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A PEDDINGHAUS PUBLICATION FOR FABRICATORS MAKING TODAY’S SKYLINE POSSIBLE V

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GENREC: Big Challenges = Big Rewards

IN THIS ISSUE Genrec 5

Big Challenges = Big Rewards

Structural Steel Fabrication in South Africa Leading Edge Technologies in a Progressive Land

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Hejamara – Portugal 9

Distributor Spotlight

Metalogalva Sustaining Their Business Future in Today’s Environment

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ASCEM Fabricators

What is the very best part of having a career in the steel construction industry? Whether you are an architect, structural engineer, detailer or fabricator – everyone agrees that it is the final result – seeing those fabricated sections erected to create the backbone of a magnificent structure. It is no wonder that “topping out” ceremonies are celebrated in the industry.

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Educational Tour of New York

Trinity Steel Lean Fabrication in the Lone Star State

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Visit FABTECH 2009 in Chicago 16

FABTECH Fest in Bradley

Software Q & A Structural Fabrication Software Questionnaire

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Getting to Know Kirk Kempen Peddinghaus CAM Software Manager

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Carlos Torres Latin American Sales Manager

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TRINITY STEEL: Lean Fabrication in the Lone Star State Trinity Steel Fabricators based in Trinity, Texas brings a new meaning to the words “Lean Fabrication”. Ask Roy Karnes Jr., President of Trinity Steel and he’ll Mr. Roy Karnes, President, be the first to tell you that their Trinity Steel Fabricators, Tomball, TX, USA. smart operations and acceptance of modern technology have made a significant difference in their over 30 years in steel fabrication. With work based primarily in the petro-chemical and power industries but also in the marine and mining industries, Trinity builds quality into every step of their processes. Maintaining three facilities just outside the “Energy Capital of the World” (Houston, TX) Trinity Steel is charged and ready to power through any project that will come their way using the latest and most cost effective methods in fabrication. See the full story on page 15

Everyone will tell you of a favorite building project of which there are many in our modern world: the Empire State Building in New York, Twin Towers in Malaysia, Bird’s Nest Stadium in Beijing and more. One of the most identifiable and unique structures in the world is a relatively new structure located in the Middle East, the magnificent Burj Al Arab hotel designed to resemble a sailing ship. This is the only seven star hotel in the world which is built on a man-made island just off the coast of the Persian Gulf in Dubai. Continued on page 5

Don Lidberg, General Manager, and Graham Hartley, Works Executive Genrec division of Murray & Roberts, Wadeville, South Africa.

METALOGALVA: Sustaining their Business in Today’s Sustainable Environment Sustainability is a word that is freely used in today’s global society, and is commonly used in the steel construction industry where a structure may require LEED certification to meet certain environmental standards. But sustainability is much more than “thinking green” – it is providing quality, value driven products that sustain the future: the future of a company, its employees/their families, and the industry it serves, not solely the environment. Continued on page 10

Mr. Adelino Silva, Owner & Administrator, Metalogalva, Irmaos Silvas, SA, Trofa, Portugal.


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STEEL FABRICATORS’ REVIEW

AUTUMN 2009

STEEL FAB REVIEW en Español, Genial !!! As editor of the STEEL FABRICATORS’ REVIEW, I am overwhelmed by the positive reception of our Spanish speaking readers to the first Spanish version of our magazine. If you receive your version in English, and would like an additional version in the Spanish language, let me know so we can provide a copy, and add you to our mailing list. Similarly if you would like additional copies in either language, let us know via email: marketing @ peddinghaus.com

Lyle Menke

In This Issue GLOBALIZATION In this issue, we take a look at fabrication technologies on three continents, courtesy of Metalogalva, Portugal; Genrec, South Africa; and Trinity Steel, USA. These pages also include in-depth views of fabrication facilities in the growth oriented countries of Africa. TECHNOLOGY Inquiring readers requested more information on today’s structural steel software technologies for production or MRP. Our readers are telling us that they are confused by the various MRP types of production and scheduling software being offered on the market. We have asked three major MRP software firms to weigh in with their thoughts on the questions YOU are asking. EDUCATION Knowledge is Power! Don’t let today’s economic challenges inhibit your ability to investigate new technologies and network at trade shows. Join Peddinghaus for FABTECH Fest – visit the FabTech/AWS Show in Chicago, and stay in Bradley for 1/4 of the hotel cost. Ask our customers, the best part is ability to build new business relationships with industry peers. Maybe there is a fabricator looking to partner up on a job – don’t miss the opportunities!

Following are a few of the responses directed to Peddinghaus’ Latin America, MD Sr. Jose (Pepe) Cavazos:

Hello Pepe: I have received a magazine of the first edition of the SFR in Spanish, Thank you very much. Regardless of the hard copy I am glad to have received, will also Peddinghaus have it available in the web site in Spanish version? (Editor’s Note: Yes!) Regards and congratulations for this first edition. Héctor Fuentes J. Edyce, Chile

Join Your National Steel Organization I have had the opportunity to visit and participate with many of the international steel construction organizations/ institutes the past years. These organizations serve many needs for the steel construction and structural steel fabrication industry. These services range for providing technical solutions to building questions, market analysis and data, techniques for enhancing engineering practices, seminars and webinars for comprehensive education in our industry. In short, these organizations provide vital communication links to help grow your business. Following are a few for your consideration: • American Institute of Steel Construction; Chicago, IL USA; www.aisc.org • British Construction Steelworks Association; London, UK; www.steelconstruction.org

Good afternoon Pepe,

• Australian Steel Institute; North Sydney NSW AU; www.steel.org.au

Congratulations for the first edition in Spanish. It would be easier to understand it now.

• Southern African Institute of Steel Construction; Melville, So. Africa; www.saisc.co.za

I would like to receive both versions, Spanish and English.

These firms exist to serve the steel construction industry – and you as a participant.

Regards, Engo. Marco Túlio Guimarães MV Construções Metálicas Ltda. Ribeirão Preto - SP São Paulo - SP

Pepe: I received the magazine. I am glad Peddinghaus made it now in Spanish. Thanks!!! Lucas Matias Salvatore Director Comercial MACROMET S.A. Buenos Aires - Argentina

Architects Thinking “Green” Some GOOD NEWS! The American Institute of Architects (AIA) reported that their September Billing Index was 59.1 – a 2-year HIGH!! That is good news for all of us in the steel construction industry. The AIA recently conducted a survey of members concerning Green Design – results: Says AIA Chief Economist Kermit Baker, “Of particular note, the survey also revealed that the number of firms practicing green design has nearly doubled since 2005. The use of BIM software has also doubled in the last three years.” ENR October 14, 2009 This is the future of our industry.

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FROM THE CEO Dear Customers and Friends,

Autumn is in full swing here in the USA. The leaves on our hardwood trees are turning to brilliant colors, and the cool days indicate that Mother Nature is definitely changing her seasons. Yes, change is in the air. Thanks to the changes in our current business climate, I have now had more of an opportunity to leave my office and travel extensively to visit more and more of our customers and industry colleagues. In fact, in the last 10 days, I have had the privilege of visiting customers in California, Colorado, and throughout the Midwest USA. I then hopped over to Europe to meet some customers in Stuttgart and then Hamburg.

Anton Peddinghaus

“The More Things Change, the More They Stay the Same” Don’t get me wrong, I’m not boasting about my travel itinerary – or frequent flyer miles, but I have to say that I am truly surprised at how small the world has really become. It doesn’t matter if you are a structural steel fabricator in Australia, Africa, or America – the problems are still pretty much the same: • “I can’t get signed approval drawings for the next job sequence!” • “Can you believe how many fabricators were on that bid list?” • “That General Contractor is just killing me with project changes and delays!” • “Guess What! The financier just put that big project on hold - again!” • “Did you see the numbers on that last bid? How can anyone survive?” Your old friend the banker is asking for MUCH more information than years before – it is a sign of the times – no matter your global location. On the other hand, some fabricators have taken this challenging time to develop new competitive strategies. Some have redesigned their shop layouts to eliminate production bottlenecks; taking advantage of a slack production time to REALLY think about improving material flow and throughput.

From there, I popped over to Warsaw, Poland and I am currently writing this editorial at an elevation of 30,000 feet – in transit to Melbourne, Australia.

