A PEDDINGHAUS PUBLICATION FOR FABRICATORS MAKING TODAY’S SKYLINE POSSIBLE
Kopp Stahlbau
Tudor Engineering Contractors & Draughting Steel Company
Structural Steel Takes Flight PAGE 4
Pioneering Productivity PAGE 8
The Innovation of the Anglemaster-HD Peddinghaus Wins Hands-Down at FABTECH 2012 Peddinghaus Finds Success at SteelFab 2013 Turning Plate into Profit with the HSFDB NASCC 2013 – Meet Us in St. Louis Stay Tuned to Peddi-TV! Getting to Know Todd Hartman, Weld Shop Supervisor Get Social with Peddinghaus
Service Means Success PAGE 10 12 PAGE 14 PAGE 15 PAGE 16 PAGE 18 PAGE 18 PAGE 20 PAGE 24 PAGE
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STEEL FABRICATORS’ REVIEW
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FROM THE EDITOR Project Pipeline Filling Up: Some Good News from AIA The American Institute of Architects provides a monthly Architecture Billings Index which records activity level from architects throughout the USA. The projects that architects are working on now, translate into construction projects – which means future work for all of us. December, 2012 marks the fourth consecutive month of continued growth by Architectural firms. They are getting busier and busier with new projects. Here’s what they say: “These are the strongest business conditions we have seen since the end of 2007 before the construction economy struggled in the USA,” says AIA Chief Economist, Kermit Baker.
Confidence Lessons from FABTECH Since our last SFR issue, Peddinghaus has attended many industry events. These range from the FABTECH International Exhibition to industry Software user’s meetings to regional fabricator meetings. And yes, we attended seminars given by some of the industry’s leading economists.
Lyle Menke
Looking to the Future? Here’s Your Crystal Ball Every fabricator is worried what the future
The FABTECH Show featured the highest attendance in the history of the exhibition! Fabricators and manufacturers in attendance were in unison with the same theme: there is business out there, and each company needs to automate their production methods to remain competitive. When breaking down the demographics of FABTECH participants, it is very interesting to note that structural steel fabricators comprised a significant number of attendees at the 2012 show. This reveals that many in the industry are seeking new methods of structural fabrication to improve their business. Could it be that one of your competitors was there?
will bring. “Backlog” is a magical term that ends sleepless nights, and provides a comforting sense of purpose every day. A lack of backlog means digging deeper and searching further for that one project that will get you over the hump. The SFR searches industry sources for reliable information that is pertinent
Steel Construction on the Rise Peddinghaus partners with industry software firms to continually promote steel construction. Thus, Peddinghaus is pleased to regularly attend these users meetings for firms such as Tekla, Design Data, FabTrol, FabSuite etc. Attendees at these industry meetings typically consist of structural detailers, fabricators, project managers, structural engineers, and similar positions. What are they saying? These groups also report encouraging news. Detailers and Fabricators report many projects “on the books” – with more on the horizon. Some firms are also working on multiple projects to meet deadlines.
to the structural steel and heavy plate fabrication industries. We attend
More Good News: Tax Incentives to Help Fabricators in 2013
meetings & seminars and examine print
As many in the USA were aware, Congress passed the American Taxpayer Relief Act of 2012 in late December. A significant portion of this bill included tax incentives for manufacturing companies – including structural steel and heavy plate fabricators:
and electronic media for that insight that provides the competitive edge.
Section 179 Federal Income Tax Deduction allows a company to deduct first $500,000 of equipment, (Section 179 Property) purchased in 2013 from their taxable income. In addition to the $500,000 write-off, companies can take 50% bonus depreciation on the adjusted basis of their qualified equipment purchased in 2013. Equipment must be purchased and placed into service on or before December 31, 2013.
Shop Technology Makes A Profitable Difference for Fabricators Fabricators who have been making an investment in technology are leading the industry. With labor issues prevalent in all parts of the world, knowledgeable managers are investing in machine technology to automate and elevate their businesses. Here’s what a 40,000 ton per year fabricator has to say: “It’s not easy out there; but when you have a plan – and a technology centered partner on your side – the odds are in your favor… Peddinghaus is that Partner!” Terry Degner, President Waiward Steel Fabricators – Edmonton, Alberta, Canada
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FROM THE CEO May 2013 Be Your Best Year!
Happy New Year to all our wonderful customers and industry members! At Peddinghaus, we look forward to 2013 with great anticipation. In the New Year, we offer our customers new products, superior customer service,
Anton Peddinghaus
and our continuing pledge of a solid business partnership.
Thanks for Reading our Magazine Recently, I have received many compliments on our STEEL FABRICATORS’ REVIEW magazine. Our customers really appreciate the focus the SFR places on our industry, and the practical information that is relevant for top management as well as the guys on the shop floor. What I especially like is the opportunity that I can talk to you in my own words about our company. Readers tell me that they can learn more about the “depth” of Peddinghaus. Not just the glamour of a slick brochure or web site, but the real story – kind of like a reality TV Show – you get the “inside scoop” of what separates Peddinghaus from our competitors. It’s our people that make the difference. My thanks to our Marketing team for making the SFR such a successful publication: Lyle Menke, Nick Hajewski, Lisa Clark, Shad Taylor, and Shawn Zeilenga.
