BROUGHT TO YOU BY:
PROUD PARTNERS WITH INDUSTRY LEADERS
Mestek Machinery is the industry-leading designer and manufacturer of the most complete, productive, and innovative HVAC manufacturing equipment in the industry. By leveraging contractor and fabricator feedback, Mestek Machinery continues to deliver HVAC metal forming solutions to enhance productivity while creating a better deliverable for straight duct and fittings. Our family of brands including Lockformer, Iowa Precision, Engel, and Roto Die have decades of experience addressing every facet of the HVAC duct manufacturing industry.
Mestek Machinery is proud to join in partnership with SMACNA and McCusker-Gill in hosting the 2025 SMACNA Fab Forum. As SMACNA’s first Premier Partner, starting 2013, Mestek Machinery has worked hand-in-hand with the industry’s most innovative and progressive minds to help shape and improve the state of HVAC duct and fittings fabrication. From unique processes that improve throughput and quality to modern solutions that automate processes for even greater productivity gains, Mestek Machinery is proud to be part of the SMACNA team which is setting the standards for the industry. And throughout our partnership, Mestek Machinery and McCusker-Gill have worked seamlessly together to develop solutions that accentuate to take their operations to the next level.
A 30 YEAR PARTNERSHIP MESTEK MACHINERY &
MCCUSKER-GILL
The relationship betwen Mestek Machinery and McCusker-Gill dates back to mid 1990’s when President Kevin Gill, looking for ways to make the company more efficient in the production of HVAC ductwork, placed a call to Oxford Machinery – the local Lockformer and Iowa Precision dealer in Boston at the time. The relationship started with consultations and eventually led to the first investments in the machinery that would help take McCusker-Gill to the next level. Among the machines that were purchased over a 5 year span were the Iowa Precision Fabriduct Coil Line, the Lockformer Vulcan 2900 Double Table Plasma Cutting System fed by the Iowa Precision Plasma Coil Feed, and the Lockformer Vulcan Water Jet for producing sound liner.
From there the relationship only grew. With a drive towards continuous improvement, Kevin Sr. and Shop Superintendent Tommy Hall continued to lean on Mestek Machinery for the "next" technology or process that would give McCuskerGill an edge. In 2014, McCusker-Gill made their most significant investment by purchasing the latest Iowa Precision ProFabriduct Coil Line with Integrated Full Width In-Line Plasma Cutting.
The partnership between McCusker-Gill and Mestek Machinery has never been stronger. It's a testament to not only having that shared vision towards continuous improvement, but also to the culture, the family atmosphere, and the ethical values that exemplify both of these organizations.
Mestek Machinery is extremely proud of our partnership with McCusker-Gill and we look forward to the next 30 years.
“The SMACNA FAB Forum, hosted at the remarkable McCusker-Gill allows our dedicated members the opportunity to exchange valuable knowledge on the subject of fabrication with their peers, while at the same time exploring cutting-edge innovations, including those presented by our esteemed Premier Partner, Mestek Machinery.”
- Carol DuncanSMACNA President
“SMACNA members are unique in the construction industry. We are the only contractors who manufacture the products we install. Events like the FAB Forum and great partners like Mestek Machinery help us grow our industrial capacity.”
- Aaron HilgerCEO | SMACNA National
Mestek Machinery that can be seen under power during the Fab Forum hosted by McCusker-Gill, Inc. HVAC
Mechanical and Sheet Metal Contractors — find details for each of these machines in the subsequent pages:
Iowa Precision Pro Fabriduct® Full Coil Line
Lockformer Vulcan® Fiber Laser Cutting System
Iowa Precision Coil Feed for Plasma and Laser Cutting Machines
Lockformer Vulcan® 1600 Water Jet Cutting System
Iowa Precision Combination Cornermatic® II Whisper-Loc Automated Corner Insertion and Pittsburgh Lock Seam Closing Machine
Iowa Precision Cornermatic® Plus Versa Automated Corner Insertion Machine Lockformer Dual Head Gore-Locker
The Iowa Precision ProFabriduct Full Coil Line at McCusker-Gill Features a 14 gauge Processor, 14 ft. Transfer System, True “X” “Y” In-Line Plasma Cutting, welded duct production, and a high speed pinspotter along with a second controller at the wrap brake.
Produce Finished HVAC Duct Sections with Less Chance of Leakage
The Pro-Fabriduct Full Coil Line from Iowa Precision is the most advanced complete coil line in the HVAC industry today. The line leverages footprint, speed, and production rates along with tolerances that no other HVAC coil line can match. But perhaps most importantly, the Pro-Fabriduct Full Coil Line helps contactors produce finished duct with a full-width longitudinal seam which significantly reduces the chances of leakage in the corners of the duct’s transverse joint (up to 25%). With the Pro-Fabriduct Full Coil Line, you can produce a better product (one with tangible benefits for your customers) while reducing your postproduction labor costs - that’s a competitive advantage you can take to the bank.
Designed for Prefabrication
Prefabrication continues to be the growing trend across the country. Pre-assembling ductwork in a controlled environment prior to shipping leads to better quality, just in time fabrication, less inventory on the job site, and a significant reduction in labor costs. The innovative Pro-Fabriduct Full Coil Line from Iowa Precision was designed with this trend in mind. First, the ProFabriduct is the only HVAC coil line in the industry with a true full-width ”X” ”Y” cutting bed In-Line Plasma Cutting System. The system includes built-in download capabilities from most CAD/CAM systems and BIM modeling acceptance from Autodesk, Trimble, Practi Cam, Shop Data Systems and others, enabling the cutting of access doors, taps, and more for duct prefabrication on the line.