Progressive fabricators are also exploring better methods to gather information by monitoring production via MRP software or our own new Peddimat Production Tracking Utility software. In the final analysis, every structural fabricator – whether he is across town or across the ocean – is looking for new ways to reduce costs. It is a matter of survival to overcome the depressed market prices for a ton of fabricated steel. Hopefully, the market turns, and good margins return… we can hope, but in the interim, we must be ready to accept these challenges.

Experience FabTech – and Much More – at 1/4 of the Price….

Last, but not least, come over to Peddinghaus; you will like what you see – and hear:

Are you attending the FabTech Show in Chicago this November 15–18? Registration is up, and this may be a great opportunity for you to take a couple of key people with you to the show. Remember, that FabTech also includes all of the American Welding Show (AWS) exhibitors so it is a good fit for fabricators. Peddinghaus will be located at Booth number 12079 in the Fabrication area of the South Building.

• The Ring of Fire thermal processor performing multiple job functions – by itself

Our Sales/Marketing team came up with a good idea to help you attend FabTech. Since money is tight, Peddinghaus can arrange for a good quality hotel room for about 1/4 or 25% the price of a downtown Chicago hotel. Plus, Peddinghaus will provide free transportation to/from the show via first class accommodations. Don’t worry about dinner, we’ll pick up the tab here at a local upscale restaurant – The Peddinghaus Way. Where else do you have a chance of visiting a major show and at night have the opportunity to network with fellow structural fabricators? This is how business relationships are built.

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• Sixteen (16) MORE new machines for you – and your team – to investigate • BDL B & BDL D & PCD = 3 Drill Lines • DGP, DG, 1250, 260, 800-510 = 4 Saw Lines • Towermaster, AFPS 643, Clipper = 3 Angle Lines • HSFDB 2500, FPD 1120, FPDB 2500 = 3 Plate Lines • ABCM 1250, Libertor = 2 Coper Lines • ...and much, much more • Have some Questions? Ask our Management team! • Jim Sutliffe, V.P. Engineering •Terry Chinn, V.P. Operations • Jim Magnuson, V.P. Research & Development • Greg Kubick, C.F.O. • Jim Bolduc, V.P. Customer Services Continued on page 4


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AUTUMN 2009

FROM THE CEO Continued from page 3 Just like Oktoberfest, please come and meet any of our employees! From our Engineers to Shop Personnel to Service Staff, you will soon learn that our people LOVE what they do, and are very proud of our new facility. NO QUESTION EVER GOES UNANSWERED.

Join the Fabrication Revolution At the FabTech Show, we will unveil our newest machine – the Revolution AFCPS 833. I can’t tell you how proud I am of our Engineering team for this fantastic new machine!! This new machine features 3 tools, capacity of 8x8x1" (200x25 mm) angle, flat/plate up to 12x1" (300 x 25 mm), and a hard stamp marker the “SignoPlate”. Can you imagine all this versatility for well under $300,000?? Oh yeah, it can punch your channel webs also.

Too Good To Be TRUE… Here is a tip for you as you read this issue. My Dad always told me that if you get an offer that is too good to be true – it probably isn’t true. Be aware of some firms promoting software that fit this category. Software is becoming a bigger part of all our lives, and the internet has everyone blogging by “twittering or linkd in”. But some people in our industry are investing heavily in software products that purport to do many things. My advice is to thoroughly investigate these software tools to insure you receive the final product you are seeking. Beware of “modules at extra cost” or “features soon to come” or “download here at cost”. I have experienced this first hand from frustrated customers who have undergone this frustrating software scenario, and voiced their agitated opinion to me. This was not only in Europe, but North America too. Selling as an “add on” and not part of the original deal is bad for everyone.

Chicago 2016? How About Bradley In November? Nope, Chicago – our neighbor to the North – did not receive the 2016 Olympic bid! We were disappointed to hear the news, but we give our congratulations to our friends in Rio de Janiero, Brazil. Since the Olympics are out, visit FabTech in Chicago and come to FABTECH Fest in Bradley. You may not get to see an “Olympic Torch”, but we can guarantee that you will see a “Plasma Torch” and “Oxy-Fuel Torch” on many machines in Bradley in November. I look forward to welcoming you to the Midwest, USA! Bring your glass, because, we are keeping it full to the brim! My glass is never half empty – always full!! Say Yes to the Future!

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GENREC

Big Challenges = Big Rewards

Kalifa Sports Complex, Qatar, a Genrec project in the Middle East.

Genrec and Burj Al Arab: Dynamic & Unique Fabricating the structural steelwork for the Burj Al Arab was an unprecedented challenge, based on the huge columns and intricate truss work required for this unique structure and the cantilevered heli-pad on the upper floors required especially demanding technology and skills to erect. So where in world could a fabricator be found that was up to and able to deliver on this challenge? It was a fabricator with years of experience that is no stranger to difficult and complex projects requiring huge fabrications with precise dimensions. The structural fabricator for the Burj al Arab was

Genrec is wholly owned by Murray & Roberts, South Africa’s leading engineering, contracting and construction services company, with a primary focus on the resources-driven construction markets in industry & mining, oil & gas and power & energy in Africa, Middle East, Southeast Asia, Australasia and Voorspoed Project required many intricate connections. North and South America. The company offers civil, mechanical, electrical, mining and process engineering; general building and construction; materials supply and services to the construction industry; and management of concession operations. Genrec offers a comprehensive range of services including structural steel fabrication and erection, heavy fabrication and machining and has successfully concluded a number of large complex structural projects around the world, of which the Burj al Arab is a typical example.

Genrec, a provider of innovative steel solutions, based near Johannesburg in South Africa.

Continued on page 6

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GENREC Continued from page 5

Capacity up to 4,000 Tons/Month

1953 – 1 Employee, 2009 – 1,200 Employees

Leveraging the broader capabilities and skills of the broader Murray & Roberts Group, Genrec covers the full spectrum of structural detailing, procurement, fabrication and construction, offering the client a unique combination of manufacturing, construction and site management that provides clients with a “one stop” turnkey source and solution.

From humble beginnings in 1953 in a small office in the heart of the Free State gold fields of South Africa, Genrec has grown into one of the largest engineering companies in Africa. The one-man business with its base in Wadeville which initially provided breakdown and repair services to gold mines, grew rapidly into a vibrant family business throughout the 1950s and 1960s.

Genrec has the capacity to produce up to 4,000 tons of fabricated structural steel per month and is located in Wadeville on the outskirts of Johannesburg. The facility has more than 55,000 square meters of workshop area under roof and the company maintains a further 19,500 square meters of open yard area, which will soon be equipped with additional productive systems.

Genrec started trading as the General Erection Company and in 1974, continued its dynamic growth that included a listing on the then Johannesburg Stock Exchange under the name of Genrec. Murray & Roberts acquired a 30% shareholding and by 1992 had acquired 100% equity, after which Genrec was delisted and operational activities were split into separate profit centers.

The Bigger the Job – the Better Genrec Likes It

The first column delivery for the new Medupi power plant project in South Africa.

Graham Hartley displays one of the huge fabrications for which Genrec is a specialist.

As an international fabricator Genrec has a sought-after reputation built on its ability and track record of fabricating very large and complex structures. Evidenced by the success of the Burj al Arab, Genrec is geared to serve many markets including:

A partial view of the Peddinghaus system at Genrec includes two powerful band saws, 2 beam drills and an extensive material handling system that provides maximum flexibility for production.

Bruce Hammond of Pedech, the local Peddinghaus distributor is comfortable in a shop environment – even though he is dwarfed by this large fabricated profile.

• Petrochemical • Mining • Sports Stadiums • Hotels and Resorts • Industrial facilities, such as Steel Plants • Power Plants and Production Facilities

Essentially, any project requiring fabrication, precise machining, and heavy fabrication can be processed by Genrec. But their specialty is “The Big Stuff”! Genrec employs two FPDB 2500 plate processing systems.


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“Based on the volume of our plate work and the complex connections, we control our plate costs with the Peddinghaus FPDB 2500.”

What Equipment Do You Need to Properly Fabricate Such Mammoth Profiles? A view of the Medupi trial assembly yard – note the size of the workers next to the huge fabrication.

“Shaya Nsimbi” Zulu translation for “Strike Metal”

“We chose Peddinghaus,” says Graham. “Peddinghaus machines contain the three components that we need to be successful – Quality in Manufacture, Strength in Productivity, and Reliability in Operation”.

As a visitor walking about the Genrec works three distinct images come to mind:

“Genrec has operated a Peddinghaus TDK 1000/9 drill here for the past 21 years – we know the quality of their equipment”.

