NEWS & INFORMATION FROM HAMILTON FORM FALL 2015

Project Profile

U-Beam for the MacArthur Interchange, New OrleansGulf Coast Pre-Stress

Form+Function

Across North America prestressed concrete is being used to build highways,bridges and overpasses. One such project is the MacArthur Interchange recon-struction near New Orleans. The MacArthur Interchange project is intended to alleviate traffic between Manhattan and Barataria boulevards, two of the mostcongested 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.

Gulf Coast Pre-Stress, in Pass Christian, MS is a large producer of precast-prestressed concrete structural components for the bridge, highway, marine and industrial markets. The company has been using formwork from Hamilton FormCompany since its beginnings in 1967. Recently, Hamilton Form built a 72” U-Beamform 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. Theform was designed for partial self-stressing to accommodate a light load at onehigh and two intermediate locations. The void configuration required the voidsto 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 tocast. 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 optedfor the manual solution.

Prestressed concrete bridges, roads and overpasses improve travel and help relieve congestion on many of the most heavily travelled highways across the USA.

The form was partially self-stressing for strand athigh and intermediate locations.

The shape of the void required the void to be madein sections that could be unbolted for stripping.

Vibrotrack was added to the side of the form.

Project Profile

U-Beam for the MacArthur Interchange, New OrleansGulf Coast Pre-Stress (continued)

The project called for multiple void lengths at variable positions within the beam. Centervoids were built at several different lengths that could be bolted together to create multipleassemblies ranging from 16’ to 27’-6” lengths. The end voids were built at 24’ lengths withthree 2’ fillers that could be removed for different length end voids. Hangers used on theedge of the base form support the voids at any location. Hook style void hold downs arethreaded and bolt in place to prevent uplift.

The formwork included two-piece trapezoidal headers to create a dap at the end of thebeam. The bottom of the beam is heavily stressed. Holes for placement of strand in this areawere burned on a plasma cutter. The plasm allows for precise positioning of the holes thatare 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. GulfCoast purchased a U-Beam form with a hydraulically collapsible core several years ago. Thatform 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 destroyedduring hurricane Katrina ten years ago.

The two different approaches to designing the void illustrate the fact that there are differentsolutions for similar products, depending on the project. The number of different productconfigurations, the quantity of each product, the adjustability required, production schedulesand labor considerations need to be factored into every project. Working in collaborationwith the customer and having this information early in the process helped determine thebest solution for this project.

Trapezoidal headers create daps at the end of the beams.

“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 EngineerGulf Coast Pre-Stress, Inc.

Equipment News

Precaster Gains Production Efficiency with Custom Utility MachinesHamilton Form has been designing and building custom produc-tion equipment for over thirty years. During that time, our UtilityMachines 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 vibratoryscreed for consolidating concrete. Screed vibrators can be either hydraulically or pneumatically driven. Another option is a knuckleboom jib crane which can be used to lift and position product bulkheads, strand depressor beams or strand tensioning jacks. Weoften include a deck that can be used to drop mesh down the bed.Some machines include a strand puller. A common combination isa 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 flatcasting table that was located in a tight space within the plant. It included both horizontal and side brushes to clean the bed. Afterthe bed is cleaned, a sprayer attached to the back of the machinedispenses 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-uptime by using the machine to service the bed. The Utility Machinewas especially valuable because it reduced the number of peopleworking on and around the bed.

If you’re ready to improve production efficiency with a customdesigned Utility Machine from Hamilton Form, contact us formore information: sales@hamiltonform.com or ask for salesat 817 590-2111.

“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. FinkVice PresidentNortheast Prestressed Products, LLC

Equipment

re-pour processes are some of the most time consuming, labor intensive tasks in precast plants. Many of these tasks can be streamlinedwith custom built machines yet there is limited use of machinery usedin bed set-up in precast plants.

Mechanized production has several benefits beyond improved produc-tivity. Machines can improve the quality, reliability and consistency ofthe 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 CARTSOne of the most popular machines we build to improve productivity isthe Hamilton Form Tarp Cart. In its simplest version, it is a cart with areel that rolls on the edges of the form and dispenses and re-rolls curingcovers. The cart has a gasoline engine, a hydraulically powered reel andhydraulically powered wheels. The Tarp Cart is operated by leversmounted on the side of the cart. Typically a single operator, walkingnext to the cart, can complete the task quickly and easily. The Tarp Cartcan 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.