The sytem also features a new Insulmatic insulation rotary cut off and pinning system. Either Duro Dyne or Gripnail Pinners between 1/2” - 2” cut most all material types, including fiberglass, Arma Cell Elastomeric, Ductmate Poly Armor, Owens Corning, Johns Manville, Certainteed, Knauff, with speed and accuracy. The system is also compatible with the New Johns Manville RC-IG Water Based Insulation which only requires water and eliminates the need for glue.
Full-Width
Longitudinal Seam Production: What’s the Difference and Why Does it Matter?
Most HVAC duct leakage occurs at the notch hole that is produced at the top and bottom of a duct section at the transverse duct connection to the fan or the unit. The Iowa Precision Pro-Fabriduct Full Coil Line has undergone a combination of modifications to the processor, transfer system, and hydraulic servo wrap brake that allow it to produce ProDuct™ — a finished duct with a full-engagement longitudinal seam which substantially reduces the chance of leakage in the corners of the duct’s transverse joint. Full-width longitudinal seam production can substantially reduce the chance of leakage with a greater deliverable thereby producing greater output with less input creating less chance of human error. The Full-width longitudinal seam production is applicable to our 5’ line, with 4’ or 5’ stock, and can be either Large-Pittsburgh and Small-Pittsburgh or Large-Pittsburgh and Snaplock.
The notch profile is altered to leave more material on the male side of the notch, allowing the male seam to extend to the edge of the duct. Dual steppermotor controlled notching die positioning eliminates an operator from needing to adjust the notchers for coil width or notch type; precise positioning is handled through the control system. The 90˚ male lock is formed after the roll forming of the connecting flange, avoiding the full length male flange from being deformed as it passes through the roll former. The servo wrap brake is altered to include locating pins to accurately locate the part parallel to the bending beam. Positioning of the leading raw edge gives very accurate and precise locations for the subsequent bends. Computer controlled leaf tooling gags have been added allowing the brake to bend the full engagement male lock seam without deformation.
Features
• Wireless pendant control system for decoil and recoil of each coil station
• Hydraulically-powered, gear-driven uncoilers, hold downs, and an in feed ramp for smoother coil loading
• E-Z load coil drum assemblies allow for quick spool changeover
• Heavy-duty nylon pockets eliminate mechanical wear and tear items
• Standard 16 gauge processor with optional 14 gauge processor systems available
• When choosing the 14 gauge system, the hydraulic hold down on station 1 is fully powered and an extra set of hydraulically actuated pinch rolls are also included to assist material into the straightening rolls
• Male seam is made on system’s re-engineered hydraulic servo-driven wrap brake
• The notch profile has been altered to allow the male seam to extend to the edge of duct
• Dual stepper-motor controlled notching dies automatically position to eliminate the need for an operator to adjust the notchers for coil width or notch type as precise positioning is handled through the control system
• The servo wrap brake also includes locating pins to accurately locate the part parallel to the bending beam, and the positioning of the leading raw edge gives very accurate and precise locations for subsequent bends
• Computer controlled leaf tooling gags have been added, allowing the brake to bend the full engagement male lock seam without deformation
• The 90˚ male seam lock is formed after the roll forming of the connecting flange, avoiding the full length male flange from being deformed as it passes through the transverse duct connector (TDC) or transverse duct flange (TDF) roll former
• When choosing Female Seam Type from the HMI Input, the hydraulically rafted female roll former automatically moves into place for either Large Pittsburgh Lock, Small Pittsburgh Lock, and/or Snaplock — this also greatly improves the cold sealant program.
• An 18 gauge Dual Head TDC or TDF forming system is standard, with a 16 gauge option available — includes automated go-to positioning from the pendant when coil widths are not a true 60 inches in width
• True full-width ”X” ”Y” cutting bed In-Line Plasma Cutting System with built-in download capabilities from most CAD/CAM systems and BIM modeling acceptance from Autodesk, Trimble, Practi Cam, Shop Data Systems and others, enabling the cutting of access doors, tabs, and more for duct prefabrication on the line — the only HVAC coil line in the industry with a this feature
• Insulmatic insulation rotary cut off and pinning system — either Duro Dyne or Gripnail Pinners between 1/2” - 2” cut most all material types, including fiberglass, Arma Cell Elastomeric, Ductmate Poly Armor, and many more, with speed and accuracy. Also compatible with the New Johns Manville RC-IG Water Based Insulation which only requires water and eliminates the need for glue.
• Punchmaster tie rod hole program not only punches the tie rod holes based on scopes and specs but also provides damper hole capabilities
• Hydraulically-actuated dual head cleat roller produces cleats while attached to coil for squareness
• Within the HMI input, the coil width and automated servo driven notching dies will position automatically for lead and trail, TDC or TDF, and/or ”S” and Drive based on input of coil width
• When Full Width Longitudinal Seam Production is not chosen, a Shear Brake System is included for male leg production for large and small Pittsburgh Lock or Snap Lock seams
• The 10 ft transfer system is standard with optional 12 ft and 14 ft systems available for larger ductwork
• System supports welded duct programs for 1/2”, 3/4”, and 1” straight right angle flange (SMACNA recommends a 1/2” leg height) — welded duct program for 18 gauge stainless steel is also available as needed
• B&R Automation control software supports machine intelligence capabilities as well as Mestek Machinery Key Performance Indicator Technology, which provides on-demand insights including machine uptime, material usage, parts per hour, and pounds per hour
• Remote self diagnostic capabilities and control software features including Auto Batch Control, an Insulation Detection System, Crop Cut Technology, and Bead Roll Up Technology.
LOCKFORMER® VULCAN® FIBER LASER CUTTING SYSTEM
The Lockformer Vulcan Fiber Laser Cutting System McCusker-Gill features a 20 ft. Cutting Table and is FDA Class 1 rated.
