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SPECIAL PRINT |CONCRETE PIPES AND MANHOLESM-Con adopts “egg laying” system to meet new market demands

SPECIAL PRINTCPI 5/13

www.cpi-worldwide.com

Concrete Plant InternationalWorldwide English Edition

OCTOBER

2013 5

CPI – Concrete Plant International – 5 | 2013 www.cpi-worldwide.com140

CONCRETE PIPES AND MANHOLES

Growing pains

M-Con’s first dry cast location was estab-lished in 1989 near Ottawa in Carp.,Ontario. That location, M-Con Products,Inc., serves the eastern and central Ontarioregions with a wide range of dry cast prod-ucts, all produced on HawkeyePedershaabPipePlus and VUP systems. M-Confounders, the Mion family, have been pro-ducing manholes and other precast con-crete products for more than 50 years.

As building permits for private, commercialand institutional construction skyrocketed in southern Ontario in the early 2000s, M-Con saw an opportunity to extend its

reach beyond its original service area. Thefirm acquired a 75-acre parcel in Ayr,which offered room for growth and a strate-gic location serving the greater Torontoarea and southwestern Ontario.

Since 2004, the M-Con Ayr plant has ex -panded three times, adding new floorspace, equipment, and staff to reach its cur-rent 70,000-square-foot size. The plant’sproduct line has also grown beyond theoriginal round pipe and manholes to nowinclude elliptical pipe, box culverts, three-sided boxes, highway barriers, retainingwall systems, and many types of custom limit-ed-run products.

Even during the recession years, growthcontinued thanks to provincial and federalgovernment funding in the form of theBuilding Canada Fund and other initiatives.Billions of dollars were and continue to bespent on infrastructure across Ontario andother provinces, including the NationalHighway System, drinking water, waste-water, public transit and green energy pro-jects.

As the quantity and size of projects hasgrown, M-Con’s Ayr plant has responded inkind, adding increasingly more robust pro-duction systems. In particular, the plantadded dual Hawkeye VUP production sys-tems, each capable of producing dry cast

M-Con adopts “egg laying” system to meet new market demands

HawkeyePedershaab, Iowa, 52637, USA

M-Con Pipe and Products, Inc., was established in Ayr, just west of Toronto, in 2004 to serve the growing needs of the Southern Ontario mar-ket. The firm uses its original HawkeyePedershaab PipePlusPlus Machine to produce concrete pipe and manholes. Over the years, demandin product volume and variety have moved the firm to expand its plant footprint and capabilities. Recently, the firm adopted an innovativenew approach to dry cast production that has enabled increased product flexibility, greater output, and significantly minimized capital andoperating costs. The new system from HawkeyePedershaab combines a modular box culvert mold system with a computer-controlled con-crete feeder and an overhead crane to enable “egg laying” style production. In addition to the box culvert equipment, M-Con has also installeda new robotic manhole base production system—HawkeyePedershaab’s Smartcast—that has reduced labor, increased accuracy and cutdelivery time for manhole bases with even the most complex flow patterns.

Figure 1 -- One of the critical elements of the new HawkeyePedershaab “egg laying” production system for box culverts is an adjustable form system that allows M-Con to produce almost any size box culvert. This cast-in-place approach provides for rapid dry cast production with no need to move the product until it’s fully cured.

Figure 2 -- The modular steel forms used inthe HawkeyePedershaab system include self-contained vibrators.. Once the form is posi-tioned on the pallet, the vibrators on thejacket and core are connected to a centralvibrator control console.

At HawkeyePedershaab we deliver more than machines. We deliver solutions.

e P a k

Designed from the ground up, the ePak machine represents a major leap forward in packerhead production technology. At

the center is the machine’s revolutionary eDrive rollerhead drive system. Powered by two gearless 30-pole direct

drive permanent magnet motors, for turning the inner and outer drive shafts, the eDrive develops

much higher than conventional torques and has a wider torque/speed operating band -

allowing precise packing control throughout the machine’s entire production range.

Mechanically, the ePak’s unique frame design permits the toptable, rollerhead drive unit, and bellpacker to continu-ously bear and smoothly travel on the machine frame, operating at speeds up to 25% faster than conventional frame designs. The machine also features a

sophisticated synchronized four-shaft bellpacker to direct up to four times more

vibration into the pallet for better bell compaction. It all adds up to making higher

quality packerhead pipe – faster. Learn more about ePak. Contact us today!

The Americas506 S. Wapello StreetMediapolis, Iowa 52637 USAPhone: +1 (319) 394-3197Telefax +1 (319) 394-3977

Africa, Asia, Australia, Oceania, EuropeSaltumvej 259700 Bronderslev – DenmarkPhone: +45 9645 4000Telefax: +45 9645 4040

[email protected]

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Figure 3 -- The HawkeyePedershaab crane-mounted concrete feeder is installed on a 15-tonoverhead crane. The system’s infinitely variable feed rate with X – Y computer controlledguidance allows the system to feed any size box culvert.