Peddinghaus Employees Enjoy Christmas In December, we gathered all of our employees and guests to celebrate Christmas together. It’s our way of thanking everyone for their hard work this year. What a great time! We enjoyed a great meal, live music, wonderful gifts, first class entertainment, and a special video visit from “Frosty the Fabricator”. The best part of our party is the employee participation, and I really love watching the camaraderie and interaction between our people. It doesn’t matter if they are engineers or machinists or welders or accountants, our people celebrate like they work – with enthusiasm, selflessness, and fun!
Frosty The Fabricator – a New Employee? I hope you took the time to watch our Christmas video “Frosty the Fabricator” which tells the magical story of a snowman who comes to life at Peddinghaus and spends his day working here until he gets a little too close to the Ring of Fire… you can catch Frosty at www.peddinghaus.com/frosty. As you know, I often speak about our amazing workforce here at Peddinghaus! These folks consistently surprise me with their dedication and astonishing flexibility. If we present our people with a challenge, the “team” gets together to form a plan – and then jump on the project! They willingly work extra hours, and do “whatever it takes” to get the job done. Our Family of Employees is a big reason for Peddinghaus’ success.
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Haven’t seen the video of Frosty the Fabricator? Just snap the QR code with your smartphone to share in the fun!
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KOPP STAHLBAU – BUXTEHUDE, GERMANY
Structural Steel Takes Flight The historic town of Buxtehude lies in northwestern Germany – not too far from the bustling port city of Hamburg, or from the neighboring country of the Netherlands. The Dutch founded the colonial part of the town by building their structures on wooden piles in the marsh. The tourist guidebooks will tell you this is a picturesque town settled in the Ninth Century, complete with scenic canals and cobblestone streets. Near Buxtehude you’ll find one of the headquarters of Airbus Industries. If you have ever flown commercially, you know the name Airbus. A young structural engineer, Mr. Hartmut Kopp worked at Airbus as a stress analysis engineer between 1962 and 1972 during the initial stage of today’s Airbus aircraft and passenger carriers. The same attitude of perfection that Mr. Kopp performed in his work for Airbus, is still very evident some 40 years later – not in aircraft – but in building steel structures. Mr. Kopp founded the company Kopp Stahlbau in 1970 in the same town of Buxtehude. Today Kopp Stahlbau produces highly buckling resistant steel structures that are used as test rigs for Airbus Airplanes...as the saying goes...everything comes full circle. Mr. Klaus Kirst, CEO, and Mr. Hartmut Kopp with their Peddinghaus Ring of Fire Thermal Fabrication Center.
The rotunda atop the Grand Hotel in the Canary Islands was an engineering marvel.
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Kopp’s unique “in floor” roller conveyor system makes moving fabricated sections from bay to bay an easy task.
STEEL FABRICATORS’ REVIEW
Kopp Stahlbau has 14 Peddinghaus machines: “Production, Production, Production - that’s why we buy Peddinghaus.”
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Kopp employs two Peddinghaus drill lines including the high speed carbide BDL-1250/9D.
Jumbo Jets to Jumbo Beams: Kopp Goes Structural From his engineering background, Mr. Kopp understood the rigors of stress analysis not only for aircraft facilities, but also for buildings and similar steel structures. He sharpened his engineering expertise, but also grew his practical skills in welding and structural fabrication. From its founding in 1970, Kopp Stahlbau Buxtehude Gmbh started small. He had two employees, some welding equipment and a universal steelworker machine to start. But he also had the knowledge and the enthusiasm to fabricate consistently high quality steel construction components. The rest is history, with a growing firm that reached 10 employees in 1975; 15 in 1982, and now employs over 100 employees today. The first landmark projects for the company were for Shell Oil in Hamburg. These petro-chemical projects consisted of pipe racks and production facilities of various tonnages, complete with all stair rails and miscellaneous steel. To stay on schedule, Mr. Kopp, his wife, and their children came in on the weekends to paint the hundreds of meters of structural steel.
Complex Projects: Kopp’s Expertise But their tenacity paid off, as the reputation of Kopp Stahlbau grew in the Petro-Chemical Industry – and then spread to other projects in the Harbor area: Industrial buildings, prefabrication for the building industry, warehouses, storage tanks, material handling, pedestrian bridges and refurbishing of traffic bridges were now the projects that Kopp performed for their clients. In addition to Airbus, other large companies, such as Dow Chemical, Sasol, Hoechst and other major customers – including public contractors – came to Kopp Stahlbau for large, complex projects. These jobs ranged from refineries to power plants, and also included building structures, elevator shafts, and flue gas canals. Kopp even took on a project of fabricating additional new stories to an existing hotel in the Canary Islands. The reputation of Kopp Stahlbau grew with their consistent success of sophisticated projects which required increased precision and complexity. To meet these demands, Kopp Stahlbau uses the latest equipment technology. And Kopp purchases that equipment from an old friend as well as a business partner: Peddinghaus.
“Making Projects Profitable – That’s Why We Buy Peddinghaus” Kopp Stahlbau has been a long standing customer of Peddinghaus. Starting with universal ironworker machines in the 1970s to the Ring of Fire today, the distinctive green/orange machine colors have been a mainstay in Kopp’s production shop. Today, the Kopp Production Shop bays number fourteen (14) Peddinghaus machines:
This exposed steel structure is a landmark in the Hamburg skyline.
