The Steel Fabricators' Review V43 - Spring 2013

A PEDDINGHAUS PUBLICATION FOR FABRICATORS MAKING TODAY’S SKYLINE POSSIBLE

Koenig Ironworks

JT Steel

Laurel Machine Co.

Big Production in the Big Apple PAGE 4

Automation – The Answer to Staying Competitive PAGE 6

Machine Shop to Fab Shop PAGE 8

The PeddiWriter Layout Marking System – Cut Costs, Increase Efficiency The Anglemaster-HD Angle Line – A Smarter, Faster, Stronger Solution GEM Buildings – A Steady Stream of Automation The HSFDB Plate Processor – The Perfect Combination of Speed and Strength Pascal Peters’ Fantastic Voyage The Zeman Steel Beam Assembler – The Way of the Future Getting to Know Ken Coulter, Vice President of Engineering NASCC 2013 – Nobody Does the NASCC Like Peddinghaus!

10 PAGE 14 PAGE 16 PAGE 18 PAGE 20 PAGE 22 PAGE 26 PAGE 28 PAGE

VOLUME 43

SPRING 2013

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STEEL FABRICATORS’ REVIEW

SPRING 2013

FROM THE EDITOR NASCC Conference – A Historical Perspective

Lyle Menke

1903 – 2013: Peddinghaus Celebrates 110 Years

It is quite a distinction for any organization to mark 110 years in existence. Occasionally, you will learn of a school or church that has reached this landmark, but rarely do you hear of family owned businesses that achieve this distinction.

Peddinghaus is one of those companies. Along with Ford Motor Company, Peddinghaus celebrates 110 years of business in 2013… and is still thriving!

What is the key to success? It’s pretty simple: a dedication to our customers and the industry that we serve.

In 2013, we will visit this topic often. It is rare that a family owned business successfully overcomes the economic, geopolitical, and financial challenges of 110 years. Through four generations of family leadership, Peddinghaus is officially classified as one of those rare, special firms.

In 1990, I had just celebrated my 10th anniversary with Peddinghaus Corporation, and in the early spring, our Marketing/Sales team was preparing to attend one of the first NASCC conferences. This one was in Kansas City at the Convention Center.

I remember it vividly because this was the first conference where LIVE fabrication machinery was exhibited to the attendees. Peddinghaus exhibited a state-of-the-art structural drill/saw combination live on the show floor.

In 1990, this was a bold move by the AISC to open up the conference to a trade show format. But as the succeeding years reveal, we now reap the benefits of those early trend setters.

The NASCC is the premier international event for steel construction. There is no other trade show or conference that is dedicated to our industry. One can walk the trade show today and experience new technologies in formats from bolting to software to galvanizing to machine tools. When you consider the top flight educational meetings/presentations, it quickly becomes a one stop center for the steel industry.

Everything you ever wanted to know about steel construction – is answered here.

Hooray for Legos Today, I’m going to depart from my usual take on the industry. My wife and I have been blessed with a wonderful family. Even though our four kids are grown, my wife and I now have the best of both worlds: grandkids!!!

When I observe my four grandkids playing, there is one toy that they all love (and clamor for) – LEGOS! Legos are the unique toys with multiple pieces that combine imagination, creativity, ability to follow instructions/diagrams and fun! What is the ultimate result? The kids BUILD things!

The end result is invaluable – kids learn the value of construction. The mathematics and physics of building are simplified into clicking small blocks together.

From building a solid foundation and supporting brace structures to esthetic windows and balconies – the whole construction package is addressed… and each kid enthusiastically displays his finished project.

I’m not an educator, but in my humble opinion, we need to keep today’s kids engaged in this type of activity. They will become the next generation of architects, engineers, software experts, and machine designers. Everything is included that we need to keep the steel construction industry strong into the next generation.

NASCC in St. Louis – Peddinghaus Wants to Talk to YOU! Visit our Booth; it’s number 405, near the front entrance.

Attend our Networking Event on Wednesday, April 17th at the Renaissance Grand Hotel.

Join us on our Harley Networking Tour that kick starts on April 12th from Bradley, IL. Sit down and enjoy a beverage with us, and let’s talk. Let’s talk steel construction. What keeps you awake at night? What machine would make your shop more productive? How can you compete in a tight market?

We may not have all the answers, but from our global perspective, we all speak the same language… steel!

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FROM THE CEO The “Spirit of Peddinghaus” at the NASCC

Welcome to St. Louis and the NASCC conference sponsored by the American Institute of Steel Construction!

St. Louis has a proud history in aviation! The Spirit of St. Louis, piloted by Charles Lindbergh, made the first solo transcontinental flight from New York City to Paris on May 20th, 1927. The aircraft was named after the city of St. Louis, as its citizens supported the building of this airplane financially as well as in the national media.

Anton Peddinghaus

Around the World in 80 Days – with Peddinghaus Oh yeah, we didn’t just visit partners in the USA. Just like the intrepid explorer, Phineas Phogg, we traveled “Around the World in 80 Days”.

Lyle and I took off weeks ago from Bradley to visit our customers all over the world. From New Zealand to Europe to Australia to the USA – and EVERYWHERE in between… our trusty balloon and basket carried us far and wide.

You will have to watch the video of our flight and customer visits. It was a pretty harrowing trip – but also pretty funny. I hope you can attend our NASCC Networking Dinner on Wednesday night for our “movie premier”.

The “Spirit of Partnership” At every NASCC conference, Peddinghaus proves why it is the industry leader in technology, networking, and partnerships.

Success in the steel construction industry requires the basics – business savvy, solid craftsmanship, fabrication shop productivity. But there is an intangible that is just as important to the success of your business – effective business partners.

Peddinghaus is that partner. From productive machine technology to shop layout expertise to superior customer service – Peddinghaus is with you for the long haul.

We know the industry – and we share our knowledge with our partners.

You know me by now! What better way to honor the NASCC city of St. Louis and all of our wonderful customers than by visiting them via air… not by airplane – but by HOT AIR BALLOON! Yep, we landed right on their property, said hello – and checked to see how their Peddinghaus machines were running.

