Steel Fabricators' Review V40 - Spring 2012

A PEDDINGHAUS PUBLICATION FOR FABRICATORS MAKING TODAY’S SKYLINE POSSIBLE

Waiward Steel Structural Fabricators Alpha SteelFab Steel Services

Looking Back & Looking Where Production Ahead: Technology Pays Off Takes Flight PAGE 5 PAGE 6

Flexing American Muscle in the Magnolia State PAGE 8

New Raptor CAD/CAM Software Takes Flight 2012 NASCC: Peddinghaus Goes BIG in Texas!

Experience the Advantage 2 PCD-1100/3C Drill Line PeddiWriter Automatic Layout Marking System Success of the PeddiWriter Fully Automated Welding is Here: The Zeman Steel Beam Assembler System Getting to Know the Peddinghaus Engineering Team Welcome to the new www.Peddinghaus.com

10 PAGE 11 PAGE 12 PAGE 14 PAGE 16 PAGE 18 PAGE 20 PAGE 24 PAGE

VOLUME 40

SPRING 2012

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STEEL FABRICATORS’ REVIEW

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More projects coming from the American Institute of Architects. The latest Architectural Index Report from the AIA reveals a third consecutive month of growth – that means that Architects are working on more projects. There is an increase in commercial/industrial and institutional projects which is good news for steel construction.

2 Lyle Menke

Confidence Breeds Success In the last issue of the STEEL FABRICATORS’ REVIEW, I described four reasons why the Structural Steel Fabrication industry should be optimistic about 2012. As I write this article at the end of the first quarter… there are valid reasons to be optimistic indeed.

Take a moment to evaluate each scenario, and you will detect a pattern of market confidence.

That confidence should be your guide as your firm moves forward in 2012 to seize the opportunities available.

AISC Year End Report Bucks Trend with 2% Overall Growth in 2011. As stated

by John Cross, AISC V.P., this fourth quarter bounce is an encouraging sign and indicates that 2012 growth will probably be in the range of 8%. These numbers must be tempered with previous yearly performance, but there is a definite positive trend on the horizon! Additionally, the AISC advises that the market share of structural steel remains strong at 58% – another good indicator.

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Steel Service Centers are Thriving. With the manufacturing renaissance in the USA (even echoed in Washington DC), service centers are seeing increased business and new opportunities from various sources. Steel is King – time to capitalize!

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New Technologies are Proving Themselves.

Last issue, we wrote about the new PeddiWriter Standalone Layout Marking System from Peddinghaus. With multiple machines in the field, users are reporting OUTSTANDING PERFORMANCE. Productivity and Accuracy are both increased – and a major benefit is the ability for their workforce to move from tedious manual layout to productive shop areas – energizing their personnel!

SPRING 2012

The goal at Peddinghaus is to promote Steel Construction/Fabrication to all future and potential industry members. There is no better way to promote our industry than to educate every attendee about the wonderful aspects of our market place.

Bringing Fabricators Together …

Serving the Industry Have you noticed that there is always a central theme to Peddinghaus’ activities? Whether it is a Motorcycle Tour, or a Networking Dinner Event, or a Show Booth Presentation on the Show Floor – Peddinghaus Brings Fabricators Together – to discuss the “state of the industry”.

Global fabricating firms make a point to attend our networking events to discuss new business opportunities in international markets.

Peddinghaus works closely with all industry organization partners: AISC, AWS, MSCI, FMA; all of them. We participate to insure you receive the information you need to successfully operate your fabrication business.

So Join Us at the NASCC in Dallas!

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Our Fabricators’ Motorcycle Tour kick starts April 13th. We head to San Antonio and Houston to visit Markle Manufacturing, Sefton Steel, and Schuff Steel. Compare notes with other fabricators on today’s techniques! We’ll also take in a NASCAR race and visit an authentic Texas ranch over the weekend.

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We Celebrate Steel at our Wednesday night Networking Event at the Glass Cactus Nightclub: join fellow fabricators in an informal atmosphere to “talk fabrication”.

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Educating the Industry – It’s in our DNA

How will Election 2012 affect your business? What will happen to structural steel fabrication the next 4 years if the Republican or Democratic candidate wins in November? Join our Political Point/ Counter point on Thursday, April 19 at 2 pm as Peddinghaus Presents: The Race to the Presidency; Where Will You Finish in 2012?

At the NASCC Conference, you will see Peddinghaus in many venues. On the show floor, at the Network Event, riding on our Fabricators’ Motorcycle Tour, at Texas Motor Speedway … Everywhere!

James Carville, Pat Buchanan, and moderator Ben Stein will lead the discussion – and will be available for an exclusive “Meet and Greet” with participants in Peddinghaus Booth 1201.

Why does Peddinghaus invest so much in the Steel Construction Industry? Easy, “this is where we live”… steel fabrication is in the DNA of every Peddinghaus employee.

Join Us for an Entertainingly Educational Event!

Don’t take our word – read from our satisfied customers in the pages of this magazine… a common term is 10 to 1 productivity over manual methods.

The PeddiWriter is a Winner – Shouldn’t your shop explore this “technology that works”?

BUCHANAN

CARVILLE

STEIN

SPRING 2012

STEEL FABRICATORS’ REVIEW

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FROM THE CEO Hope Springs Eternal

It is that special time of the year again — Spring time! And as everyone in the Steel Construction industry knows, Spring is a time for renewal and experiencing groundbreaking events: like new construction projects — and the NASCC Conference.

The NASCC is a benchmark event for all of us who participate in steel construction, and this year promises new opportunities for all sized fabricators! As we travel across the USA, fabricators advise that they are very optimistic about the future. They advise that some delayed structural steel projects are progressing and more new steel projects are coming on-line as well. “Better margins and fewer competitors on

Anton Peddinghaus

Nobody Does the NASCC Like Peddinghaus…

• Our Fabricators’ Motorcycle Tour of Texas kicks off events on April 13th with a 5 day tour of the Lone Star State: NASCAR, Dude Ranch, and Fabricator Networking – a great combination!

