea and a Hamilton Form curing blanket is a good choice. Just like our forms, Hamilton Form's insulated blankets are custom made. Our blankets are made with closed cell insulation to eliminate gaps and the absorption of water. The insulation can't tear loose, shift or bunch up. Protect Your Blanket Investment The easiest and most convenient method for rolling and unrolling a curing blanket is with a Hamilton Form Tarp Cart. The tarp cart can be operated by a single person, saving time and labor. The cart can be designed to roll on a track next to the form or on the edge of the form. A steerable tarp cart can be used on several beds in the plant. Another advantage of a Tarp Cart is that it provides a safe place to store your blanket when it's not in use. Adhesive bonding and heat-weld joining of sections makes it possible to make blankets of virtually any length and width. This bonded construction makes a very durable blanket. No sewing helps prevent leakage and seam unraveling. Hinged skirts can be incorporated to fit over the side of the form. Add riveted tie down rings to hold the blanket firmly in place. You won't find a better made, more durable custom curing cover or tarp. If you need a durable, high quality, custom made curing blanket or tarp, sales@hamiltonform.com or call Tarp carts quickly and easily roll and unroll blankets and provide a safe storage place for your blanket when it's not in use. Anatomy of a Better Built Blanket Riveted D ring tie-downs are up to four times stronger, won t tear out like grommets. Outer layers are strong, a b r a s i v e - r e s i s t a n t, v i nyl-covered fabric which makes for a longer lasting blanket. Continuous adhesive bonded construction for durability. No sewing means no leakage or seam unrav e l i n g.

5 Productivity Place Employee Involvement is Key in a Lean Organization The process of lean manufacturing is not just a matter of the type of tools and machinery a plant has; it s dependant on the personnel. The goal of lean manufacturing is to eliminate waste to improve cycle time and quality. Streamlining operations, automation and tools can help, but the real difference in a lean organization is the people. There is a perception that lean manufacturing puts a lot of pressure on people to perform. There is some truth to that belief, but at the same time, many people actually prefer to work in a lean manufacturing environment. One big advantage for workers in a lean organization is that they are a major part of the company s decision making process. In order to improve operations and prevent waste, employees are actively encouraged to make suggestions and take action. Who better understands how to eliminate waste, and improve a process than those that are directly involved in the day to day process? Employee involvement helps eliminate fear, stimulates new thinking and improves morale. Many people actually prefer to work in a lean manufacturing environment. Work cell concepts are commonly used to improve processes in a lean organization. When we speak of work cells it s more than just rearranging machinery, it s having a group of people work differently than they would if they were on a factory assembly line. In a lean organization workers are trained to do several tasks, making the system more flexible and giving employees more freedom and responsibility. Each worker in a lean manufacturing plant is a leader in their own area of expertise. In a lean organization you don t see a big hierarchical structure. Individuals are important to the entire structure and are empowered to make day to day decisions. This allows each employee, no matter what their role in the company, feel like a vital piece of the whole. In this type of environment people feel appreciated, are motivated and contribute even more. When it comes to lean organizations, no one piece is more important than another; they all have an important role to play. Everyone is part of the lean manufacturing system, no matter what department they work in. In this type of environment people feel appreciated, are motivated and contribute even more. There is no better way to create a sense of family and loyalty. Steppin' Out Need easy access to your Double Tee form? Hamilton Form devised a simple solution. These sliding steps make it easy to gain access to the top of the form. Pull the steps out when you need to reach the top, and simply slide them back in and out of the way when finished. The steps are painted so that it's easy to see where they're located. Next time you order a Double Tee, ask about adding access steps. Taylor Slate, Hamilton Form's Engineering Manager, designed a simple solution for a cumbersome problem.

6 News Employee Profile The Flat Deck Cleaner Saves Time and Improves Product Quality Hamilton Form's Flat Deck Cleaner machine has been completely redesigned with a powerful 24hp gasoline engine and variable speed control through a hydraulic drive train. Both the machine speed and the brush rotation speed can be adjusted. The machine is easy to operate and quickly and efficiently cleans steel and concrete flat deck surfaces. Since its introduction last summer, several of these machines have been shipped and are being used to help improve productivity in precast plants. Several more are in stock and ready to ship to help you improve your form cleaning operation. Please call Jonathan Daily for more information: MCPX Show This Fe b r u a ry Hamilton Form is at t e n d i n g the MCPX show. The show is from Fe b r u a ry 7-9 at the Colorado Convention Center in Denver. The show features e d u c ational sessions, plant tours, p r o d u c t d e m o n s t r ations and hundreds of exhibits filling over 200,000 square feet of exhibit space. Stop by booth 341 on the show floor and say hello to your friends from Hamilton Fo r m. Deanna Mansell Estimating and Sales At Hamilton Form, it s rare to find two projects that are ever the same, that s why estimating is so important. For example, we ve built thousands of Double Tee forms over the years and almost every one is different. In addition to the overall dimensions, the header design, stressing capacity, side forms or rail configurations, jacking plates and strand pattern, all affect the material and labor that goes into a form. That s why, to be fair to our customers, when a customer calls for a quote, we take the time to detail a project in order to provide an accurate quote and realistic time frame. Deanna Mansell has an excellent knowledge of form design and is detail oriented. T h at s what makes her a great estimat o r. Deanna has worked in sales at Hamilton Form for more than ten years. If you ever have a question about the status of your quote or project, she s a good one to go to. Deanna and her husband Tom have two children. Their son Tyler and daughter Sarah are both in college. Tom is an avid hunter and fisher; while Deanna prefers more artistic hobbies. She does stained glass, scrap booking, painting, gardening and a variety of arts and crafts for her family, friends and to help raise money for charity. Hamilton Form Company, Ltd 7009 Midway Road Fort Worth, Texas Ph Fx