The Pursuit of Happyness Peddinghaus’ networking dinner brings you one of the greatest motivational and inspirational speakers of our era – Chris Gardner.

His story is the basis for the smash-hit movie, The Pursuit of Happyness featuring Will Smith. Homeless, and with a young son, Chris loses everything: his job and their home.

But Chris doesn’t give up; he summons his inner strength, business savvy, and genuine enthusiasm, and sets off to obtain an internship – and finally a full time position – as a stockbroker. Chris displays initiative and forward thinking to prove his mettle.

The story of Chris Gardner will touch your soul, as you learn the basics of success: Never lose sight of your goal… never give up.

The “Spirit of Networking” As a fabricator, how do you learn more about our industry? By networking with other fabricators… who can make that happen for you? Peddinghaus!

Peddinghaus sponsors our annual NASCC networking dinner this year on April 17th.

Our dinner will feature the best entertainment for the industry... so don’t miss out!

Chris Gardner and John Pinette headline our events for Wednesday night. Food, Fun, Fantastic motivation – we’ve got you covered all night long.

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STEEL FABRICATORS’ REVIEW

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KOENIG IRON WORKS – NEW YORK, NEW YORK, USA

Big Production in the Big Apple This city with such rich history in steel construction continues to reinvent itself. Many structures for commercial or real estate continue to receive internal refurbishments that maintain the legacy of the structure, while modernizing aesthetics and functionality. Located in the heart of Queens, just across the East River from Manhattan, Koenig Iron Works has played a critical role in New York fabrication since 1907.

Koenig’s design, fabrication (miscellaneous as well as structural), and erection team are tasked with projects that provide challenges from both a technical, and production standpoint.

Taking a Bite out of the Big Apple

L to R: Pete Demarco (Shop Foreman), Barry Leistner (President and CEO), and Nick Morisset (Executive Vice President) of Koenig Iron Works.

There are many ways to describe New York City - The Big Apple, The City That Never Sleeps, The City So Nice They Named It Twice. New York is also a city filled with internationally recognized civic icons — Ellis Island, the Statue of Liberty, and Wall Street to name a few. Over eight million people call New York City home, and are proud of the heritage which this international city boasts. Part of this heritage, is a long history of iconic skyscrapers and architecture. From 1908-1974 New York City held the world record for the tallest buildings in the world, including the Empire State Building and Chrysler Building. These towering titans are only one chapter in New York’s history of architecture; a prologue to deeper seated architectural development that starts on the inside.

Antique iron, such as this hand made European gate from the 1700s, adds history to the already iconic refurbishments that Koenig performs.

Barry Leistner, President and CEO, is the third generation of family management at Koenig Iron Works. Koenig was originally founded by Barry's grandfather in the city over a century earlier with a staff of only seven. Today the firm employs over twenty office workers and fifty shop floor employees. Due to the unique nature of many refurbishments or structural remodels, Koenig even employs a full time black smith for ornamental iron and miscellaneous fabrication applications.

Koenig’s history with CNC automation began in 2004 with the installation of a BDL-760 three spindle drill line in tandem with band saw, however their relationship with Peddinghaus started much earlier. “Our first machine was an old mechanical 210 ironworker. We purchased this machine over thirty years ago and it still runs to this day. It is a perfect example of the quality and strength of the Peddinghaus machines,” states Barry.

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The very first Peddinghaus machine Koenig had purchased was a used mechanical iron worker - first built in 1964!!!

The small workspace of Koenig's facility makes the Peddinghaus equipment a perfect fit for their production needs.

As business has evolved at Koenig, the desire to revolutionize production was apparent, and the need to increase productivity, and versatility continued to grow. It was time to write the next chapter in production for the firm, and the Advantage-2 drill line from Peddinghaus was the perfect solution for Koenig.

Accelerating Production with New Technology With no space to spare, the shop at Koenig is the perfect example of a fabricator located in an urban jungle. Although the facility in Queens allows for greater flexibility than Koenig’s previous multi-story Manhattan production complex, floor space stays at a premium. The smaller footprint of the Advantage-2, paired with the production capabilities of the machine have proven to be a perfect fit for the team at Koenig. Installed in place of the previous BDL-760 drill and sawing system, the Advantage-2’s conveyor spans three production bays, and passes through an interior wall of the building.

The change in technology from the previous BDL-760 drill line allows for bigger beams than ever before. Nick Morisset, Executive Vice President of the firm describes the change in production as a result of their latest investment, “we need to have steel moving through our shop, otherwise the whole facility gets bogged down. The faster drill allows us to tackle larger

sections than the older one due to its speed, and bigger operating envelope. We are processing beams that before would have been outsourced.”

The Advantage-2 drill line and material handling spans several small production bays, and passes through multiple openings to accommodate the tight space at Koenig.

Barry further elaborates by stating, “we can bid bigger jobs with confidence using our new machine. When you sub-out work you lose control of the project. Now we stay in control of quality, and delivery times.”

The Advantage-2 drill line at Koenig is equipped with 4-axis scribing, powered by Raptor software. This powerful combination allows Tekla information to be imported directly into Peddinghaus software and processed on the machine. Layout marks for copes and welds are automatically generated as a result, further expediting production at Koenig. This technology combined with high speed carbide drilling means faster production than ever before.

“Sections that used to take 20 minutes are now taking 6 to 7 to drill on the new machine because of the technology. The new machine is like night and day compared to the older one,” states Nick.

Investing in the Future Barry and his team see no signs of slowing down.

The firm continues to capture momentum by investing in technology that improves the firm.

Barry attests to this as he describes recent acquisitions that benefit the company, “we just placed an order for a new Anglemaster that allows us to

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With the newer, faster, and more advanced automation of the Advantage-2 drill line, Koenig can now tackle larger sections than ever before and minimize the need to outsource structural work.

punch and shear flat bar so we can make connections faster. Speed allows us to better serve the customer.” By reinventing production, Koenig secures their place as one of the most modern fabricators in an iconic city.