The Optimal System for Producing HVAC Fittings
The Vulcan® Fiber Laser is the next evolution in cutting systems from Lockformer. Using over 30 years of sheet metal cutting experience, we’ve designed the Lockformer® Vulcan® Fiber Laser Cutting System to meet the specific needs of sheet metal fabricators to help take your operation to the next level. Faster, more precise cutting, better quality parts, coil feeding capability, quicker access to cut parts (no enclosure) and many more features all designed to improve the productivity and profitability of your fittings operation while setting the standard for safety (accession number and coveted Class 1 safety rating from the Food and Drug Administration).
The Key Benefits of the Lockformer® Vulcan® Fiber Laser Cutting System
• Cut speed up to 1,200 inches per minute (28 m/min) on 24ga mild steel
• Cut speed on 10ga to 26ga mild steel up to 3X faster than a conventional plasma cutter
• Cut quality like that of a high definition plasma cutter on mild steel and stainless
• Uses less heat than plasma so edges are not hardened leading to less wear and tear on other machinery
• Standard 5’ x 10’ zoned exhaust cutting table with an option of 5’ x 20’ produces minimal exhaust — can be sheet fed or coil fed
• Exclusive patent-pending open architecture design (no enclosure) provides access to parts directly from the table, eliminating the need for a pallet shuttle system and allows for easy integration into existing workflows — FDA Accession Number and coveted Class 1 Safety Rating
• Patented shroud design further elevates its operational safety and cutting precision, ensuring high-quality results while mitigating hazardous risks
• Equipped with a Windows 10 ® Professional PC with 19” Monitor and Printer, the Fiber Laser can be integrated with most CAD to CAM software systems for maximum shop productivity and seamless connectivity with other machines throughout your operation
With 30 years sheet metal cutting experience, the Fiber Laser Cutting System is the next evolution in Vulcan® cutting systems
Exclusive patent-pending open architecture design (no enclosure) received an accession number and a coveted Class 1 safety rating from the Food and Drug Administration (FDA)
CNC Mach III and Color Graphic Mouse Driven Control 2D x 3D Tool Path & 3 Axis X1-X2,Y,Z
All rack and pinion 4-Axis (2-Y, 1-X, 1-Z) controlled Z is servo driven with automatic torch height control.
The fiber laser can be coil fed with the Iowa Precision Coil Feed Machine with with 60" or 48" coil stock with capacities from 14 gauge to 26 gauge.
Coil Feed for Lockformer Vulcan Fiber Laser Cutting System
Iowa Precision Coil Feed
The Lockformer Vulcan Fiber Laser Cutting System can be coil fed with 60" and 48" coil stock with maximum 26 gauge to 14 gauge. The Iowa Precision Coil Feed Machine is comprised of a drive motor and a series of rolls to feed and remove coil set from the material. The operator uses an on/off switch attached to an electrical cable to advance the material. This allows the operator to feed the material to the proper location along the fiber laser table. Drive is by way of entry and exit pinch rolls and straightening is accomplished with a fifth roll, which is located between the entry and exit rolls. This straightening roll is controlled by a hand wheel to vary the amount of flattening. Cut-off of the sheet length is standard and an optional shear cut-off system is also available.
CUTTING UNIT
• 1.5kW & 2.0kW fiber laser resonators available
CUTTING SPEED
• Maximum cutting speed up to 1,200 inches per minute (28 m/min) with maximum positioning speed up to 1,400 inches per minute (35.56 m/min)
CUTTING AREA / TABLE CAPACITY
• Standard: 5'x10' (1.5 m x 3.0 m)
• Optional: 5'x20' (1.5 m x 6.0 m)
CUTTING CAPACITY
• 10 gauge to 26 gauge mild steel based on Laser Resonator selected
Get a precision cut on unique edges
MACHINE CONTROL
• Mach III & Color Graphic Industrial Touch Screen
SOFTWARE / COMPUTER SYSTEM
• MACH III Windows 10 Based Control System accepting of Autodesk CAM Mep, Trimble Fab Shop, Practi Cam, Shop Data Systems and others upon request
DIMENSIONS
• Length: 168” (4270 mm)
• Width: 96" (2438 mm)
• Height: 63" (1600 mm)
• Weight: 3,200 lbs. (1450 kg)
IOWA PRECISION® COIL FEED FOR PLASMA AND FIBER LASER CUTTING SYSTEMS
The Iowa Precision Coil Feed at McCusker-Gill feeds the company’s 20’ plasma table and is an integral part in saving both labor and material cost. Can also be used to feed the Lockformer Vulcan Fiber Laser Cutting System.
Maximize Cutting Productivity and Meet the Demands of Growing Trends in HVAC Duct Construction
The Iowa Precision Coil Feed was designed for the decoil and recoil of Plasma and Fiber Laser Cutting Systems. This highly integrated system is equipped with wireless capabilities to eliminate the need to load material by hand. The Coil Feed system is comprised of a drive motor and a series of rolls to feed and remove coil set from the material. The material is advanced by the operator using a wireless pendant. This allows the operator to follow the material to proper location along the cutting table. Drive is by way of entry pinch rolls and exit pinch rolls. Straightening is accomplished with rolls located between the entry and exit rolls, which are controlled by way of a hand wheel for depth penetration. Length of feed is at the operator’s discretion, as the machine does not measure the material. Plasma or laser cut-off of the sheet length is standard, optional sheet cut-off system is available.