Figure 5 -- When in position, the computer-controlled belt feederautomatically fills the box culvert form with even layers of concrete.A home setting returns it to the central batching system for refilling, if necessary.

Figure 6 -- The modular form core includes integrated, synchronizedvibrators to provide the primary source of vibration. This vibrationprocess allows the form to be built with rigid stiffeners to minimizeform deflection for the manufacture of precise and dimensionallyaccurate products.

Figure 4 -- The feeder is filled with dry-castconcrete conveyed from a central batchingsystem. The scissor action mounting systemenables the feeder to be moved both verti-cally and horizontally without swaying,thereby enabling accurate filling of any boxculvert size and length. The feeder is radioremote controlled and can store box shapedesigns for future recall.



concrete pipe up to 12 feet (3600 mm) indiameter. In addition, the plant has addeda complete wet cast area that specializes inall types of manholes and associated pro-ducts. Further expansion is currently under-way.

Larger projects, larger products

According to Doug Galloway, president ofM-Con’s Ayr operations, new highway infra-structure projects, in particular, have led toan increased demand for large and diverse

types of products. “For instance, Highway407 here in Southern Ontario has needed alarge number of large box culverts,” henotes. “We didn’t have that productioncapacity in large box culverts and wanted toadd it to meet current and future demands.”

Centralized dry cast production using a vibratory table or wet cast-ing using individual forms were two options the firm considered.Each of these production methods would have required extensivecapital investment in equipment and building modifications, includ-ing a larger rolling crane—up to 80 tons—and building reinforcementor redesign. In early 2012, Galloway learned of HawkeyePedershaab’s “egglaying” style production system that would enable the firm to pro-duce larger box culverts without requiring major modifications to

the Ayr facilities or investment in a larger overhead crane. The newsystem includes several main components:

• Modular Box Culvert Forms HawkeyePedershaab system of adjustable steel forms (see figure 1) enable M-Con to produce dry cast box culverts,three-sided boxes, and chambers up to 5.1 meters in span and3.6 meters in rise in varying lengths and wall thicknesses. Thesystem of forms includes built-in core vibrators (see figure 2)and a computerized vibration control console. M-Con can alsowet cast box culverts, three-sided boxes and chambers up to12 meters in span.

• Crane-mounted Computer Controlled Concrete FeederThe HawkeyePedershaab four-cubic-yard capacity concretefeeder (see figure 3) provides precise, automated filling thanksto a scissor-action mount (see figure 4) that allows vertical andhorizontal movement without swaying. The feed system is oper-ated by radio remote control in semi-automatic (“dead man”switch) or manual mode. In semi-automatic mode, the operator

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Figure 9 -- The egg laying process is excellent for large boxes, suchas this 4.8 m x 3.6 m box culvert HawkeyePedershaab’s modularbox system enables M-Con to produce a wide range of sizes using a basic set of adjustable forms.

Figure 10 -- Finished box culvert, cured and ready for yarding.

Figure 7 -- Finished box culvert with the outer jacket and inner coreremoved. The product will remain on the pallet with the press headassembly in place until the product is fully cured.

Figure 8 -- Multiple box culverts poured in place withHawkeyePedershaab’s new modular “egg laying” process. A canopy kiln (stored against the back wall) is deployed to cover the products during curing.



depresses the dead man switch andthe computer control automatically fillsthe box culvert mold (see figures 5 &6) based on the selected parameters.The computer controls allow storage ofbox designs for tracking of moldshapes, variable feed rates, and futurerecall.

• Hydraulic Product TipperAllows finished box culverts to be safe-ly moved from vertical to horizontalposition for yarding.

• Batching System Shared concrete batching system pro-vides dry cast mix via conveyor to thecrane mounted feeder.

HawkeyePedershaab’s modular box culvertform system provides flexibility in the selec-tion of critical dimensions, including length,span, rise, and wall thickness. The formsinclude a torsional tongue-forming palletdesign that ensures structural integritythroughout the production process and agroove-forming presshead. A single set offorms and accessories in combination withthe egg-laying style of production enablesM-Con to meet their growing box culvertmarket demand.M-Con installed their new modular box cul-vert production system in the summer of2012. “The egg laying system allows us todry cast the box culverts in the same placethe products are cured,” Galloway explains.“We advance the pre-set adjustable jacketand core to the next pallet and cage assem-bly, set the forms in place, and the systemautomatically fills and vibrates. As soon asit’s done, we are able to remove the form as

a unit, leaving the product in place, andmove it to the next pallet and cage set-up.”

Several reasons for the theHawkeyePedershaab production system

Galloway notes that the firm chose theHawkeyePedershaab egg laying style pro-duction system for several reasons, including: • Eliminated the need for large machine

pit and vibratory table.• Enabled the production of a variety

product sizes and types, including verylarge box culverts.

