NEWS & INFORMATION FROM HAMILTON FORM SPRING 2013

Form+Function

Between the girders, piling, stadia, double tees and casting tables that are the bulk of our work at Hamilton Form, every once in a while, a unique request comes our way. When it’s a form for a residential product, it’s unusual. When it’s a form for a residential roof, it’s really unusual.

Hamilton Form recently fabricated forms for a precast housing project, including forms for an insulated gable style roof. Two forms were designed, one for the gable end of the roof and a second form for the side sections.

For the gable end, two base forms were supplied. This allows the customer to set up the first form, cover and pour. While the concrete sets, a second base form is set up. Once the concrete in the first set up reaches preset, the top is removed and installed on the second base form to cast a second product. The top unbolts and lifts off the base in one piece. A slight draft was created in the shingled top to help strip the product. The base has a chamfer rail that creates a drip edge for water protection at the edges of the roof. Block outs were supplied to allow for gable end roof vents.

The side section of the roof is cast separately. Two sets of forms were supplied. In these two forms the shingles are cast down with a hanging back pan that fits over the base. The form casts a twelvefoot long product that is nine foot high. Provisions were made so that the two forms can be bolted together to make longer roof sections.

Recent storms have underscored the need for resilient housing. Total precast construction can meet that need. Through its formwork, Hamilton Form is proud to play a part in the delivery of safer, more resilient homes.

Formwork

Roof Forms for Resilient Housing Project

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Quality from the Start

igh quality products can be produced only from highquality raw materials. That’s true in concrete production,form production and almost any industry.

As one of the most discerning buyers of steel in the area,Hamilton Form is a demanding buyer. We only purchasesteel from ISO certified U.S. mills. Domestic steel is typicallybetter quality with tighter tolerances and a smoother finishthan imported material; plus U.S. materials are sometimesrequired for state and federal projects.

Incoming steel is checked for tolerance and overall qualitywhen it’s delivered to the plant. Only after passing ourquality control checks is material accepted and placed into inventory. On occasion we have to reject steel that falls short of our standards.

Tolerances are critical in fabricated long-line steel beds.While most steel fabricators work at 1/8” tolerance; ourtolerances are plus or minus 1/64”. Imagine a 500 foot bedmade up of 10 foot pieces, each out of tolerance by 1/32”.The result could be a variance of almost 2 inches over thelength of the bed. This example illustrates the importanceof maintaining strict control of tolerances in the productionof long line forms.

Before use, each piece of steel is cut or sheared to length and width at our factory. Here, equipment comes into play. Hydraulic shearing and CNC press brakes are used.Hamilton Form also uses high definition plasma cutters.Plasma cutting uses high velocity ionized gas to cutthrough steel. Our plasma machines cut intricate shapesand configurations in one process without distortion. These machines are extremely valuable in fabricating forms.

Raw materials and our cutting and shearing operations lay the foundation for keeping within our dimensionalstandards so that we can deliver high quality finished product to our customers.

Production

A Peek Inside Hamilton Form

Hydraulic shears are used to provide sheet and plate material that are dimensionally accurate for production.

Plasma cutters produce accurate and consistent intricate shapes and configurations.

Since 1966, Hamilton Form has been fabricating steel forms for the precast/prestressed concrete industry. Over the years, the industry has evolved and so has Hamilton Form. Equipment upgrades, vendor relations, improved processes and an experienced staff have all contributed to better efficiencies and increased capabilities. Take a peek inside Hamilton Form.

A flexible solution

Because we can’t predict the future,many customers don’twant to invest in aform that falls short of future needs. Thatwas the case with thisInverted Tee form.

The form was designed to expand the producer’s capabilities to produce a variety of inverted tee and ledger beam configurations.The ledge height, beam height and beam width of the inverted teeare all adjustable. Block outs used for casting ledger beams can be bolted at various locations. Risers are used to change beamheights. The form opens hydraulically for stripping.

This self-stressing form has an 8 foot wide jacking abutment.Stressing bars in the jacking abutment move the prestress reactioncompletely out of the sideforms so that the sideforms can be easily adjusted. Adjustable locking top ties complete the formwork package.

