hanley plant

Hanley PlantHanley Plant

LOCATION:LOCATION:

Route 28Route 28

Summerville, Jefferson County, PASummerville, Jefferson County, PA(approx. 80 miles NE of Pittsburgh)(approx. 80 miles NE of Pittsburgh)

Plant Manager:Plant Manager:Terry BullersTerry Bullers

General Manager:General Manager:Phil RaubPhil Raub

Distribution Manager:Distribution Manager:Craig WonderlingCraig Wonderling

Hanley Hanley PlantPlant

HistoryHistory• The original Hanley plant was built in 1893 in Bradford, PA, and ran until The original Hanley plant was built in 1893 in Bradford, PA, and ran until

1983, when it was sold to an unknown buyer.1983, when it was sold to an unknown buyer.

• The Hanley Plant in Summerville was builtThe Hanley Plant in Summerville was builtin 1925.in 1925.

• Hanley Plant was built by Lee Hanley,Hanley Plant was built by Lee Hanley,brickmaker and celebrated tunnel kiln designer.brickmaker and celebrated tunnel kiln designer.Considered “visionary” in his approach to brick-Considered “visionary” in his approach to brick-making, Hanley was also famous for building notoriously quirky kilns. making, Hanley was also famous for building notoriously quirky kilns.

• Glen-Gery purchased Hanley Plant inGlen-Gery purchased Hanley Plant inFebruary 1986.February 1986.

• The two Hanley kilns present at the timeThe two Hanley kilns present at the timeof our purchase were the last Hanleyof our purchase were the last Hanleytunnel kilns in the world. They were builttunnel kilns in the world. They were builtaround 1960 and razed for thearound 1960 and razed for theModernization project that began inModernization project that began inthe fall of 2001.the fall of 2001.


Hanley ModernizationHanley Modernization

$18 million upgrade$18 million upgrade

• Improve availabilityImprove availability• Improve product qualityImprove product quality• Broaden range of product Broaden range of product offeringsofferings

REASON FOR UPGRADEREASON FOR UPGRADE


Hanley ModernizationHanley Modernization

• AVAILABILITYAVAILABILITY

– – the plant’s capacity is increased 32% fromthe plant’s capacity is increased 32% from 35 million (former) units to 50 million (new) 35 million (former) units to 50 million (new)

SpecificallySpecifically . . . . . .

• QUALITYQUALITY

– – consistent color, tighter color ranges consistent color, tighter color ranges (3 vs. 5 shades)(3 vs. 5 shades)

– products conform consistently to FBX specs– products conform consistently to FBX specs

• SELECTIONSELECTION

– – addition of flashed brick addition of flashed brick (vs. clearburn only)(vs. clearburn only)

– clay/shale blends – clay/shale blends (vs. shale only)(vs. shale only)


Hanley ModernizationHanley Modernization$18 million upgrade began in Nov. 2001 and was completed – on time $18 million upgrade began in Nov. 2001 and was completed – on time and within budget – in 18 monthsand within budget – in 18 months

• 1 280 ft. Ceric, air-tight tunnel kiln and attached dryer (total length 503 ft.) 1 280 ft. Ceric, air-tight tunnel kiln and attached dryer (total length 503 ft.) replace 2 old Hanley kilnsreplace 2 old Hanley kilns

• Robotic dehacker (new to Hanley – carousel in use prior)Robotic dehacker (new to Hanley – carousel in use prior)

• New robotic setting equipmentNew robotic setting equipment

• Advanced-design kiln carsAdvanced-design kiln cars

• New glaze application boothsNew glaze application booths

• State-of-the-art computer management system to track manufacturing State-of-the-art computer management system to track manufacturing processprocess

• Installation of environmentally-friendly wet scrubberInstallation of environmentally-friendly wet scrubber