• Reduced the size of overhead cranerequired – instead of an 80-ton cranethat would have been required withconventional methods, the egg lay sys-tem uses a 15-ton crane because theproducts do not have to be movedsince they are poured and cured inplace. A preexisting 40-ton crane isused to remove cured product from thebuilding.

• Existing building could be used withoutmodifications such as additional rein-forcement or expansion.

• Dry casting offered higher productionvolume versus the wet cast alternative.

• Enables production of two three-sidedboxes in a single pour.

• Enables the use of a continuous single-offset rubber gasket for products up to12 meters in span, providing a strongand unique competitive advantage

“We were able to get up and running veryquickly because the required infrastructurewas minimal compared to other alterna-tives,” Galloway notes. “We saved about$2 million over other options we consid-

ered and we’re getting added benefits thatother systems could not provide. The factthat we’re not moving products by cranemeant we could get away with a muchsmaller crane, sized just for lifting the con-crete feeder and forms. We also didn’tneed to modify our building.” M-Con’s Ayr location has been using theHawkeyePedershaab modular box culvertsystem for nearly a year. The new produc-tion system has enabled the firm to meet theneeds of a wide range of customer require-ments, including major highway projects,and private and municipal storm water andwaste conveyance works.

According to Galloway, the adjustable boxculvert forms enable the firm to producealmost any size up to 12 meters in span(see figure7 to 10). “We needed to get into the market quicklybecause the opportunity was there,”Galloway says. “This type of productionsystem not only provided a quick turn-around, but lets us meet our customers’needs for almost any size box culvert.”

Custom benching made easy

Doing more with less—less labor, less waste,less time—is a challenge for every business.Not only has M-Con gained a competitiveedge in box culvert production, it has addedan innovative new capability that is helpingit deliver manhole products that offer morevalue for their customers.

The firm, earlier this year, installedHawkeyePedershaab’s Smartcast monolithicmanhole base production system (see figure11). This new production system provides M-

Figure 11 -- M-Con’s Smartcast monolithic manhole base productionsystem enables the firm to create wet cast base sections with an infinite number of channel possibilities. The system combines designsoftware and a six-axis milling robot to create EPS mold formers for the production of monolithic bases with standard or custom flowchannels with smooth, glass-like flow surfaces.

Figure 12 -- Finished EPS mold insert ready for installation in themold. Inlet and outlet openings are also molded in to eliminate theneed for coring. The system saves labor and provides consistent,reproducible accuracy.

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Con with a holistic approach to producing wet cast base sectionsencompassing an infinite number of channel possibilities. “Manhole bases are one of the things that used to be done on site,”Galloway ex plains. “However, precast bases offer so many advan-tages to the contractor. Speed, accuracy, and quality are all betterwith a precast product. In the past, we would manually bench thechannels called for in the design. With that, there was finishing, trow-eling, and coring involved.” The new Smartcast system uses stock or customer-provided manholebase designs to mill a complete channel mold out of solid EPS (seefigure 12) using a software-driven robotic milling system. M-Conacquires its EPS blank stock locally and recycles milling and mold-ing waste to achieve the greenest and most cost-effective processpossible. The system control software allows the engineer or designer to inputa few key variables, including the number of connections, connec-

tion angles, elevations, and the type of connections (e.g., PVC, con-crete, clay, etc.). In just a few minutes, the Smartcast system createsa manhole base design that controls a six-axis industrial millingrobot. Each manhole base design may be stored for future recall,enabling accurate repeatable production. This process results in the production of monolithic base products(see figure 13) with very smooth flow surfaces; thereby reducing theimpact of scour and optimizing hydraulic flow through the unit (seefigure 14). “We use the system to bench manhole base up to 1200 millimeters,including the inlet and outlet openings, in a fraction of the time itused to take with manual methods,” Galloway notes. The Smartcastsystem can handle up to 1800-millimeter bases. “The Smartcast sys-tem eliminates a lot of steps and the quality is exceptional—glass-likefinish.” Was it hard to decide to invest in these new solutions? “I’ve been inthe business for 40 years,” Galloway notes. “The demand for alltypes of precast products is growing every year. These new andinnovative solutions are helping us meet current demand and willenable us to adapt and meet future needs as well. We’ve relied onHawkeyePedershaab for more than 20 years—they are our firstchoice for the bulk of our production systems. We trust their solu-tions.” �

Figure 13-- The milled EPS former fits tightly against the mold jacket,complete with inlets and outlets.

Figure 14 -- At left, a channel former milled out of EPS on the HawkeyePedershaab Smartcast system is installed, ready for filling. On right,finished base product has glassy smooth flow surfaces for optimal hydraulics.

FURTHER INFORMATION

M Con Pipe & Products Inc.2691 Greenfield Road,Ayr, Ontario N0B 1E0, CanadaT +1 519 632 9112F +1 519 632 [email protected]

HawkeyePedershaab506 S. Wapello St. Mediapolis,Iowa, 52637, USAT +1 319 3943197F +1 319 [email protected]

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