Form+Function NEWS & INFORMATION FROM HAMILTON FORM FALL 2015 Project Profile U-Beam for the MacArthur Interchange, New Orleans Gulf Coast Pre-Stress The form was partially self-stressing for strand at high and intermediate locations. Prestressed concrete bridges, roads and overpasses improve travel and help relieve congestion on many of the most heavily travelled highways across the USA. Across North America prestressed concrete is being used to build highways, bridges and overpasses. One such project is the MacArthur Interchange reconstruction near New Orleans. The MacArthur Interchange project is intended to alleviate traffic between Manhattan and Barataria boulevards, two of the most congested interchanges on Route US 90 near New Orleans. This part of the highway is important to the offshore petroleum industry, as it connects the cities of Lafayette and New Orleans to port cities along the coast. The shape of the void required the void to be made in sections that could be unbolted for stripping. Gulf Coast Pre-Stress, in Pass Christian, MS is a large producer of precastprestressed concrete structural components for the bridge, highway, marine and industrial markets. The company has been using formwork from Hamilton Form Company since its beginnings in 1967. Recently, Hamilton Form built a 72 U-Beam form for Gulf Coast that was needed for the MacArthur Interchange project. The base form was built as a one-piece, vessel type form, 155 in length. The form was designed for partial self-stressing to accommodate a light load at one high and two intermediate locations. The void configuration required the voids to collapse in order to strip the product from the form. Although a hydraulic option would have been possible, there was a small quantity of each beam to cast. As a result, Hamilton Form provided an option for voids built in sections that manually unbolt to dismantle the center core for stripping. To prove the functionality of the design, HF engineers built a small model. Gulf Coast opted for the manual solution. Vibrotrack was added to the side of the form.
Project Profile U-Beam for the MacArthur Interchange, New Orleans Gulf Coast Pre-Stress (continued) The project called for multiple void lengths at variable positions within the beam. Center voids were built at several different lengths that could be bolted together to create multiple assemblies ranging from 16 to 27-6 lengths. The end voids were built at 24 lengths with three 2 fillers that could be removed for different length end voids. Hangers used on the edge of the base form support the voids at any location. Hook style void hold downs are threaded and bolt in place to prevent uplift. The formwork included two-piece trapezoidal headers to create a dap at the end of the beam. The bottom of the beam is heavily stressed. Holes for placement of strand in this area were burned on a plasma cutter. The plasm allows for precise positioning of the holes that are clustered close together. This stressing area was handled by the customer s abutments. This is not the first U-Beam form Hamilton Form has built for Gulf Coast Pre-Stress. Gulf Coast purchased a U-Beam form with a hydraulically collapsible core several years ago. That form was designed for high volume production, therefore, a hydraulic solution was warranted to save time and labor. That form, along with the entire plant, was destroyed during hurricane Katrina ten years ago. Trapezoidal headers create daps at the end of the beams. The two different approaches to designing the void illustrate the fact that there are different solutions for similar products, depending on the project. The number of different product configurations, the quantity of each product, the adjustability required, production schedules and labor considerations need to be factored into every project. Working in collaboration with the customer and having this information early in the process helped determine the best solution for this project. Considering the complexities involved in the forming, the success we have had during production is because of all the forethought that went into form design. Andrew Levens, P.E. Chief Engineer Gulf Coast Pre-Stress, Inc.
Equipment News The brush/oiler machine s versatility has made our deck panel production more efficient by combining three functions into one perfect solution to reduce manpower needs while fitting into a tight production space. Dennis R. Fink Vice President Northeast Prestressed Products, LLC Precaster Gains Production Efficiency with Custom Utility Machines Hamilton Form has been designing and building custom production equipment for over thirty years. During that time, our Utility Machines have proven to reduce labor costs and improve efficiency. Mechanizing production processes can not only save labor costs, but also improve production quality. Most of the Utility Machines we build combine two or more functions and are designed specifically to match the needs of the individual precaster. Many machines we build include a vibratory screed for consolidating concrete. Screed vibrators can be either hydraulically or pneumatically driven. Another option is a knuckle boom jib crane which can be used to lift and position product bulkheads, strand depressor beams or strand tensioning jacks. We often include a deck that can be used to drop mesh down the bed. Some machines include a strand puller. A common combination is a brush system to clean the bed and sprayer to apply form oil or release agent. Recently, Hamilton Form designed and built a machine that combined three functions for Northeast Prestressed Products in Cressona, Pennsylvania. The machine was designed to service a flat casting table that was located in a tight space within the plant. It included both horizontal and side brushes to clean the bed. After the bed is cleaned, a sprayer attached to the back of the machine dispenses form oil. A strand puller attached to the front of the machine can pull multiple strands down the bed. Northeast Prestressed Products has significantly improved set-up time by using the machine to service the bed. The Utility Machine was especially valuable because it reduced the number of people working on and around the bed. If you re ready to improve production efficiency with a custom designed Utility Machine from Hamilton Form, contact us for more information: sales@hamiltonform.com or ask for sales at 817 590-2111.