PROJECT HIGHLIGHTSPROJECT HIGHLIGHTS


Hanley Plant OverviewHanley Plant Overview


Hanley 2002 Market OverviewHanley 2002 Market Overview

1.1. New YorkNew York 10,018,00010,018,000 28.8%28.8%

2.2. PennsylvaniaPennsylvania 3,700,0003,700,000 10.7%10.7%

3.3. IllinoisIllinois 2,737,0002,737,000 7.9%7.9%

4.4. MarylandMaryland 2,576,0002,576,000 7.4%7.4%

5.5. OhioOhio 2,461,0002,461,000 7.1%7.1%

6.6. MichiganMichigan 2,331,0002,331,000 6.7%6.7%

Primary markets / brick shipmentsPrimary markets / brick shipments

Total Total ShipmentsShipments = 34,745,000 = 34,745,000

Total Total ProductionProduction = 31,683,000 = 31,683,000


Hanley 2002 Customer OverviewHanley 2002 Customer Overview

1.1. Tri-State Brick (NY)Tri-State Brick (NY) 2,302,6102,302,610

2.2. Glenwood Mason Supply (NY)Glenwood Mason Supply (NY) 2,158,3692,158,369

3.3. Prairie Brick Co. (Chicago)Prairie Brick Co. (Chicago) 2,021,0002,021,000

4.4. Capital Brick & Tile (D.C.)Capital Brick & Tile (D.C.) 1,607,7951,607,795

5.5. Extech Industries (NY)Extech Industries (NY) 1,516,1741,516,174

6.6. The Thomas Brick Co.The Thomas Brick Co.(Cleveland, OH)(Cleveland, OH) 1,151,9531,151,953

Top customers / brick shipmentsTop customers / brick shipments


Hanley Product OverviewHanley Product Overview

First and most importantly . . . First and most importantly . . . ALLALL Hanley brick is Hanley brick is FBXFBX..

FBX brick conforms to a “higher degree of precision and FBX brick conforms to a “higher degree of precision and lower permissible variation in size than permitted forlower permissible variation in size than permitted forType FBS (general use masonry).” Type FBS (general use masonry).” Cf. ASTM C216-99Cf. ASTM C216-99

Basically, that means a superior, Basically, that means a superior, precision-smooth face (and not precision-smooth face (and not necessarily the edge!) that shows little necessarily the edge!) that shows little or no chips, bumps or cracks. Hanley or no chips, bumps or cracks. Hanley attributes the quality of its FBX brick to attributes the quality of its FBX brick to find grind that they use on their raw find grind that they use on their raw materials.materials.


Tawny Beige – S32

Dolomite Grey – S181

Smoky Quartz – S72


Example of Hanley shape that conforms to Example of Hanley shape that conforms to FBXFBX standards. standards.


Hanley’s 6 Price List ProductsHanley’s 6 Price List Products

• Engobe Engobe (aka “claycoat”)(aka “claycoat”)

• MattMatt• Coarse Coarse (Canyon Series exclusively)(Canyon Series exclusively)

Hanley also makes:Hanley also makes:-- “Stylo,” aka 8-square, in certain textures . . . but it is not a Price List item-- “Stylo,” aka 8-square, in certain textures . . . but it is not a Price List item-- Complete assortment of shapes to complement product line-- Complete assortment of shapes to complement product line


• GlazedGlazed• Wire cutWire cut• SmoothSmooth

Hanley’s Product Line OverviewHanley’s Product Line Overview

• GlazedGlazed• EngobeEngobe• SmoothSmooth

PRODUCTS:PRODUCTS:

• TuscanTuscan (smooth face brick)(smooth face brick)• CanyonCanyon (coarse face brick)(coarse face brick)

SERIES:SERIES:

STOCK SIZES:STOCK SIZES:thickness x height x lengththickness x height x length

Note: All of Hanley’s 6 Price List products are made in the above sizes.Note: All of Hanley’s 6 Price List products are made in the above sizes.

The plant also makes a “jumbo norman” (3-5/8 x 2-3/4 x 11-5/8), The plant also makes a “jumbo norman” (3-5/8 x 2-3/4 x 11-5/8), but it is only as a special order.but it is only as a special order.


• MattMatt• Wire CutWire Cut• CoarseCoarse

• ModularModular 3-5/8 x 2-1/4 x 7-5/83-5/8 x 2-1/4 x 7-5/8• JumboJumbo 3-5/8 x 2-3/4 x 83-5/8 x 2-3/4 x 8• EconoEcono 3-5/8 x 3-5/8 x 7-5/83-5/8 x 3-5/8 x 7-5/8• UtilityUtility 3-5/8 x 3-5/8 x 11-5/83-5/8 x 3-5/8 x 11-5/8 • NormanNorman 3-5/8 x 2-1/4 x 11-5/83-5/8 x 2-1/4 x 11-5/8

Spice White Blue Grey Black

Maroon Evergreen Bermuda Blue

Spice WhiteOyster White/

Speck White/Speck

Current stock glazed colors. Hanley also makes Current stock glazed colors. Hanley also makes custom colors.custom colors.