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JT STEEL – WEST JORDAN, UTAH, USA

Automation – The Answer to Staying Competitive Located in the western part of the USA, Utah is home to wide open spaces, mountain ranges, and a culture that has sparked one of the most rapid growth rates of any state in the union. A state that has continually bounced back from the impact of every modern business recession, Utah's resilience can be exemplified by firms such as JT Steel of West Jordan. JT Steel's story is one of true grit, and willpower.

L to R: Mike Arnold (Vice President), Jerry Taylor (President), and Dustin Walk (Production Manager) of JT Steel.

Necessity is the Mother of Invention Jerry Taylor, President of JT Steel, recounts how the firm began over 30 years ago. It was the end of a severe economic recession which spanned from 1980 to 1983 and the structural steel industry was reeling from the effects of high unemployment and low GDP. As the recession began to dissipate, hard working laborers, such as Jerry Taylor, continued to find themselves searching for employment. The birth of JT Steel was an act of necessity during this time of economic change and uncertainty.

“I was out of work, and looking for a job in early 1983 when I started JT Steel with $230. My father helped me get a loan on a portable welder and it went from there,” reminisces Jerry with a smile, “I started doing anything I could with that welder. Our big break was a small structural job refurbishing a pizza place for just over $2,000 and we took off.”

From Start-Up to Major Player From that first $2,000 project, JT Steel continued to serve partners of all shapes and sizes, growing as their partners grew in size and scope. “Our customers are never too small,” states Jerry, “in fact the diverse range of project sizes that we entertain is what makes us unique. From a single clip angle to a multi-story structure, we make sure our client gets what they need.”

JT Steel’s “can-do” attitude has endured over three decades of business, and sustained a corporate culture that thrives on innovation. “Change is necessary to stay competitive, and continue to serve our customers,” states Jerry, “speed is what our customers want, so efficiency is our goal. That is why JT Steel began to investigate automation.” With this in mind, Jerry and his team began to explore ways to reduce lead times, and minimize overhead costs to better serve their core group of clients.

“When we started out we had one small truck and a portable welder. The next step was a mechanical ironworker and stick welders. Now wire-feed welding equipment, and Peddinghaus automation is what we rely upon. With our Peddinghaus we really went from the stone age to modern technology,” states Jerry. “In construction things move so fast, you don’t have time to drill the holes or layout the material the way you used to. This industry is automated. In order to step into this century, you have automate, or else you are going to be left behind. At JT Steel we believe in being simply the best when it comes to customer satisfaction, and that is what we offer with our Peddinghaus machines.”

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The Advantage-2 drill line from Peddinghaus allows JT Steel to process as much as 150 tons per 40 hour week.

The Method Behind the Machinery

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The underside scribing unit of the Advantage-2 expedites the production of manually cut copes, and welded connections by providing automated layout.

Dustin Walk, Production Manager of JT Steel describes their ascent into automation, “The Ocean Avenger was our first big investment in technology. Changing from magnetic drills and hand layout to automation at first was a little bit scary. After having seen the automation work and experiencing how efficient it was, it was without a doubt the right move for us.”

After seeing the results of the Ocean Avenger, JT Steel realized that automation was the answer to staying competitive in today's marketplace. It was obvious that the next step for the team was more technology. This has allowed them to stay ahead of the industry standard for efficiency.

“Having seen what the Avenger was able to do, we had the confidence to invest further in a three spindle drill with saw and four axis scribing. This has really increased our production even beyond what the Avenger has done for us. With the new Advantage-2 drill line, things are moving through the shop a lot faster than ever before. It’s really amazing to see what our shop guys can now do in a shift. As a result of our equipment we are capable of processing approximately 150 tons of steel in a single forty hour work week,” states Dustin.

Even though production is now driven by a three spindle carbide drill line, complete with tool changers and automatic scribing, the Avenger still plays a useful role in production for miscellaneous items such as detail components, and odd shapes. These two machines complement each other perfectly at JT Steel.

The Advantage-2 drill line is powered by Peddinghaus’ very own 3D software - Raptor.

Aiming to be the Best Jerry Taylor’s dream has become reality. What started as an idea to make ends meet has evolved into a company capable of achieving great feats. With an impressive project list that includes Zion’s Bank Basketball Center (home of the Utah Jazz Basketball Team), and the Brigham Young University baseball stadium, JT Steel continues to add to this legacy moving forward. Beyond technology, JT Steel’s success can be attributed to a desire to be “simply the best”.

Jerry Taylor says it all when he states, “It’s all about service, it’s all about taking care of the customer, and at JT Steel we strive to do this better than anyone else. When you are the best, there is no need to worry about your future – you will always be around, and will always have business. That’s why every day we aim to be the best in the industry, and we continue to pursue this goal with the investments we make in technology, and talent.”

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The Ocean Avenger complements the new Peddinghaus system by allowing for the automation of detail component, and unique shape processing.

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LAUREL MACHINE COMPANY – MOUNT BRADDOCK, PENNSYLVANIA – USA

Machine Shop to Fab Shop A step into Laurel Machine’s facility reveals a world dictated by precision equipment. CNC lathes, mills, shears, and presses of a wide variety adorn the halls of the firm which has long been known for their machine shop capabilities.

As clientele came to acknowledge Laurel as a company with a reputation for quality and on-time delivery, they began to ask for more from their trusted supplier. John Novak, owner of Laurel Machine Company, describes this further when he states, “We started out as a machine shop, but when our customers came to recognize the quality of work we were doing, they started to ask for us to process more and more aspects of each project. This included assemblies that would support the machined parts we were processing. That is how we got introduced to the world of structural steel.”

Fine Tuning Fabrication Production

L to R: David Novak and John Novak, Owners of Laurel Machine Company.

Laurel Machine was founded in 1986 by John Novak and his brother David in Mount Braddock, Pennsylvania.

A job shop by nature, Laurel focuses on specialized work from an array of industries. Whether it’s parts for the circuit breaker industry, or replacement parts for the coal mining industry, Laurel has the talent and technology to exceed customers’ expectations.

With a strong knowledge of machining for an array of requirements, structural steel was a fairly basic task for the skilled team at Laurel.