• Booth 1201 is the hot spot on the show floor! See the highly successful PeddiWriter, rugged 1250-510 band saw, and the Advantage 2 under power • You are invited to our Special Networking Event on Wednesday, April 18, as we celebrate steel with comedian John Pinette, the Dallas Cowboy Cheerleaders, live music – and more surprises…

• Peddinghaus Presents: The Race to the Presidency; Where will You Finish in 2012?

the bid list”, are frequent comments.

Join us for an exclusive Executive Briefing, featuring hot topics that affect you and everyone in the structural steel fabrication industry.

Learn “both sides of the argument” from James Carville, Pat Buchanan, and moderated

by Economics Expert, Ben Stein.

We’re Listening to YOU I want to thank you again for reading our STEEL FABRICATORS’ REVIEW magazine.

Our Marketing team does a great job of researching industry topics that our readers tell me are educational, informative, and useful for their companies.

Speaking of marketing, check out Peddi-TV on the internet! This video magazine covers new industry topics in a lively, entertaining style. Learn how Selvaggio Steel used their Peddinghaus equipment to provide new markets and revenue for their firm. Check out Peddi-TV on the web: www.peddinghaus.com/pedditv.

What Makes an Industry Leader?

Why do our customers, industry colleagues, and business partners consider Peddinghaus to be number one in the steel construction/fabrication industry? Without sounding too arrogant, we believe these facts have a lot to do with it: • The New PeddiWriter Standalone Layout Marking System – the labor saving Game Changer in Structural Fabrication profitability • The Advantage 2 High Speed Carbide drill with 5 station Tool Changer – Tomorrow’s Technology Today for profile drilling • Our new Raptor Software – 3D Design for today’s modern software platform • 24 Hour World Class Customer Service and Support – unparalleled in the industry • Made in the USA by skilled craftsman who understand quality

Partner Up With Peddinghaus

At the NASCC, you will experience what our current customers understand already. In uncertain times, you need a solid business partner to support you. You require an established teammate, well schooled in the steel fabrication industry, and dedicated to your firm – not just now – but into the future as well.

For more information visit nascc.peddinghaus.com

Continued on page 8

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FROM THE CEO Continued from page 3

It’s Really Pretty Simple: You Want a Business Partner that Won’t Let You Down at a Critical Time A listing of a few fabricators that have placed their confidence in Peddinghaus over the past few months.

Continued on page 8

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STEEL FABRICATORS’ REVIEW

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WAIWARD STEEL FABRICATORS

Looking Back & Looking Ahead: Technology Pays Off

The PeddiWriter is fed by 3 Peddinghaus drill lines at Waiward Steel.

Peddinghaus’ Technology Makes the Difference

Terry Degner, President and Rob Wright, V.P. Shop Operations Manager.

Oh yes, one more thing – they have applied Peddinghaus’ technology which has helped grow their business steadily through the ups and downs of a turbulent market.

In 2005, our STEEL FAB REVIEW article started like this…

A Working Partnership: Waiward Steel & Peddinghaus

Waiward Steel Fabricators, Edmonton, Alberta, Canada, is an industrial fabricator specializing in the oil and gas, pulp and paper, and petrochemical industries. Founded in 1971, Waiward’s services include the fabrication and installation of structural and miscellaneous steel, equipment components, hoppers, plate work, material handling equipment & conveyors, and bridge girders… among others.

The SFR staff sat down with Waiward President Terry Degner and Shop Operations Manager Rob Wright, to discuss the “state of the industry” now and in the future. Here are their comments about a commitment to automation and technology.

7 Years Later, Waiward is Still Thriving…

Essentially, that statement is true, Waiward still fabricates virtually all types of structural steel applications that come their way. No job is too big or too small for this 40,000 ton/year shop.

Waiward is grateful to their customers; they are proud of their workforce and facility; and they have confidence for the future.

The PeddiWriter supplies steel to an array of welding stations.

“We started our automation process in 1989. We purchased a Peddinghaus drill/saw line, a Fabripunch plate machine and an AFPS 643 Anglemaster.

By 2005, we were running nine (9) Peddinghaus machines in our shop: • 3 drill/saw lines (2 of BDL 1250/9 and BDL 760) • 2 plate lines (FPB 1800 & FDB 1500) • ABC Coping system • Anglemaster AFPS 643 Today, in 2012, we employ these Peddinghaus machines every day in our Production: • 3 drill/saw lines (1 BDL 1250 D-carbide; 1 of PCD B; 1 of BDL 1250/9 B) • 3 plate lines (2 of HSFDB high speed; 1 FPB 1800 – still running from 2001) • ABC Coping System (still running from 1992) • Anglemaster AFPS 643 (from 2005) • The new PeddiWriter Standalone Marking System WOW – what a machine!!!

Why Invest in the Latest Technology – the PeddiWriter?

Waiward Steel purchased one of the first PeddiWriter Standalone Layout Marking Systems from Peddinghaus.

The PeddiWriter is strategically positioned to feed the welding bay at Waiward.

(Editor’s Note: When we mentioned the word “PeddiWriter” – both Terry & Rob began smiling.)

TERRY: “The PeddiWriter machine concept was very intriguing for us – could one machine actually “write” all the data onto a beam – just like our existing layout and fitters?” The answer is “YES”!

ROB: “We explored the best location in our shop for the PeddiWriter, and we positioned it after our drill lines, integrating with our Peddinghaus conveyor/transfer handling system … Wow does it produce steel!”

Layout a Beam or Column in Minutes – Not Hours? YES PeddiWriter!

In side by side comparisons of an experienced shop layout technician (or fitter), the PeddiWriter reveals a 10 to 1 productivity edge.

ROB: “We started slowly as we became more familiar with the Plasma marking technology, but today we average about 60 beams/columns per 10 hour shift.”

Robbi Dosanj is the foreman in the fit up area, and he monitors production closely.

ROBBI: “What impresses me is that it is simple to operate. Peddinghaus software can extract the exact shape (beam, column, channel, tube) from the 3D model, and we are ready to run. The operator need only check for the right beam and the corresponding program.”

Continued on page 6

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WAIWARD STEEL

SPRING 2012

ALPHA STEELFAB

Continued from page 5 “Also, with the plasma technology, we don’t use many consumables – we have spent only $50 on plasma electrodes and nozzles in 3 months on a multi-shift basis.”

