Stadium Construction Remains Brisk

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1 Fall 2008 N e w s & I n f o rmation from Hamilton Form Company Stadium Construction Remains Brisk Even in a slow economy there is still a number of stadium projects that are both underway and being planned. And that s good news for the precast industry, since most stadiums incorporate a significant number of precast concrete products. Two new projects to report on in this issue come from Minnesota, The Land of 10,000 Lakes. Hanson Structural Precast Midwest in Maple Grove, MN is supplying and installing the precast/prestressed components for the TCF Bank Stadium, home of the University of Minnesota Golden Gophers. The original plan actually called for steel, but was successfully converted by Hanson to precast structural components and precast risers. The precast conversion was so compelling that during initial production meetings, the General Contractor asked Hanson about also supplying precast pipe. Hanson Pipe and Precast in Apple Valley, MN was awarded that portion of the contract. Architectural precast is being supplied by Gage Brothers in Sioux Falls, SD. The stadium is located at the gateway of the University s Twin Cities Campus. It is an open air, horseshoe design with seating for 50,000. Hanson is producing and installing more than 4,600 precast pieces including columns, beams, stadia risers, stairs, walls, raker beams and spandrel panels. Hamilton Form Company supplied the forms. Self-stressing single rise stadia form with pivoting back pan. One of the forms that Hamilton Form built for the TCF Bank Stadium is a 50 foot self-stressing, single riser that casts the product upside down. The form includes a recess in the tread of the casting surface to accommodate a textured liner used to finish the walking surface of the riser. Fillers and bolt down rails were provided to cast additional products. The form included pivoting back pans that are hinged and can be easily lifted to speed up the stripping process. The back pan can also be hinged back to cast an L-shaped riser. (continued) Hanson Structural Precast is supplying more than 4,600 precast pieces for the University of Minnesota's TCF Bank Stadium.

2 Equipment Spotlight Hamilton Form Utility Machines Made to Order Mechanized production systems reduce labor, save time and help improve safety. Hamilton Form Utility/Casting Machines mechanize the precast/prestressed concrete production process. Although we have been building utility machines for over 30 years, no two machines are exactly alike, just as no two customers are exactly alike. Each utility machine we build is custom designed to meet the specific needs of the customer to make the production process more consistent, shorten set-up time, decrease production costs and help improve overall finished product quality. A utility machine can be designed to do just a few tasks or a number of different features can be added to make it even more versatile. Most machines include vibratory and oscillating screeds, but that s just the beginning. A utility machine can help reduce set up time by pulling strand and distributing mesh. Handling headers can be aided with the use of a header cart that stores and carries headers down the bed for placement. A jib crane can be added to place and pick-up headers. Other addons can include a spray and mop to apply form oil and can even include flat deck or stem cleaner brushes to clean the form before the next set-up. A utility/casting machine can automate many of your most difficult and labor intensive production processes. Most utility machines are built to service a particular bed. The machine can ride on the edge of the form or on a track next to the bed. Machines are normally operated from a platform where the operator has a good view of the operation. Controls are typically lever operated, but can be designed for remote operation. The photo above shows a four wheel drive Utility Casting Machine equipped with vibrating and oscillating screeds, jib crane and strand pulling legs that adjust for five-foot or six-foot stem spacing. A Tarp Roller with an insulated blanket, bows and bow rack is used behind the Utility Machine to cover the bed for curing. Consider the features that you want on your machine from our list, or let us know of any unique requests that you may have.once the functions of the machine are defined, the Hamilton Form engineering staff will design a utility machine to match your requirements. A Utility Machine is a versatile and practical investment that will help save time and money. Below are a few of the options that you can consider when designing a custom machine to mechanize and improve your operations. Vibratory screed for consolidating concrete Oscillating screed for concrete finishing On board air compressor to operate pneumatic vibrators Hydraulic vibrators can be used to eliminate the need for air Product header cart to place headers along the bed Jib crane to lift and position product headers or depressor beams A deck to store and distribute mesh Stem or deck cleaner attachment Attachment for pulling strands Power take-off and valve for strand depressor tool Tarp roller/dispenser attachment Form oil spray and mop system