With 50 - 53 employees throughout the facility at any given point in time, the firm had acquired several pieces of basic equipment to accommodate the production of angle and flat bar. As work continued to aggregate, Laurel found themselves processing 1,000 tons of flat bar and angle on an annual basis using a combination of manual labor, six ironworkers and several band saws on two shifts. As labor requirements continued to grow within this realm, Laurel Machine Company decided it was time to search for an automated solution to the situation.

John discusses how they found the solution to this problem with Peddinghaus, “Our local equipment dealer, Gary Danley of Demmler Machinery, approached us and recommended that we explore an angle line from Peddinghaus.

We researched our options and chose the Revolution Anglemaster due to its speed and versatility. We are now running the parts that used to be processed on our ironworkers and saws on the Peddinghaus machine. As opposed to running staff on two shifts for the saws, and one ten hour shift a day for the ironworkers, we now have the machine operator on a single eight hour shift to do the same work.”

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BEFORE: Multiple band saws operating on two shifts

BEFORE: Six ironworkers and a team of six to eight workers.

Laurel Machine Company processes 1,000 tons of angle and flat bar annually.

AFTER: One Revolution Anglemaster to process all angle and flat bar requirements.

Final product awaiting shipment to customers after galvanizing.

The Revolution Anglemaster from Peddinghaus allows Laurel Machine company to process their entire range of flat bar (their requirements range from 1/4" thick to 3/4" thick [6mm to 19mm]) and angle (their requirements range from 2" x 2" x 1/4" to 8" x 6" x 5/8" [50mm x 50mm x 6mm to 200mm x 152mm x 16mm]) with CNC accuracy. Additionally, typical production consists of components with two to three hole sizes per section, which is easily accommodated by the machine’s triple tool punch press.

Labor Shortage to Lead Times, Peddinghaus Provides the Solution

which in the past, took 6-8 of our staff to do,” states John.

Just as with many other firms, Laurel prides themselves on the talent and skill of their workforce. This team boasts a low turnover with many of the staff working 15-20 years with the company. Unfortunately, new talent is growing harder and harder to come by in today’s world.

An added benefit of the Revolution Anglemaster from Peddinghaus is that it allows Laurel to make better use of existing labor, and alleviates the need to search for new staff in today’s competitive hiring environment. “It’s hard to find anybody out there to do this kind of work. This machine virtually eliminates having to look for those people, and allows us to put our existing staff on tasks that require skills that can't be automated. This machine is now doing work,

John adds that these team members have not been eliminated, but are now moved to tasks that allow Laurel to absorb the higher production of the Peddinghaus machine. As lead times continue to shrink, demand only grows and Laurel is ready to tackle projects in a steadfast manner. “We recently had a project which was very fast paced, and would typically take us 2-3 days to process manually. Our operator already had the program on hand, and was able to process the parts in 2-3 hours. This is the type of turnaround that our customers need to do their job, and at Laurel Machine Company, we make that happen!” exclaims John.

“Being a job shop we process many different types of work every day, and the versatility of the Peddinghaus far exceeded anything else that was out there. The ability for the machine to process flats and angles of such a variety of sizes and hole size combinations is a huge help for us,” states John.

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THE PEDDIWRITER CNC LAYOUT MARKING SYSTEM

CUTCOSTS, INCREASEEFFICIENCY, IMPROVEACCURACY, S INDEPENDENT TOP TORCH • Multi-axis articulating torch for marking on the top of profile, top flange, and bottom flange • Completely independent from the underside marking system for simultaneous marking • X-axis motion independent from material drive rollers

SIEMENS ELECTRONICS • All electronics on the PeddiWriter are state-of-the-art Siemens solutions • 10 year spare parts guarantee

CONTINUOUS SURFACE DETECTION • Eliminate the need to apply redundant torch probe sequences • Mechanical surface detection maintains proper torch standoff while marking throughout a program

INDEPENDENT BOTTOM TORCH • For marking on the bottom of a profile • Completely independent from the top torch mechanism • X-axis motion independent from material drive rollers • Mark using both torches simultaneously with ease

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SUCCEEDIN TODAY’S MARKET! HYPERTHERM ARCWRITING • Industry leading plasma marking technology • 2 units, each mounted on the machine for minimized footprint • Superior speed and versatility – marks twice as fast as carbide milling

SIEMENS CONTROL • Robust and intuitive user interface • Allows for modern remote assistance and webcam technology for fast and painless troubleshooting

ELIMINATE YESTERDAY'S LAYOUT PROBLEMS Within some of today’s fab shop facilities, you may find an army of layout personnel – equipped with t-squares, prints of assemblies, and soap stone marking tools. 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.

Until now…

INNOVATE WITH TOMORROW’S LAYOUT MARKING ADVANTAGE Eliminate the manual layout of structural sections with the PeddiWriter. The perfect combination of speed and strength, the PeddiWriter applies modern technology to the actions of measurement and layout marking.

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!

Metal Processing Capabilities

Metric

Inch

Max Profile Dimensions

1250 mm x 610 mm

50" x 24"

Min Profile Dimensions

75 mm x 75 mm

3" x 3"

19,900 kg

43,800 lbs

Max Profile Weight Type Of Marking

PEDDINGHAUS ROLLER FEED MEASUREMENT

Number Of Marking Units

• The industry standard for Roller Measurement • Superior accuracy and flexibility on all profiles • Easily integrate into an existing system due to the completely modular design

Markable Surfaces No. Of Surfaces Marked Simultaneously Acceptable Profiles

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Hypertherm Plasma ArcWriting 2 ArcWriting Torches Top of Web, Under side of Web, Top Flange, Bottom Flange 2 Surfaces Beams, Angles, Channel, Flat Bar, Tubing

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FROM THE CEO Continued from page 3

Two Wheeled Fab Shop Tours

The “Spirit of New Technology” Visit us at booth 405 on the NASCC show floor. Enjoy refreshments as we tour you through the best, most productive machine technology on the market today.

On display will be the latest in today’s plate technology, the HSFDB; a totally new heavy duty Anglemaster; and the PeddiWriter layout machine which has taken the world by storm.

Is your firm interested in CNC robotic technology? In partnership with Zeman Baulemente we now offer a comprehensive solution for the automatic welding of structural profiles. You are in the right place with Peddinghaus… always the industry leader.