Where Production Takes

Automation (+ Accuracy / - Man hours) = Competitiveness TERRY: Like every fabricator in North America, we compete in a tough, competitive market. Even in Western Canada, we compete with fabricators in Asia and other global locations. The only way to stay competitive is to reduce man hours per ton with “workable technology”.

Peddinghaus has brought that automation technology to Waiward since 1971.

ROB: If you look at the carbide drilling technology that we employ on our BDL 1250 D drill line and our two HSFDB plate processing machines – it is hard to imagine where we would be, if we had not pursued the latest technologies.

We are producing holes now in 2-3 seconds compared to 9-10 seconds. The productivity speaks for itself, and gives us the edge against competitors using older technology.

It is all about producing a quality product faster and more accurately. A quality product remains the benchmark in today's competitive market.

Waiward Needs Round the Clock Service: Peddinghaus is There Being a good partner is true in any relationship – you need to be available and resourceful to assist where possible in any type of situation or circumstance.

Clayton Hanson (Akhurst), Bruce Hemphill (Peddinghaus), and George McCarthy (Akhurst) insure that service is priority for all Peddinghaus customers.

How does Peddinghaus help Waiward?

1. Peddinghaus has an experienced service technician available within the area 2. Peddinghaus’ local dealer, George McCarthy and Akhurst Machinery, maintain parts AND service technicians as well 3. 24 hour telephone customer support from the Bradley, IL USA headquarters with knowledgeable Peddinghaus technicians on the phone 4. Same day parts shipments if required from the largest parts inventory in the industry 5. Today’s electronic trouble shooting technology: from web cams to remote diagnostics – Akhurst/Peddinghaus uses them all – and then gets a qualified technician to you pronto 6. Peddinghaus CARES about customers…it’s in their DNA

Since 2005, Some Things Never Change: It’s Still People Embracing Technology “Waiward was founded in 1971 by two young Alberta farm boys who took their rural work ethic and love of steel construction and started a new enterprise. By applying these same strengths, Waiward Steel has flourished.”

(Yes, that’s a quote from the 2005 SFR article.)

Isn’t it refreshing to learn that a good work ethic, smart decision making, and having the foresight to invest in tomorrow’s technology today, makes the difference in today's structural steel fabrication market?

“It ain’t easy out there, but when you have a plan and a technological partner on your side – the odds are in your favor.”

The Alpha SteelFab Team from Right to Left: Bobby Owens (Plant Superintendent), Britt Fletcher (VP of Operations), and Chad Brewer (Plant Manager)

When Airbus describes their latest aviation innovation, the A380 jetliner, they simply make the statement “Love at First Flight”. The world’s largest commercial aircraft, the A380 has the capacity to carry up to 525 passengers on a single flight. It may be hard to imagine the experience as a passenger aboard this flying titan, but even harder to imagine is the experience of an emergency situation aboard such an aircraft.

All airports have what is known as “fire trainers”. These “mocked-up” metal vessels are what firefighters use to practice emergency circumstances aboard grounded airplanes.

Since the A380 is such a massive vessel, with multiple decks of passengers and cargo, a life sized model needs to be made to prepare local fire teams if such an emergency ever were to occur. That’s where Alpha SteelFab comes into the picture.

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STEEL FABRICATORS’ REVIEW

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Flight

Even the overhead bins are simulated on the A380 mock-up.

The inside of the A380 mockup is as real as it gets – from staircases to restrooms – it's all made with steel.

The PCD-1100/3B drill line in tandem with 1250-510 band saw are the perfect pair for Alpha's unique production requirements.

When Airbus describes their latest aviation innovation, the

True Texan Tenacity

A380 jetliner, they simply make the statement “Love at First

The team at Alpha SteelFab in Melissa, Texas exhibits the true Texan tenacity needed to attack complex fabrication projects. Britt Fletcher, Vice President of Operations, fosters a can-do approach which is evident in all aspects of operations.

“Whether it’s churches, stadiums, petro-chemical, or office buildings, the team at Alpha SteelFab never backs down from a challenge,” states Mitch Reeves, President of Alpha SteelFab. “I was confident that our team was capable of succeeding with this project. Not a lot of people in my place can say that.” With production designed to soar above the competition in any bidding bout, the prospect of engineering and fabricating a mock-up A380 jetliner was an intriguing challenge to say the least.

Combining good old fashion know-how with modern technology, the team at Alpha SteelFab truly takes flight.

sensors, propane piping, and irrigation that all come together to make this project a success.

Flight”. The world’s largest commercial aircraft, the A380 has the capacity to carry up to 525 passengers on a single flight.

It may be hard to imagine the experience as a passenger aboard this flying titan, but even harder to imagine is the experience of an emergency situation aboard such an aircraft.

All airports have what is known as “fire trainers”. These “mocked-up” metal vessels are what firefighters use to practice emergency circumstances aboard grounded airplanes.

Since the A380 is such a massive vessel, with multiple decks of passengers and cargo, a life sized model needs to be made to prepare local fire

The A380 Project Lifts Off

teams if such an emergency ever were to occur. That’s where

22' wide, 26' tall, and 160' long are the dimensions of the mock-up airplane. Literally a 3 story building, the airplane mockup has simulated seats, overhead bins, and yes – toilets. “Who thinks that a fireman needs to know that there is a third deck?” states Britt Fletcher. “This plane is different than a 737, and firefighters need to be familiar with the obstacles they would encounter in an emergency.”

Alpha SteelFab comes into the picture.

The 500,000 lb airplane mock-up is designed for the full firefighting experience. There are heat

“The project will ship in 10 sections, the heaviest of which is 60,000lbs. We had the pleasure to take this project from design to completion and are scheduled to finish on time in April 2012,” states Britt.

Top Class Technology for an Innovative Fabricator Complex projects such as the A380 mock-up require versatile equipment. The Peddinghaus Advantage drill line provides the strength, speed, and flexibility that Alpha SteelFab demands.

“Originally the only equipment we had was a band saw. All holes were drilled using magnetic drills,” states Britt. “When we got ready to pursue new equipment we looked at Peddinghaus because we knew their reputation for quality machines and service support. When we installed our PCD-1100 drill line we had the chance to move our manual drilling team into other jobs such as assembly, or fitting/welding. Beyond the efficiency we had gained, our accuracy was increased substantially.