1. The enormity of the fabrication complex 2. The massive structural fabrications currently under manufacture 3. The rugged, durable machinery processing these huge sections Large fabricated profiles are no problem for the BDL 1250/9 drill line at Genrec.

With capacity to 19,800 kg (40,000 lbs), the Peddinghaus BDL drill gives Genrec the power to meet the largest projects.

The Peddinghaus profile handling system provides the answer to moving heavy sections from sawing to drilling to fit up and layout.

A fourth image is one of employee enthusiasm, diligence and pride in their contribution to success. This is very fitting for the term “Shaya Nsimbi” which translated means “Strike Metal”, symbolizing strength in the organization. Graham Hartley is Genrec’s works executive, who has been principally involved in the company’s massive expansion plan. “Genrec has a vision to be the very best structural fabricator on the continent,” comments Graham, “We have undertaken our expansion to bring us to the top level of productivity and efficiency in our industry.”

Peddinghaus & Genrec – 21 Years of Productivity As you walk the vast fabrication shop floor you finally come to the fabrication bays and as you climb the catwalk, you finally have a “bird’s eye view” of how steel is fabricated here. Because of the huge sections processed by Genrec much of the plate used is processed into “welded up” or fabricated beams and columns. These massive profiles are often over 1.2m wide with flanges measuring 75 mm (+) thick and web thickness of 38 mm and larger (50” wide x 3” thick x 1.5”). Many of the fabricated profiles measure 18m (60 ft) in length and weigh over 20 tons.

In 2009, as part of its expansion, Genrec invested in new Peddinghaus equipment: • BDL 1250/9 – a powerful nine spindle structural drill machine • DGP 1270 – a robust band saw which pivots to 60 degrees right and left • 1250-510 – a strong “speed sawing” band saw for 90 degree cutting • Two Accumeasure systems – precise accuracy for the above saws • Two FPDB 2500 – a commanding plate processor for sections 2500 wide by 75mm thick by 13M length • Brawny Handling System – featuring rugged conveyors and cross transfer systems that move these massive profiles with ease With the goal of fabricating up to 4,000 tons per month, Genrec depends on the strength and reliability of Peddinghaus equipment.

Plate Sets the Table at Genrec Such massive fabricated sections require some serious plate connections. This is why Genrec invested in not one, but two Peddinghaus model FPDB 2500 plasma plate punch/drill systems. “Based on the volume of our plate work and the complex connections, we needed to control our plate fabrication costs and the FPDB fits that role perfectly. The machines are strong, accurate, and reliable.” “Many fabricators under-estimate the value of plate processing equipment, thinking that connections and fittings are not as vital as beam processing. I can assure you that plate fittings can be labor intensive if you don’t have the proper equipment”

Genrec Has Business Plan For Future Goals

“Many fabricators under-estimate the value of plate processing equipment…” Graham Hartley

Under the leadership of Murray & Roberts, Genrec is positioned to achieve its goals of productivity and profitability. Coming off the base of the company’s past achievements and its commitment to expansion and improvement, Genrec stands poised to participate in many “topping out” projects in the future! More information can be found at www.genreceng.co.za

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STRUCTURAL STEEL FABRICATION IN SOUTH AFRICA:

Leading Edge Technologies in a Progressive Land Peddinghaus Corporation recently sponsored a fabricators tour of South Africa where participants were able to witness some of the most modern state of the art fabrication workshop facilities in the world. These tours serve to educate fabricators and industry members about new techniques and innovation in structural steel fabrication. We always enjoy mixing business with a little pleasure in our own eclectic style. The safari to Pilanesberg Resort yielded first hand view of exotic African animals in their own habitat. The Steel Fab Review is pleased to highlight some of these advanced workshops for you on these pages. The shops depicted here are only a sample of the progressive methods of steel fabrication employed for the construction industries in this breathtaking land.

TASS ENGINEERING 63 Rigger Road, Spartan Kempton Park 1620 Tel (27) 11 975 0647 Mr. Tim Tisoulas Mr. Henk Van Eden henk@tasseng.co.za Mr. Henk van Eden, Production Director of Tass Engineering is flanked by two of his Peddinghaus machine operators.

TUBULAR HOLDINGS 16B Melodie Street Klarinet P.O. Box 222 Witbank 1035 Tel (27) 13 690 2334/5/6/7/8 Tel (27) 11 553 2000 Johannesburg Mr. Carlos DeMelo Mr. Pierre Van Rooyen www.tubular.co.za Mr. Carlos DeMelo, Works Director, and Mr. Pierre Van Rooyen, Production Manager, of Tubular Holdings.

The world will have a glimpse of this beautiful land when South Africa hosts the World Cup in 2010.

COSIRA INTERNATIONAL (SA) P.O. Box 16390 Dowerglen 1612 Gauteng Tel (27) 11 626 2317 Mr. John da Silva, Sr. Mr. John da Silva, Jr. Mr. Smit Craill www.cosira.com Mr. John da Silva Jr. (L) Chief Executive Office - Group, and Mr. John da Silva, Sr (R) Chairman of Cosira Group.


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Pedech Named New Peddinghaus Distributor Peddinghaus Corporation is pleased to announce the appointment of Pedech Pty. Ltd as the new distributor for Peddinghaus products in the African Sub-Sahara region including South Africa. Mr. Bruce Hammond is the International Sales Manager of Pedech, which is based in Bedfordview, near Johannesburg. Hammond brings much experience in structural steel fabrication to the position. As a past Sales Manager for Lincoln Welding Products, Bruce was integrally involved in problem solving for welding and production applications both in the workshop as well as on site. He also conducted seminars on improving existing shop welding/fabrication methods and his principal tasks included bringing new, sophisticated technologies to the fabrication workshop. “I am delighted to be involved with Peddinghaus,” advises Hammond, “their international reputation for machine quality and strength is unsurpassed.”

Peddinghaus Customer Service is Unrivaled: Two Techs in South Africa The first project undertaken by Pedech was to train two experienced service technicians on Peddinghaus equipment. This intense training was undertaken at the Bradley, IL USA headquarters. While this training was intact, Peddinghaus insured customer continuity with two technicians in South Africa for months at a time. “We wanted to insure that on-site Customer Service was readily available for all of our customers,” commented Hammond, “Serving customers is the most important priority for Pedech.”

Pedech Pty Ltd. P.O. Box 1342 Bedfordview 2008 Tel (27) 13 690 1671 Fax (27) 11 458 4696 pedechinfo@gmail.com

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With much fabrication experience, Mr. Bruce Hammond is the Peddinghaus Specialist for the new distributor, Pedech, in South Africa.


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METALOGALVA

Sustaining Their Business Future in Today’s Sustainable Two Brothers, Three Employees, 1971 There is an established company in Portugal, who has been practicing “sustainability” in their fabrication processes since its inception in 1971. That company is Metalogalva - Irmaos Silva, S.A., founded by two brothers, Mr. Adelino Silva and Mr. Joaquim Silva. From a humble beginning with 3 employees, a 500 sq meter (5,380 sq feet) facility, and annual revenue of 1,500 Euro, Metalogalva has grown to a 40,000 sq meter (over 430,000 sq feet) manufacturing campus with 450 employees. From the beginning, the business principles of leadership, responsibility, and production quality have been at the core of the Silva’s corporate business plan. Metalogalva, based in Trofa, (near Oporto) Portugal specializes in the manufacture of steel structures for the transport and distribution of electrical energy, commonly referred to as “electrical power”. The company manufactures towers of high, medium, and low tension, as well as substations for the transformation and distribution of electrical energy.

This Anglemaster model AFPS 643 is one of eight Peddinghaus angle processing systems at Metalogalva.

This new building – part of the Metalogalva manufacturing complex – houses thirteen Peddinghaus machines.

Five (5) Peddinghaus plate machines make all connections for Metalogalva's product lines from towers to substations to safety barriers.

Infrastructure Products that “Deliver”

Metalogalva: Your Mobile Telephone Connection

an important role in road safety and the protection of human lives as well as transported goods.

Telecommunication towers are a mainstay of their production, and provide the “lifeline” link for many mobile service providers – and users on the continent. Antenna manufacturing remains a vital part of their production program.

With the largest hot dip galvanizing facility on the Iberian Peninsula, Metalogalva can process their coating requirements quickly and easily to meet customer deadlines.