Peddinghaus’ motorcycle tour is an annual hit with fabricators.

Peddinghaus sponsors a Motorcycle Fab Shop Tour every year, just prior to the NASCC. We take customers from all around the world on a tour of the local area.

This year we focus on the Midwest featuring four top shops with the latest technologies and throughput capabilities. We also visit the top tourist stops in the area.

Oh yeah, we travel on motorcycles (or you can ride in a four wheeled vehicle) – it is a lot of fun, with an educational twist.

Pick the brain of fabricators from Australia, Germany, South Africa, Peru, Canada, USA, New Zealand…learning and laughing – it doesn’t get any better.

The “Spirit of Customer Service” You know me – Customer Service is the heartbeat of Peddinghaus.

From our 24 hour service “hot line” to our 40+ field service techs to our multimillion dollar parts inventory, Peddinghaus provides the knowledge and expertise that let you sleep at night.

That’s what good partners do.

Good partners that always carry the “Spirit of Peddinghaus”.

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THE ANGLEMASTER-HD – ANGLE/FLAT LINE

A SMARTER, FASTER, STRONGER SIGNOMAT PART STAMPING • 36 station (number / letter) part marking press • Marks at a rate of 1 character per second • Capable of being stationed for marking on near or far leg of angle

SIGNOSCRIPT CARBIDE SCRIBING • Versatile carbide marking station allows for marking of any shape, number, or character • Mark at multiple depths or sizes without tool change

TRIPLE TOOL PUNCH PRESS • 169 inch tons (153 metric tons) three speed punch cylinder • SmartCylinder© technology • Punch up to 3 different tool shapes or sizes per leg of angle in a single pass through the machine

ROLLER MEASUREMENT • Peddinghaus Roller Measurement • Continuous feed with no stop in production • Capable of 200 FPM (60 MPM) x-axis material positioning speeds

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SOLUTION MINIMUM QUANTITY LUBRICATION SYSTEM • Optional lubrication system for punches and shear • Eco-friendly vegetable oil based lubrication dramatically extends shear and punch life

SIEMENS TOUCH SCREEN CONTROL • 480mm (19”) touch screen control panel • Powerful enough for today’s 3D CAD/CAM packages

PC WORKSTATION • Allows for streamlined access to e-mail, modeling systems, server, and other critical programs *Personal Computer Not Included

FROM BASE PLATES TO CLIP ANGLES THE ANGLEMASTER-HD DOES IT ALL The Anglemaster-HD is designed to not only be fast, but versatile. Capable of punching and shearing flat bar up to 12” x 1” (300 mm x 25 mm), and angle up to 8” x 8” x 1” (200 mm x 200 mm x 25 mm) typical structural detail sections are processed with ease. The Anglemaster-HD is also capable of punching (not shearing) channel sections up to 12” (300 mm) wide adding further versatility to the capabilities of the machine.

COMPREHENSIVE MATERIAL DIMENSIONING FOR FASTER PRODUCTION The Anglemaster-HD utilizes comprehensive material dimensioning to not only increase production, but also create a user friendly atmosphere. By utilizing an array of dimensioning feedback, the Anglemaster-HD can identify the length of stock, thickness of material, and leg lengths (or flat bar width). Once the machine understands all dimensions of material, it optimizes punch and shear motion to increase production efficiency. If stock loaded does not match that of the selected program, the machine will notify the operator and provide the option to continue to program, or locate the appropriate stock type.

A SMARTER ANGLEMASTER - SMARTCYLINDER© TECHNOLOGY Using the information gathered by the material dimensioning system, the Anglemaster-HD understands the thickness of material loaded, and employs this information to automatically adjust the three speed punch and shear cylinders. By adjusting the amount of power needed per section size, the machine can take full advantage of lower tonnage / high speed operations when thinner material is being processed. When thicker material is loaded, the machine will maximize tonnages in order to process these sections accordingly.

Metal Processing Capabilities

Metric

Inch

SINGLE CUT SHEAR

Max Angle Capacity

200 mm x 200 mm x 25 mm

8" x 8" x 1"

• 467 Metric ton (515 Inch ton) three speed shear cylinder • SmartCylinder© technology • Single cut shear tooling eliminates the creation of shear slugs commonly experienced with double cut shear tooling

Min Angle Capacity

40 mm x 40 mm x 5 mm

1-1/2" x 1-1/2" x 1/4"

300 mm x 25 mm

12" x 1"

Min Flat Stock Capacity (Narrowest)

50 mm x 5 mm

2" x 1/4"

Min Flat Stock Capacity (Thinnest)

75 mm x 6 mm

3" x 3/8"

Max Punch Tonnage (3 Speed Cylinder)

153 Metric Tons

169 Tons

Max Shear Tonnage (3 Speed Cylinder)

467 Metric Tons

515 Tons

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Max Flat Stock Capacity

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STEEL FABRICATORS’ REVIEW

SPRING 2013

GEM BUILDINGS – BRIGHAM CITY, UTAH, USA

A Steady Stream of Automation In 2010, Our Steel Fabricators’ Review Article Ended Like This…

GEM Buildings considers themselves to be in a continual pursuit of growth. By offering a wide array of services they are constantly looking for ways to win jobs and increase revenues. The future is bright in Brigham City for the team at GEM. With their streamlined production and time tested safety practices, there is little that can hold them back.

L to R: Lance Balls (Safety Manager), Kyle Hansen (President), Shaun Christensen (Director of Operations), Jake Larsen (Shop Manager), and Garrett Timbimboo (Cut & Prep Supervisor).

GEM Buildings utilizes a Peddinghaus Anglemaster to process all of these detail parts for their fabrication needs.

Today, GEM Continues to Follow their Goal

Discovering A Bottleneck in the Fabrication Process

GEM is the type of company that stays true to their word regardless of what it takes. Kyle Hansen, President of GEM Buildings, has discovered that no matter how successful your business may be, there is always room for improvement. As they find themselves fabricating buildings in excess of 1 million square feet (92,903 square meters) in size, GEM is no stranger to the solutions automation presents. Kyle and the team at GEM continually analyze production to see what can be done to keep them ahead of the competition and at the cutting edge of fabrication.