The minimalist approach

Flexibility is a goodthing, especially whenthe future is uncertain,but for high volumeproduction; a straightforward, hard-workingform is called for.

The inverted tee pictured here also produces inverted tee and ledgerbeams. The bottom pan has a fixed width of 24 inches with 48 inchsideforms. The depth can be changed with a filler in the lower pan.Bolt on block outs were supplied to cast ledger beams. Multiple bolting locations were provided so the block outs could be raised or lowered. The sideforms are hydraulically actuated, opening flat for easy access to the product for stripping.

The abutment for this form is 3 feet wide. This more compact designuses less material and fewer components than the example at theleft. Although this inverted tee has less flexibility, it’s also less complicated and less expensive.

Same Form, Two Approaches

Formwork

This form has a fixed width, but can adjust for differentheights and depths of inverted tees and ledger beams.

This form will adjust for different widths, depths and heights of inverted tees and ledger beams.

Prestressing EquipmentHamilton Form’s prestressing equipment is rugged, durable and made with the same attention to detail and quality as our forms.

Power Units

Each power unit is configured with gauges, pressure settings, hoses and quick disconnects to pull either half-inch or six-tenthsstrand. It has been described by users as “well thought out, easy to use; with a smooth, precise operation,” and features an advanced, energy saving variable displacement pump, large, dual scale gauges that measure PSI and force for initial and final set, a safety strobe and an alarm that sounds only when strand isbeing pulled. The power unit can be moved with a forklift, by its lifting lugs, or can be ordered with a wheeled cart.

Pull Type Tensioning Jack

Hamilton Form’s pull type tensioning jacks for single stroke tensioningare available in 24, 36, 48 and 60-inch strokes. Jacks can be orderedfor pulling up to half-inch special strand or six-tenths strand. It has ahardened steel jacking sleeve that allows the jack to sit square againstthe chuck, a Y-sling chain and magnetic torpedo level for positioning,and an anti-twist bar on the pulling yoke that can be used to measure elongation.

Positioning Frame and Hoist

Designed to be used when prestress-ing at the end of the bed; the framehas a chain hoist to help lift and levelthe stressing jack and a trolley toslide the jack from one side of theform to other. Twelve inch dualwheels with pneumatic casters makeit easy to maneuver the cart for usein different areas of the plant.

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Test Table Reaches New Heights

hen Heldenfels Enterprises in San Marcos TX switched production to all self-consolidating concrete; the number and frequency of spread tests required to check the concrete mixincreased. As is typical in many outdoor plants, tests were performed on a level surface in the production area. When the number of tests increased, so too did the frustration with the process.

Jorge Guerrero works in production at Heldenfels. He saw an opportunity to improve the way the tests were performed. First, a waist high table was built to eliminate having to bend over to perform tests. The second innovation was to build a chuteon one side of the table so the concrete can be scraped off thetable top after the test is complete. A receptacle is placed under the chute to allow for recycling of the concrete waste. Scales andequipment needed for testing were moved to a steel box next tothe test table.

The process improvement not only came from the ground up; (literally by moving the table waist high), but the idea to improvethe process came from production, not management. Bottom upprocess improvements are usually the most sustainable. Whenemployees are encouraged and given the opportunity to makeprocess improvements, it results in greater employee motivation,retention and morale.

Productivity Place

Equipment Highlights

Heldenfels’ SCC test table is waist high and has a sloped chutefor easy clean-up.

ompe disease is a genetic disorder that damages musclesand nerve cells; especially the heart, skeletal muscles, liver andnervous system. This little known disease strikes 1 in 60,000adults and 1 and 140,000 infants. Although that number seem small compared to more publicized diseases, when it’s one of your own, that number takes on new meaning.

At one time, a diagnosis meant a death sentence; but today,due to the heroic efforts of families and friends of those affected by the disease there are some promising treatments,although still no cure.

For the past two years, the Precast Manufacturers Associationof Texas (PCMA-TX) has hosted the Pull for Pompe to raiseawareness and money for research. This year, the event will be held on Saturday, April 20th in San Antonio, Texas. It’s a fun day of clay shooting, refreshments and camaraderie.