This is important to us as our reputation is for being on target, and on time. Our clients expect nothing but the best from us. We expect the same from the machines we operate.”

The Advantage drill line in tandem with 1250-510 straight cut saw eliminates the manual layout for hole drilling, increasing accuracy and efficiency.

For detail components, an Ocean Clipper angle line has brought production to a whole new level.

“I remember when we installed the Clipper,” stated Chad Brewer, Plant Manager. “We ran the machine for part of the week, and finished ALL of our angle work! I was worried that this was going to be a problem, but in the end it was exactly what we needed. When the operator wasn’t on the Angle Line he could do other work. We don’t even worry about angle detail anymore because our system is setup so well for it.”

From heavy structural members, to angle processed on the Ocean Clipper, Peddinghaus equipment delivers paramount production.

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FROM THE CEO Continued from page 4

STRUCTURAL STEEL SERVICES – MERIDIAN, MISSISSIPPI

Flexing American Muscle in the Magnolia State At Peddinghaus we pride ourselves on our 24 Hour customer support.

We pride ourselves on strong, solid equipment that uses today’s “workable” technologies. We pride ourselves on having a deep organization that is totally dedicated to customer satisfaction. Make a trip to Bradley or Andrews and experience it for yourself. We LOVE to have visitors!

Thank You to Our Customers/Friends I wish to personally thank all of our customers and friends who have expressed their confidence in Peddinghaus Corporation by purchasing our equipment in the past months. We deeply appreciate it.

As you review this industry list on page 4, I’m sure you will see some structural steel fabrication firms: some are very established and some are relatively new. However, all have become Peddinghaus’ partners in the last year.

See You in Dallas…

I’m looking forward to meeting you at any of our upcoming events at the NASCC. If you are riding a motorcycle, enjoying John Pinette, or learning about America from Buchanan, Carville, or Stein – remember one thing – Peddinghaus is always on your side. So why not join the Peddinghaus Partnership?

We won’t disappoint you.

Remember, the market is improving, labor saving Peddinghaus machines are

Tony Dean, Executive Vice President and General Manager at Structural Steel Services.

Bigger, Faster, Stronger Located near the eastern border of the Magnolia State, Structural Steel Services has proven to be the king of the Queen City – Meridian, Mississippi. Heavy industrial work takes on a whole new meaning for Tony Dean and his team at Structural Steel Services. From power plants to petrochemical work, it’s common to see anywhere from 1,000 tons – 1,500 tons per week of fabricated steel leave their facility. Sections that commonly exceed 500 lbs per foot are in abundance, projects that reach 30,000

available, tax incentives exist in 2012,

tons are commonplace, and a tenacity to tackle big projects with short lead times is

and you have a reliable partner.

contagious. Armed with their Peddinghaus equipment, the sky is the limit for

Let’s toast to a fantastic 2012 –

Structural Steel Services.

because my glass is ALWAYS half full!

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STEEL FABRICATORS’ REVIEW

Angle detail is processed by a Peddinghaus AFPS-643 Angle Line.

Sections such as this W14x730 beam are common sights at Structural Steel Services.

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The BDL-1250/9B Drill Line is ideal for sections up to 730 lbs per foot.

Growing with Automation Automation has long been a key component to the success of the firm. With a critical eye for the strength and speed needed to accommodate their workload, machinery is something that Structural Steel Services knows well. From self made milling machines to state-of-the-art welding systems every aspect of production is viewed as a link in a chain advancing production.

The machine was processing 3 pieces per shift. On two shifts we had 120 tons of steel pass through that drill in a twenty four hour period! Nobody touches that machine.”

Peddinghaus plays a major role in the production at Structural Steel Services.

With a reputation for dependability, speed, and capacity, Steel Services demands the same attributes from their equipment, and Peddinghaus delivers.

Structural Steel Services' methods are so advanced that at the point other fabricators were bidding below cost, they were capable to match bids while still turning a profit. This capability is not due to powerful equipment alone.

Beyond their ingenuity and powerful equipment, Structural Steel Services holds customer service to a high standard when meeting deadlines and satisfying clients. Running two ten-hour shifts each day, seven days a week, the 24 hour service department that Peddinghaus provides has become a useful tool for Structural Steel Services’ production.

“We researched other makers of machinery when looking for new equipment.

We visited shops to checkout their machines. We always looked for the best and most dependable machines in operation in the field, and we chose Peddinghaus,” stated Tony Dean, Executive Vice President and General Manager of Structural Steel Services. “Even at the time of the F-1170 duplicator Peddinghaus was ahead of the industry. If my competition didn’t have one I would beat their bid every time. Peddinghaus machines are reliable, dependable, and make you money!”

Progression is in their Blood The BDL-1250/9D heavy duty carbide drill line is the backbone of production at Structural Steel Services. With the ability to handle the heaviest sections, and eliminate the need to change tools by applying a nine spindle design, the production of this machine proves to be unmatched.

Having replaced an existing BDL-1250/9A, the more advanced D-model has shattered production figures when compared to yesterday’s drill line. “The BDL-D is five times faster than our previous drill for the heavy industrial work we process,” stated Tony Dean. “We had one specific job with 350 columns over 500 lbs per foot. These sections were 20 tons per piece!

A Trusted Partner

“Peddinghaus customer service does a great job helping us with our machines.

There are many veteran service techs that we know from decades of doing work with Peddinghaus. Additionally there are a lot of new technicians that are well prepared to help us out when we call in,” stated Tony Dean. “Our needs are met extremely fast by Peddinghaus’ service department. We wouldn’t change a thing about it.”

Competing in a Global Marketplace In a world where international competition is affecting the global marketplace, Structural Steel Services is turning the tables on international competition by exporting to Asia. For over five years the firm has been competing within Asian markets. There have been some growing pains along the way; language barriers have been evident, deliveries can be complicated, and international export has its surprises; but Structural Steel Services continues to succeed in foreign lands.

On Structural Steel Services’ first major power project shipped internationally, the plant began generating power an entire 27 months ahead of schedule!

The proof is in the project, and it’s easy to see that no matter the location in the world, Structural Steel Services delivers.