• HSFDB-2500 plate processor with carbide/8 station tool changer • FPB-1800 plasma/plate punch system • FPB-600 oxy/drill plate system • Anglemaster AFPS-643 • Ring of Fire 500/7 (7 axis) multi-functional plasma processing system • 4 universal ironworker machines
“Production, Production, Production – That’s Why We Buy Peddinghaus” Why does Kopp maintain such a large stable of Peddinghaus equipment? We asked Klaus Kirst, CEO, and Uwe Gerdau, Production Manager that question; they said “It’s essentially pretty simple” 1. The market is tight, so the projects always have competitive margins 2. The projects are always complex, and getting the drawings is always a problem 3. We have to fabricate quickly – sometimes in hours – to meet some deadlines 4. The Peddinghaus equipment ALWAYS does the job – accurately/ quickly/with today’s BIM technology
• BDL-1250/9D carbide drill line with DGP-1270 miter band saw • BDL-1250/9B drill line with DG-1250 miter band saw
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KOPP STAHLBAU Continued from page 5
The HSFDB-2500 at Kopp delivers finished plate parts just in time with minimal scrap.
“Going After New Markets – That’s Why We Buy Peddinghaus” Mr. Kirst and Mr. Gerdau comment on today’s fabrication market… 1. “At this time, the global economy affects every fabricator, including Kopp Stahlbau. 2. We accept many project challenges that others may turn down. 3. EX: We fabricated Steel for a hotel project in the Canary Islands – a little out of our comfort zone – but it was very successful.”
“We Have an Effective Business Partner – That’s Why We Buy Peddinghaus” 1. Many companies give you “lip service”– Peddinghaus provides “Customer Service” a. 24 hour telephone assistance b. Webcams/remote diagnostics help c. Qualified local service technicians 2. Why we attend Peddinghaus’ tours and functions: a. We become more industry educated (you always learn something new) b. We have developed new industry relationships that help our business c. We have achieved new fabrication projects from attending Peddinghaus tours 3. Kopp Stahlbau and Peddinghaus have the same business philosophy – when you think alike, you can achieve more together Mr. Kopp is proud of the achievements of his company for the past 40 + years, thanks to the support and motivation of all his employees and the use of Peddinghaus equipment. Kopp Stahlbau has a reputation for Quality Steelwork, Project Flexibility, and Providing “Just-In-Time Delivery” that always meets the customer’s deadlines. They maintain this reputation by not out-sourcing any part of a project – from planning and drawings to fabrication and erection, Kopp Stahlbau does it all. In finalizing his thoughts on the accomplishments of his company, Mr. Kopp is very pleased with his business relationships with prestigious firms like Airbus, Dow Chemical, RWE, Sasol, and many others which have all turned into true partnerships which will never be jeopardized. Mr. Kopp also says with a smile: “We have many friends in the industry whose demands we would always like to live up to – that’s why we buy Peddinghaus.”
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TUDOR ENGINEERING & DRAUGHTING – BENONI, GAUTENG, SOUTH AFRICA
Pioneering Productivity Located in the heart of Gauteng, South Africa, Tudor Engineering & Draughting is a medium size firm with big ambitions. In South Africa, the mining, petrochemical, and power generation markets keep the steel industry thriving. However with competition growing both within South Africa and abroad, Tudor knew automation was necessary to stay competitive. By taking the critical steps to automate, Tudor’s production capabilities have grown tenfold. Braam Beukes, Owner of Tudor Engineering & Draughting stands with the PCD-1100/3B (Advantage Drill Line) at his firm in South Africa.
The Perfect Solution At the firms’ origin, Tudor purchased a Peddinghaus Ironworker to accelerate manual fabrication. Long after their Peddinghaus purchase, Tudor realized the true meaning of Peddinghaus quality and craftsmanship. At over 50 years old, Tudor’s Ironworker is still a viable solution to unique components within their fabrication shop and is in daily operation. With competition intensifying daily, Tudor decided to search for a machine tool company that could advance their firm and leave manual fabrication behind them. When they came across a familiar name in their explorations,
Tudor knew their automation answer was with a partner they had already grown to trust – Peddinghaus. To streamline their workflow and automate production, Tudor invested in a Peddinghaus system to help them compete for larger projects. By automating the production of drilling and cutting beams, columns, tubes, and punching and shearing channels, angles and flat bar, Tudor’s capabilities have increased immensely. “The purchase of Peddinghaus equipment was a significant step for medium sized fabricators throughout South Africa, as Tudor Engineering was one of the first to invest in modern day equipment,” stated Braam Beukes, Owner of Tudor Engineering & Draughting.
Peddinghaus equipment helped to increase Tudor’s tonnage from an output of around 30 metric tons (35 inch tons) per month to 350-400 metric tons (400-450 inch tons). This increase in production alone paid for the Peddinghaus machinery investment many times over. “While the initial strategy was to both increase production and reduce personnel, we soon realized that it was better for our personnel to remain the same. By doing this we managed to drastically increase our production output while cutting down on double shifts and overtime, thus increasing profits,” stated Braam. Peddinghaus technology brought Tudor enormous labor savings enhancing their competitiveness. Tudor now has the capacity to compete for larger projects, thus increasing their profit and flexibility. By eliminating the human error associated with fabrication, utilizing Peddinghaus machinery allowed Tudor’s production to increase, material handling to decrease, and lead times to become reduced immensely. When looking into a machine purchase, Tudor knew that investing in machinery with the service and support to back it was very important. Peddinghaus has local service and sales support in Johannesburg, South Africa. “These nearby support and spare parts services allow us to
With competition intensifying daily, Tudor decided to search for a machine tool company that could advance their firm and leave manual fabrication behind them.
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Running in tandem with the PCD-1100/3B is the DG-1100 band saw from Peddinghaus.