GlazedGlazed

Glazed brick are extruded brick to Glazed brick are extruded brick to which a non-permeable, smooth which a non-permeable, smooth coating has been applied.coating has been applied.

EngobeEngobe

Engobe brick are extruded brick to Engobe brick are extruded brick to which a water vapor-permeable, which a water vapor-permeable, coating has been applied.coating has been applied.

The manufacturing process for both The manufacturing process for both glazed and engobe brick is the glazed and engobe brick is the same: A coating is sprayed on the same: A coating is sprayed on the green column of clay on the green column of clay on the extrusion line. The coating is dry to extrusion line. The coating is dry to the touch by the time it gets to the the touch by the time it gets to the setting stage. setting stage.


Smooth, Wire Cut, Matt, CoarseSmooth, Wire Cut, Matt, Coarse

Hanley’s face brick products are all Hanley’s face brick products are all extruded and, at this time, all clay-based extruded and, at this time, all clay-based materials.materials.

At left is an example of “Smoky Quartz” (72) in At left is an example of “Smoky Quartz” (72) in smooth texture (top) and wire cut texture smooth texture (top) and wire cut texture (bottom).(bottom).

SMOOTH TEXTURESMOOTH TEXTURE

WIRE CUT TEXTUREWIRE CUT TEXTURE


Hanley’s Top-Selling ProductsHanley’s Top-Selling Products

Rome Grey*Rome Grey* (s 93)(s 93) Tawny BeigeTawny Beige (s 32)(s 32) Smoky QuartzSmoky Quartz (s/w 72)(s/w 72) Toledo GreyToledo Grey (s/w 75)(s/w 75) Dolomite GreyDolomite Grey (s/w 181)(s/w 181)

*Rome Grey (utility) is the brick used on the *Rome Grey (utility) is the brick used on the outside of the new kiln. It serves only a cosmetic outside of the new kiln. It serves only a cosmetic

purpose and offers little insulating value.purpose and offers little insulating value.


HanleyHanleyProduct DevelopmentProduct Development

PlannedPlanned for 2003, is the for 2003, is the introduction of Hanley introduction of Hanley RedRed (S/W15), a 100% shale,(S/W15), a 100% shale,authentic red brick.authentic red brick.


Interesting Facts . . .Interesting Facts . . .

• New kiln normal operating temperature is 2100 – 2200New kiln normal operating temperature is 2100 – 2200°°FF

• Kiln-dryer combo holds 45 cars (1 car in pre-dryer stage,Kiln-dryer combo holds 45 cars (1 car in pre-dryer stage, 17 cars in dryer, 27 cars in kiln) 17 cars in dryer, 27 cars in kiln)

• New kiln cars hold about 5,200 modular size brick.New kiln cars hold about 5,200 modular size brick. Old cars, about 2,000 Old cars, about 2,000

• New kiln cars measure 10 ft x 15 ft. wide. Old cars, 61 inchesNew kiln cars measure 10 ft x 15 ft. wide. Old cars, 61 inches wide x 9 ft. long wide x 9 ft. long

• New kiln push rate is 54 min. Old kiln rate was 36 min.New kiln push rate is 54 min. Old kiln rate was 36 min. Push rate refers to the amount of time it takes to move a carPush rate refers to the amount of time it takes to move a car one car length. Basically, a car is removed every 54 min. one car length. Basically, a car is removed every 54 min.

• “ “Firing curves” from the old kiln are programmed into the newFiring curves” from the old kiln are programmed into the new kiln to minimize the adjustment time needed to zero in those kiln to minimize the adjustment time needed to zero in those temperatures that produce the desired effect. “Firing curves” temperatures that produce the desired effect. “Firing curves” refer to those temperatures for individual products known to refer to those temperatures for individual products known to produce quality brick. produce quality brick.

• “ “Pre-dryer” stage is where moisture content is reduced to,Pre-dryer” stage is where moisture content is reduced to, normally, below ½% in brick. It’s important to take out as normally, below ½% in brick. It’s important to take out as much moisture prior to entering the higher temperatures. much moisture prior to entering the higher temperatures. Excess moisture can vaporize and explode brick. Excess moisture can vaporize and explode brick.

““Deck blocks” Deck blocks” on kiln caron kiln car


hanley plant

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