The BDL-1250/9D Drill Line is the backbone of production at Structural Steel Services.

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New Raptor CAD/CAM Software Takes Flight Raptor CAD/CAM software from Peddinghaus takes flight in Dallas at the 2012 NASCC. Designed to match the robust build quality of Peddinghaus machinery, Raptor simplifies operations while providing value added production options.

A 3D Design Interface for Streamlined Programming

For a world that demands complex layout marking on four surfaces of a structural profile, Raptor provides the ability to manipulate nests and part programs within a custom designed 3D user interface.

Designed with user friendliness in mind, the Raptor 3D User Interface is intended to create programs using the following features: • Generate holes using the single hole, hole matrix, or hole circle development tabs • Generate copes by entering basic data in one of 3 cope creation tabs • Automatically apply "pop-marks" or scribe marks using one of several tabs • Create weld layout scribes using the user friendly weld layout scribe tab • Add corrections using the enhancements tab in order to dictate cope modifications such as rounding radii, web clearance, lead in cut radii, etc.

• Nest parts onto a common stock length for batch processing

Data Import Features for All Fabricators DSTV IMPORT MODULE In today’s world of structural fabrication buildings are commonly designed within modern BIM programs. BIM software such as Tekla, Design Data, AceCad, Steel Office, and much more transfer the original design of connections directly from the BIM model into common file standards (such as DSTV) which are then capable of being imported into CAD/CAM software platforms. For fabricators that rely on this established standard of DSTV to program equipment, a DSTV import module is available for use with the Raptor software platform.

OPTIONAL TEKLA API MODULE Users of Tekla structures have the option of importing Tekla geometry directly into the Raptor software platform. Although Tekla allows for export into a common file standard (DSTV) the optional Tekla API module allows for a variety of advantages which not only expedite machine and programming operations, but allow for value added file features not previously available.

The intuitive data transfer configuration between Raptor and Tekla structures is condensed into a single dialogue box where one may only need to select the part within the building model and click the button “GO!”. The program is then automatically generated with the selected presets and stored at the desired file location ready for production.

THE BENEFITS OF THE RAPTOR TEKLA API MODULE: • Automatically generate layout and scribe marking directly from the building model • Automatically generate part identification - scribe the part, assembly and project name on any surface of material with no manual programming • Automatically program lead-in cuts for thermally cut components • Properly align flange thinning with web material compensation. This ensures that copes don’t cut into web material as can occur with DSTV file conversions • Capable of selecting or omitting specific features required to program a certain type of machine (For example, When programming a drill line, it may be necessary to omit coping information)

Raptor’s Peddimat Export Module Existing software is not forgotten with this latest version of Peddinghaus CAD/CAM programming. For fabricators with multiple machines already installed operating with Peddimat software, a Peddimat export module is available for seamless integration between platforms. All programming, or data importation can take place within Raptor and easily exported into a Peddimat part file for drilling, cutting, or layout marking.

For more information on the new Raptor CAD/CAM program visit Booth #1201 and request a live demonstration!

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EXPERIENCE THE P C D - 1 1 0 0 / 3 C

D R I L L

L I N E

A

B

H F

H D

G

H C

E

Thrive in a Global Market Faster production means lower cost per ton of fabricated steel. When everyone buys and sells steel for similar prices, how do you win contracts and stay profitable?

CAMELOT METALS: Roseville, Minnesota BEFORE: Two TDK-1000 Drill Lines

A POWERFUL SIEMENS SPINDLE MOTORS

AFTER: One PCD-1100/3C Drill Line

• High Speed 25 HP / 18.6 kW Siemens

RESULT: Faster Production and lower overhead

spindle specific motors • Break-neck speeds of up to 2250 RPM

“The new Advantage 2 significantly reduces the amount of time it takes to process material,” David Kudebeh, General Manager of Camelot Metals said. “This machine increased production volume by 35%! We were drilling holes at about 8-9 seconds per hole, and now we can run them even faster at 3-4 seconds per hole.”

B FIXED LEAD SCREW SPINDLE MOTION • Siemens servo motors paired with a robust fixed lead

screw make for a powerful combination on the Advantage 2 • Rotating positioning nuts on each of the spindles are the source of movement for each spindle axis

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C 5 STATION TOOL CHANGERS • Each

of the three spindle axes on the ADVANTAGE 2 comes fully equipped with 5 station automatic tool changers • Automatic tool changing on the ADVANTAGE 2 minimizes the need to manually switch tool sizes or enter the machine operating area

STEEL FABRICATORS’ REVIEW

F NEW VERTICAL HOLD DOWN DESIGN

• Roller measurement with automatic height control

makes for paramount accuracy and unmatched versatility • Start your conveyors outside unprotected in any climate to free shop space for other processes such as welding and fit-up

E DUAL HORIZONTAL CLAMPS

line are designed to firmly hold thin flanges rigid for drilling with carbide tipped tooling and eliminate unwanted vibration

• An available scribing tool is placed into the automatic tool changer and selected by the machine when scribing is used in a program • The ADVANTAGE 2 is capable of scribing any character or shape in multiple orientations and depths • Scribing is possible in each of the spindle axes, as well as the underneath side of a profile

OLD WAY

G THROUGH THE TOOL MINIMUM QUANTITY LUBRICATION SYSTEM • Ecologically friendly minimum quantity lubrication is

implemented on the new ADVANTAGE 2 drill line • This vegetable oil based lubricant can utilize as little as 5% solution to 95% air when drilling. Parts come off the machine nearly dry and ready for the next operation, whether it is welding or painting, without the need for excessive cleanup operations

4

Axis Scribing

I ONBOARD HYDRAULIC UNIT • The footprint of the ADVANTAGE 2 is further

minimized by using an onboard hydraulic unit • The limited use of hydraulics on the ADVANTAGE 2

drill line allow for a lighter and smaller 5 HP (4 kW) power unit than on previous versions of the PCD-1100 drill series

METAL PROCESSING CAPABILITIES & MACHINE SPECIFICATIONS

• The independently operating horizontal clamps on the

ADVANTAGE 2 allow for more direct and rigid clamping than ever before

H MULTI-AXIS CARBIDE SCRIBING

• The new vertical hold downs on the ADVANTAGE 2 drill

NEW WAY

D ROLLER MEASUREMENT MATERIAL HANDLING

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INCH

METRIC

Maximum Profile Dimensions

44" x 18”