Features
• E-Z Load system for ease of use when loading coils
• Complete hands-off technology once coils are loaded
• Productivity and savings can be increased with the addition of beading
• Down-bead or up-bead patterns are available
• One-man operation system that reduces material handling
• Instead of storing material on racks, coil stations are ready to feed cutting tables
• Small footprint saving valuable shop floor space
• Reduction in scrap material
• Reduced material costs with coil versus sheet stock production
• Labor savings when decoiling coil stock vs. handling sheet stock
• Material utilization completely optimized when cutting from coil especially when operating a 20’ table
Specifications
MAXIMUM WIDTH CAPACITY
• 72” (1829 mm)
MAXIMUM GAUGE CAPACITY
• 16 gauge with option for 14 gauge
PASS LINE HEIGHT
• 32.5” (826 mm)
ROLL DIAMETER
• 4.167” (105,7 mm)
MATERIAL JOG SPEED
• 35 FPM (10,7 MPM)
ELECTRIC MOTOR SIZE
• 3 HP (2,3 kw)
MOTOR / VOLTAGE
• 5 HP | 230/460 volts, 60 cycle, 3 phase
DIMENSIONS / WEIGHT
• Length - 13' 4” (for 2 uncoilers)
• Height - 26' 8” (for 4 uncoilers)
• Width - 77”
• Weight - 3,900 lbs. (for 2 uncoilers)
• Weight - 7,800 lbs. (for 4 uncoilers)
Available Beading Option
Down-Bead or Up-Bead pattern is rolled into the material as it is being fed onto the cutting table. The bead pattern is produced by bead rings that ride in grooves machined into a pair of pinch rolls with the the bottom roll powered and the top roll adjustable up and down by means of a hand wheel. The bead pattern is not intended to be a half radius, but more of a rounded shallow vee to form a cross-break in the material for stiffening.
Bead Specifications
BEAD PATTERN SPACING
• 12” (304,8 mm) centers 6” (152,4 mm) from edge
MINIMUM GAUGE
• 28 gauge (0,5 mm)
BEAD PATTERN HEIGHT
• 0.060” (1,5 mm) – 0.120” (2,5 mm) adjustable
MAXIMUM GAUGE
• 16 gauge with option for 14 gauge
LOCKFORMER® VULCAN®
1600 WATERJET CUTTING SYSTEM
The Lockformer Vulcan 1600 Water Jet Cutting System is, perhaps, the most innovative machine in the industry with the highest return on investment — the biggest time-saver in the production of HVAC lined duct fittings.
Maximize the Productivity and Quality of Your Insulation Cutting Operation
The Lockformer® Vulcan® 1600 Water Jet Cutting System automates the slow, costly, and inexact manual process of cutting insulation delivering an unrivaled level of quality and efficiency. The machine will cut fiberglass or foam insulation as well as gasket rubber and many other types of insulation products up to 4" thickness at a maximum positioning speed of 2,000 inches per minute. Whether you require precise insulation shapes for square to rounds, radius elbows or transitions, the Lockformer Vulcan Waterjet Cutting System can fabricate insulation fittings for about one-tenth of what it costs to buy them or one-tenth the time it takes to cut them by hand.
The Lockformer Vulcan Waterjet Cutting System can be integrated with the most CAD to CAM Software systems for maximum shop productivity and seamless connectivity with other machines throughout your operation. The software optimizes the cut pattern to maximize the pieces that can be cut from a single sheet of insulation — and, unlike a laser or plasma, the precision of the Water Jet can cut right to the edge of a previous cut for a zero scrap factor — that’s zero waste from part to part. The software also streamlines your fittings operation by matching the cut insulation to the corresponding metal blanks. And the precision quality of each cut is unmatched in the industry — from the simplest of shapes to the most complex, the Lockformer Water jet can handle them all.
The Complete Solution:
The unsurpassed engineering excellence of Lockformer integrated with the operating software from QuickPen, a leading software supplier to the mechanical construction industry makes the Lockformer® Vulcan® 1600 Waterjet Cutting System the most complete solution in the industry.
Virtually Eliminate Scrap:
Insulation can be more costly than sheet metal and cutting it manually is inefficient and wasteful. The Lockformer Vulcan 1600 Water Jet Cutting System can help you virtually elminate your scrap and increase your profitability. The operating software optimizes the cut pattern to maximize the pieces that can be cut from a single sheet of insulation. And unlike a laser or plasma, the precision of the Water Jet can cut right to the edge of a previous cut for a zero scrap factor — that’s zero waste from part to part. Your cut parts will fit perfectly into your metal blanks completely eliminating trim cuts and the re-fabrication which can bottleneck your operation — allowing you to work smarter and more efficiently.
Elastomeric Foam Materials:
The new trend in the HVAC industry is for specifying engineers to replace fiberglass duct liner with open or closed cell elastomeric foam. This foam insulation has no mold issues or potential to break down and get into the airstream. The Lockformer Vulcan 1600 Water Jet Cutting System will cut fiberglass or foam insulation as well as gasket rubber and many other types of insulation products up to 4" thickness at a maximum positioning speed of 2,000 inches per minute.
Superior Control:
The Lockformer Vulcan 1600 Water Jet Cutting System can be integrated with the most CAD to CAM Software systems for maximum shop productivity and seamless connectivity with other machines throughout your operation. One software tool for all applications and all systems — PLC, drives, communications, operator interface, programming, and diagnostics — integrated with robust hardware made for the industry — no moving parts, no fans, no hard disks, plus a high ambient temperature specification.
Long Term Availability:
Components made by the manufacturer, not outsourced. This control of components allows Lockformer to provide components for the long haul.
Better Maintenance:
Central program storage to all components in the system and field replacements without programming for servo drives, HMIs, etc. Excellent drive diagnostic features — ACOPOS software oscilloscope.
Performance:
CPUs have the highest performance in the PLC industry and the fastest hardware — PLCs, inverter, trigger inputs, etc. Complex functions are programmable in high-level languages. Scalable for quick development with saleable and compatible hardware. Software can easily be adapted to different hardware configurations and machine applications.
