Form Functio n NEWS & INFORMATION FROM HAM+ILTON FORM FALL 2014

Project Profile Kyle Field at A&M Heldenfels Enterprises

Steeped in tradition, home to the and known The $450 million redevelopment is being done in two phases. for its raucous fans - renovating an iconic such The first phase began in November of 2013. It consisted of as Kyle Field can be a daunting task, but has replacing the entire lower east side deck, including lowering done their fair share of iconic designs, and this one is no it seven feet to bring the fans closer to the field, and the exception. The overall vision is to enhance the game day building of a new south end zone. experience by adding more public areas, plazas and gather- ing spaces. Fans will have more seating options including After a break in construction to play the 2014 season, suites, loge seating and an exclusive club area. Seats placed phase two will begin after the Aggies play their last home close to the field and a canopy over the seating areas will game in November. Phase two consists of replacing the not only provide shade from the hot sun, but will help entire west side of the stadium and will be completed in contain the noise level, keeping Kyle Field one of the August of 2015. When completed, the stadium will grow most intimidating for visitors. from 82,600 to a seating capacity of 102,512, with 12 seats reserved and kept empty in memory of the Aggies lost in the bonfire tragedy of 1999.

The subcontractor for the structural precast is Heldenfels Enterprises, Inc. in San Marcos, Texas.The project was especially significant for Heldenfels, not only because of its size, but because several employees are former Texas A&M students, including owners Fred and Gil Heldenfels and VP & Chief Estimator Kurt Schriefer. (continued inside)

“The Kyle Field Redevelopment project presented a demand- ing schedule as well as some unique design challenges. In typical Hamilton Form fashion, they were responsive to our needs and quickly improvised solutions that helped us stay on schedule.” – Fred Heldenfels, President and COO Project Profile

Kyle Field at Texas A&M, continued

The project calls for more than 2,400 precast pieces. H amilton Form worked closely with Heldenfels to identify the number of forms needed for the project, and which forms could be multi-purposed to cast several products. The between season construction schedules made timing critical.

The majority of the forms are double risers, with some tub forms. Due to the number of unique riser configurations, multiple forms were needed. Most of the forms are 55 feet in length, longer than typical stadia forms. The tub form for the loge box seating was notably unique. The overall form was 56’-1” long with a 5’-9” deck that pushed the overall form width to 12’-2 ”, This two tier tub form is 52’-8” long and has a 5’-9” deck that pushed the making it one of the largest stadia forms Hamilton Form has overall width of the form to 12’-2”, one of largest stadia forms ever shipped ever shipped. from Hamilton Form.

56’ double riser stadia form Double stadia riser with 12” stems and deck strand in the lower tread

Adjustable Stadia Form for McLane Stadium

To cast the stadium, Hamilton Form developed a single, highly adjustable double stadia riser form. The package included several risers, fillers and two different back pans. Heldenfels produced approximately 185,000 feet of risers for the stadium; including single and double risers, in the same form. Formwork

Baylor Bears – McLane Stadium Heldenfels Scores another Texas Stadium

Wh ile many college stadiums are expanding to capacities of 100,000 and more, Baylor University’s new stadium in Waco, Texas seats 45,000; 5,000 less than the old stadium built in 1950.

The new stadium is on 93 acres with a pedestrian bridge connecting it to the campus. The site on the Brazos River includes boat slips for “sailgating” around the stadium. The stadium has a canopy to provide shade from the Texas sun and open concourses to allow for airflow throughout the stadium.

Heldenfels Enterprises secured the contract for the precast for the stadium. To produce the risers, Hamilton Form developed an approach that allowed Heldenfels to cast all of the risers in a single, highly adjustable form. The form - work included several fillers, risers and two different back pans. In all, ten different products were cast in the same base form; including both double and single risers. Technically Speaking

Last Issue we discussed detensioning strand and its effects on the concrete product, and the form. To complement that Pretensioning Self-Stressing Forms discussion, this article discusses pretensioning.

Know your limits Allow for movement Self-stressing forms are designed to resist both the hydrostatic forces Proper installation requires the form to be anchored at centerline of concrete and the compressive forces applied to the form by with the remainder of the form clipped down with slide connections prestressing. Longitudinal stiffeners, the form skin, and in some to resist uplift. This is critical because as the strands are tensioned, circumstances compression bars, are used to resist the prestressing the compressive force from prestressing causes the form to shorten. forces when designing a self-stressing form. The size, location, and When the form shortens, it must be allowed to move longitudinally. number of stiffeners and compression members are determined The center of the form should be anchored so that it shortens in both based on the amount of prestress force the form is designed directions instead of allowing it to “walk” or move in one direction. to resist. If the entire form is anchored or welded in place, movement will be At the end of the bed, a jacking plate bears against the end of the restricted. This can cause the form to buckle under load, damaging form. Holes drilled through the jacking plate allow strand to pass the form and creating a dangerous situation. through. The jacking end of the form is stiffened since this is where the prestress load is introduced. Our engineers design forms based on Measure the movement the amount and placement of prestressing force as specified by the When pretensioning, it is important to measure the amount of form customer. The first rule in pretensioning is: Never Exceed the Capacity movement in order to properly calculate strand elongation. Put a of the Form. reference mark on something stationary at the end of the form in an unloaded condition. After you fully tension, measure the difference Balance the load between the reference mark and the end of the form. Record the When prestressing, it is critical to balance the prestressing load being movement, and do it every time you tension until the plant is satisfied applied to the form. This helps protect your form from eccentric load - that the maximum movement by strand pattern is understood. ing that can cause serious form damage. First, make sure the jacking Checking form movement on a periodic basis will help to ensure plate is evenly bearing against the form, then balance the load being that form movement is always being used in stressing calculations. applied to the form by paying attention to the following: Keep a log book with form movement history to help you understand variables such as strand patterns, temperature, bed set-up and other • Ease the form into tension by symmetrically loading the form. factors that affect shortening. Move from side to side and up and down so that the load is being evenly applied. Form shortening is not something that can be predicted with a formula. The type of form, conditions and your processes are unique. The only • In general, you should tension the lower strands first, then way to know how much movement is taking place is to measure it. move upward in an ascending pattern. Keep up with maintenance • When tensioning a double tee, tension a few strand in one stem, Finally, you should regularly inspect the form connections and anchor then move to the other stem, tensioning this stem with the same bolts. Make sure connections are clean and free of any concrete designated number of strand. Moving side to side in an upward build-up. Check the form level. Make sure shims are still in place, manner will ease the form into full loading and also allow for free if not, replace them. movement of the form as tensioning is completed.