Although GEM has already invested in numerous types of automation, GEM found themselves in a position where production needed to increase, thus a second shift was required to accommodate the volume of work they were handling. Like many other fabricators, GEM struggled with the task of finding qualified personnel for the layout and fit-up of structural members. After evaluating their options, GEM discovered the PeddiWriter CNC layout marking machine from Peddinghaus.

“When we heard about the new technology on the market for fabrication layout, we knew we had to investigate it. We felt comfortable with Peddinghaus due to our previous experiences with them, and as a result we were excited about the acquisition of the PeddiWriter. We were confident that this machine would provide a great advantage in helping us solve our fitting and layout challenges now and in the future,” stated Kyle. After visiting several installations, where users attested to the benefits of the technology, GEM knew that the PeddiWriter was the next step for automating their production process.

GEM’s Newest Employee: The PeddiWriter Soon after the installation of the PeddiWriter, GEM already began experiencing the benefits of the machine. No matter the complexity of a component, the PeddiWriter has reduced their production time dramatically. GEM has experienced extremely intricate pieces that in the past would take around an hour and twenty minutes to manually mark now take up only twenty minutes of processing time on the PeddiWriter.

The PeddiWriter allows for faster turnaround times on welded or coped sections.

“Our fabricators and shop personnel have been very happy with, and very supportive of the PeddiWriter. Our entire team was very excited for its implementation,” stated Shaun Christensen, Director of Operations for GEM Buildings.

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STEEL FABRICATORS’ REVIEW

After visiting several installations, where real users attested to the benefits of the technology, GEM knew that the PeddiWriter was the next step for automating their production process.

Utilizing the PeddiWriter has reduced GEM's production times dramatically.

A Partner with Peddinghaus GEM understood that the PeddiWriter performs solely layout operations, thus it was a different animal than their Peddinghaus drill line, coper, and Anglemaster. Even though the PeddiWriter acquisition would mean training staff members on a new way of programming, GEM had confidence that they could call on Peddinghaus whenever they needed a hand. “Our experience with Peddinghaus Customer Service has always been first rate.

We can get people on the phone, we’ve got video access, and we’ve got webcams on the machines, software support, all the way up through sales and management. I know that Peddinghaus people are just a phone call away when we need them,” stated Kyle.

Looking Ahead GEM’s future is looking bright and busy. Kyle stated, “Moving forward, GEM is going to continue to find customers that have unique challenges and provide solutions for those challenges. Wherever steel structures will supply the need that our customers have, that’s where we’re going to be able to design and supply across the world.”

Knowing that automation is the key to success has set up GEM to be a force to be reckoned with in the business of the steel industry across the globe.

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STEEL FABRICATORS’ REVIEW

SPRING 2013

THE HSFDB PLATE PROCESSOR

THE PERFECT COMBINATION OF SPEED 8 STATION ROTARY TRAVELING TOOL CHANGER • Capable of holding up to 8 tools for drilling, tapping, countersinking, milling or scribe marking.

CARBIDE SCRIBING/MARKING SYSTEM • An available scribing tool is placed into the automatic tool changer and selected upon program command.

• Eliminate the human error of manual layout operations.

AUTOMATED TOOL HEIGHT MEASURING • Automatically measures tool length before putting into operation.

• By mechanically probing for tool length before operation, the HSFDB assures optimal functionality.

PLENUM CHAMBER & EASY UNLOADER • Standard automatic dump table mechanism.

• Parts up to 1,000 pounds (453 kg) can be unloaded with ease.

• Copper lined plenum chamber is integrated for easy removal and containment of machine byproduct.

• Further parts handling options available.

OXY/PLASMA CUTTING • High Speed Plasma: An efficient 260 or 400 amp high speed plasma system is available for exceptional cutting speed and quality finish.

• Oxy-Fuel Cutting System: The economic alternative to plasma cutting. Offers total thickness versatility.

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STEEL FABRICATORS’ REVIEW

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AND STRENGTH POWERFUL SIEMENS SPINDLE MOTORS • High Speed 48 HP (36 kW) Siemens intelligent spindle motors.

• Spindle speeds of up to 2250 RPM.

THROUGH THE TOOL MINIMUM QUANTITY LUBRICATION SYSTEM • 97% air, 3% eco-friendly vegetable oil based lubricant.

• Eliminates flood coolant mess.

• No need to clean parts before secondary processes (welding, painting, etc).

ADVANCED SIEMENS ELECTRONICS • Siemens drives, PLC, servo motors and more.

• Siemens 840di Control Panel.

THE PLATE PROCESSING PAST Within some of today's fab shop facilities, you may find a large burn table with numerous employees removing parts, scrap, and swarf from its bed. This is common practice throughout the industry, and rightly so. Few options were previously available that focused solely on the plate processing needs of today’s structural fabricators.

Until now…

THE PLATE PROCESSING FUTURE The HSFDB plate processor is the one stop machine for all plate processes.

Drill, mill, tap, countersink, oxy-fuel cut, deburr, layout mark, and plasma cut on one machine, with one operator. The perfect combination of speed and strength, the HSFDB applies modern technology to the age old application of plate processing.

Advanced material handling, carbide drilling technology, and the absolute latest in plasma cutting techniques make the HSFDB the most modern plate processor in the world today. With installations spanning the globe, the unique pass-through system of the HSFDB is the trusted technology of advanced fabricators in all markets. Fabricators commonly indicate production figures from 1-2 tons per hour depending on program complexity.

IMAGINE ONE MACHINE THAT CAN...

• Completely process plate within one cell • Start a nested program utilizing Edge Start cutting to reduce scrap • Reduce overall footprint by allowing material to be fed through an exterior wall • Change the way you process plate

Metal Processing Capabilities

Metric

Inch

Max Material Thickness

75 mm

3"

Min Material Thickness

6 mm

1/4"

Max Material Width

3.2 M / 2.5 M / 1.8 M Widths Avail.

6’, 8’, 10’ Widths Avail.