Metalogalva holds a major national market share in the manufacture and assembly of safety barriers for highways and motorways. The most important aspect of the safety barriers is the buffer which absorbs vehicular shock – which is designed, manufactured, and welded at Metalogalva.

Meticulous Manufacturing Makes the Quality Difference

Today, the transport and distribution of electrical energy is a key factor for the development of a country and for the well being of the entire population. Metalogalva is proud to be acknowledged by various global countries for their vital contributions to infrastructure improvement. But the product lines of Metalogalva do not end with electrical energy distribution. Their manufacturing expertise is used in the production of steel columns for public lighting. Because of their production flexibility, they can provide a single column up to 12M (40ft) in a single section – or provide it in multiple parts for erection on-site. Similarly, they provide large dimension structures which provide lighting for stadiums and similar large venue.

Besides safety barriers, Metalogalva provides overhead signs, their structural supports and related equipment for drivers on Iberian highways and motorways. Thus, Metalogalva plays

What separates Metalogalva from their competitors? How do they gain market share? It is quite simple – excellence in manufacturing and fabrication. Mr. Adelino advises, “We insure that our manufacturing processes are always cutting edge technology and the best methods for achieving a quality product.”


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Environment

Mr. Andelino Silva with stock angle iron ready to be processed on his Peddinghaus angle lines.

Three production bays in the new shop are filled with Peddinghaus processing equipment.

Here are only a few ways that Metalogalva insures quality manufacturing: • Purchase Quality Machine Tools that are durable and built for high production • Metalogalva has 8 Peddinghaus Anglemaster/Towermaster machines • Metalogalva has 5 Peddinghaus Plate Processing Machine Systems • Quality employees “become an extension of your business” • Metalogalva offers extensive employee training and education • An on-site medical facility is another way that Metalogalva cares for its employees • If a tool is not available for your specific application need – build it yourself • Metalogalva has “invented” their own welding equipment to meet production requirements for new tower designs • Material grade and quality are essential • Every incoming shipment of steel is carefully tested (in Metalogalva’s own laboratory) to insure all criteria are met for tensile strength, rigidity, etc. • Constantly seek improvement: in materials, engineering, and methods

business, and we know the Peddinghaus machines will always be running.

Metalogalva invested in more of the multipunch angle processing systems.

We house all the Peddinghaus machines in a new 40,000 sq meter building which further increases our production capabilities.”

The Peddinghaus “Towermaster” APS 2063 is a high speed angle processing system that positions up to 100 Meter per Minute (300 fpm). With capability to punch up to three holes in each leg of the angle, a 400 ton single cut shear, and part marking capability, the Towermaster has been invaluable for the growth of Metalogalva.

Thirteen (13) Peddinghaus Machines in Production

Eight (8) Peddinghaus Anglemasters Tower over Production Challenges

Mr. Adelino says it best, “We purchase Peddinghaus because the machines are very strong and durable. You can see the quality in the manufacture of each machine. We have many delivery commitments to meet in our

Starting in the 1989, Metalogalva purchased their first Peddinghaus machine – an Anglemaster model AFPS 643. The machine served them well, and as business grew,

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Spain Fabricator’s Group ASCEM Enjoys New York Peddinghaus Corporation was pleased to welcome the Asociacion Para La Construccion De Estructuras Metalicas (ASCEM) Fabricator’s Tour group to New York and the USA on October 10 - 17. The group found the trip both interesting and educational – with much fun and entertainment along the way. Peddinghaus assisted the ASCEM Behind the scenes, tour of the stadium.

with an educational steel fabrication and construction program that was enjoyed by all. On Monday morning, October 12, the group departed via coach for an especially interesting tour! They visited the New York Giants new stadium construction site in the nearby Meadowlands. Working with Thornton Thomasetti, the premier steel construction firm for stadiums in North America, Peddinghaus arranged for a personal tour. Many technical questions were asked to learn more about the construction techniques used for this huge stadium. “We speak Steel here!” was a common thread among the Spanish and American fabricators. The group enjoyed a leisurely lunch at “Harold’s Deli” in nearby Edison, NJ for a wonderful New York style dining experience, courtesy of Peddinghaus.

According to Thornton Thomasetti, the General Contractor, the stadium is 6 - 8 months ahead of schedule.

The new Meadowlands Stadium seats 82,000 people.

The group from ASCEM in Spain, headed by President Joan Delriu Real, poses for a photo during their tour of New York.

On Tuesday, the Spanish group visited three distinct structural steel fabricators in the area:

The stadium features 26,000 tons of structural steel from premier fabricators all with Peddinghaus equipment.

Barone Steel, Brooklyn, NY – The group learned how a structural fabricator can thrive in the city of New York, and the special challenges that they face in fabricating steel. Mr. Nick Barone and Mr. Ralph Barone were the hosts. The group then departed the city via motor coach for a different view of America. They enjoyed a scenic drive through the Autumn foliage to visit nearby Pennsylvania where they witnessed two more state of the art structural fabrication facilities.

A total of 480,000 bolts were used on the project – with the holes for those bolts made by Peddinghaus equipment.


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Hejamara Named Peddinghaus Distributor in Portugal Peddinghaus Corporation is pleased to announce the appointment of Hejamara, Comercio e Servicos de Equipamentos Industriais, S.A. as the distributor for Peddinghaus equipment in Portugal.

Thanks to Thornton Thomasetti for a fantastic tour of this beautiful stadium.

L & M Structural Fabricators, Bath, PA – Mr. Keith Ashner and Mr. Daniel Zellner hosted a tour that featured large fabricated sections for the industrial/commercial construction industries. They feature a Peddinghaus BDL 1250 B drill, model 1250-510 saw, and an FDB 2500 plate processing system.

Hejamara is truly a family organization – dedicated to value and customer satisfaction.

Hejamara is a family company owned by Helder and Ana Ramires, founded in 2006. Hejamara currently has twenty (20) full time employees. Hejamara is presently the largest importer of machine tools in Portugal. The cornerstone of Hejamara’s business philosophy is communication and customer service. Of the twenty employees, five (5) are full time service engineers. These technicians are factory trained, and superbly qualified to service and maintain CNC machine tools. “Customer Service is vital for our customers,” advises Helder Ramires, CEO, “that is why we dedicate 25% of our total staff as service engineers”. Eng. Carlos Silva is the Hejamara Peddinghaus Sales Specialist, and is very knowledgeable of structural steel fabrication in Portugal. “We have been working closely with Peddinghaus the past few months, and we are very pleased with the quality products, their engineering expertise, and they share the same customer commitment as we do here at Hejamara”, says Carlos.

New technologies in fabrication were exhibited at both Kinsley Manufacturing and L & M Structural.

Hejamara, Comercio e Servicos de Equipamentos Industriais, S.A. Rua Charneca de Baixo Armazem F - RAL 2710-453 Sintra Portugal Tel (351) 219 152 415 Fax (351) 219 152 417 hramires@hejamara.com or csilva@hejamara.com

www.hejamara.com

Kinsley Manufacturing, York, PA – Kinsley Manufacturing also featured multiple Peddinghaus machines including a BDL 1250 B drill line, with DG 1100 miter band saw, Anglemaster AFPS 623, and FDB 2500 plate processor. Mr. Bobby Chenault and Mr. Fred Hebst were the hosts for the group.

Mr. Steve Farrow

Mr. Roland Jones

The Peddinghaus tour guides were Mr. Juan Manuel Oliviera, Mr. Roland Jones, and Mr. Steve Farrow, Peddinghaus Vice President. The group reported a most enjoyable and memorable visit to the USA!

Mr. Juan Manuel Rivera

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Mr. Carlos Silva is the Peddinghaus product specialist for Hejamara.


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METALOGALVA Continued from page 11

The 1992 FPB 500 at Metalogalva is one of the first 10 FPB machines manufactured by Peddinghaus.

One of the FPB 1800 plate processors runs multiple shifts at Metalogalva.

“The Peddinghaus machines are capable of high production and exacting accuracy. As you see from our shop layout, we always purchase the systems with complete material handling systems - loaders and unloaders. It only makes sense for a high production machine to process steel automatically,” Mr. Adelino Silva

So what does all this engineering, manufacturing, and fabrication expertise provide?