3 Project Spotlight Stadium Construction (continued) A thin brick column supplied by Gage Brothers for the TCF Bank Stadium. Same Duo for the Twins Hanson and Gage Brothers are also supplying precast products for the new Minnesota Twins ballpark in downtown Minneapolis. Hanson was awarded the structural contract and will produce and install more than 2,800 pieces for this project. The structural contract includes columns, beams, wall panels, raker beams, stadia risers, double tees and hollow core. To design the forms for the project, Hamilton Form worked closely with CEG and Mike Lewis, Production Manager of Hanson. As in most stadium projects, the goal is to design forms that can be adapted for a number of different cross sections and can be built economically. One example is the design of the tub forms that cast the walkway sections. THESE STRAND WERE MOVED TO A LOWER POSITION TO REDUCE COST OF JACKING END. Gage Brothers is also supplying approximately 1,000 pieces of locally mined Quarry Creek Vetter Stone clad precast panels for the exterior skin on the Twins Stadium. REMOVABLE BLOCKOUT FOR SLOPING DRAIN. Tub form with sloping drain detail Pivoting single stadia form Each section includes a 6 x 6 sloping drain that shifts position from section to section relative to the center of the product. Tub forms were built at a sufficient length to allow the headers to shift position to accommodate different drain locations. The form also included block-outs made in sections to make them lighter and easier to reposition as needed. On the same form, Hamilton Form worked with CEG to relocate 2 strand positions to eliminate the need for extra plate material at the top of the form. CEG was able to accommodate this change, reducing the cost of the form. Attention to detail and small adjustments in the form design added up to significant labor and material savings. The collaborative process used to design the forms for these stadiums illustrates the importance and the value of experience and teamwork when working on a project. The Big Chill You can t count on global warming to help cure your concrete this winter, but you can count on an Insulated Curing Blanket from Hamilton Form. Capture the heat of hydration and protect concrete from the environment with an energy free insulated blanket. Weather Alert: Numb s the Word According to the Farmers Almanac at least two-thirds of the country can expect colderthan-average temperatures this winter. The almanac also predicts above-normal snowfall for the Midwest, and abovenormal precipitation for the South while the Northeast and Mid-Atlantic regions will likely be unusually wet and snowy. Just like our forms, Hamilton Form s insulated blankets are custom made to fit your needs. Adhesive bonding and heat-weld joining of sections make it possible to make blankets of virtually any length and width. Our blankets are made with closed cell insulation to eliminate gaps and absorption of water. The insulation can t tear loose, shift or bunch up. And, our riveted D-ring tie downs are stronger and won t tear like grommets. Now is a great time to order a new blanket in time for the winter chill. For a durable, high quality, custom made curing blanket or tarp, your specifications to sales@hamiltonform.com or call

4 Technically Speaking Maintaining Hydraulic Systems A proactive maintenance program is required to maximize service life and minimize operating costs of hydraulic systems such as those used in Tarp Carts, Utility Machines, Hydraulic Form Opening Systems and Stressing Jacks. A regular maintenance program takes discipline and an investment in time and effort, but can be very cost-effective. The investment is quickly recovered through increased component life, better machine performance and less downtime. The most important element of a good maintenance program is a systematic filter maintenance program. Clogged filters are at the root of many hydraulic system failures. In fact, more than 85% of hydraulic system failures are caused by clogged filters. Concrete plants need to be especially diligent when it comes to changing filters because concrete plants generate a great amount of dust. Especially harmful is fine particle dust. Each particle acts as a grinding compound, causing wear as it passes through the pump, valves, cylinders and motor. Filters help protect your hydraulic systems from wear by helping to trap these contaminants; but, the filters need to be clean to work. Just because the oil is re-circulated in a closed loop system doesn t mean that it is dirt proof. Contaminants can enter hydraulic systems through seals and through reservoir breather caps when the system is opened for maintenance and repairs. If you suspect that contaminants are present in the oil, the oil can be sampled and sent to a lab for testing. Contact your local hydraulics supplier for an oil sampling kit so that you can have your oil tested. In order for your hydraulic system to perform properly, here are a few routines that should be consistently followed. The hydraulic oil filter cartridge should be changed after the first 30 days of operation and at subsequent 500 hour intervals, but not less than every 365 days. Inspect filter elements that have been removed from the system for signs of failure that may indicate the need to shorten the service interval and the possibility of other system problems. When checking the oil tank filter, open one of the drain plugs to check for water. Be sure to drain all water present in the tank. If more than a few ounces of water are present, switch to a hydroscopic (water absorbing) filter element. Replenish oil in the tank as recommended by the manufacturer. Most equipment built by Hamilton Form Company will use DEXTRON III ATF fluid. Use clean containers, hoses and funnels when filling the reservoir. Make sure that all clean-out holes, filler caps, and breather cap filters on the reservoir are properly fastened. Always keep the supply of fresh fluid covered tightly. The hydraulic tank breather also contains a 10U filter. This is a disposable type filter and should be replaced annually in a concrete dust environment. Maintain proper hydraulics system settings. Refer to your owner s manual for the proper values. Do not use the system unless all normally provided filtration devices are in place. CAUTION Never Operate a Tarp Cart or Utility Machine When Either the Warning Horn or Flashing Light is Not Operating! Check that both of these safety warning systems are working before every use.