If you would like to be a part of the fun, or if you want tomake a donation to help benefit this important research,please call 866.944.7262 or 210.633.6743 or e-mail Chris Lechner, PCMA of Texas at lechner@pcmatexas.org

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t Hamilton Form, we encourage ourcustomers to think ahead when orderingforms. Sometimes additions to the capacityor the capability of a form provides flexibilitythat will pay for itself in dividends in the future.

We also encourage customers to resist theurge to try to do too many things with oneform. Too many variables can result in acumbersome design that may not be asuser friendly or as efficient as desired.

By all means, if you are casting a low volume product and want to get the mostout of your formwork investment, exploreoptions that will extend the use of theform; but one form can’t do everything –and usually can’t do it well. Over the years,we've found that customers who focus on80% of the products they anticipate willbring in the most volume, instead of a longlist of options, get the best results.

First, when thinking about making multipleproducts with one form, make sure you consider the extra costs to produce theform. Design and drafting requirementsincrease with the complexity of the form. The cost to manufacture the form increaseswith the number of different componentsthat need to be fabricated.

Sometimes it’s more cost effective to buyseparate forms than to incorporate toomany variations in one form.

Second, factor in the labor cost of breakingdown and setting up the form to cast different products. You will also need to keep extra parts organized, cleaned andstored when not in use.

Also consider product quality. Multiple bolt-on pieces may show a number of seamsthat compromise the aesthetic quality of the finished product.

Like you, we want to make sure your investment in formwork provides a payback.To that end, we would be happy to exploreoptions with you to get the most out ofyour investment. Some common optionsinclude:

� Designing tables for spandrel loading so you can cast L-beams or small box beams on your casting table

� Making provisions on sideforms for futurerisers to cast different product depths

� Designing for additional stressing capacity than currently required, especially with the trend toward increase use of 0.6 over ½” strand

� Hydraulic cylinders to open and close sideforms to make it easier to work the form and save wear and tear on the form

� Magnetic side rails to eliminate the need to drill holes through the skin of the table

� Adding additional bolting locations to change product width

Other value-added ideas include addingdesign features to make it easier and moreefficient to work the form such as hingedjacking plates on vessel type forms to makethem easier to clean; hooks welded to theside of the form to hold hoses or storeaccessories and catwalks on tall sideforms.

We realize each customer and each case is unique. Based on the product shape, number of pieces expected to cast andfuture project expectations, there is no one answer that fits all scenarios.

Hamilton Form has been helping customersmake some of the decisions they face when ordering new formwork for manyyears. To put that experience to work for you, give us a call or e-mail sales@hamiltonform.com

Flexible formwork designs can expand capability, but trying to do too many things in a single form may not be an effective solution.

Saturday, April 20, 2013

Technically Speaking

Formwork Design: A Balancing Act

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Hamilton Form Company, Ltd7009 Midway Road • Fort Worth, Texas 76118Ph 817.590.2111 • Fx 817.595.1110www.hamiltonform.com

oy is the friendly voice you hear when you call HamiltonForm. More than just reception, Joy also acts as a sales assistant, office organizer and payables clerk. She keeps the office organized and running efficiently.

Joy’s husband Jim is a CPA and a small business owner. Joy has worked with her husband in the past making her keenly aware of the importance of first impressions and customer service. She also knows that wearing many hats and being a team player is important to the success of a company. She’s always willing to dig in and help out.

Their daughter Jolene is a freshman in college. When Joy was in college, she and her sister rode bikes (that’s bicycles…) from Tucson to the Grand Canyon. They hiked the Canyon and then returned home – a 780 mile round trip.

Joy has a strong German heritage. Her mother escaped fromEast Germany after World War II, came to the United Statesand settled in Chicago. That’s where she met Joy’s Dad, animmigrant from West Berlin. Joy’s parents travelled extensivelyacross the USA with their two daughters. As children, theirsummers were filled with visits to National Parks and NationalMonuments. The parents had a deep appreciation and affection for their new found home and instilled the same in their daughters.

We believe having a live person answer our phones providesbetter service for our customers. Joy always knows who’s in, who’s out and when they’ll be back. Even under pressure, she’s always friendly and pleasant and the perfect personality as the first point of contact at Hamilton Form.

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Joy KlenzendorfReception

Employee Profile