Five (5) Peddinghaus FPB Plate Lines Make the Connections Metalogalva has always been on the leading edge of manufacturing techniques, and found the perfect solution for their multiple connection plate requirements in 1992 – a Peddinghaus FPB 500/3 plasma plate punch. In fact, this machine is one of the first 10 FPB machines ever manufactured by Peddinghaus. With capacity for triple punching up to 3 hole diameters, part marking, and plasma contour cutting of all shapes – the Peddinghaus FPB series was the ideal choice for Metalogalva’s fast paced production environment. The success of the FPB 500 soon led to the purchase of additional FPB plasma plate punching systems. The model FPB 1800, with 1800 wide x 30 mm thick capacity enabled Metalogalva to purchase plate width from their steel suppliers. It minimized scrap, yet provided fast, accurate parts. “The Peddinghaus FPB plate machines

also run very, very well. They are very high production machines.”

• Capacities up to 3,000 metric tons per month for structural sections. • Capacities up to 500 metric tons per month for light standards • Capacities up to 1,200 metric tons per month for telecommunication towers Metalogalva stands ready to meet any production challenge.

“Our strength is in our organization and the diligent work ethic of our employees”, says Mr. Adelino Silva with pride. Mr. Adelino should be proud – the dynamic growth of the company, its status in the metal working industry, and also his position as a founder of the firm. But Mr. Adelino is a little modest about one point – he remains an excellent futbol (soccer) player – who enjoys playing the game weekly, as does his brother Joaquim. Sustaining their future together.

Sustaining Metalogalva What does the future hold for Metalogalva? Think of it in a “sustainable manner”: • The world is attuned to our environment; recycled steel will provide the ideal construction resource • The global infrastructure needs to be expanded and improved; bringing wind tower solutions to the power grid in North America is only one small example of the need for energy transmission towers • The galvanizing process (and paint coating) developed by Metalogalva is also eco-friendly for recycling • Telecommunication is bringing the world together, and the network requires expansion Metalogalva is driven by technology, quality, value, and the continuing desire for improvement. Their employees are industrious, and their management is dedicated to customer satisfaction.

Metalogalva’s products are galvanized on site and shipped throughout the world.


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TRINITY STEEL

Lean Fabrication in the Lone Star State Trinity Steel Fabricators - An Unpredicted Leap of Faith It was shortly after his service in World War II when Roy Karnes Sr. started his career in steel fabrication. Little did he know that he would someday become the Vice President of International Steel, a Houston based fabricator and grow to be a well respected professional in the steel fabrication community. So well known and respected that in 1976 he would eventually be urged to branch off and start his own business in Trinity, Texas. It was the local people of Trinity that approached Roy with this proposition, and with a leap of faith Roy launched a family business that still thrives today.

Trinity's Tomball plant houses the Robust BDL-B and High Speed 1250 band saw for fast paced fabrication.

Today his two sons,Roy Jr. and Randy, carry on the family business, but with the modern twist needed to stay competitive in today’s markets.

Trinity and Technology - Forward Thinking Fabrication Current Trinity Steel President Roy Karnes, Jr. knows good technology when he sees it. Long before he joined his family’s business in steel fabrication he held a successful career as a Software Product Manager for IBM helping businesses succeed with the proper application of technology. When Roy was given the opportunity to retire early from his duties at IBM he took the chance to join his Brother and Father in the family Steel Fabrication business. Roy joined the Trinity team with an outside perspective on how technology can impact a firm. While the organization had a long established reputation for superior quality and superb customer service Roy wanted to apply some of the knowledge he had acquired at his previous career in order to take Trinity to the next level.

The ABCM-1250 automatic coper increases efficiency for Trinity’s complex industrial fabrication projects.

“I was in the mindset that technology could help a firm cut costs and stay competitive long before I had come to steel fabrication. What I saw when I started to work at Trinity in 1991 was that the fabrication industry had yet to completely discover what software and automation had to offer. I remember when getting our first fax machine was a big step forward in modernizing our processes, and today we utilize automation while relying on software technology to keep most every facet of our business up and running smoothly. That fax machine was a very small first step to a long relationship with modern technology!” Continued on page 18

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It’s time for FABTECH 2009 in Chicago – and FABTECH Fest in Bradley! It’s time for FABTECH 2009 and Peddinghaus will once again join the steel fabricating industry at McCormick Place in Chicago, Illinois for this five star exhibition. If you are planning on visiting the Windy City for this year’s show you might want to consider the many offerings Peddinghaus will have in store for industry professionals making the trip. Visit Peddinghaus’ BOOTH #12079 at McCormick to witness the latest in cutting edge machine tool technology – the NEW Anglemaster REVOLUTION AFCPS-833. Don’t miss this innovative machine that will reinvent Angle and Flat bar processing for generations to come! BUT, the excitement doesn't stop at McCormick Place.

• If you want to stay in Bradley... it will give you a chance to visit our expansive showroom, our world class manufacturing facilities and enjoy the FABTECH Fest atmosphere Peddinghaus style. • We’ll provide luxury transportation to and from McCormick. • 17 Peddinghaus machines will be on display running live demonstrations by request throughout the day Monday, Tuesday, and Wednesday during FABTECH. • Peddinghaus engineers will be on hand for question & answer sessions throughout the event. Specifically, Anglemaster REVOLUTION engineers will be there to fill you in on all the exciting details this machine offers. Don’t miss out on tapping the knowledge of these industry experts! • Dinner will be on us! For more information call Ms. Tami Day at 815. 937. 3800 Ext. 210 and ask her about transportation schedules! Visit http://fabtech.peddinghaus.com for the latest info on Peddinghaus at FABTECH!


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The Patented Anglemaster AFCPS833 REVOLUTION The REVOLUTION is the latest addition to the Peddinghaus Anglemaster series of machines. Boasting a unique rotating punch press capable of processing a wide range of angle, plate, and channel sizes – the AFCPS-833 is designed to expedite processes and cut costs for steel fabricators all over the globe. The latest features of this Anglemaster model include: • Triple tool punching capabilities • 44 Character part stamping • ALL-NEW SignoPlate system • Ability to run wider flats up to 12" (300mm) wide • Can process plate from either side of the conveyor • Runs plate WITHOUT needing to change shear tooling on most materials • Part marks on BOTH sides of an angle • A CNC control station able to house both the CNC control and a PC – which allows programming and part modifications right from the control console • Unique swinging cylinder arrangement which improves capabilities by eliminating many X axis movements during the punch cycle The AFCPS-833 isn’t just another Anglemaster... it’s an angle and flat bar processing REVOLUTION!

REVOLUTION – AFCPS – 833/A SPECIFICATIONS MATERIAL SPECIFICATIONS

INCH

METRIC

Maximum Angle Capacity

8 x 8 x 1"

200 x 200 x 25mm

Minimum Angle Capacity

1-1/2 x 1-1/2 x 1/8"

40 x 40 x 4mm

Maximum Flat Stock Capacity

12 x 1"

300 x 25mm

Minimum Flat Stock Capacity

2 x 1/4" OR 3 x 3/16"

50 x 6mm OR 75 x 5mm

Acceptable Channel Sizes

MC12 x 50 OR C12 x 30 Anything under these sizes can be run

300mm wide maximum

Industry professionals who were given a special preview have given rave reviews... “A concept so simple yet so innovative, I’ve never seen anything like it!” (Structural Fabricator)

“This is the future of angle and flat bar fabrication.” (Steel Service Center)

“Peddinghaus engineers have done it again. Advanced technology in a simple design!” (Manufacturer of Structural Components)

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TRINITY STEEL Continued from page 15 After establishing three plants in Trinity (1976), Lufkin (1989), and Tomball, Texas (1994) the need to automate and innovate became a necessity. It was decided that the Tomball plant would be the central hub for Trinity Steel's production process containing the CNC equipment, while the Lufkin and Trinity plants would be home to a majority of the fit-up and welding processes. Several trucks are employed that take the material from CNC production, to fit-up and welding, to galvanizing and for final inspection before delivery. All of the parts of this process need to work together like a well oiled machine. A chain is only as strong as its weakest link and that’s where efficient and durable equipment becomes a priority.

Two FDB-2500 plate processors drive the modern plate operations at Trinity Steel.

The efficient production of plate components is critical for Trinity’s profitability.