L to R: Ian Walker, International Sales Manager for Peddinghaus; Braam Beukes, Owner of Tudor Engineering & Draughting; and Patrick Pereira, South African Regional Sales Representative for Peddinghaus
operate our business with the utmost confidence in our equipment because of the service behind it. After the purchase, service is paramount to the operation and production quality of the machine,” stated Braam. Tudor proved to fabricators in South Africa that it is possible to automate without sacrificing profit margins or deadlines.
Streamlining Automation A great deal of Tudor’s projects involve the mining, Power Generation and Petro Chemical industries of South Africa. With an abundance of oil, gold, copper, and silver located throughout the continent of Africa, the need for industrial steel fabrication continues to grow. “Cost, quality, and on time delivery will always remain a challenge when working in any industry. The structural products vary from heavy to light weight/labor intensive systems. Good planning and sequencing must be maintained to eliminate delays during production. Having invested in both the Peddinghaus saw and drill line for structural sections and the angle line for angle and flat profiles has enabled us to meet and exceed these challenges,” stated Braam.
Fabricating steel for the mining industry requires a shop flow that is designed for maximum productivity. Tudor looked to Peddinghaus Corporations’ layout personnel to produce a shop layout fit for timely fabrication. Seasoned layout experts at Peddinghaus set up Tudors’ firm in a way that worked best for their production requirements. As a result, “good planning and sequencing was achieved eliminating delays that could be caused by intricate component production,” stated Braam.
The PCD-1100/3B is a staple in Tudor’s daily operation.
A Bright Future Tudor is optimistic about the future. Pioneering their way as a first class fabrication facility, Tudor is proving that productivity and quality go hand in hand with the automation solutions offered by Peddinghaus. With a growing customer base, Tudor is creating a legacy as a progressive fabricator within the industry.
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Utilizing an Anglemaster from Peddinghaus, Tudor has the opportunity to tap into the large market of towers in South Africa.
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CONTRACTORS STEEL COMPANY – LIVONIA, MICHIGAN, USA
Service Means Success Donald R. Simon is not just a steel person, but a family person. These two parts of his life converged in August of 1960, during a discussion with his wife Esther. “We formed Contractors Steel after Esther approached me and said, ‘Don, $137 a week just doesn't cut it to support our family.’ So I said to my wife, ‘the only thing I know is steel, so I better go into the steel business’.” Don purchased 25 tons of steel, an old used truck, a tracked crane with 40' boom, and rented space behind a lumber yard to store steel on the ground. Joined by his wife Esther and colleague Marc Bokas, Sr., Contractors Steel Company was born. Today, over fifty years later, and with over one million square feet (ninety-three thousand square meters) of space under roof, the original pickup has been long
L to R: Dennis Blount, Robert Simon, Donald Simon, and Marc Bokas, Jr. of Contractors Steel Company with their Peddinghaus HSFDB plate processor.
retired and in its stead stands a fleet of over ninety trucks. With five steel service center facilities throughout the Midwestern USA, Don still works his fifty hours per week, but now the children of Marc and Don are assuming active roles in the firm’s management. Now doing more than simply delivering steel, Contractors Steel Company offers an array of processing capabilities using equipment that is second to none in the service center industry.
Over Half a Century in Business Takes More than Luck As anyone in the steel business will tell you, it takes more than luck to stay in operation for over fifty years. Throughout those fifty plus years, Contractors’ key to success has been superior customer satisfaction. Technology has played a large role in servicing their diverse client base, and today the firm maintains a vast arsenal of automation to produce parts in the fastest manner possible. Robert Simon, CIO/CFO, states, “We get the material to the customer when the customer needs it. There is no two or three day delay. It’s not uncommon that a customer calls us at five o’clock for a next day delivery. At Contractors Steel we get it done, whatever it takes.”
Contractors’ primary production facility in Belleville, Michigan has over 430,000 square feet (40,000 square meters) under roof.
Parts from the HSFDB are immediately packaged for shipment upon completion.
Continually searching for ways to improve, the team at Contractors found themselves searching for a “game changing” piece of technology to help them better service their OEM, and miscellaneous/structural fabricator clientele. Dennis Blount, Special Projects Manager, states, “It’s common for customers to ask for holes in parts but in some scenarios these holes cannot be burned and must be drilled. In the past, we would either cut the part to shape, and provide it to the customer so that they could complete the drilling process on their own, or we would perform the drilling here in the shop manually using a magnetic based drill or radial arm drill. This inevitably takes extra time, and quality becomes harder to control. We were looking for a machine that combined these processes.”
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The powerful spindle of the HSFDB is capable of drilling, milling, tapping, countersinking, scribing, and more.
The HSFDB at Contractors Steel Company employs the latest in Hypertherm plasma cutting technology.
The measurement system of the HSFDB doubles as a clamping system, providing 12 tons (11 metric tons) of clamping power across the entire width of material.
Peddinghaus Presents NEW Possibilities
Built to last, Marc further comments on the machine’s design, “The Peddinghaus machine is very solid. All the components are built to do what it is designed to do and more. We have bought a lot of equipment, and we have seen a lot of equipment that was advertised to do certain things, but it seemed like they were under-engineered, but not the Peddinghaus. This piece of equipment, if anything is over-engineered and it does an excellent job in regards to what we need done in an efficient and productive manner.”