5 Productivity Place None of us is as smart as all of us. Ken Blanchard The success of a process improvement project is largely dependent on the ability of a team coming together and working cooperatively toward a common goal or objective. In order for a team to succeed, individuals need to learn how to be a team player. This is often difficult because human beings by nature are fiercely independent animals, with their own opinions and their own independent way of doing things. From an early age we have been taught to be competitive, opinionated and independent in order to succeed. But, times are changing. Teamwork is rapidly becoming one of the most important traits to develop to assure success in business today. A national workplace survey recently reported that Americans believe that being a team player is the most important factor in getting ahead. It ranked higher than merit and performance, leadership skills, intelligence, making money for the organization, and long hours. It is essential for the success of any organization, big or small, to hone the skills of its employees to be better team players. Many objectives in business today cannot be obtained by individuals working independently. Work teams and process improvement teams, by definition, require team efforts. Many companies have acknowledged the importance of teamwork by changing the title of supervisor and manager to team leader. Individual commitment to a group effort - that is what makes a team work, a company work, a society work, a civilization work. -Vince Lombardi Communication: good communicators can express their ideas and are direct and honest Respect: treat others with respect and support their ideas Participation: team players are not passive observers, they volunteer, take initiative Cooperation: teams need to cooperate and be supportive; work with, not against each other Reliability: be dependable, deliver on your promises, meet deadlines Flexibility: roll with the punches, accept change, don t argue a point to death, learn to move on Commitment: a team can t function without the loyalty and dedication of its members The Reward Factor The following chart is based on an internet survey that ranked the most important factors to team success. Shared values and trust rank highest, while rewards factor very little in team success. Gettin' good players is easy. Gettin' 'em to play together is the hard part. -Casey Stengel Qualities of a Team Player What qualities make a good team player? A team player learns to put personal aspirations aside in order to work in a coordinated manner toward a common goal. The most important trait of a good team player is the ability to work cooperatively with others. That ability comes from a number of factors that can be developed and practiced. Some of them include: Listening: a good team player knows how to listen and understand other points of view Teamwork is the ability to work together toward a common vision. The ability to direct individual accomplishment toward organizational objectives. It is the fuel that allows common people to attain uncommon results. -Andrew Carnegie

6 News Employee Profile Convention The PCI Annual Convention will be in Orlando the first week of October. Stop by and see us at booth 413. James Whaley Estimator/Drafter Jimbo, as he s known around the office is the go to guy for the Sales and Engineering Departments. He estimates forms for sales, does drafting for the engineering department, releases jobs for production and is a quick draw artist at locating and pulling drawings from the archives. He s a jack of all trades that makes everyone s job easier. One of the things James enjoys most about his job is the fact that he works with different departments and is often involved in a project from estimating through production and shipping. He s been with Hamilton Form for eight years. Don t forget to pick up the brand new 6th Edition of the Handy Epicurean Cookbook, along with a special gift from your friends at Hamilton Form. If you are not going to the convention feel free to call us or us at recipes@ hamiltonform.com and we will send you a cookbook. James is married to Brigette, a 7th grade math teacher and has a 12 year old son, Bo. The Whaley family are all avid readers. Mention one of the latest best sellers and you ll find that James, Brigette and Bo have read it, discussed it and are eager to share their impressions of the book within days of going on sale. They also enjoy travelling. One of James favorite places is Colorado where he enjoys hiking and fishing. FORWARDING AND ADDRESS CORRECTION REQUESTED