1100mm – 460mm

Minimum Profile Dimensions

2" x 3/4”

50mm – 20mm

Spindle Power

25 HP (S6-40%)

18.5 kW (S6-40%)

Layout Marking

4 Axis Carbide Scribing

Maximum Spindle RPM

2250 RPM

Tooling

Carbide – High Speed Steel Insert, Twist Drills as Desired

Tool Changer

1 Each Axis x 5 Stations Each

Lubrication System

Minimum Quantity Lubrication

BEAMS

CHANNELS

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SQUARE TUBING

ANGLES

FLAT STOCK

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A concept so advanced, so innovative, Peddinghaus is the first in the world to provide it…

The PeddiWriter Automatic Layout Marking System • Faster than 5 Fitters • Layout 7 - 8 Profiles per Hour • Accuracy, Accuracy, Accuracy…

Don’t ask us – Peddiwriter users tell the story on page 16

Streamline the Layout of Any Welded Connection Including: • Web Stiffeners • Base Plates • Shear Tabs / Fin Plates • Flexible End Plates • Bearing Pads • Moment End Plates • Welded Flange Plates • Moment End Connections • Welded Splice Plates

• Gusset Plates • Cap Plates • Welded Angle Seats • Welded Beams to Columns • Haunched Beam End Plates • Uniform Force Bracing Connections • Uniform Force Bracing Connections

Cut Costs, Increase Efficiency, Improve Accuracy, Succeed in Today's Market!

Peddinghaus, Masters of Measurement… from Beams to Plate and Everything In Between

Within some of today’s fab shop facilities, you may find an army of layout personnel – equipped with t-squares, prints of assemblies, and the dreaded soap stone marking tool. This is common practice throughout the industry, and rightly so. Few options were previously available that focused solely on the fit up requirements of today’s structural fabricators.

Peddinghaus has long been a pioneer in the

Until now…

machine tool industry. This began with the first drill lines, plate processors, and much

Bust the Layout Bottleneck! – Introducing the All New PeddiWriter

more. What do these technologies have in

Eliminate the manual layout of structural sections with the all new PeddiWriter. The perfect combination of speed and strength, the PeddiWriter applies modern technology to the actions of measurement and layout marking.

common? They all apply automatic MEASUREMENT to the processes of drilling, cutting, punching, and shearing.

What happens to these parts when they leave the CNC machines of today’s fab shop?

Many of these parts are involved in larger assemblies that involve welded joints – much of which require measurement and marking as a reference for their final assembly.

Imagine one machine, integrated into your existing system that can…

• Mark on all 4 sides of a profile as a standalone operation without slowing other processes • Layout faster and more effectively than ever before with a dual torch system – do the work of an entire team of layout personnel with a single machine!

• Minimize the potential for human error by reducing manual practices • Utilize your drill line for drilling operations by relying on an offline marking station – increasing efficiency and maximizing throughput • Minimize the overhead associated with manually marking weld data and locations onto a profile – lower labor cost means lower cost per ton and higher profitability / competitiveness for your firm!

• Streamline material handling by minimizing crane handling of a profile – easily integrate into your existing Peddinghaus system due to its modular design Measurement and layout is a critical part of any fabricators operation – any operation worth investing hours of labor is worth automating and expediting to help fabricators compete in today’s market!

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The World’s Latest Technology for the Most Innovative Fab Shops: 1 MULTIPLE MARKING DEVICES FOR SIMULTANEOUS OPERATION • Two torches are better than one!

• Each marking torch on the PeddiWriter operates independently of the other in all axes of motion • This allows for doubled efficiency for 4 surface layout marking on a wide array of structural profiles

1

2 TOP TORCH: 5 AXIS ARTICULATING HEAD FOR MULTI-SURFACE MARKING VERSATILITY • The top torch on the PeddiWriter maintains a 5 axis articulating head • This torch is capable of marking on the top of web, top flange, and bottom flange of material being processed by the PeddiWriter

3 BOTTOM TORCH: STREAMLINED, INDEPENDENT UNDERSIDE MARKING • The underside marking on the PeddiWriter is facilitated by a multi-axis marking mechanism • This operates completely independent of the overhead marking system allowing for simultaneous marking of the bottom and top portions of a profile

2

4 CONTINUOUS MATERIAL SENSING • The marking mechanisms of the PeddiWriter apply constant surface detection to eliminate repetitive torch probing throughout a program • Two robust roller probes are fixed to the torch, allowing it to mark, and maintain proper standoff distance throughout a marking program

3 5 ROLLERFEED MATERIAL HANDLING • Seamless integration with existing rollerfeed production lines • Store material outside to minimize overhead and utility costs associated with maintaining large facilities • Unmatched material handling simplicity, and streamlined efficiency

6 HYPERTHERM ARCWRITING PLASMA MARKING • Clear, concise part and layout marking using the very latest in marking technology • Superb marking clarity regardless of material condition • Visible after painting and galvanizing processes • Plasma units mounted onboard machine for minimized footprint, and expedited installations

4

MODERN SIEMENS ELECTRONICS (NOT PICTURED) • Siemens 840Di Control • Siemens drives and axis control

5 METAL PROCESSING CAPABILITIES & MACHINE SPECIFICATIONS INCH

METRIC

Maximum Profile Dimensions

50" x 24”

1250mm – 610mm

Minimum Profile Dimensions

3" x 3”

75mm – 75mm

Maximum Profile Weight

43,800 lbs.

19,900 kg

Type Of Marking

Hypertherm Plasma ArcWriting

Number Of Marking Units

2 ArcWriting Torches

Markable Surfaces

Top of Web, Underside of Web, Top Flange, Bottom Flange

Number Of Surfaces Marked Simultaneously

2 Surfaces

Acceptable Profiles

Beams, Channel, Tubing, Angle, Flat Stock

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PeddiWriter Users Tell of Their Succe$$ Hot Projects are No Match for the PeddiWriter at Agate Inc. in Scottsdale, Arizona - USA. When Les McCauley witnessed the PeddiWriter at the Pittsburgh NASCC, he could only sum it up one way – “Game Changing”. The concept of the machine was an obvious step for modern structural fabrication. By creating a direct connection between shop floor automation and the Tekla BIM model, Peddinghaus introduced a whole new solution to eliminate human error.