Contractors examined all of their options, starting with familiar designs that used table and gantry systems, but decided to try a newer method of plate processing which focused on functions besides just burning. Dennis recalled, “We have had a lot of traditional burning machines in our production. These machines can be retrofitted or upgraded to have a drill spindle included, but the machine isn’t really designed for that. It almost seemed like the drill spindle was an afterthought. With the Peddinghaus HSFDB, the design starts with the spindle. It’s a drilling machine that also is designed to cut, which means better performance.” After careful consideration, Contractors Steel Company decided to partner with Peddinghaus for their latest plate processing center. The Peddinghaus HSFDB is adding a new dimension to what customers can receive from their trusted steel supplier. With the ability to drill, mill, tap, countersink, scribe, cut, and more in a single cell, the HSFDB helps produce higher quality parts faster than ever before. “We had seen Peddinghaus before and knew lots of customers who had mentioned them. We understood they have a reputation for reliability, durability, productivity. Using our Peddinghaus we are able to perform an array of functions and cut parts to shape, all on one machine. This is a lot more efficient, and a lot more profitable than before. The Peddinghaus has enabled us to create a better product for our customers, and get into different markets that we didn't have exposure to in the past,” stated Marc Bokas, Jr., COO.
Words to Live By Technology is just a vehicle to achievement. To continue to thrive, a firm needs deep conviction to provide a quality product. This is evident when Don Simon describes his company, “Over the last fifty-two years we have been in business I would say that we have been successful because we work hard, we’re honest, and we give the customer the best service that we can provide. I think if you talk to our customers, not only are we honest and ethical with how we work, but when they want something it’s our fondest desire to deliver parts in the fastest manner possible. Our philosophy has always been to give them a dollars value for a dollar’s worth of product. There's no secret to success, it's just good business.” For more information on Contractors Steel Company and the services they provide visit www.contractorssteel.com.
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STEEL FABRICATORS’ REVIEW
PUNCHING, SHEARING, AND PART MARKING FOR TODAY’S FAB SHOP
The Innovation of the Anglemaster-HD The Anglemaster-HD is an angle line like none other. When it comes to this latest generation of Anglemaster technology, the robust build quality of the machine is only matched by its intelligent design. Not your typical angle line, the Anglemaster-HD ushers in a new era of CNC punching and shearing devices. Faster, more responsive, more versatile, and more agile the Anglemaster-HD is designed to increase productivity and stand the test of time.
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The First of its Kind - Comprehensive Material Dimensioning When the Anglemaster-HD takes hold of material, it detects the exact dimensions of that section. The Anglemaster-HD measures material by employing high precision transducers fixed to the clamping, and punching mechanisms of the machine. The heavy duty roller clamps locate leg length/width of material, and the punch mechanism concurrently senses material thickness. If loaded stock doesn’t match that of the program desired, the machine will automatically notify the operator of the discrepancy, providing the opportunity to either continue the program or re-evaluate the setup of the machine. In scenarios where an incorrect program is loaded, or incorrect stock is placed within the machine, this mechanism will prevent unnecessary loss of valuable steel and operating time.
Intelligence in Action - Smart Cylinder Technology
The Anglemaster-HD comes optionally equipped with a hard stamping (above), and/or carbide scribing system (below) for layout and part marking.
Using the information provided by the all new material dimensioning system, Smart Cylinder technology is enacted by the Anglemaster-HD. Unlike heavy duty angle lines of the past which were powerful enough for the heaviest of sections, yet lacked the speed and nimbleness desired for processing lighter profiles, the Anglemaster-HD exceeds expectations in all scenarios. Smart Cylinder technology uses data collected from the material dimensioning system, and actually adjusts the amount of power used to stroke each punch or shear cylinder. This reduces the amount of hydraulic mass the machine must handle in scenarios where full power production is not necessary, thus increasing the speed of each cylinder cycle. Using three different cylinder speeds/strengths, the Anglemaster-HD provides process times 50% faster than previous models.
Smart Cylinder Technology Cycle Time Comparison HIGH POWER
MEDIUM POWER
LOW POWER
PUNCH CYCLE TIME
1.3 Seconds
.92 Seconds
.74 Seconds
SHEAR CYCLE TIME
5.1 Seconds
3.6 Seconds
2.9 Seconds
*Please note - these times are based on full cylinder strokes, not using short stroke technology
Faster Production - Short Stroke Punching and Shearing Further adding to the efficiency of the machine, short stroke punching and shearing is additionally employed to expedite productivity. Using the dimensions of material gathered by the automated material dimensioning system, punch and shear assemblies return to a safe distance above the surface of material at the conclusion of each stroke, but do not return to the top of cylinder stroke for each cycle of the press. This greatly reduces the amount of motion executed by the machine, thus further decreasing overall process time.
Triple tool punching of the Anglemaster-HD allows for higher production, and a lower amount of tool changes.
Built to Last – World Renowned Peddinghaus Quality The most intelligent angle line ever produced by Peddinghaus is also the most rugged model in history. Proudly exhibiting the strength of 169 (153 metric) ton punch presses and a 515 (467 metric) ton shear press, the Anglemaster-HD is suited for both the heaviest and lightest of section sizes. With a powerful super structure to match, the Anglemaster-HD is a machine truly built to stand the test of time in any shop environment. The powerful 515 (467 metric) ton shear of the Anglemaster-HD utilizes single cut tooling.