• When tensioning a dual, triple or quad pile form, use the same logic as a double tee. Partially tension one side, then, move side to Stay safe side and upward to reach full loading. As you know, strand tensioning activities are very dangerous. • If you need to cast only one side of a dual cavity piling form, A tremendous amount of force is placed on each strand and you may need to partially stress the side not being used to help in turn high stresses are induced to the strand. If a strand balance the loading on the form. fails, the failure is instantaneous and can cause damage and great bodily harm. • If you have a triple pile form and need to pour only one cavity, use the center cavity not one of the side cavities so that you do Tensioning strand requires strict safety procedures to keep not eccentrically load your form. workers out of the line of strand during tensioning. Make sure all equipment is properly functioning and safety alarms, • Never pour one side of a dual form and not the other without signage and flaggers are properly positioned. paying proper attention to how the form is being stressed. Product News

Vibrotrack

H amilton Form designs many of its forms with our Vibrotrack Double Tee forms typically have Vibrotrack installed on both sides Vibration System ™. The Vibrotrack System consists of continuous of the form. Girder sideforms and other tall forms are typically track sections welded to the form and a vibrator mounted on a designed with Vibrotrack placed low on one side of the form and steel base that rides along the track. The base is fitted with an high on the other. Flat casting tables are usually built with two air-loc air pad diaphragm. A hose whip connects to the air loc or three tracks, depending on the width of the table, welded to pad, the vibrator and compressed air. When compressed air is the underside. turned on, the pad inflates, locking the bracket in place, and simultaneously, starting the vibrator. The vibrator and base can Vibrotrack can be added to existing forms. We supply the track be moved manually or by a winch system. This system has proven sections that can be welded to your existing form and the bracket, to deliver efficient and effective concrete consolidation. vibrator and hose whip to complete the package.

See our web site: www.hamiltonform.com for complete details or call 1-817-590-2111.

Employee Profile Loi Doan Lead Man – Equipment

Hamilton Form builds custom equipment Oklahoma. There he and several other teen including tarp carts, utility machines, stress- boys lived with the parish priest and attended ing equipment, vibration products and form high school. After graduation he made a cleaner machines. Those are the products living as a contractor, eventually making lead man Loi Doan is responsible for. his way to Texas and settling in Fort Worth. Loi has been with Hamilton Form since 1996. If you have one of our tarp rollers, utility machines, form cleaner machines, or if you Today Loi is married and has four children use our stressing equipment, Loi has had who are 17, 15, 13 and 10 years old. When a hand in getting those products to you. he has free time, he enjoys putting his contractor skills to work by taking on home Loi is a refugee from Vietnam. He left improvement projects around the house. home, alone, at age 16, to make his way But, with four children - three of them to the USA seeking freedom and political teenagers - free time is pretty hard to come asylum. His first stop was Malaysia. He was by. We’re glad Loi made his way to Fort Worth then transferred to a refugee camp in the and made his way to Hamilton Form where Philippines along with thousands of other we keep him busy too, supervising the refugees. He was eventually sponsored by, fabrication and testing of our plant and sent to, a Catholic Church in Lawton, production equipment. Hamilton Form Company, Ltd 7009 Midway Road • Fort Worth, Texas 76118 Ph 817.590.2111 • Fx 817.595.1110 www.hamiltonform.com

Industry Recognition Titan of the Industry

Hamilton Form Company President, William F. Daily was by developing named a “Titan of the Industry” at the 2014 Precast/Prestressed forming details Concrete Institute’s (PCI) Convention held in September in that carefully Washington D.C. PCI Titans of the Industry are an esteemed aligned sections group of dedicated professionals who have had a profound of long line forms, effect on the industry over a long period of time. In 2004, distributing the fifty Titans were named. This year, in honor of PCI’s 60th prestressed force Anniversary, eight more Titans, including Mr. Daily, across the entire were named by the Institute. form cross section. This innovation Mr. Daily has been the President of Hamilton Form Company and Bill's leadership has given his firm the for over 40 years. Originally a plant manager at Schokbeton in capability of moving the prestressed industry forward.” Kalamazoo, Michigan; Bill became president of Hamilton Form in 1972. His unique perspective as a precast producer and his Upon news of the award, Mr. Daily noted; “From the time problem solving skills has led to innovations that have saved I was introduced to precast concrete while working on my time and money for Hamilton Form customers. Mr. Daily’s engineering degree at Purdue University, I have been intrigued nomination reads, “Few suppliers have had the impact on by the potential of the material. I am both honored and the precast/prestressed concrete industry as Hamilton Form. humbled by this recognition from the industry.” Bill pioneered the use of the "stress against form concept"