Equipment Streamlining Production P re-pour processes are some of the most time consuming, labor intensive tasks in precast plants. Many of these tasks can be streamlined with custom built machines yet there is limited use of machinery used in bed set-up in precast plants. Mechanized production has several benefits beyond improved productivity. Machines can improve the quality, reliability and consistency of the process. Plus, using machines to free up production personnel to do other tasks, not only saves labor, but is also a better utilization of labor. TARP CARTS One of the most popular machines we build to improve productivity is the Hamilton Form Tarp Cart. In its simplest version, it is a cart with a reel that rolls on the edges of the form and dispenses and re-rolls curing covers. The cart has a gasoline engine, a hydraulically powered reel and hydraulically powered wheels. The Tarp Cart is operated by levers mounted on the side of the cart. Typically a single operator, walking next to the cart, can complete the task quickly and easily. The Tarp Cart can be designed to service any width and length bed. When not in use, the reel provides safe storage to protect your curing cover from damage. A Tarp Cart for a double tee bed typically has a bow rack to store bows that hold the cover above the concrete. MULTI-PURPOSE UTILITY MACHINES Hamilton Form Utility Machines can complete a number of tasks. Many of the machines we build are designed to do more than one task. Choices include brushes to clean the bed, a strand puller, oiler, jib crane and vibrating screeds. Utility Machines can be designed to do one or more tasks. Tarp Carts have a gasoline engine with hydraulically driven wheels and reel drive. DOUBLE TEE TARP CART To utilize a cart on a double tee form, we often include a deck and rack used to stack and store bows that attach to the edge of the form. The cover lays over the bows so the cover doesn t touch the concrete. MULTI-BED TARP CART One tarp roller we recently built was designed for use on three different pile forms; a 14 quad, 16 triple and an 18 dual pile form. This cart was made with flanged wheels that ride on the edge of the form. The wheels and wheel carriages were made adjustable to accommodate different width beds. CUSTOM SOLUTIONS As you think about the production process, think about using machinery to help improve production. From the simple to the complex, Hamilton Form has built Tarp Carts and other production equipment for many different applications. We have built Tarp Carts for girder beds, piling forms and double tees. We have built machines dedicated to one bed and machines that service multiple beds. Needless to say, each customer and each plant have unique needs that require unique solutions. When you are ready to discuss your needs to streamline production with custom built production equipment, contact us at sales@hamiltonform.com or call our sales department, 817 590-2111.
Technically Speaking TIP The best time to make a machinery purchase is when you are ordering new forms. Alot of planning goes into the purchase of new formwork, including the production process. As you plan the production process for your new forms, think about using machinery to help improve production. That way, the form and the machine can be designed to work together. The form can be designed to support the machine to ride on the edges of the form. Machines that ride on the edges of the form or in the Vibrotrack are typically the easiest to use, most economical to build and they use less space. Run outs installed at the ends of the form to store equipment can be provided and planned. Any clearances needed for the equipment can be planned in advance. Machines that run on the edge of the form work well in tight spaces. Monthly check that shims are in place and forms are still straight and level. Form Maintenance A t Hamilton form, we know forms are a big investment. We pride ourselves in the fact that we design and fabricate durable forms that are built to last for years. In fact, we ve seen many forms that were purchased and installed in the 1980s and even earlier that are still in service today. On the other hand, we ve seen forms that need to be repaired, refurbished or even scrapped in less than 10 years. The biggest difference in these two scenarios is in the way the forms are used and maintained. Most producers clean and oil their forms before each pour. Cleaning also includes keeping debris away from the outside of the form. Not only does it present a safety hazard, but concrete build-up around the form can hold moisture and promote rust and corrosion of the steel form. Stem fillers should also be removed and cleaned monthly. Don t let dirt and moisture accumulate under the fillers. While the fillers are out, clean and oil the leg of the tee or whatever casting area is under the fillers. In addition to keeping them clean, forms require regular maintenance. Regular maintenance includes: Checking that the form is straight and level. Make sure shims are in place. Check that lap plates, welds and connections are in good shape. Make sure clips and anchors are holding. Regularly clean debris, check connections and repair rust. Check the underside of the form for rust and corrosion. Rust should be removed and the form should be repainted as necessary. If your form has vibrators attached, check the vibrator mounts. Welds should be periodically checked anywhere vibration is attached to forms and repaired immediately. If your vibrators are mounted to Vibrotrack channels, make sure the channels are clean so the vibrator sled can move freely on the track. While you re checking the vibration mounts, it s also a good time to check your air supply connections and hoses for air leaks. Check all of your form s moving parts. Make sure hinges are greased or oiled and keep tracks clean and clear. Self-stressing forms require special attention: Inspect your abutments and anchorages. Check that jacking plates fit over the end of the form and bear evenly against the form. Remember as forms get older, they require more maintenance. Be diligent. Develop a regular maintenance schedule for your forms and you ll be rewarded with many years of reliable service.
Hamilton Form Company, Ltd 7009 Midway Road Fort Worth, Texas 76118 Ph 817.590.2111 Fx 817.595.1110 www.hamiltonform.com Employee Profile Vuong Nguyen Lean Man H amilton Form s production facility has a supervisor and a lead man in each department. The lead man in department one is Vuong Nguyen. This is the department that measures, cuts and bends steel for form production. The lead man executes all of the material layouts and makes sure dimensions are precise and accurate. This is a key role in production as the lead man makes sure materials move efficiently to the next department for fabrication. Vuong has proven to be dependable and detailed, successfully fulfilling his role as lead man in department one. Vuong escaped from Vietnam with his two brothers and came to the Dallas Fort Worth area in 1980. After arriving in Texas, Vuong attended a machine trade school where he learned about modern production including CNC machine operation. Vuong became an American citizen in 1991. He worked for another steel fabrication company before coming to Hamilton Form in 1997. Today, Vuong is married and has three teenage daughters. His wife works in the aerospace division of Parker Hannafin in Fort Worth. Vuong juggles work and raising three daughters with volunteer activities at his church. He is a Boy Scout leader, helping boys participate in camping and other outdoor activities. Although he wasn t born in Texas, Vuong has established roots here the evidence? He is an avid Longhorn and Cowboys fan!