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Peddinghaus Wins Hands-Down in Las Vegas Peddinghaus empowered fabricators at FABTECH 2012 with groundbreaking technology and revolutionary designs. The HSFDB plate processor and Anglemaster-HD angle line were on display like never before, as visitors were encouraged to touch and feel the difference that Peddinghaus quality presents. A bold statement to be made, Peddinghaus stripped away the outside of the machine to illustrate that strength and reliability starts on the inside. Exhibited for the first time, the Anglemaster-HD received high praise in Las Vegas for its robust blueprint, and cutting edge material sensing technology. Attendees seized the opportunity to experience the advanced design that the Anglemaster-HD presents with features that include Smart Cylinder technology, SignoScript and SignoMat marking, triple tool punch presses, and single cut shearing. The Peddinghaus engineering team has done it again, as this latest addition to the Anglemaster line-up encompasses every aspect of Peddinghaus design - Smarter, Faster, and Stronger. The HSFDB plate processor continued to be a crowd favorite by flaunting its innovative design, and game changing build quality. With the ability to drill, tap, countersink, mill, mark and thermal cut plate using patented roller measurement technology, the HSFDB is completely unique in today’s market. From top to bottom, the craftsmanship of the HSFDB is unparalleled. As always, Peddinghaus continues to advance the industry with state of the art designs and user friendly software. Next year will be no different as FABTECH returns to Peddinghaus' home in Chicago, Illinois – USA. Don’t miss out!
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Peddinghaus Finds Success at SteelFab 2013 in the United Arab Emirates Peddinghaus was proud to be an exhibitor at the 2013 SteelFab to support their partners throughout the Middle East. The 9th annual SteelFab Exhibition has concluded at the Sharjah Expo Center in the United Arab Emirates (UAE), and Peddinghaus equipment is still the topic of conversation. During the four day exhibition, Peddinghaus representatives met with customers from around the globe searching for a solution to automate their production, and they found answers with Peddinghaus. Peddinghaus is proud to be a long time partner with business leaders throughout the Middle East. With local service and spare parts staff in the area, customers in the Middle East receive the best support available. Peddinghaus employs local service technicians dedicated to the region for faster response times, and steadfast spare parts support. Included with every machine purchase is 24-hour technical support to ensure there is service available for all time zones. Peddinghaus is committed to fabricators in all corners of the world, and provides world class expertise to all regions. Roland Jones, International Sales Manager for the Middle East, has extensive experience as a plant manager and recognizes the challenges fabricators in the market face. Roland has been on both sides of the spectrum. From overseeing the fabrication of multiple plants throughout the Middle East and Europe, to working for the world’s leading machine tool provider, Roland understands the market factors and the project management aspect of many operation scenarios. With local support, and advanced technology, SteelFab 2013 proved that Peddinghaus continues to be the provider of choice throughout the Middle East. From automation techniques, to advanced software technology, SteelFab attendees experienced it all. Visit Peddinghaus at SteelFab 2014 to see what type of advanced technology Peddinghaus will come up with next! For more information on Peddinghaus’ commitment to the UAE, contact: Roland Jones, International Sales Manager – roland@peddinghaus.co.uk
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THE HSFDB PLATE PROCESSOR
Turning Plate into Profit
The HSFDB plate processor is quickly becoming the PLATE PROCESSOR OF CHOICE throughout the steel fabrication industry. Structural fabricators, service centers, and manufacturers all enjoy the benefits that this single pass system offers. Hear what the industry is saying about the TECHNOLOGY THAT IS REDEFINING PLATE PRODUCTION.
THE MANUFACTURING SECTOR Balzer Incorporated - Mountain Lake, MN, USA
Warrior Mfg., - Hutchinson, MN, USA
WEBSITE: www.balzerinc.com
WEBSITE: www.warriormfgllc.com “We have had other plate processing machines, most recently a punch plasma, and over time they simply needed replacement. Our materials grew from 1/4" (6mm) to 1/2" (12mm) thick as our products continued to grow in size. We went to an exhibition looking for a laser or similar machine and learned that the plate processor could do 90% more than any other machine on the market.
Before we had the Peddinghaus in our plant, we were outsourcing as much as $80,000 of thick plate per month. We have eliminated that with the Peddinghaus machine. Before, even after the outside processing, many of the pieces still required drilling and machining when they had returned to our plant. With the Peddinghaus we get it all. We can do tapping, counterboring, milling, drilling, cutting all in one step. We had a vendor that used a very large laser which made great parts but in our industry we have a lot more drilling, tapping, machined holes which still required processing. In some scenarios we were laser cutting holes oversized, placing a bushing inside of the hole and welding it in order to achieve the machined surface we desired. If you can simply machine those parts from the start you are saving an incredible amount of steps in that process. We can now do that with our Peddinghaus. Floorspace also became a concern at Balzer, due to how the company has grown. With the way we have setup our machine the material starts outside and passes through the wall to feed into the operating area. With the new machine we use at least 33% less space than our last plate machine and can do more processes as well.” – Lee Lidtke, Plant Manager