AUTOMATED MATERIAL DIMENSIONING

Min Material Width

150 mm

6"

• Plate edge dimensions are detected by Peddinghaus’ state-of-the-art laser probe system.

• Plate thickness is determined by a transducer that is mechanically linked to the plate roller.

Spindle Power

36 kW

48 HP

Max Drilled Hole Size

75 mm

3"

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STEEL FABRICATORS’ REVIEW

SPRING 2013

PASCAL PETERS’ FANTASTIC VOYAGE Located just a stone’s throw from the Netherlands, Peters Stahlbau GmbH is a family business with family values. Under third generation family management, Peters Stahl is growing by leaps and bounds. Peters Stahlbau is currently managed by Heinz-Geert Peters, founding director Heinrich Peter’s grandson. Before Heinz-Geert took over the company, his father allowed him to go on a much-needed journey to experience the global steel industry.

Decades later, Heinz-Geert had a serious conversation with his own son, Pascal.

Heinz-Geert told Pascal that in order to truly understand how a family business operates, he needed to see other aspects of production outside of their own and experience how people in different parts of the world do business. In the 1960s Heinz-Geert took the trip from Germany to Los Angeles to improve his English skills and understanding of the steel fabrication industry.

In late 2012, Pascal Peters traveled to the United States to follow in his father’s footsteps; however, Pascal took a different route as he became the newest intern at Peddinghaus Corporation.

Life at Peddinghaus Life in Bradley wasn’t all fun and games for the young protégé. From day one Pascal was put to work with the goal of experiencing every facet of the company. As Pascal journeyed from a comfortable desk in engineering, to the ice cold At the weld shop, Pascal had the opportunity to weld different components for Peddinghaus machines.

Pascal learned that teamwork within the assembly department is key to great equipment for each customer.

Pictured is Pascal with an FDB-1500 in the assembly department ready for the controls to be mounted.

Peddinghaus fabrication shop during winter, he learned valuable lessons about teamwork and camaraderie. Peddinghaus’ skilled craftsmen took the opportunity to share with Pascal the secret to making quality equipment, and the impact that a single employee can have on the outcome of a project, regardless of the task or department.

took interest in how businesses like his were reducing overhead costs, and increasing the quality of their product. While in Australia, Pascal had an “ah-ha” moment and couldn’t wait to share what he had discovered.

Young Peters also gained comprehensive knowledge of the Peddinghaus machine development process from design to creation. In engineering, Pascal participated in the conceptualization and methodology behind Peddinghaus equipment. While in the weld shop, he saw the machines come to life.

Pascal spent his shift each day running standard parts for Peddinghaus machines on the FDB-2500 plate processor and received experience both editing and running part programs. Here is where he saw Peddinghaus machines come full circle.

Pascal learned that without each piece of the puzzle in place the big picture cannot be achieved. While at Peddinghaus, Pascal learned the valuable lesson of teamwork and the importance of each position within a company. From start to finish, the seamless integration between departments is key to a successful business, no matter your product or geographic location.

A Whirlwind Trip During his experience at Peddinghaus, Pascal was swept away by Peddinghaus’ CEO, Anton Peddinghaus on a trip to Australia and New Zealand. On this trip, Pascal had the opportunity to see how structural fabricators operate in a very different part of the world. Pascal was amazed to see so many companies automating plate production. As a future Managing Director of his family’s firm, Pascal

Upon returning to Bradley, Illinois – USA, Pascal called his father and grandfather to discuss the FDB1500 plate machine manufactured by Peddinghaus.

Pascal had experience with the FDB both within the weld shop and assembly department at Peddinghaus.

He knew how the machine operated, the strength behind it, and understood how much money it could save Peters Stahl. When Pascal’s father realized how quickly they could pay for the FDB-1500 with money saved from outsourcing, the deal was made.

Peters Stahlbau GmbH would be the proud new owner of a Peddinghaus plate processor and the future Managing Director found the solution all on his own.

The Souvenir of a Lifetime From the experience at Peddinghaus, Pascal feels he is better prepared to take over his father’s role as Managing Director of Peters Stahlbau. “I see things differently now. I can appreciate numerous ways of fabricating but I am most happy to have learned what goes into building a machine from start to finish and the true quality that Peddinghaus provides. I am proud to have a new partner in the business, and am glad to call Peddinghaus a second home.” The knowledge that Pascal has gained both at Peddinghaus and during the travels with Peddinghaus has greatly impacted his way of thinking.

While at Peddinghaus, Pascal was able to take part in building his own machine, operating it during testing, and completing the machine check out before it made its’ way to Germany. “It was the opportunity of a lifetime, building my own machine. I know the FDB from the bottom up.

I understand how it works and the strength it was created with. This will help our firm in the future, as we implement the machine in our production.”

SPRING 2013

STEEL FABRICATORS’ REVIEW

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STEEL FABRICATORS’ REVIEW

SPRING 2013

THE ZEMAN STEEL BEAM ASSEMBLER

AUTOMATED WELDING: THE WAY OF THE FUTURE Imagine One Machine That Can… • • • •

TACKING AND WELDING ROBOTS

Increase your productivity by 85% Automatically weld structural steel sections without manual intervention Follow the geometry of the 3D building model with complete accuracy Complete the work of 9 fitters/welders with 1 operator

This particular system has four tacking and welding robots that will tack the detail part into place on the profile before welding to finish production.

An Industry First 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!

The Zeman Steel Beam Assembler (SBA) is Born This is a machine that can fully assemble profiles in a single pass.

Detail components enter one end of a machine, beams another and both leave the SBA fully fit-up and welded as dictated by the original design intent of the 3D building model. The future is now, and Zeman is setting the tone for automatic welding in structural fabrication.

OUTFEED CONVEYOR Finished parts are conveyed out of the fabrication area by the outfeed conveyor to be moved to other processes.

DETAIL PARTS RETREVIAL ROBOT This robot will take the detail parts from the parts feed belt and hold them in place on the profile while the tacking and welding robots secure the part in position.

SPRING 2013

OPERATOR STATION From this station the operator runs the entire operation of the Steel Beam Assembler.