Les McCauley, Vice President of Agate, Inc. with the PeddiWriter.

Peddinghaus is making history with the success of the PeddiWriter CNC layout machine. The first machine of its kind, the PeddiWriter is quickly defining the CNC layout marking product category with its lightning fast production times, and serious advancements in software technology.

“Our production is 25% faster with the installation of the PeddiWriter,” stated Loren Kunzie, Production Manager of Agate Inc. “I don’t mean that it made fitting 25% faster, it made everything faster. The parts just go together quicker, there is far less rework, it simply minimizes indecision on the shop floor and there are less mistakes. There’s less drawings lying about the shop, and matching parts to their weld locations is as simple as reading the numbers scribed onto the beam.”

Les McCauley, Vice President at Agate Inc. confirms with hard numbers, “We took a drawing out of Tekla and had our very best fitter layout the part. He took one hour and forty-five minutes. We then took the same part and ran it on the PeddiWriter and it only took six minutes! The machine is so efficient, that if we took it off the floor tomorrow we would need at least five fitters to replace the production that it provides. Not only does it make our production faster, but Agate saves money in erection as well. Our organization estimates that in a recent project we have saved 1,000 hours of erection time due to the increase in accuracy in our welded components! We project that we will save 2,000 hours of erection time at the conclusion of the project. I can justify this machine in one year of operation.”

Released during the 2011 NASCC in Pittsburgh, Pennsylvania, the PeddiWriter has quickly found its way into modern fab-shop facilities in all corners of the world. Fabricators in South America, North America, Europe and more are experiencing production gains that are second to none.

For more information on the PeddiWriter or to schedule a visit to an installation contact marketing@peddinghaus.com

Waiward Steel Freezes Production Costs with the PeddiWriter in Edmonton, Alberta - Canada When the team at Waiward viewed the PeddiWriter they had immediately identified how the machine could improve their production process. Always on the cutting edge of technology, Waiward invested in the machine and has not looked back yet.

“The PeddiWriter has processed as many as 153 profiles in one shift," states Rob Wright, V.P. Operations at Waiward Steel. "A conservative The PeddiWriter at Waiward has processed as many as 153 beams in average of throughput is 7-8 profiles per hour.” a single 10 hour shift.

Even the operators at Waiward are thrilled about the productivity the machine presents. It minimizes the need for printed drawings throughout the facility, and clearly identifies exactly where parts belong on welded members.

“Versus the drilling and sawing machines the PeddiWriter will process three to six sections for every profile that is drilled. We have FAST drills, the fastest in the industry. This just shows how fast the PeddiWriter is. It eliminates the bottleneck of fit-up and layout and now everyone is busy welding to keep up with the machine.”

Robbi Dosanj, Fit-up Foreman, professes the low cost of plasma layout using ArcWriter technology, “With the plasma technology we don’t use many consumables – we have spent only $50 on plasma electrodes and nozzles in 3 months on a multi-shift basis.”

STEP 1

STEP 2

STEP 3

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FULLY AUTOMATED WELDING IS HERE The Zeman Steel Beam Assembler System An Industry First

Does the work of 9 fitter/welders • Increases productivity by 85%

Automatic welding is no new feat, but structural steel has long struggled with the challenge. Although manufacturing facilities which require high levels of repetitive production have long enjoyed the cost savings of this technology, the unique aspects of structural steel weldments have provided challenges to automating the welding process within this realm, until now…

Zeman “Gets it Right” Imagine a world where detail components enter one end of a machine, beams another, and both leave the system fully fit-up, welded as dictated by the original geometry of the 3D building model. This isn’t fantasy, this is reality with the Zeman Steel Beam Assembler.

The first of its kind, a fully automated welding system for structural steel sections.

How it Works:

Benefits:

• Detail components are dropped onto a conveyor by a material handler

• SUPERIOR ACCURACY VIA COMPLETELY AUTOMATED MEASUREMENT No manual intervention during the welding process.

• These components are identified by a laser scanning system

• FASTER PRODUCTION TIMES AND HIGHER LEVELS OF THROUGHPUT Reductions in process time are commonly 85%!

EXAMPLE: Before the Steel Beam Assembler 1 ton of steel can take up to 8 hours to process manually. After the Steel Beam Assembler that same ton of steel takes just under 2 hours to process!

• Structural members are fed into the fitting/welding area as plate parts are brought into position • There are 3 robots involved with welding and fitting. 1 robot is dedicated to automatically placing parts in the correct positions, and 2 are dedicated to welding (as 1 tack welds parts to members the other creates complete welds) • Beams are automatically rotated as dictated by CNC program in order to process all sides of the profile in question • Upon completion parts are fed outside of the machine automatically as new components enter the operating area

• HIGHER QUALITY WELDING Welds are unmatched as far as quality and consistency when compared to manual labor.

• GUARANTEED SKILL In today’s world it can prove difficult, or even impossible to find the skilled labor needed to run production. Automation guarantees the labor of 9 skilled fitters and welders with the automation of a single machine.

All that is needed is 1 material handler, and 1 CNC operator!

The Zeman Steel Beam Assembler is available with a single welding line, or a double welding line to maximize throughput.

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GETTING TO KNOW…

The Peddinghaus Engineering Team Meet the minds behind the machinery…

Tapping New Technology, the Drill Group Advances Spindle Design

Just a small portion of the Peddinghaus Engineering Team.

Working together for a common goal, each of Peddinghaus’ engineers maintain individualized specialties in order to satisfy a global market for CNC fabrication technology. “There are several teams within our engineering department, each working like a cog in a well oiled machine.” Ken Coulter, Vice President of Engineering states, “their work culminates into what is widely considered the strongest, fastest, and most reliable machine tools on the market today.”

Plasma to OxyFuel, The “Burn Group” Specializes in Hot Technology As structural equipment evolves, applications for plasma or OxyFuel cutting continue to grow. The Burn Group at Peddinghaus specializes in all machines that maintain a torch assembly.