Trinity Steel and Peddinghaus - A Winning Combination When Trinity started adding automation to their Tomball shop they made informed decisions and grew or automated each process as needed. A burn table was added and Roy’s background in software made working with nesting programs easy, but parts were only cut to shape when they left the burn table. That’s where Peddinghaus came into the picture… “We had a burn table that cut plate parts quickly but we had no way of efficiently making holes in them. We were making the holes manually but instead of increasing efficiency we had actually created a whole new bottleneck in our shop. Then we bought the Peddinghaus F-1170 plate

The original Peddinghaus F-1170 at Trinity Steel proves to be an irreplaceable part of production.

duplicator. The machine fixed our hole making problem and has been reliable ever since. It was only natural to complete the progression by adding a complete plate processor with the FDB-2500. When we saw and measured the productivity of the first FDB we purchased a second one!


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“Since the addition of the two FDB plate machines I have toyed with the notion of removing the F-1170. I felt like we had replaced it with the plate processors but every time I think about it my shop people stop me. It’s a reliable machine that has never had a hiccup – and they always find an application for it! It's just a rock-solid piece of equipment.” After their first successes with CNC efficiency Roy and Randy knew that their shop would only continue to grow. When Trinity Steel approached Peddinghaus about adding a BDL-1250 drill line, 1250-510 straight cut band saw, and ABCM-1250 coper to their shop Peddinghaus experts helped them achieve the ideal layout to suit their needs.

The Peddinghaus Coper, Drill, and Saw system are all housed inside of this shelter outside and out of the way of other space consuming processes.

“We wanted to add a drill/saw/coping system to our existing building. Greg Carpenter (Peddinghaus Layout Engineer) worked with us to find the best solution that fit our needs. Greg opened our eyes to the ability of keeping material handling outside of the shop. When he told us we didn’t need to rearrange our existing building, and that we could just build a small shelter for the new machines we thought that was a great idea for us! Now we have a separate shelter that houses the three new Peddinghaus machines, with all of the material handling outside and out of the way. We have never been as efficient as we are now. The Peddinghaus machines do exactly what they advertise.”

Communication is Critical With the multiple shops and main offices located in Trinity away from the Tomball CNC plant Roy and Randy couldn’t just walk out into the shop to monitor a job anymore. Today’s production control software technology paired with a bar code system is critical to Trinity Steel's success. The production information generated by these systems actually helps Trinity share job status with their customers. Each customer receives a username and password to access the Trinity website and can see exactly what the status of each job is – this technology also helps Roy communicate with his Galvanizer, and shop foremen effectively.

The Peddinghaus BDL-1250 drill line is used for the heaviest sections Trinity is required to process.

“The barcode system makes things easier for both us and the customer. We receive less phone calls asking where orders are and the ability to monitor the activities of each of our plants from our main office is an invaluable tool for our company. The software we use from FABTROL is a comprehensive program that suits our needs. We are able to make inquiries from it for our processes, and that is critical for what we offer our customers.”

Trinity Today And Into The Future

“We have never

Roy Karnes will tell you that he is optimistic about the future of Trinity Steel. Although markets have been unpredictable, work has been steady for the organization and with the strong relationships they maintain with their industry partners they are poised and ready for anything that comes their way.

been as efficient as we are now. The Peddinghaus

“We have been through some downturns before and this definitely won’t be the last one we see. We have some big plans on how to stay very competitive now and into the future and the added capacity we can achieve with our Peddinghaus equipment will play a crucial role in that game plan.”

machines do exactly what they advertise.” A state-of-the-art bar coding system is used to track progress and share job information with customers online.

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Structural Fabrication Software Questionnaire The past few months have seen an increased number of new and recycled software

The Industry Panel Response to these Frequently Asked Questions:

programs entering the marketplace. Some are being heavily promoted by software specialists, some by hardware manufacturers, and some via the internet. You – the STEEL FAB REVIEW readers – report that this software situation has created some confusion in the marketplace concerning capabilities of various software packages. To investigate this situation, the SFR staff contacted three of

1. There are many various types of software in the market, how can I be assured which ones best fit the business plan of my structural fabrication firm? AceCad: It is vital that the software you select covers all the current standards for maximum compatibility and future proofing. The software should be modular such that it can grow with your business and meet your entire organizational needs both today and in the future.

the leading MRP software firms for their expertise on some of your questions.

FabSuite: Don’t make your decisions based on the bells and whistles that the salesperson shows you. They are supposed to make it look easy.

AceCad (StruMis), FabTrol, and FabSuite have answered your questions from their

1. Make a list of capabilities that you must have, a list of features that you would like to have, and list of features that you want for the future. 2. Make sure that you get to use the software in a demonstration mode.

unique perspective. The steel fabrication industry has seen many changes in the past few years, and we feel that a simple Question/Answer format will be helpful for our readers. The STEEL FABRICATORS’ REVIEW wishes to thank these firms for their participation and spirit of industry cooperation in the preparation of this information.

AceCad Software Whiteland Business Park Exton, PA 19341 610. 280. 9840 610. 280. 9841 Fax www.strucad.com

FabTrol 825 Springdale Drive1025 Willamette Suite 300 Eugene, OR 97401 888. 322. 8765 www.fabtrol.com

FabSuite 6704 Tarpley’s Tavern Rd. Williamsburg, VA 23188 757. 645. 9266 www.fabsuite.com

If they wont give you a demo there’s probably something that they don’t want you to know about until after the sale. Fabtrol: As well as the appropriateness of the software itself, you need to consider the company that delivers it and their skill and investment in understanding and enhancing your business in line with your plans. On the software side, integration is critical. This means your software solution provides a single coordinated solution to address the complex problems steel fabricators face daily. You want a material management solution that automatically takes the production plan into account and vice versa. And your purchasing, nesting and stock management efforts should automatically establish traceability from parts to heat numbers. Completeness is important. The software should address estimating, material, and production concerns so that you get an end-to-end solution designed to meet the specific needs of a steel fabricator. You also want software that is in common use and has established its interoperability in the marketplace. This means other software and equipment manufacturers have learned how to work with it. For example, it should work with Peddinghaus and your other equipment and software. Your fabrication management software needs to broaden your choices, not limit them.

2. A variety of firms offer detailing software, production software or some combination of the two. What do I really need for my business? What do I need to run the machines in my shop effectively? AceCad: A genuine production management system will have full compatibility with all modeling systems via established international standards. The production module should have the ability to interrogate, edit and route CAM/DSTV formats to all your hardware. FabSuite: Companies that advertise “All-in-one” software offer the same argument as a tool company who states that “all you need is a crescent wrench.” 1. Make a list of capabilities that you must have, a list of features that you would like to have, and list of features that you want for the future. 2. Make sure that the software supports published exchange files (CIS/2, DSTV, KISS). 3. Use the best software tool for the job. Continued on page 22


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STRUCTURAL FABRICATION SOFTWARE Q&A Continued from page 20

Fabtrol: Whether you’re detailing is handled in-house or by an outside firm, you need a disciplined detailing specialist who uses leading 3D modeling software like Tekla or SDS/2. Then you need software that is specifically designed to both drive and track production, materials and shipping. It should take CNC data from the model and deliver it to the CNC controllers in your shop in batches that match your production plan-even down to driving production by truckload.

3. What is the difference between a “Scheduling” and “Production Control” software? AceCad: Scheduling is planning ahead and should enable the identification of shop bottlenecks before they occur. CAM/DSTV routing and associated analysis is Production Control and any production module should supply appropriate hardware with work prioritized by least time or cost and post processing, should supply automatic feedback for budgeting, estimating and subsequent analysis. FabSuite: Scheduling software helps you plan for the future in the shop. Production control software helps you inform the shop what to do (cut lists, etc.) and capture current activity. You cannot plan for the future unless you can measure your current capabilities. Therefore, production control software should be implemented first. Fabtrol: Software like Microsoft Project is commonly used for generating and maintaining the high level schedule for a project. FabTrol MRP can export data to MS Project to help you with this task. The spreadsheet most fabricators review at their weekly production meetings is another scheduling tool. Production Control software goes much deeper and covers the synchronization of drawings, purchasing, stock, fabrication, painting-all the way to loading the truck and verifying it reached the galvanizer or job site. It manages delivery of the right information, including CNC data, to the right person or machine at the right time. Basically, production control software should cover managing and reporting on all of the detailed activities involved in taking the project plan from fabrication drawings to delivery of the right truckload on the right day.

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Fabtrol: Experienced estimators are worth their weight in gold – you need to leverage this guy by moving his mental shop model into software. Build a model that penalizes work that doesn’t match your shop and equipment and becomes aggressive with work that is a good match for you – in other words, a software model that becomes aggressive or cautious exactly when he would. This will dramatically improve the productivity of your best guy and increase the value and confidence of junior estimators. Now your senior estimator can spend his time reviewing the results the software generates – allowing him to apply his skill to many more bids in less time. Or he can spend time looking for the value engineering opportunities that contribute to a more attractive bid and better match the capabilities of your shop.