DOUBLE TEE TARP CARTTo utilize a cart on a double tee form, we often include a deck and rackused to stack and store bows that attach to the edge of the form. Thecover lays over the bows so the cover doesn’t touch the concrete.

MULTI-BED TARP CARTOne tarp roller we recently built was designed for use on three differentpile forms; a 14” quad, 16” triple and an 18” dual pile form. This cartwas made with flanged wheels that ride on the edge of the form. Thewheels and wheel carriages were made adjustable to accommodatedifferent width beds.

MULTI-PURPOSE UTILITY MACHINESHamilton Form Utility Machines can complete a number of tasks. Manyof the machines we build are designed to do more than one task.Choices include brushes to clean the bed, a strand puller, oiler, jib craneand vibrating screeds.

CUSTOM SOLUTIONSAs you think about the production process, think about using machineryto help improve production. From the simple to the complex, HamiltonForm has built Tarp Carts and other production equipment for manydifferent applications. We have built Tarp Carts for girder beds, pilingforms and double tees. We have built machines dedicated to one bedand 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 tostreamline production with custom built production equipment, contact usat sales@hamiltonform.com or call our sales department, 817 590-2111.

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Streamlining Production

A Tarp Cart for a double tee bed typically has a bow rack to store bows that holdthe cover above the concrete.

Utility Machines can be designed to do one or more tasks.

Tarp Carts have a gasoline engine with hydraulically driven wheels and reel drive.

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Technically Speaking

t Hamilton form, we know forms are a biginvestment. We pride ourselves in the factthat we design and fabricate durable formsthat are built to last for years. In fact, we’veseen many forms that were purchased and in-stalled in the 1980s and even earlier that arestill in service today. On the other hand, we’veseen forms that need to be repaired, refur-bished – or even scrapped in less than 10years. The biggest difference in these two scenarios is in the way the forms are used andmaintained.

Most producers clean and oil their forms before each pour. Cleaning also includeskeeping debris away from the outside of theform. Not only does it present a safety hazard,but concrete build-up around the form canhold moisture and promote rust and corrosionof the steel form.

Stem fillers should also be removed andcleaned monthly. Don’t let dirt and moistureaccumulate under the fillers. While the fillersare out, clean and oil the leg of the tee orwhatever casting area is under the fillers.

In addition to keeping them clean, forms require regular maintenance. Regular mainte-nance 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.

• 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 requiremore maintenance. Be diligent. Develop aregular maintenance schedule for your formsand you’ll be rewarded with many years ofreliable service.

Form Maintenance

Monthly check that shims are in place and forms are stillstraight and level.

Regularly clean debris, check connections and repair rust.

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The best time to make a machinerypurchase is when you are orderingnew forms.

Alot of planning goes into the purchase ofnew formwork, including the productionprocess. As you plan the production processfor your new forms, think about using machinery to help improve production.That way, the form and the machine canbe designed to work together.

The form can be designed to supportthe machine to ride on the edges of theform. Machines that ride on the edgesof the form or in the Vibrotrack are typically the easiest to use, most eco-nomical to build and they use less space.

Run outs installed at the ends of theform to store equipment can be pro-vided and planned.

Any clearances needed for the equip-ment can be planned in advance.

Machines that run on the edge of the form workwell in tight spaces.

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

amilton Form’s production facility has a supervisor and a lead man in each department. The lead man in department oneis Vuong Nguyen. This is the department that measures, cuts andbends steel for form production. The lead man executes all ofthe material layouts and makes sure dimensions are precise andaccurate. This is a key role in production as the lead man makessure 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 cameto 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 Americancitizen in 1991. He workedfor another steel fabricationcompany before coming toHamilton 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 daughterswith 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 rootshere – the evidence? He is an avid Longhorn and Cowboys fan!

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Vuong Nguyen Lean Man

Employee Profile