“When we saw the Peddinghaus plate machine design we knew we needed one. Everything happens in one place on the Peddinghaus machine. There is no picking up parts and taking them to a separate station, which used to be common place in our production. The machine eliminated 4 additional workstations within our shop. This means there are 4 people that are no longer spending their time processing plate, and can focus on other tasks such as welding, fit up, or painting. Not only does this make our production more cost effective, but our reaction time is second to none, giving us a real competitive edge when deliveries are concerned. We commonly process base plates, tower stiffeners, splice plates, gussets, and more on our HSFDB and have seen immense drops in scrap waste compared to other plate production methods. A 10% difference between machines on common parts is a very fair estimate when comparing the HSFDB with our burn table. When I look back at the plate machine purchase experience it was a ‘no brainer’ decision. This machine made us an even bigger player in our industry. Now that we can process our material faster, with less labor, and at a higher level of quality, the sky is the limit.” - Paul Soukup, President
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THE STRUCTURAL FABRICATION SECTOR Sperling Industries - Sperling, MB , Canada WEBSITE: www.sperlingind.com “Our plate machine has become a great asset to our organization. It has such a wide variety of options, and is incredibly fast and accurate. We are now dealing with less scrap than we ever have before. With the nesting of the machine, we may see 5 - 10% scrap depending on the shape of parts being cut. The reason we went with Peddinghaus is because we don't have a large infeed material handling or outfeed material handling footprint. We liked the way it handled material and it kept a very small footprint in the plant. The productivity of this machine has increased the options of our production tremendously within our organization. It’s a one man operation with this machine. Once the plate is loaded outside the worker processes all of our connections and such when I previously had at least 5 people doing layout of plate parts, cutting, and trimming using manual processes and the speed has easily increased 10 to 1 compared to before. Our customers experience faster turnaround times, and higher quality/higher accuracy parts as a result of our Peddinghaus machines.” - Jeff Nicolajsen, Owner
Waiward Steel - Edmonton, AB, Canada WEBSITE: www.waiward.com “We initially purchased an HSFDB-1800, which is a 6' (1800mm) bed, and we quickly we saw how fast that was for our plate production. When the 10' (2500mm) version came on the market we were supposed to return our HSFDB-1800, but we couldn't part with our first machine so now we have both plate processors working in our shop. We use edge start a lot, and we are able to put as many parts as possible on the sheet. Basically the only scrap created are some of the edges of the plate that need to be cut down so parts are the accurate shapes and sizes. Typically you get around 5% scrap depending on the parts you are processing. We can go from 1/4" (6 mm) all the way up to 3" (75 mm) material, and 1/2" (12 mm) to 3" (75 mm) holes. We have had hardly any issues with the machine since it was installed five years ago - running 5 days a week, 24 hours a day.” Robi Dosanj, Detail Foreman
STEEL SERVICE CENTERS SECTOR DenCol - Denver, CO, USA WEBSITE: www.dencol.com “DenCol does a lot of work for a number of industries including mining, transportation, buildings, bridges, and a lot of other sorts of first stage fabrication using our Peddinghaus plate machines. We have one HSFDB-2500 plate machine, three FDB-2500 plate machines, and enough work to keep them busy 16 hours a day. We have one FPB-1800 (punching), and we run that machine 18 hours per day. In the fabrication business you have an awful lot of material handling issues. The Peddinghaus equipment is very efficient because it has a pass through system. You can set material on roller conveyors, run it through the machine, drop the parts, and not have to deal with the unloading of a table system. The handling of the machines has been a great benefit to us, and add an efficiency to our company that burning tables can’t offer. Peddinghaus has helped us develop techniques to become more efficient, and we have showcased their equipment to demonstrate that the machines will indeed do what they say it will do. In the past 10 years, DenCol's relationship with Peddinghaus has allowed us to become a national supplier of first stage plate products, and we value their support.” DeWayne Deck, President and Owner
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NASCC 2013 –
Meet Us in St. Louis! April 17-19th meet Peddinghaus in St. Louis, Missouri – USA, for the 2013 North American Steel Construction Conference (NASCC). Peddinghaus takes pride in being the top provider of all things steel at the annual NASCC conference. Whether it is quality machinery, or the experts to keep you informed about the market today, Peddinghaus is your trusted partner. With a new route for the Peddinghaus Fabricators Motorcycle Tour, innovative technology, and a special event unlike any other, Peddinghaus promises to entertain, enlighten, and enthrall attendees of the 2013 NASCC at America’s Center Convention Complex in St. Louis, Missouri. Leading up to the NASCC, Peddinghaus partners have enjoyed touring different parts of the country on two wheels via the famous Peddinghaus Fabricators Motorcycle Tour. Totaling over 60 attendees for the 2012 NASCC in Dallas, Texas, the tour keeps growing. Riders enjoy the beautiful scenery of the surrounding areas and tour fabrication shops on their way to the NASCC conference. For 2013 Peddinghaus will expand the tour group even further while traveling throughout America’s Heartland for the annual Motorcycle Tour. The Peddinghaus booth at the NASCC is always the talk of the show. For the past 10 years Peddinghaus has introduced new technology exclusively to our partners at the exhibition. Attendees have experienced everything from a political debate to world class comedy, and musical performances. As has been the case over the past few years, Peddinghaus hosts a Special Event for all NASCC attendees with countless networking opportunities. Attendees of the Peddinghaus Special Event rant and rave about the ability to network with industry peers from across the globe in a relaxed environment. From Pittsburg, to Orlando, to Dallas, Peddinghaus ensures an experience unlike any other. In the past, Peddinghaus has been known to bring in comedians such as the Blue Collar Comedy Tour star Ron White and the ever hilarious Saturday Night Live actor Dana Carvey. Accompanied by world class dining and locations that wow the crowd, St. Louis promises to be the “best event yet” with a venue that is truly second to none. For updates on the 2013 NASCC, follow Peddinghaus on twitter: @peddinghaus and check the Peddinghaus website often for technology and special event announcements. And remember, no one does the NASCC like Peddinghaus, no one!