Specifications
Note: Configurations vary based upon equipment and options selected
Overall:
• 60" x 120" effective cutting area
• 60" x 240" optional cutting table size
• Up to 3,000 IPM positioning speed depending on the material type and thickness
• Cutting Speeds up to 2,000 IPM with a safety standard of 1,200 IPM
• 4" maximum cutting thickness
• +/- 1/32" positional accuracy
• All Premium "plug-in" components
• Unitized, fixture-welded, 3" x 3" steel tubing framework for strength and stability
• Stand-alone control console
• All axis home positioning using motor torque measurement
• 8" x 8" steel table leg pads with leveling feature
Table:
• 1/4" steel plate perimeter
• “Gull Wing” table design to protect the machine’s drive system and reduce the footprint size
• Complete stainless steel table lining for rust-free performance longevity
• Rectangular exhaust plenum at the back end of the table for easy access connection
• Strategically located Emergency Stops [1 = controller; 1 = x-axis carriage]
Drive:
• Dual precision Y drive
• Double deck, 24 strand steel, precision reinforced radial timing belts
• HIWIN® linear x-axis bearing and way
• 3" diameter x 128" long, turned, ground snd polished, heavy duty Y-axis guidance rail — Armaloy surface coated
• Precision cam followers
• X-axis brush guard
• Steel enclosed housing for X-axis servo drive motor
• Y-axis drive house enclosed and integral to the machines frame
• SNC® brand - vertical dual cylinder pneumatic torch lifter with adjustable up/ down pressure
Machine Control:
• Lockformer 759 CNC-TS control system with 15" color graphic industrial touch screen with leveling feature
• Digital drive devices
• Manual speed increase/decrease override
• Kerf compensation
• Auto home sense to set 0/0 automatically
• Automatic corner slow down
• Brushless AC servo motors with resolver feedback
• Remove safety stop switches and current limiting devices for safety
Karolin Machine Tool (KMT) Steamline® SL-VI Waterjet Intensifier
The cutting power of the Lockformer® Vulcan® 1600 Water Jet Cutting System comes from the Steamline® SL-VI Waterjeft Intensifier from KMT.
System:
• Cutting power delivered via a horizontal whip that can be installed in most any fab shop, regardless of the height of the ceilings
• Pneumatic valve cutting head with .007 diamond office
• Intensifier cycles a maximum of 8 times per minute to reduce pressure fluctuations and improve component life
• Designed for non-abrasive pure water cutting only
• 55,000 PSI maximum continuous cutting pressure
• Maximum 3 GPM of water with 80 GPM inlet pressure
• Full amp load = 52A; Circuit Breaker = 80A
• Motor is totally enclosed & fan cooled
• Pump footprint is 59'L x 42"W x 41"H
Electrical:
• Machine CNC Control: 230 Volt, Single phase, 60 Hz (Dedicated circuit)
• High Pressure Water Pump: available in 208, 240, or 480 Volt, Three phases, 60 Hz
Water:
• Customer’s water supply may need to be softened or treated. Please refer to proposal for manufacturer minimum water quality
Air:
• 90 PSI low volume (less than 5 SCFM). The machine requires an Air Compressor to supply 99.997 percent dry compressed air at 5.0 SCFM @ 90 PSI. An Air Compressor is not included in the machine price. We recommend the purchase of the Air Filter and Dryer (option) to insure a clean, dry air supply for the water jet pump
IOWA PRECISION® COMBINATION
CORNERMATIC II WHISPER-LOC PRO
AUTOMATED CORNER INSERTION AND PITTSBURGH LOCK SEAM CLOSING MACHINE
The Iowa Precision Combination Automated Corner Insertion and Pittsburgh Lock Seam Closing Machine fully automates longitudinal seam production and automated cornering by combining both technologies into one machine.
Improve Productivity, Workflow, and Safety of Your Square Duct Fabrication Operation
The Iowa Precision Cornermatic II Whisper-Loc Combo is a unique, innovative machine that not only inserts and crimps corners into both ends of ductwork but also closes longitudinal Pittsburgh seams on the same ductwork when required. This design allows the operator to accomplish both corner insertion and seam closing on one machine without having to handle the ductwork between processes. The system will close the Pittsburgh seam on any ductwork that uses the duct flanges conforming to T25-a or T25-b under the SMACNA Duct Construction Standards. It will also close the Pittsburgh seam on ductwork that uses the raw edge or slip and drive method as well as slip-on flange type ductwork.
Key Features
• Designed for ductwork corner insertion and seam closing without having to handle the ductwork between processes
• Pneumatic operation automatically inserts corners into both ends of ductwork that use the transverse duct connection (TDC) or transverse duct flange (TDF) method of joining and crimps them securely and permanently into place in seconds
• Corners are inserted square and fully crimped — no need to change the crimping adjustment when inserting corners in 16 to 26 gauge fittings
• Electric motor and gearbox with variable frequency drive powers the seam closing operation
• Works with SMACNA-conforming, T-25a and T-25b flange and many other flanged duct systems without changing settings
• Will also close the Pittsburgh seam on ductwork that uses the raw edge or slip and drive method as well as slip-on flange type ductwork
The Iowa Precision Cornermatic II Whisper-Loc Combination Automated Corner Insertion and Pittsburgh Seam Closing Machine will operate with all widely available Genuine Cornermatic ® Corners, Ductmate ® Cornermatic ® Strap-Pak ™ and RapidMate™ Corners, and revolutionary DuroDyne ® EZ Connector® Corners for ”C” and ”F” flanges. For best results use in conjunction with Lockformer® Transverse Duct Connector (TDC) Roll Formers and Engel® Transverse Duct Flange (TDF) Roll Formers.