STEEL FABRICATORS’ REVIEW

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INFEED TRANSFER Profiles are delivered via crane for fork truck to this area. Once ready for production they are transferred over to the infeed conveyor.

INFEED CONVEYOR The profile is conveyed into the processing area via the infeed conveyor.

DETAIL PARTS SCANNING SYSTEM

CLAMPING/ROTATION POINTS

PARTS FEED BELT

Once the profile is in position for fabrication, it is clamped by the clamping/rotation points and moved as necessary for all parts to be assembled and welded.

Detail parts that are to be welded to the profile are handled via the parts feed belt.

As detail parts are being conveyed towards the profile to be welded are scanned in via a camera system.

This system recognizes the parts and their location on the parts feed belt. From here the detail parts retrieval robot knows where each part is located and will retrieve it in the proper order for welding.

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STEEL FABRICATORS’ REVIEW

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STEEL FABRICATORS’ REVIEW

SPRING 2013

GETTING TO KNOW…

Ken Coulter Vice President of Engineering

What type of projects do you manage within the Engineering Department at Peddinghaus?

I manage all engineering projects at the Bradley location, including mechanical, electrical, controls & software.

As a hands on manager, Ken is constantly in the shop seeing We also supply electrical, how they can improve upon machine design. control & software engineering for Peddinghaus Corporation South Carolina (PCSC). The projects we participate in range from new product design and updating/improving existing products to testing new tooling/techniques to help our customers reach new levels of productivity that at one time was thought unattainable.

While working at Peddinghaus, what has been your favorite project/machine that you worked on, and what was the result?

How did you start here at Peddinghaus? Have you always been the VP of Engineering?

I received my Bachelors of Science in General Engineering from the University of Illinois. From there I went on to receive my Masters in Business Administration in Operations Management at DePaul University in Chicago. My education then led me to a residential/light commercial building supply manufacturer where I was the Engineering Manager for 18 years. From there I decided it was time to broaden my horizons, and I started my career here at Peddinghaus. In April of 2010 I started as the Continuous Improvement Manager and in November of 2011 I was promoted to the Vice President of Engineering which is where I stand today.

Tell us a little bit about your background? How did you qualify for your current role here at PC? I have a strong production background so I like to emphasize design for manufacturing and serviceability. When I started at Peddinghaus as the Continuous Improvement Manager, I was tasked with improving the longevity and technology of existing equipment while simultaneously ensuring optimal performance. By working with the engineering staff, the machine shop and the assembly department, we were able to reduce labor costs and machining time to reach these goals without having to resort to using lower quality materials. As the Vice President of Engineering, I continue to push this concept and encourage strong communication between the engineering, production and service departments.

I really enjoy experimenting with new and different tooling for our machines. We have expanded our capability for milling far beyond what we ever imagined we would be able to do. Currently we’re testing better ways of processing Hardox wear plate and looking at advanced milling techniques for thread cutting.

What are the strengths of the Peddinghaus Engineering department?

The strengths of the Peddinghaus Engineering department are absolutely teamwork and experience. I have a diverse group of engineers (Mechanical, Electrical, Controls, Software, Robotics) who all work as a team to make these designs go from concept to production machines. The engineering department has over 250 combined years of experience at Peddinghaus and there are 5 engineers with 25+ years tenure.

What projects are currently on the engineering “hot list”?

The hottest projects we have at any given time are the new machine designs.

On the horizon we will be experimenting with using robotics for everything from material handling to fabrication. This will be an exciting new step for Peddinghaus.

How would you say Peddinghaus’ fabrication technology has evolved since its’ conception 110 years ago?

While Peddinghaus has evolved with technology, we haven’t deviated from the design concept that our equipment is built to last. All of our machines are designed for continuous use in the most demanding of applications.

After being with Peddinghaus for 3 years, where do you see Peddinghaus in the next 10?

I see Peddinghaus continuing to help customers achieve higher manufacturing efficiencies that include faster processing, more intelligent material handling and integrated production lines. Software will play an important role in pulling data from BIM packages and distributing the data to multiple machines and material handling. Our machines have always been “strong”…and now we’re making them “smart”.

Ken stands alongside the Engineering Department at Peddinghaus.

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STEEL FABRICATORS’ REVIEW

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VOLUME 43

STEEL FABRICATORS’ REVIEW

SPRING 2013

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

PRSRT STD U.S. POSTAGE

PAID PERMIT NO. 157 Joliet, IL

MOTORCYCLE

FAB SHOP TOUR Peddinghaus will start the adventure at their Global Corporate Headquarters in Bradley, Illinois – USA. Riders will enjoy the scenic route to St. Louis, Missouri traveling historical roads on this two wheeled tour. With numerous stops along the way including lunch in the final resting place of Honest Abe Lincoln, a paddlewheel boat ride in the birth place of American author Mark Twain, and a final stop at the St. Louis Blues Hockey game before arriving at the NASCC, the 2013 tour will be one to top them all.

2013

WORLD CLASS TECHNOLOGY

On Wednesday, April 17th at 7:00pm, Peddinghaus will host their Annual Networking Event at the Grand Renaissance Hotel in St. Louis, Missouri.

After enjoying the opening day of the show, attendees are invited to see what Peddinghaus is all about at the 2013 Networking Event.

Peddinghaus is known as the technology leader in the industry and will prove it again at the 2013 NASCC. Featured in booth 405 will be the innovative PeddiWriter CNC layout marking machine, the powerful Anglemaster-HD angle line, the HSFDB plate processor, and simulations of the Zeman Steel Beam Assembler, the true automated welding solution!

NETWORKING EVENT

Registered guests will experience cocktails and fine dining while enjoying some of the best entertainment around.

2013 will bring entertainment including the motivational Chris Gardner, author of The Pursuit of Happyness, and Comedy Central comedian, John Pinette to wow the crowd. Of course when Peddinghaus is concerned, there are sure to be surprises along the way and St. Louis will be an NASCC you won’t want to miss!

nascc.peddinghaus.com

BOOTH 405

Stop by the booth to see what all of the Peddinghaus buzz is about. Not only will you be able to feel the difference at the 2013 NASCC, Peddinghaus will also show you the difference Peddinghaus machinery can make.