5. I use outside detailers who all use BIM modeling software – does it make a difference what type of production software I use? AceCad: Yes a system must cover all software modeling systems for maximum flexibility. The system must be able to import, process and where necessary edit multiple formats and ideally record production data back to the model. FabSuite: Project schedules are such that unless you can exploit data exchange, you’ll be struggling to keep up. CIS/2 files (which can be converted to IFC) offer the greatest opportunity for data exchange. Everyone can use them to keep abreast of the job: engineer, architect, detailer – and even the fabricator. Fabtrol: Absolutely. The production software needs to serve as a hub for all of your production information. First, it has to break the model data down into loads or production batches, and then coordinate the drawings, questions (RFIs), material, CNC data, part routing, assembly tracking and shipping information to deliver thousands of tons in effective 20 ton doses. Not only that, it has to have the capacity to do all this in a world where model data often changes on a weekly basis. And when the model data does change, your software should make it crystal clear what changed between the last model update and the current model, as well as show you how the changes impact your work in process – POs, nests, in process parts, assemblies, etc. A key thing here, though, is that modeling software can’t display the “I” (information) unless the production software can record the status of assemblies and parts and push that information back into the model. FabTrol MRP has collected status data and communicated it to a Tekla Structures or SDS/2 model for many years.

4. I am told that I am “old fashioned” if I do my estimating manually – but this is vital for my business – what is best? AceCad: A true estimating package should enable importing of job data from any electronic source – i.e. from Architects, Engineers, Design and Modeling software. This reduces costly errors and significant data entry time. An Estimating package should also enable cost extras and facilitate budget analysis for comparison and variations. FabSuite: There is a simple retort to the “old fashioned” argument: Do you make money? Software should conform to the business that implements it – not the other way around. If you have to change the way you do business just so you can make use of software, then the software probably isn’t the best fit for your company.

6. Is there a specific yearly annual tonnage that dictates the best software for my company? AceCad: All solutions should operate equally well regardless of data storage or size of shop. Companies should offer a scalable or modular solution to facilitate your business now and in the future. FabSuite: Absolutely not. Anyone who says otherwise is selling something. Purchase software the suits your needs and is flexible to your business process.

Continued on page 24


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STRUCTURAL FABRICATION SOFTWARE Q&A Continued from page 22

Fabtrol: Looking strictly at tonnage could send you down the wrong path. It’s important to purchase software that meets your needs today, but also has the capacity to help you grow. During your evaluation, look for companies like yours that depend on the software you’re considering. But also look for companies that have grown while using the software, as well as companies using the software effectively that are the size you want to be in the future. In your discussions, the sales consultant should be able to demonstrate an understanding of where you are today, and help you implement the part of the solution that you’re ready for right now. And as you grow? What will the software provider have to offer?

7. Some firms offer production software with a machine purchase – where does that software fit in? AceCad: Most hardware manufacturers do not themselves develop production management software. While they may attempt to tie you to their machines through a software product it is unlikely that they will have considered the best interests of your business. A production management software should be developed by an international software specialist that delivers benefits to the fabricator – not the hardware manufacturer. FabSuite: Find an easy-to-use group of programs that will allow you to enter data once and use it throughout the estimating, purchasing, inventory and production process, with consistent interface screens and targeted reports. A production control program is key to tracking material and getting accurate reports, but the interface to other fabrication management systems is necessary to efficiently use the data without multiple inputs or lists. Every machine will need software to run effectively. The question is, does that software stay within the scope of the machine? Always use the best tool for the job.

8. What is a DSTV file? Why do I need it for the CNC machines in my shop? AceCad: This is the standard recognized internationally and offers the greatest opportunity for integration and interoperability. DSTV+ also offers further benefits and should be a consideration when looking at software. FabSuite: DSTV files are text instructions that describe a part to a machine. DSTV was invented as an open standard to exchange data – thus allowing everyone to conform to the same set of rules during data exchange. Fabtrol: A DSTV file is the CNC file format FabTrol MRP most commonly receives with the bill of material and drawing data from Tekla Structures or SDS/2. FabTrol MRP uses the contents of this file to route parts to the proper work area and then delivers the DSTV file to the proper machine controller to match your production and material plan.

9. What type of customer service/support can I expect from a software firm?

Fabtrol: Of course this software is useful for driving the machine. Time is money, though, and you don’t want to spend it implementing the wrong software to drive something as important as your business. FabTrol provides an efficient, supportive, cost-effective journey from your installation to realization of the return on investment. This starts with the analysis performed by the sales consultant and continues on to the custom implementation provided by current staff who have brought hundreds of companies up to speed with our software. For instance, Peddinghaus machines and controller software, combined with FabTrol MRP can provide the fabricator a complete solution for managing the flow of production through his shop.

AceCad: You should expect the highest standards of support and localization from your software vendor. They should have localized support, development and training and utilize the very latest standards in software development technology – .NET SQL 2005 for maximum integration and future proofing.

DesignData: Changing software based on an equipment purchase isn’t necessarily a good idea for your business. It’s like changing software because you bought a new printer – it doesn’t make sense. You already have a software that works for you, which was probably chosen based on features that complement your business methods.

Fabtrol: During your office hours, your calls should typically be routed directly to someone in support with little or no delay. When that isn’t possible, you should be able to leave a brief description of your problem and receive a call-back within a very short time period.

— Design Data SDS/2, Lincoln, Nebraska

FabSuite: Your software company should be: 1. Located on your continent 2. Experienced in the type of fabrication that you do. 3. Familiar with the quality standards that you must conform to. 4. Employ more than one or two people from your industry.

Even more important, though, the software company can only service your business if it understands it and if it is staffed to support your growth – which means being able to handle your major process or strategy changes. FabTrol addresses this need by keeping many highly experienced support, training and implementation specialists on staff. In addition, our team of sales consultants is experienced in process analysis so all our customers start out with a customized software training, implementation and ongoing support package designed to meet their specific needs.


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Tekla Annual User’s Meeting The 300 attendees at the Tekla annual user’s meeting were the first to experience Peddinghaus’ latest software technology updates. During a special presentation, Peddinghaus Software Manager, Kirk Kempen, and Software Specialist, Istok Budic announced two new software programs that are certain to have a dynamic impact on the world of structural fabrication. Under the theme, “Don’t Just Fabricate – INNOVATE”, Lyle Menke, V.P. Marketing explained that Peddinghaus’ software technology continues to set the pace for a growing technologically demanding industry. Acclaimed as the global leader in machine tool innovation, Peddinghaus continues to provide a leadership role in the areas of both mechanical and software expertise. The new Peddinghaus software essentially encompasses two areas of application: A new, highly effective Production Tracking Software Utility and an all new Peddinghaus/Tekla API Interface program. The Production tracking utility provides a superior format for tracking production data – a necessity in order to enhance your position in today’s supremely competitive environment. The Peddinghaus/Tekla API interface provides exciting new levels of enhanced operation within the Tekla model. Peddinghaus thanks Tekla, Inc. for providing the perfect platform for this strategic announcement.

Peddinghaus’ latest software announcements captured the attention of user meeting visitors.

User meeting visitors networked with industry professionals from all over the country while learning about the latest and most innovative software applications.

Peddinghaus & Design Data – SDS 2 – Interoperability Partners “We relish the opportunity to work closely with our business partners to improve software technologies for the entire steel construction industry.”

The Design Data - SDS 2 interoperability meeting in Lincoln, Nebraska was heavily attended by industry professionals.

On September 30, Peddinghaus Corporation participated in the second Design Data – SDS 2 Interoperability Network Conference. According to Damon Scaggs, President, “Interoperability is an opportunity for major players in the structural steel software industry to showcase interoperability with other software… it highlights the need for disparate software to interoperate seamlessly with one another.” Peddinghaus, a major partner with Design Data, displayed their latest software innovations for the attendees. These included the major enhancements for Peddimat software as they pertain to the SDS 2 program. A highlight was the implementation of the Production Tracking Utility for Peddinghaus equipment – a program specifically designed to enhance productivity on the shop floor. Lyle Menke, VP of Marketing for Peddinghaus and Jim Dager, Founder of Design Data/SDS 2 discuss market trends and the future of fabrication software.