Iowa Precision Cornermatic II Whisper-Loc Combo
Specifications
CAPACITY
• Mild Steel: 16 to 26 gauge for automated corner insertion
• Mild Steel: 16 to 26 gauge for seam closing
• Stainless Steel: up to 20 gauge
• Galvanneal: All gauges
• Aluminum: All gauges
FLANGE TYPE FOR INSERTION
• Transverse Duct Connector (TDC) or Transverse Duct Flange (TDF)
Customer to Specify
SPEED
• Approximately 2.5 seconds per corner
AIR
• 9 CFM @ 100 psi
MOTOR / VOLTAGE
• 460/3/60 2.3 Full Load Amps
Other 3 phase voltages available
DIMENSIONS / WEIGHT
• Length - 30 1/2”
• Width - 34”
• Height - 96”
• Weight - 1,800 lbs.
The Iowa Precision Cornermatic technology takes the sheet metal hammer out of the workers hands. This Automated Cornering machine operates on all fittings from 16-26 gauge down to 2” throats.
Improve Productivity, Workflow, and Safety of Your Fittings Fabrication Operation
The Cornermatic Plus Versa is the most flexible unit for production available. Similar to the Cornermatic Plus, the Cornermatic Plus Versa was designed for the fabrication of duct FITTINGS — from standard fittings to odd fittings like tight square throat elbows, flex connectors, offsets down to 2″ throats, and even the toughest inside or outside angle off-set transition fitting from 16-26 gauge. The Cornermatic Plus Versa features the same above ground, ergonomic table height setting as the Cornermatic Plus, but also adds a floor level setting which allows for sliding over larger, heavier fittings and cut duct sections (machine goes from in-ground to above ground in less than 1 minute with a simple push of a button).
Key Features
• Specifically designed for the fabrication of both small and large duct fittings from 16-26 gauge on one machine — from standard fittings to odd fittings like tight square throat elbows, flex connectors, offsets down to 2″ throats, and even the toughest inside or outside angle off-set transition fitting
• Operator friendly above ground, table height setting is ideal for fabricating small fittings — adjustable legs to match most bench heights
• Floor level setting allows for sliding over large duct sections and fittings to automatically insert the corners
• Heavy gauge switch for 16-18 gauge performance and light gauge switch for 20-26 gauge performance enhances the Crimping process — slows the Cornermatic down for heavy gauge and speeds it up for light gauge
• Completes eight (8) corner inserts in seconds
= Floor Level
• Fully automated — no switches or foot pedals — just push in and Cornermatic does the rest
• Corners are inserted square and fully crimped — no need to change the crimping adjustment when inserting corners in 16 to 26 gauge fittings
• Corners feed from below the worksurface allowing a clean, unobstructed work area
• Light bar indicates when the material has fully engaged on the right or left side of the infeed guide clamps — green light = Go, red light = No
• Light bar also indicates empty corner magazine
• Works with SMACNA-conforming, T-25a and T-25b flange and many other flanged duct systems without changing settings
• Each quick loading box holds eighty (80) corners and loads in ten (10) seconds
Specifications
CAPACITY
• Mild Steel: 16 to 26 gauge
• Stainless Steel: up to 20 gauge
• Galvanneal: 16 to 16 gauge
• Aluminum: 16 to 26 gauge
FLANGE TYPE FOR INSERTION
• Transverse Duct Connector (TDC) or Transverse Duct Flange (TDF)
Customer to Specify
SPEED
• Approximately 2.5 seconds per corner
AIR
• 85 to 100 PSI (5.5 - 7 Bar)
MOTOR / VOLTAGE
• 230/3/60 (Single Phase)
DIMENSIONS / WEIGHT
• Length - 32”
• Width - 36”
• Height - 34”
• Weight - 600 lbs.
The Iowa Precision Cornermatic II Whisper-Loc Combination Automated Corner Insertion and Pittsburgh Seam Closing Machine will operate with all widely available Genuine Cornermatic ® Corners, Ductmate ® Cornermatic ® Strap-Pak ™ and RapidMate™ Corners, and revolutionary DuroDyne ® EZ Connector® Corners for ”C” and ”F” flanges. For best results use in conjunction with Lockformer® Transverse Duct Connector (TDC) Roll Formers and Engel® Transverse Duct Flange (TDF) Roll Formers.
LOCKFORMER® DUAL HEAD GORE-LOCKER
The Lockformer Dual Head Gore-Locker can produce gored elbows from 4”60” along with end cap production as well.
The Most Advanced Technology In One Of The Smallest Footprints In The Industry
Lockformer’s Dual Head Gore-Locker is your quality, efficient and costeffective solution to the production of elbows, reducers, end caps and offsets. Lockformer’s operator friendly Dual Head Gore-Locker provides the power to fabricate quality standing seam fittings in-house. On a single machine platform, the Dual Head Gore-Locker offers the ability to flange/ swage on one end, while simultaneously closing the seam at the other end. The Dual Head Gore-Locker allows operators to modify controls when flanging/ swaging, providing complete control of production speeds. After closing on the second station and creating a standing seam, the Dual Head Gore-Locker delivers an airtight seal, eliminating the need for sealing or painting. Using minimal power and floor space, the Dual Head Gore-Locker handles a variety of materials and thicknesses – up to 16 gauge (1.5mm) – to produce standing rib diameters from 4"–60"(100–1500mm) with included tooling and can produce standing rib diameters from 4" and 50"–60" with additional tooling.
Offset Fitting End Caps Galvanized Steel Elbow Reducer
CAPACITY
• 16 gauge
DIAMETER RANGE
• Included Tooling: 4"–60"
• Additional Tooling required for 4" and 52"–60"
MOTOR / VOLTAGE
• 460V/3ph/60Hz
DIMENSIONS / WEIGHT
• Length - 106"
• Width - 32"
• Height - 44"
• Weight - 2,310 lbs.
