NEWS & INFORMATION FROM HAMILTON FORM SPRING

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1 Form+Function NEWS & INFORMAION FROM HAMILON FORM SPRING 2014 Project SPOLIGH Mall of San Juan Precaster: Marxauch Precast Solutions he $405 million Mall of San Juan is the first luxury retail development in Puerto Rico. his state-of-the-art, 650,000 square foot, enclosed mall will feature the first Saks Fifth Avenue and Nordstrom in the Caribbean. he project s website states; he architecture will have a timeless character and utilize quality materials and finishes to enrich the shopping experience. And that means precast. he precast producer for this multi-year project is Marxauch Precast Solutions. he project includes interior, exterior and corner columns; precast stairs with landings, spandrels, double tees and wall panels. Hamilton Form provided Marxauch with new forms for most of the products for the project. o produce the columns, Hamilton Form designed an adjustable form to produce columns with one, two and three corbels. he form was made in sections to allow the corbels to be removed and replaced with sideforms to change the column heights. A corbel can also be replaced on one side with a straight sideform to produce a column with a single corbel. Alternately, a bolt on riser is added to produce a corner column with three corbels. Spandrels are produced on a casting table with side rails and a hanging back pan. he back pan hanger has slots that can be adjusted from 1-10 on one end to 1-0 on the other to create an L shaped sloped product. he back pan pivots back for ease of stripping. he slotted back pan with slots allowed Marxauch to easily adjust the forms to produce different sloped products. Martin Marxauch, the president of Marxauch Precast comments One thing that helped us out more than anything else were the rotating and slope adjusting spandrel hung pans.

2 Project SPOLIGH Mall of San Juan (continued) o produce the stairs, two stair forms were fabricated to accommodate two different pitches. Both forms are easy to configure to cast either left or right stair wells. Fillers are used at the bottom to form the recess for the right hand railing. A block-out used at the top of the form casts the recess for the right hand rail. he product is cast on edge with a floating soffit, making it possible to change the width of the stairs. Each form has both upper and lower landings. he landings can be adjusted with internal headers. o increase productivity and mechanize double tee production, Marxauch ordered a Double ee Stem Cleaner. he Cleaner quickly cleans the stems after product is stripped to prep the double tee for the next casting. o improve curing, two arp Carts that ride on the side of the double tee beds are used to dispense and re-roll an insulated curing cover. New forms and improved production efficiency has helped Marxauch Precast Solutions gear up to deliver product for one of the island s most significant building projects. Stair Form he stair form includes an upper and a lower landing. he landings can be adjusted by moving the header. A floating soffit allows change in the width of the stairs. A filler installed at the bottom, or a block out attached at the top of the form creates a recess for the hand rail attachment. Double ee Stem Cleaner op quality products are cast on forms that are cleaned before each casting. he Double ee Stem Cleaner has become the standard in the industry to quickly and easily clean the hard to reach stems of a double tee. he Cleaner brush is custom configured to fit the width and depth of the double tee. Brushes are easy to attach and replace so the same machine can be used on multiple forms. If you re not using the Double ee Stem Cleaner, you re missing out on the most effective and most productive method of cleaning double tee stems.

3 echnically Speaking Approving Drawings APPROVED FOR PRODUCION Communication is the key to any successful relationship including supplier/customer relationships. he drawings we send to you for approval are how we communicate what we intend to build for you. It s important for you to carefully check all details on the drawings and communicate any changes or concerns to make sure we understand your needs. he approval drawings we send for your review are based on the best information we have at the time. In the absence of detailed information, we may make some assumptions that may or may not be correct. hat s why we frequently ask for verification of items like form stressing capacity, the draft on the product, strand pattern and size of chamfer before generating a set of drawings for approval. In addition to product information, make us aware of any production details we need to take into consideration. hese include items like holes for heat or steam, plans to use machinery on or around the form and clearances or accessories that need to be incorporated into the form design. Detailed information makes it easier and faster for us to get a good set of drawings to you for approval. here are occasions when we are asked to make the same form as a previous order. he truth is this rarely happens. It s usually the same EXCEP, with a few minor modifications. When this is the case, we try to highlight those modifications on the approval drawings to make sure we have the details right. Form approval drawings should be reviewed for both the product the form is making and to verify how the product is going to be produced. Many customers have drawings checked by several departments including engineering and production. We typically plan one week from the time we send drawings until we expect to get them returned. A one week turnaround will allow us to keep on schedule. When it takes several weeks, or there are extensive changes to the drawings, we often need to adjust our production schedule, and that may affect delivery. Once again, communication is the key. If you need more than a week to review drawings, let us know. Carefully checked and approved shop drawings are the key to us fabricating forms that produce the products you need and work efficiently in your facility. Communicating your specific needs as early as possible, having drawings checked by everyone involved in the process and getting drawings back to us as soon as feasible is the best way to help us, get you, exactly what you need. Equipment Quick Curing Solution Insulated Curing Blanket An insulated curing blanket captures the heat of hydration and improves the curing process. Our blankets are custom cut sized to fit your bed. arp Cart with Roller he easiest way to pay-out and re-roll a blanket is with a Hamilton Form arp Cart. he cart can mount on the side of the form, run on tracks installed next to the bed or fitted with steerable tires. A hydraulically operated roller dispenses the blanket over the bed. In most cases, a single operator can complete this task, saving time and labor. Plus, storing your blanket on a roller is the best way to protect it from damage when not in use. Improved curing, quick pay-out and re-rolling, plus a storage solution for your curing cover are three good reasons why your investment in an automated arp Cart will provide a quick return on your investment and improve profits.

