CONCRETE PIPES AND MANHOLES

Transcription

1 Concrete Plant International AUGUST CONCRETE PIPES AND MANHOLES Texas-Size Pipe Plant Installed At Hanson Pipe and Precast SPECIAL PRINT CPI 07/02

2 The Hawkeye Group, Mediapolis IA-52637, USA Texas-Size Pipe Plant Installed At Hanson Pipe and Precast Everything is bigger in Texas! And that includes Hanson Pipe and Precast s new fully automated pipe manufacturing facility in Houston. Equipped with a Hawkeye PipePro96 Machine and form modules that produce up to six pipe at-a-time, Hanson s new facility is designed to produce tremendous quantities of pipe for the growing Houston market. Pipe are produced on a Hawkeye Pipe - Pro96 Machine. The form modules used with the machine range in diameter from 12 (300mm) to 72 (1800mm) and in - clude modules for manufacturing six 24 (600mm) pipe at a time; four 30 (750mm) pipe at a time; and two 48 (1200mm) pipe at a time. Additionally, any three modules can be simultaneously run on the PipePro96 for maximum production flexibility and output. According to Hanson Pipe and Pre - cast Production Manager Ken Morrison, outputs of more than 500 tons per production shift are achievable. The facility is designed as a single shift, double shift, or even continuous three shift operation. All manufacturing, transport and post-processing operations are fully automated. 3 The PipePro96 Machine manufactures three different sized pipe at a time on a rotary turntable. 1 A 24 (600mm) Sixpack form module is shown being demoulded at the moving floor. 2 A 48 (1200mm) Duoform module is shown being demoulded at the moving floor. Pipe are manufactured on a three-station rotary turntable PipePro96 Machine. The finished pipe are automatically offborne from the machine to a moving floor sys - tem. The moving floor is part of a circulating kiln system that transports the pipe through curing chambers. The sys tem is designed for any length or continuous production shifts. After curing, a manipulator retrieves the pipe from the moving floor system and transports it to a depalletizer. The bottom pallet and the top joint ring are automatically removed, cleaned and stored in an automatic joint ring storage and retrieval area. The pipe is then tipped, deburred, vacuum tested, marked and transported outdoors for storage. Since three different sized pipe are manufactured simultaneously, there are three separate storage rails. A built-in sorter automatically directs pipe of a given size to each storage rail. The cleaned joint rings are stored in an 2 CPI Concrete Plant International

3 Pipe are transported to curing chambers with a circulating moving floor system that permits continuous or any length produc - tion shift. 4 6 Pipe shown in the joint ring removal sta - tion. The bottom pallet and the top spigot former are simultaneously removed and fed to cleaners. The pallet and spigot former removers automatically adjusts to the pipe size entering the station. 7 After the joint rings are removed, the pipe is tipped to horizontal for presentation to the post-processing line. automatic storage and retrieval area. The individual pallet and top joint ring manipulators used to store the rings are also used to retrieve and feed rings to the Pipe Pro96 Machine. If a new mould is put into production, the manipulators automatically retrieve and feed the appropriate size of joint rings to the PipePro96 Machine. To enhance the facility s production flexibility, mould changeover time is less than one hour and the robotic handling and post-processing equipment requires no changeover as it automatically adjusts to any pipe size entering the system. To produce quality concrete pipe with excellent cosmetics, Hawkeye s new synchronized vibration technology is utilized in Hanson s new facility. This vibration technology assures dense, well compacted concrete. In addition, the form sets are equipped with attachments to enhance pipe cosmetics. These attachments include replaceable, machined jacket and core tops which permit close fits. 5 8 Manipulator shown removing 48 (1200mm) diameter pipe from the moving floor system for joint ring removal and post-process - ing. A manipulator automatically retrieves six 24 (600mm) diameter pallets and places them on a shuttle. Shuttle presents the pallets to an oiling station, cage placement station and for pickup with the demoulded form set. CPI Concrete Plant International

4 9 All pallets and spigot forming headers are retrieved and fed to the PipePro96 machine from an automatic storage area. 4 CPI Concrete Plant International

5 collector. Silos are protected by a silo overfill protection system. Even considering the large tonnage of pipe that is produced, Hanson s new facility is very safe and provides advancement and training opportunities for highlevel production staff. Morrison reports that the facility s products are receiving top reviews and that the level of quality is consistent with Hanson Pipe and Precast s corporate objective to supply superior quality products to the industry. 10 The bell and spigot end of the pipe are simultaneously deburred. Deburring equipment is designed for both round and elliptical concrete pipe. Also, top spigot forming headers are used and remain on the product throughout the curing process to insure precision joints. With the combination of stay-in-place headers and automated header removal and handling equipment, Hanson not only produces a superior joint, but actually reduced their labor costs as compared to using hand-placed shaping rings. The batching and mixing plant is a Wiggert/ACT MobilMat Mo 110 plant with a HPGM 3750 planetary mixer and a production capacity of 153 Tons Dry Cast Concrete per hour. The 4 bin aggregate row type silo has 260 CuM storage capacity (or 460 tons storage capacity), 2 X 550BBL cement silos and PCS control for unattended control room operation. The concrete batch is initiated by the Hawkeye control which monitors the concrete weight in the Pipe Pro Plus machine hopper. A Deluxe Call station with tough screen allows the operator to make changes in order quantity, batch size etc directly from the Hawkeye machine operator station. The mix water is automatically adjusted by the microwave Hydromat system that compensates water batch to perfectly maintain water/cement ratio. Aggregate Hydrotester probe in the aggregate bins compensate and maintain batch yield. The silo dust collection system is serviced by a ground mounted dust Further information: The Hawkeye Group 506 S. Wapello St. Mediapolis, Iowa, USA T F [email protected] Pipe are automatically labeled during post-processing. Wiggert/ACT MobilMat Mo 110 plant CPI Concrete Plant International