From the Ring of Fire to the PeddiWriter, the Burn Group analyzes and executes new applications for torch technology.

Burn Group Engineers Ed Brzezniak and Dan Lahners “Plasma layout marking is discuss the processes of the Ring of Fire. something we have recently implemented with the PeddiWriter CNC Layout Marking System. This machine revolutionizes layout marking” states Ed Brzezniak, Design Engineer.

Thick to Thin, the “Plate Group” Advances Flat Stock Production Plate processing can become a time consuming task. Beyond simply drilling holes, many applications require multiple operations to be performed on a single component. The devil is in the details when it comes to plate processing and Peddinghaus’ Plate Group designs solutions. “With new material handling for our plate machines, we are able to lower labor costs for our customers and reduce process time required from start to finish. Plate production is now a load, process, unload system, with no stops in between” states Ned Windeler, Plate Group Engineer.

Mike Mullikin and Jon Czernik of our Electrical & Controls Engineering group go over instructions for an electrical panel

Eric Simek and Steve Stageman of the Drill Group discuss the nuances of carbide drilling on the Advantage 2 line.

“Today’s drill spindle looks nothing like the technology of just a few years ago” states Eric Simek, Design Engineer for Peddinghaus’ Drill Group.

Using an array of precision feedback, Peddinghaus’ carbide drilling machines not only maintain optimal tool life when making holes, but are also capable of face milling, slot milling, tapping, and countersinking. Steve Stageman, Drill Group engineer reflects on his latest designs, “When we created the HSFDB spindle I relied upon my previous experience designing spindles for machining centers. The HSFDB’s design opened the door to milling, and has become the cornerstone for Peddinghaus drill spindle designs.”

Controls and Electrical Engineering Power the Future The Controls and Electrical Engineering team at Peddinghaus uses Siemens controls throughout their products to ensure the highest level of strength and versatility while performing machine functions. Peddinghaus’ Siemens controls are designed to withstand harsh shop environments unlike yesterday’s PC controls. Mike Mullikin, Electrical & Controls Engineer stated, “With our latest innovations, including the Advantage 2 Drill Line and the PeddiWriter Layout Marking Machine, we can maintain our electronic motion on all axis and limit our dependency on hydraulics. This way, we are taking part in a more environmentally friendly way of fabrication.”

Continued on page 22

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GETTING TO KNOW Continued from page 20

The Research and Development Team – Designing Fabrication’s Next Big Advancement The Research and Development Engineering team’s goal is to utilize forward thinking and come up with the next big thing. They originate an idea and bring it to life from concept to execution. Depending on the phase of the task, whether it is design or Keith Wilkey of the Research and Development production, the projects they are Team works rigorously to finish his latest working on are constantly evolving. designs.

“We always have something new coming.” States Jim Magnuson, 30 year veteran of Peddinghaus Corporation and Vice President of Research and Development. “Our type of work isn’t what we need now, it’s what customers will need in ten years.”

Leading a Digital Age, Advanced Software Engineering Connects Hardware to Software Today’s innovative machinery demands software that is equally advanced.

From the latest Raptor 3D CAD/CAM software to the Tekla API, Advanced Software Engineering continually advances the art of software programming for Peddinghaus structural steel machinery. “The Tekla API has revolutionized how our machines communicate with BIM model data. Using the Tekla API we can reduce software labor in the programming office, while simultaneously increasing efficiency on the shop floor.” stated Istok Budic, Software Engineering Manager.

Kirk Kempen of the Legacy Software Team mingles with customers and industry icons at the annual Design Data user meeting.

Legacy Software Engineering – Because Peddinghaus Never Forgets their Partners Peddinghaus recognizes the importance of maintaining original software and dedicates a team of engineers to support each of the existing 3,500 installations of Peddimat software spanning the globe. “With software available in English, German, Spanish, Polish, Portuguese, and Russian, the legacy software department ensures that no matter where in the world you are, your support is nothing but the best,” States Kirk Kempen, Advanced Software Development Manager.

Continuing to Improve Industry Benchmarks for Today’s Fabricator Peddinghaus machines are built to last, and fabricators trust Peddinghaus with their production ability. With this in mind, Peddinghaus never stops striving to be something better. “We continue to evolve our machinery not only with new designs but continually improving our existing equipment.

Our department is dedicated to keeping the customer happy. That’s what working at Peddinghaus is all about” states Norm Becker, Continuous Improvement Engineer.

To speak with a Peddinghaus engineer, contact marketing@peddinghaus.com

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VOLUME 40

STEEL FABRICATORS’ REVIEW

STEEL FABRICATORS’ REVIEW Washington and Grove Street Bradley, IL 60915 815. 937. 3800 www.steelfabreview.com

SPRING 2012

PRSRT STD U.S. POSTAGE

PAID PERMIT NO. 157 Joliet, IL

Welcome to the new Peddinghaus.com As innovative as the equipment and information it contains…

Introducing the new www.peddinghaus.com. This long overdue enhancement of Peddinghaus' website provides an intuitive insight to the world of steel fabrication machinery, and offers an online experience that is second to none.

Explore Equipment Like Never Before Online information about Peddinghaus’ products has evolved past simply advanced mechanics, and has expanded to include the key benefits provided to users. In addition, viewers have the opportunity to explore international case studies, literature, and media that is unrivaled in today's CNC machine tool world.

View the New Peddi-TV Portal Peddi-TV, your source for all things steel, has inaugurated an all new portal for video streaming. No matter where you are in the world, videos are streamed at rapid speeds. Additionally, the custom video engine designed by Peddinghaus' web development team suggests media you may want to explore as you investigate the site.

Update Yourself on All Things Peddinghaus with the SFR and Weekly Newsfeed

www.peddinghaus.com/pedditv

The industry standard for structural fabrication news, The Steel Fabricators' Review, gets a facelift on Peddinghaus’ new site with an array of features. Additionally, Peddinghaus' weekly newsfeed remains front and center, ready to dish out the absolute latest in Peddinghaus info.

And Much, Much, More...

At Peddinghaus, innovation doesn’t stop at machinery. We invite you to take a moment and experience this cutting edge resource for industry knowledge.

www.peddinghaus.com/sfr