Desgined to Meet the Welding Needs of Today’s Duct Fitting Fabrication
The new QuickStitch 2.0 Rotary Stitch Welder from Lockformer® was desgined to meet the needs of today’s duct fitting fabrication. The QuickStitch 2.0 optimizes your welding production output by giving the operator a controlled and consistent longitudinal weld from end to end with a minimal overlap. With a new operator-friendly touch-screen control panel wth a memory feature for ease of production, the operator can choose from a continuous or stitch weld that provides an excellent solution for welding of both galvanized and stainless steel straight tubes and round fittings. A manual welding pressure system is also included for welds and changeovers. The system also features digital temperature switches for chiller temperature and water flow adjustments. The QuickStitch 2.0 produces air-tight weld seams with an adjustable weld speed from 3 ft/ min to 49 ft/min for maximum productivity and efficiency. The QuickStitch 2.0 is available in three (3) models to meet your operational needs allowing you to create longitudinal seams of 2" - 40", 2" - 50", or 2" - 60" respectively.
Specifications:
MODEL 40"
MODEL 50"
GALVANIZED STEEL MATERIAL THICKNESS RANGE
• 30 gauge to 18 gauge (0.012" to 0.048")
• 30 gauge to 18 gauge (0.012" to 0.048")
STAINLESS STEEL MATERIAL THICKNESS RANGE
• 30 gauge to 22 gauge (0.012" to 0.032")
DIAMETER RANGE
• 3" to 40"
• 30 gauge to 22 gauge (0.012" to 0.032")
• 3" to 40"
LONGITUDINAL SEAM LENGTH
• 2" to 40"
• 2" to 50"
STANDARD OVERLAPPING (Special on Request)
• 0.236" (1/4" nominal)
POWER | STITCHWELDER
• 460VAC, 3PH, 60Hz, 125A
POWER | CHILLER
• 120VAC, 1PH, 60Hz, 10A
COPPER WIRE
• 0.078" round (optional 0.070" round)
• 0.315" (5/16" nominal)
• 460VAC, 3PH, 60Hz, 125A
MODEL 60"
• 3 ft/min to 49 ft/min
WELD SPEED DIMENSIONS / WEIGHT
• Length: 115"
• Width: 45"
• Height: 69"
• Machine Weight: 1,323 lbs.
• Copper Wire Coil Weight: 44 lbs
• 120VAC, 1PH, 60Hz, 10A
• 0.078" round (optional 0.070" round)
• 3 ft/min to 49 ft/min
• Length: 115"
• Width: 45"
• Height: 69"
• Machine Weight: 1,356 lbs.
• Copper Wire Coil Weight: 44 lbs
• 30 gauge to 18 gauge (0.012" to 0.048")
• 30 gauge to 22 gauge (0.012" to 0.032")
• 3" to 40"
• 2" to 60"
• 0.315" (5/16" nominal)
• 460VAC, 3PH, 60Hz, 125A
• 120VAC, 1PH, 60Hz, 10A
• 0.078" round (optional 0.070" round)
• 3 ft/min to 49 ft/min
• Length: 115"
• Width: 45"
• Height: 69"
• Machine Weight: 1,389 lbs.
• Copper Wire Coil Weight: 44 lbs
ROTO-DIE® HYDRAULIC SHEET METAL BRAKE PRESSES
The Roto-Die Sheet Metal Brake Press at McCuskerGill is the Model 15. RotoDie are the most versatile hydraulic benders for HVAC and Commercial Roofing Related specifications.
Maximize the Productivity of Your Sheet Metal Bending Operation
The patented Roto-Die Hydraulic Sheet Metal Brake Presses have been a fixture in thousands of sheet metal shops for over 45 years. As simple to operate as a hand brake – but with infinitely more production capacity — Roto-Die Hydraulic Sheet Metal Brake Presses form full length ducts, gravel stops, standing lock seams, flashing and hemming operations accurately, economically, with just one handling by one operator —reducing abor costs and maximizing shop productivity.
Features
As simple to operate as a hand brake with infinitely more production capacity
• Merely by rotating the selections lever, one operator can perform all basic sheetmetal forming operations — no dies to change
• Forms full length ducts, gravel stops, standing lock seams, flashing and hemming operations accurately and economically
• The compactness inherent in the cylindrical die design permits acute reverse bends not possible with conventional wide-bend machines
• Indexes quickly and accurately to all forming stations — automatic detention assures positive die alignment
• Centerline machined upper dies are instantly interchangeable in all openings without special stops or adjustments
One handling by one operator for most
sheet-metal configurations
• All basic sheet metal-forming operations can be made without die change or major adjustments — infinitely variable speed control for easy selection of ram speed
• The ram may be jogged, stopped or returned to “up” position at any point of the stroke — it may also be inched for accurate positioning of the work, reducing material loss and gauge adjustment time
• Disappearing pins are conveniently located for fast one-person positioning in cross-braking (stiffening) and rectangular duct forming — pin gauges are easily removed and relocated
Engineered to reduce labor costs while increasing shop productivity
• The patented Roto-Die principle reduces setup time by as much as 70%, compared with other power forming equipment — gauge and clearances are adjusted more quickly than on conventional hand brakes
• One-man operation cuts labor requirements in half on virtually all handbrake operations
• Simple adjustments permit operating speeds up to 50 strokes per minute for maximum production output
• Multiple handling of sheet stock is kept to a minimum — this allows you to fabricate most commercial ventilating jobs, including the TDC duct system, in the Roto-Die in one-fourth the time ordinary benders require
Specifications
MODEL 5
MODEL 10
BENDING CAPACITY (* = 7/8” die opening with angle insert)
• 60” x 16 gauge
• 3”
LENGTH OF STROKE STROKES PER MINUTE (* approximate)
• 20 to 50
DIE CLEARANCE
• 2-1/8”
DIE SPACE
• 7-1/2”
DIMENSIONS / WEIGHT
• Length - 94-1/2”
• Width - 22”
• Height - 63-1/2”
• Weight - 3,300 lbs.