Peddinghaus and Design Data software engineers maintain close working relationships to serve the steel fabrication community effectively.

Lyle Menke, Peddinghaus V.P. of Marketing,

Menke attended along with Mr. Istok Budic, a senior Peddinghaus software programming engineer. Mr. Budic answered many questions from the participants concerning the interoperability of Peddinghaus software with today’s industry software.


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GETTING TO KNOW…

Kirk Kempen Peddinghaus CAM Software Manager Being one of the many multi-decade veterans of Peddinghaus Kirk Kempen has been with the company through a multitude of innovations in his time. Kirk currently manages the CAM software portion of the Peddinghaus Software staff and plays a definitive role in designing and guiding the future of Peddinghaus Software technology.

How long have you worked at Peddinghaus and what has been your impression in that time? Next March will be my 35th anniversary. In my time here I have seen our product line and level of technology advance at a pace beyond what anyone could have imagined. I was at Peddinghaus with the introduction of the first version of Peddimat, and I am here today as we employ new technologies such as Microsoft’s “.NET” software development system, the C# (C Sharp) programming language, as well as numerous other advanced software tools. Peddinghaus has always been first to incorporate the newest and most reliable technology, and we plan to continue that trend well into the future.

How is the Peddinghaus software department structured? Currently I manage a team of software engineers using the latest software tools devoted to the continuous advancement or our growing product family. This allows us to provide our customers the best software for our machines, resulting in the highest level of performance. Each of the CAM team members has his own specialty and unique talents providing a good mix to the department. We have a close relationship with our Electrical, Control Software, and Mechanical Engineering groups allowing us to provide the best solutions for each technical innovation our customers need to stay competitive in today’s global economy. We also work very hard at maintaining relationships with outside software firms that our customers frequently use. This assures the best software options for their unique processes.

With your role being immersed in the latest technological innovations, what are some of the defining projects you have been involved with in your time at Peddinghaus? I remember our first custom machine controls, the advent of the first “Personal Computers” and now the application of incredibly powerful CNC controls employing the newest programming tools. Many changes in our industry including 3D design, BIM modeling, and software detailing have allowed us to dramatically reduce or eliminate manual data entry for our machines through the application of data import utilities using DSTV, DXF, and direct 3D conversion methods.

What changes have you seen in Peddinghaus since you began? What changes in technology have you seen in your tenure with Peddinghaus? I have seen the Peddinghaus product line evolve dramatically since I began years ago. One thing that’s evident is that modern machine design is reliant on cutting edge electronics and innovative software. I remember years ago, to advance beyond proprietary custom built machine controls, we used Hewlett Packard desktop computers to create our machine programs. This allowed us to use more reliable commercial “NC” controls. Those early personal computers were really just overgrown desktop calculators with extremely limited programming capabilities by today’s standards but nonetheless were amazing advancements in technology for their time. In contrast the simple controls of yesterday's machines have been replaced by the newest “CNC” technology allowing us to provide features like hole counting, and tracking of parts and machine productivity in real-time. This allows us to incorporate numerous features not possible with previous control technology. Using the latest tools from Microsoft, we’ve recently introduced two new software products:

The Tekla Import Utility Using the Tekla API, we developed a tool to directly access the Tekla 3D model. This software runs alongside Tekla, and can extract extensive part data directly from the model. In addition to the information available through DSTV, this tool can provide connection information, marking for fitters, welding, and other final assembly processes. This tool provides direct access to the model, so any necessary information for our machines is readily available.

Production Tracking Utility This software is loaded onto our Siemens CNCs where it tracks part production in real time. An ASCII file is produced listing all parts processed including start time, end time, and process time. This information is easily used for Production Control to track the progress of work in the shop. These two new utilities will provide features not previously available, and I’m sure our customers will be anxious to take advantage of them.

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KIRK KEMPEN Continued from page 28 needs. We don’t believe in “One size fits all” software packages for plate nesting, BIM, or production control. No two of our customers are exactly alike, so their needs and software requirements often vary. We let them decide what is best for their business and help them achieve the vision they share with us.

How does Peddinghaus software work to make the overall fabrication process easier for Peddinghaus customers?

More of our newest developments will include many tools to further improve efficiency. Machines like our new “Ring of Fire” offer our customers capabilities not available from any other manufacturer. Using our customers’ feedback and insight our engineers have been working hard to assure that these new products provide the level of performance that customers have come to expect from Peddinghaus.

The big thing that we can provide is efficiency through lower labor content. By eliminating many of the manual steps previously required, our customers can fabricate more steel, more accurately, with fewer man hours. This is possible largely due to the automatic features and user friendliness we always try to provide in our software. Many of these additions are a result of direct customer feedback. Another unique thing about Peddinghaus is our open relationship with 3rd party software companies, and our willingness to offer any assistance necessary to provide the best solutions for our customers. We continually strive to maintain relationships with the number one providers of nesting, production control, and BIM software.

Can you describe what you think will be on the horizon for software? What is the missing link that Peddinghaus fills as far as software in today’s market? It’s important for fabricators to balance ease of operation with functional versatility of their software programs. Peddinghaus has continued to work with many of the world’s leading software providers in order to ensure that customers are able to find comprehensive solutions to their production

Engineering managers Mike Mullikin (left) and Kirk Kempen (right) have worked together to help create a user friendly software environment on all Peddinghaus equipment.

Employee Profile

INTRODUCING CARLOS TORRES LATIN AMERICAN SALES MANAGER Carlos Torres, Latin American Sales Manager brings his vast experience as a CNC professional to Peddinghaus’ Latin American team. Before joining Peddinghaus’ Latin American office Carlos sold Peddinghaus equipment to steel fabricators throughout the continent. His career has been spent learning how to deliver to most efficient and cost effective services to structural fabricators of all sizes. Carlos’ nearly 10 years of experience in the steel fabrication industry and collective knowledge of Peddinghaus machinery has already become an invaluable asset to Peddinghaus customers. To contact Carlos for more information email: carlos-torres@peddinghaus.com or call: (+52) 8110 017088. Carlos Torres – recently brought his knowledge and expertise to Colombian fabricators at a show in Medellin, Colombia.


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VOLUME 32

STEEL FABRICATORS’ REVIEW

AUTUMN 2009

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

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AISC CELEBRATES

SteelDay 2009 and Honors Award Winners More than 7,000 people attended more than 170 free events across the USA on September 18, 2009 for SteelDay. This is the first-ever national networking and education day for the design and construction community, hosed by the American Institute of Steel Construction (AISC) and its members. Architects, engineers, university faculty and students, and the general public visited steel mills, fabricators, service centers, galvanizers, Peddinghaus, and other steel facilities to network, witness advanced technologies in action, and learn how the structural steel industry is building high-performance and sustainable projects.

Roger Ferch, Bob Freeland, Bob Owen, Terry Peshia, Lou Gurthet, Rex Lewis

SteelDay guests were able to learn first-hand about how steel is produced while strengthening relationships with others in the industry. A number of hosts partnered together to offer unprecedented tours of multiple facilities that showcased various aspects of the steel supply chain.

AISC Honors Owen, Peisha, and Dager at Annual Meeting The AISC Annual Meeting held September 24 – 25, in Braselton, GA was the location for the AISC Annual Meeting, in which three of its members were awarded for outstanding achievement within our industry. Mr. Bob Owen, Paxton & Vierling Steel, Owen Industries; and Mr. Terry Peisha, Garbe Iron Works received the prestigious Robert P. Stupp Leadership Award, the Institute's highest honor. Mr. Jim Dager, the founder of Design Data/SDS 2 software received the Special Achievement Award for his outstanding contributions to the technical growth and education of the industry. In recognizing Jim’s achievement, David Harwell, Chairman of the Board of Directors of AISC and President of Central Texas Iron Works (CTIW), said, “Jim is definitely the visionary behind the development of 3D modeling. He revolutionized the engineering interface and detailing practice in our marketplace. He’s a pioneer, and certainly deserving of the Special Achievement Award presented on behalf of AISC.”

Roger Ferch, Jim Dager, Rex Lewis

Peddinghaus is proud to congratulate these distinguished gentlemen on their recognition by the industry.

Peddinghaus Steel Fabricators' Review Volume 32  

SFR Volume 32 - The Peddinghaus Steel Fabricators' Review is a magazine published by Peddinghaus Corporation - the acknowledged global leade...