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Stamping/Presses

Sound footing

By FFJournal staff

Above: Delta Industrial works with the manufacturer and the customer to tailor a foundation to specific needs.

Attention to detail, field experience and cradle-to-grave services help metalformers tackle large press installations

December 2019 - The strength of a house, a building or a press pit lies in its foundation. In Greek mythology,  Atlas was responsible for bearing the weight of the heavens on his shoulders for eternity. While manmade structures don’t have to last quite that long, these foundations need to be able to bear a building’s load, anchor it against natural forces and isolate it from ground moisture.

In the case of a press pit and foundation project, Delta Industrial’s team understands what it takes, starting with a geotechnical report on soil conditions.

“There are a lot of variables to consider when you are talking about a press that can weigh several thousand tons,” says Delta Industrial Vice President Tom Lytle.

Based in Chesterfield, Michigan, Delta Industrial has 25 years of experience as a design-build specialist that can work with both the customer and the machine manufacturer to meet the requirements of the capital equipment purchase.

When attempting to evaluate the needs for a press pit and/or machine foundation, Delta Industrial recommends manufacturers employ a checklist that includes a construction process description, identification of additional services, bolster rails, tie-rod sumps, trenching, conveyor systems and the need for diamond plating machine foundations.

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Delta’s services include press pits, machine foundation designs, construction, steel design and fabrication, concrete flatwork and complete contracting.

Installation

When Newman Technology Inc., decided to add an 80,000-sq.-ft. addition to their operating facility in 2017, it chose Delta Industrial to install the building foundations and slab on grade. More recently, Delta was brought back to install foundations for Newman’s new 400-ton, 600-ton and 2000-ton presses. 

Delta had to work with varying subgrade soil conditions, while also tying into existing scrap tunnels. This process required drilling through soil and rock for H-pile and wood lagging earth retention. Special equipment was needed for the demolition and excavation of the rock subgrade. 

Once shoring and excavation was complete, existing scrap tunnel walls were cut and removed so the construction crew could tie into the new press foundations. During the construction process, Delta Industrial engineered and maintained a temporary air ventilation ductwork system to protect the workers from any potential harmful fumes, debris and dust. 

The project was completed ahead of schedule, despite being a complex project tailored to match existing foundations, centerlines and scrap conveyor tunnels. 

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Delta provides turnkey installations from rigging to building additions.

Fortress

The press pits and machine foundations that Delta Industrial builds sometimes seem to be more along the lines of an underground fortress because the presses they are supporting are gargantuan —weighing anywhere from thousands of pounds to several tons. 

“These massive presses can create some significant heavy-duty vibration and impact with each cycle every couple of seconds,” Lytle says. “And that requires the factory floor beneath them to be able to withstand this heavy abuse.” 

Variable conditions combined with the size and scope of these engineered jobs requires a press pit foreman who can direct a crew, ensure the proper equipment and personnel are on the job, handle inspections, oversee changes and keep the communication lines open to keep the process moving. Delta Industrial is able to provide individuals with skill sets and field experience to see these projects through.

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Safe, well-managed workspaces are crucial to a design/build project.

Pack leader

Good people, a good process and a guarantee to deliver a superior product have helped put Delta at the forefront of a challenging industry, according to some of its customers. For example, Topre America Corp. turned to the foundation specialist to take on a project for its new plant, which required foundations for a 1,000-ton press and a 3,000-ton press. Delta built additional foundations, conveyor tunnels, slab on grade, spotting press utility trenches, and exterior paving for the Topre plant.

Delta’s services include jobs such as creating a micro silica concrete mix designed to strengthen the foundation under the Gate Gage Products Co.’s tank farm to prevent deterioration in the event of a spill. This process also reduced construction costs and shortened the build time by several weeks.

The foundation specialist takes compressed time schedules in stride. When Fukai Toyotetsu Indiana Corp. (FTIC) needed a 3,000-ton press foundation, 1,000-ton blanking line press foundation and 1,600-ton press foundation built concurrently, it chose Delta Industrial. Bringing in the additional manpower, materials, and equipment necessary to tackle the simultaneous projects, Delta worked a 24/7 schedule to maintain the aggressive schedule and completed it on time and on budget.

Whether a manufacturer needs a turnkey installation or help refurbishing an existing foundation, preparation and spending time to consider important details is crucial before construction begins. Delta advises companies to consider equipment type, applications the new machine will be used for, where it will be located, the processes to be used for removing the existing concrete floor, and how construction processes will impact plant flow and production, among other variables.

Delta provides companies with a road map that helps them navigate a process that can be full of pitfalls. FFJ

Sources

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Company Profiles

AIR FILTRATION

IRONWORKERS

NESTING SOFTWARE

SERVICE CENTERS

Camfil APC - Equipment Trilogy Machinery Inc. Metamation Inc. Admiral Steel
Camfil APC - Replacement Filters

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Alliance Steel
Donaldson Company Inc. AMADA AMERICA, INC. Messer Cutting Systems Inc.

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Mazak Optonics Corp.

PLATE

Enmark Systems Inc.
MetalForming Inc. MC Machinery Systems Inc. Peddinghaus Lantek Systems Inc.
RAS Systems LLC Murata Machinery, USA, Inc.

PLATE & ANGLE ROLLS

SecturaSOFT

BEVELING

TRUMPF Inc. Davi Inc. SigmaTEK Systems LLC
Steelmax Tools LLC

LINEAR POSITION SENSORS

Trilogy Machinery Inc. Striker Systems

COIL PROCESSING

MTS Sensors

PRESS BRAKE TOOLING

STAMPING/PRESSES

Bradbury Group

MATERIAL HANDLING

Mate Precision Tooling AIDA-America Corp.
Burghardt + Schmidt Group EMH Crane Rolleri USA Nidec Press & Automation
Butech Bliss Fehr Warehouse Solutions Inc.

PRESS BRAKES

STEEL

Red Bud Industries UFP Industrial AMADA AMERICA, INC. Alliance Steel
Tishken

MEASUREMENT & QUALITY CONTROL

Automec Inc.

TUBE & PIPE

CONVEYOR SYSTEMS

Advanced Gauging Technologies MC Machinery Systems Inc. BLM Group
Mayfran International

METAL FABRICATION MACHINERY

SafanDarley HGG Profiling Equipment Inc.

DEBURRING/FINISHING

Cincinnati Inc.

PUNCHING

Prudential Stainless & Alloys
ATI Industrial Automation LVD Strippit Hougen Manufacturing

WATERJET

Lissmac Corp. Scotchman Industries Inc.

SAWING

Barton International
Osborn Trilogy Machinery Inc. Behringer Saws Inc. Jet Edge Waterjet Systems
SuperMax Tools

METAL FORMING

Cosen Saws Omax Corp.
Timesavers FAGOR Arrasate USA Inc. DoALL Sawing

WELDING

HYDRAULIC PRESSES

MetalForming Inc. HE&M Saw American Weldquip
Beckwood Press Co.

MICROFINISHING TOOLS

Savage Saws Strong Hand Tools
Triform Titan Tool Supply Inc.

 

T. J. Snow Company

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