Stay Tuned for the Latest Segment from Peddi-TV! A new year means fresh segments from Peddi-TV are in the works… 2013 has begun and Peddi-TV is ready to report on the topics and stories that matter to YOU, today’s modern fabricator. Each new year presents new challenges and projects for each fabricator and steel service center. From global steel industry news to the innovations in the machine tool sector, Peddi-TV is your source for all things steel. In 2013 Peddi-TV will report on topics including: • Cutting Edge Machine Tool and Software Technology • Upcoming Show News – Such as Austech, Euroblech, NASCC, SteelFAB, & FABTECH • Relevant Interviews from Peddinghaus Partners from Across the Globe Don’t miss your chance to receive breaking industry updates with Peddi-TV anchor, Lyle Menke, seasoned veteran of the steel construction industry. Stay tuned to see what Peddi-TV will come up with next! Subscribe via the Peddinghaus website so you won’t miss the next installment of Peddi-TV. www.peddinghaus.com/pedditv
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GETTING TO KNOW…
Todd Hartman Weld Shop Supervisor
The Peddinghaus Weld Shop has 15 AWS D1.1 certified welding professionals.
What is your job at Peddinghaus and what does it entail? I am the Weld Shop Supervisor and in this position I have the opportunity to oversee all projects that we plasma cut, weld, form, and fabricate. A fun fact that not many people know is that at the Peddinghaus Weld Shop, we make Peddinghaus machines WITH Peddinghaus machines! We rely on our own equipment to fabricate the steel parts that comprise all Peddinghaus machines. Many people think that all our partners build sky scrapers, but not everyone knows that we have other partners just like us that utilize Peddinghaus equipment for manufacturing.
We understand that you make Peddinghaus machines with Peddinghaus machines, but what kind of machines and operating stations do you have in the Weld Shop to create the components? The different capabilities of our shop include a total of 15 AWS D1.1 certified welding professionals, our Peddinghaus machines, and our welding stations. Our welding stations include large positioners for larger weldments, small positioners for smaller projects, and table tops for accessible jobs that can be flipped if needed via our overhead cranes and stationary jibs. We also have several industrial sized saws, a shear, an ironworker, an FDB-2500 plate processor, a Ring of Fire-500 plasma cutter, a de-burring station, and our very own inspection area to ensure quality parts for Peddinghaus machine assembly.
You mentioned that you have 15 AWS D1.1 welders; can you explain what an AWS D1.1 welder is? D1.1 is just one of the many certifications the AWS (American Welding Society) offers in this field. The title D1.1 is specifically for the commonly used carbon and low-alloy construction steels. We realize the importance of having qualified and skilled employees to ensure the parts we are producing for Peddinghaus equipment are of the very best quality. Continued on page 22 “At the Weld Shop, we know if there is a part we need, we can look to the Ring of Fire and it will perform.” – Todd Hartman, Weld Shop Supervisor
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GETTING TO KNOW TODD HARTMAN Continued from page 20
Utilizing the FDB, Peddinghaus has the capability to produce parts to create Peddinghaus machines.
Building Peddinghaus machines is only possible by utilizing our machines as well as our skilled welders and personnel.
You also mentioned that you use an FDB-2500 within the Weld Shop, what Peddinghaus machine components do you use this machine to fabricate? On the FDB we produce anything from 1/4" (6 mm) all the way up to 3” (75 mm). We produce plate components for every machine model that Peddinghaus makes, from the sideplates of our plate machines to a variety of smaller, more intricate components needed throughout Peddinghaus’ product lines. The FDB is one of Peddinghaus Corporations’ most innovative plate machines of its time, which enables us to nest many of parts that share the same material in one run. Leaving minimal “clean up” on the parts allows many jobs to be completed within a small timeframe. Trust me when I say when working in a weld shop and being able to produce both quality as well as quantity in minimal amount of time, makes everyone a winner.
What about the Ring of Fire, what Peddinghaus machine components do you use the Ring of Fire to fabricate? The Ring of Fire will hold anything 20" x 20" (500 mm x 500 mm). Very similar to the FDB, the Ring of Fire can produce just about every steel component for the machines we make here at Peddinghaus. One of the most interesting things about the Ring of Fire is that it is one of the only coping machines in the industry that can completely process tube in a single pass. Tubing processed on the Ring of Fire is used for a wide variety of parts including the top frame carriages, foot-mountings, and bases of
our drill lines. At the Weld Shop, we know if there is a part we need with any of the above processes, we can look to the Ring of Fire, and it will perform. The Ring of Fire helps us cut back on the time we would be spending on our fabrication process, such as hole punching, precision cutting and measuring. The program that the Ring of Fire utilizes makes it capable of producing very intricate parts extremely fast. When tube components were fabricated in the past, they would take up to a half a day’s work. Now with the Ring of Fire, we can process these sections in minutes.
Given that you have been around Peddinghaus for a while, how would you say Peddinghaus’ fabrication technology has evolved? In the past ten years alone, we have gone from making machines that relied on mechanical design to function, to machines that virtually think for themselves. This also means that we fabricate to tighter tolerances than ever before. Although our electronics are more involved, the structure is still the same - bulletproof. With an engineering team that is pushing the limits of design, and a research and development department that is continually refining tomorrow’s technology, Peddinghaus is paving the way for the future of fabrication.
After being with Peddinghaus for 25 years, why do you stick around? Peddinghaus has the values I was taught as a child. Our customers and employees are treated with the same respect, which says a lot about our company as a whole. Peddinghaus Corporation is a family, and I am honored to be a part of this team.
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STEEL FABRICATORS’ REVIEW Washington and Grove Street Bradley, IL 60915 815. 937. 3800 www.steelfabreview.com
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