4 Productivity Improve Productivity and Quality with Magnetic Products Magnetic Side Rails Magnets adhere better to thicker steel surfaces. A magnet placed on a 3/8-inch steel casting surface provides better adhesion than 1/4- inch steel. hat s why the casting surface you intend the use the magnets on is also important. Magnetic Corners Magnetic side rails with button magnets, bottom chamfer and magnetic chamfer at the top of the rail. Magnets have been used for many years to lift, hold, transfer and stack heavy loads. In precast production, magnets are increasingly used to hold sideforms in place on steel casting tables. Repositioning magnetic side rails is considerably easier and quicker than unbolting, moving and re-attaching bolt down rails. he use of magnets also eliminates the need to drill and fill multiple bolting locations on the casting surface maintaining the quality of the casting surface. here are several factors Hamilton Form takes into consideration when designing magnetic side rails. Depending on the length and the height of the rail we may recommend three, four or even five magnets per section. One fact to keep in mind is magnets are good in adhesion, but the shear force of a magnet is considerably less. Although a 20-foot four inch rail may only require three magnets to hold it in place, add two more inches and you ve increased the shear force by almost double. hat s why extra magnets are required if you intend to use a riser on top of a magnetic side rail. Magnetic corners are a convenient alternative to building wood corner block outs for use on steel casting tables. Steel corners are always straight and true, making them easy to build with. Steel lasts longer than wood and steel corners eliminate the hassle of having to dispose of or recycle wood. Either steel or wood side rails can be attached to the corner. Hamilton Form magnetic corners are custom made to order. You specify the height and if you want chamfer added and, we ll deliver. Magnetic Chamfer Magnetic corners can accept steel or wood side rails. Chamfered magnetic corner with bolt holes for adding risers. Another time saving product is magnetic chamfer. Magnetic chamfer and reveal strips lay flat and smooth against steel surfaces to form a crisp edge, and they re easy to reposition. Hamilton Form stocks 1/2-inch and 3/4-inch magnetic chamfer and reveal strips in ten foot lengths. hreading Headers, Better Strand Needles hese handy devices are used to guide strand through multiple bulk heads or headers, easily and quickly. Strand needles have a receiver on one end and a pointed tip at the other end. he steel needles are rigid to guide strand through header to header with ease. Pushing strand through multiple headers doesn t have to be frustrating. Abandon the frustration and increase productivity with these simple and efficient devices. Strand needles are sized for half-inch or six-tenths strand, and are available in six and nine foot lengths. Give us a call at to order yours.

5 Formwork Getting Girders Going Photo courtesy of CPCI Aging infrastructure is driving Departments of ransportation in the USA and Canada to develop more economical solutions to fill their bridge and highway construction needs. As a result, more efficient girder designs have been developed, including the NU I-girders, developed at the University of Nebraska. Another benefit to this layout is the catwalk. Hamilton Form installed Saf--Mate channels to the top of the NU1600 form. Because the top is used on all girder configurations, except the 1200 which does not require a raised platform with a railing to work the top of the form, the same catwalk is utilized for production of all of the profiles. he NU girder is now used in several states in the U.S. as well as Canada. Hamilton Form has supplied a number of precast plants with NU girders. One recent project was a request to produce the NU1200, NU1600, NU2000 and NU 2400 all in a single bed with the most efficient means of changeover. Our solution used the 1600 girder as the foundation to develop an interchangeable system for all four profiles. he 1600 girder is a split form. he NU2000 is produced by using 400 fillers between the 1600 halves. he 2400 is accomplished with 800 fillers between the 1600 halves. o produce the NU1200, the 1600 bottom is used with a 400 top. hese configurations allowed the bottom half of the form to remain constant and eliminated the need to use any more than one filler at a time. For vibration, the NU1600 had Vibrotrack installed on both halves. his provided high and low concrete consolidation for each of the girders produced with fillers. he 400 top used with the 1600 base to produce the shallower NU1200 did not require top vibration, eliminating the need to add Vibrotrack to those sections. he NU 2400 girder made up of two 800 halves and an 800 filler with Saf--Mate, hinged catwalk and railing installed on the top section.

6 Hamilton Form Company, Ltd 7009 Midway Road Fort Worth, exas Ph Fx Employee Profile Raul Rivas Leadman R aul Rivas came to Hamilton Form as a crane operator in He worked in production and as a welder before becoming the lead man on jig two. Jig two is one of Hamilton Form s primary jigs where double tees and other large forms are assembled. Raul is one of the most likable people at Hamilton Form. He s pleasant, good natured and has good communication skills with supervisors and his team. He likes to collaborate with others to improve or refine a task or process. An open mind and a learning attitude have made him always willing to try something new. Raul s easy going nature also makes him a good trainer. Over the years, he s trained some of the best welders and fitters in the plant, adding to the depth of expertise at Hamilton Form. Raul helps drive quality and takes pride in his work... Over the years we ve made significant improvements in the way we fabricate forms. oday we make better use of materials, parts are cut more precise which has helped the way we fit; and, we ve improved the way we weld on a form. He has also seen changes and variation in the design of the forms. Double tees have a lot more variety than in the past, Raul notes. We ve made wider double tees, double tees that split in the center, heavy-duty double tees with huge compression bars, and even double tees made in three sections to change the deck width. Raul is a family man. He has been married for 15 years and his greatest joy is spending time with his family. A 14 year old son and 12 and 9 year old daughters keep him busy when he s away from work. We re glad he s part of the family here at Hamilton Form.