• 120” x 16 gauge
• 72” x 10 gauge*
• 3”
• 20 to 50 • 2-1/8”
• 7-1/2”
• Length - 145”
• Width - 22”
• Height - 63-1/2”
• Weight - 5,700 lbs.
MODEL 15
MODEL 15/12
BENDING CAPACITY (* = 7/8” die opening with angle insert)
• 120” x 14 gauge
• 120” x 10 gauge*
LENGTH OF STROKE
• 144” x 14 gauge
• 144” x 10 gauge*
• 3” • 3”
STROKES PER MINUTE (* approximate)
• 20 to 50
DIE CLEARANCE
• 2-1/8”
DIE SPACE
• 7-1/2”
DIMENSIONS / WEIGHT
• Length - 150-1/4”
• Width - 22”
• Height - 73”
• Weight - 8,950 lbs.
• 20 to 50
• 2-1/8”
• 7-1/2”
• Length - 174”
• Width - 22”
• Height - 73”
• Weight - 10,000 lbs.
Optional Equipment for Roto-Die Hydraulic Sheet Metal Brake Presses
Light Curtain Safety System
Business owners who use Roto-Die Hydraulic Brake Presses are responsible for the safety of each person that operates these hydraulic benders. In accordance with all documented safety guidelines, business owners are responsible for ensuring that safeguarding is provided, installed, maintained, and used. The Roto-Die Light Curtain Safety System not only meets ANSI B11.3, but can also be retrofitted to your existing Roto-Die Hydraulic Bender.
• Main control panel including lockout/ tagout requirements
• 18” Category 4 Light Curtain offers maximum protection above the upper die and below the lower die
• Muting function 1/4” die opening
• Redundant (primary and secondary) proximity sensors and electric sonenoid valves
• Push-button operator station
• Front fixed-guard for added safety in the die area
• New piping, high-pressure fittings and installation hardware
• Manual jog of upper die remains intact
Back Gauge Manual Operation
Rear Operated (RD00900)
Front Operated (RD00975)
Single Station Ajustment system
Permits depth-of-stroke adjustment from one side of machine (RD900001)
Foot Pedal Conversion Kit
Converts oldstyle “Treadle Pedal” to an OSHA-Approved covered foot pedal (RD93012)
Tooling and Dies for Roto-Die Hydraulic Sheet Metal Brake Presses
Merely by shifting the selections lever, one operator can perform all basic sheet-metal forming operations. No dies to change.
Roto-Die Hydraulic Brake Presses form fulllength ducts, gravel stops, standing lock seams, flashing, and hemming operations accurately and economically.
All Roto-Die Hydraulic Brake Presses include tooling for five (5) basic forming operations:
• One (1) #37 Roto-Die® with 7˚ crossbraking groove, 85˚ die opening 3/8 ” wide, 85˚ die opening 7/8 ” wide, 30˚ die opening 1/2 ” wide
• One (1) #1 Forming Die 85˚
• One (1) #24 Hemming Die 30˚
• Six (6) sheet support arms with clips
• Six (6) #52 gauging blocks
• Six (6) #53 disappearing spring-pin gauges
Additional Available Dies
All models are equipped with depth-of-stroke adjustment with indicators, length-of-stroke adjustment, motor and controls for 230/460 Volts, 3 Phase 60 HZ. (Other 3 Phase voltages also available.) ] ]
A — #24 Hemming Die B — #1 Forming Die
C — Gravel Stop Adapter Die
D — #49 Adjustable Damper Die
See next page for more information on dies
E — Narrow #1 Forming Die used with TDC Conversion Die
F — TDC / TDF Conversion Die
G — Heavy Gauge Angle Insert
H — #5 Gooseneck Die
Tooling and Dies for Roto-Die Hydraulic Sheet Metal Brake Presses
A. Forming
B. Open Hemming (B) Forming and open hemming bends are accomplished with standard 30° upper die and No. 37 Roto-Die. Following these sequences, a standing lock seam may be formed without die change or multiple handling of the sheet.
C. Blade Forming
Many degree-of-bend combinations are quickly and easily formed by bottoming and air-bending.
D. Heavy-Gauge Forming
Machined inserts increase bender capacities up to 120” of 10 gauge materials for heavygauge or large-radius forming.
E. Box Forming
Depths to 1-3/4” may be formed with standard dies.
F. Architectural Gravel Stop Adapter Plate
This combination die will form 120” of 24-gauge gravel stop with a 3/4" rise. Easy removal of the rear forming section converts the die to acute-angle forming and hemming operations.
G. Channel-Forming
90° gooseneck dies (with or without angle inserts) simplify forming light and heavygauge channels.
H. Multi-Forming
Damper blades and V-rib shapes may be formed in one stoke in 20 gauge galvanized steel up to 120” long. Shorter lengths may be formed in heavier gauges. Die is adjustable for metals with springback.
Custom Dies to Increase Your Capabilities
As you develop creative uses for your Roto-Die Hydraulic Brake Press, adding a custom die set will increase your capabilities and your profitability. To the right are a few custom dies we have manufactured to customer specifications. These are available by special order or we can have a die made to fit your unique application.
Remanufacturing Program for Roto-Die Hydraulic Sheet Metal Brake Presses
Roto-Die® will remanufacture your machine to the latest specifications or sell you a remanufactured machine. Remanufactured machines carry the same full one-year warranty as our new machines.
Have your old machine completely remanufactured into a brand new machine. Everything is replaced on the machine except the original bed, ram, and side plate weldment. All new dies are included.
