Con Cast Pipe provides both drycast and wetcast produced precast concrete products to the marketplace. Our drycast capabilities include pipe from 300mm to 3600mm diameter; 1200mm to 3000mm diameter maintenance holes; various catch basins; box units up to 3000mm spans; and elliptical pipe from 900mm to 1950mm equivalent. Our wetcast capabilities include a variety of box sizes; the CON/SPAN System; tunnel segments; and valve chambers. Our Guelph operation utilizes numerous assets within its 120,000 square foot drycast facility and 30,000 square foot wetcast facility to produce these products.

In the requirement to reinforce concrete for applied loads, there are two different reinforcing materials used. Wire mesh is used to reinforce a large majority of the concrete products. Wire mesh rollers and/or benders are used to shape the wire mesh mats in order to fit the product formwork. Wire mesh mats range in an assortment of grid layouts, as well as various wire gauges. Wire mesh mats are supplied to Con Cast Pipe by outside suppliers.

For circular products like pipe and maintenance holes, the MbK Cage Machine is able to turn and induction weld a circular or elliptical wire cage from a single length of wire. Product geometry (round or oval), wire spacing, wire diameter, and length spacing are all programmed into the MbK Cage Machine to produce the final product. A resident wire draw machine is also used to produce straight wire cut lengths to compliment the cage operation.

In the need to meet higher reinforcing requirements, steel rebar ranging from 10m to 25m is used. The steel rebar includes the use of both black or epoxy bars. Individual bars are cut to length and bent to shape. Welders use jig assemblies to arrange the bars for welding purposes into a rebar cage which is then transported to the formwork.

Products are manufactured in formwork through drycast or wetcast processes. Drycast allows multiple turns (or repetition of pours) off the same formwork; machines used are Pipe Plus and VUP Hawkeye equipment. Wetcast uses a more fluid concrete mix that must be cured in the formwork and stripped the next day. Sectional modular formwork is used in the wetcast process which permits infinite combinations of length and width.

Concrete is available to each process from two batching facilities located at the plant; there is a turbine mixer and a cross current mixer. These concrete mixers have a capability of producing an excess of 1,300 tonnes per day. Overhead and shuttle lift cranes are used to maneuver product around the plant floor and into Hawkeye kilns for curing. Forklifts are used to empty product out of the kilns and yard this product to inventory. For excessively large and/or heavy products, a mobile gantry crane is used to yard product.

The NPC Coring Machine is used to core holes into the walls of blank maintenance holes to allow for pipe connections into the structure. Core hole diameters can range from 100mm to 1500mm.

This is only a summary of the equipment Con Cast Pipe utilizes each day to produce just about any configuration of precast concrete product. We combine our equipment with leading edge information and logistics systems to produce and deliver the highest quality product possible for our Customers when they want them. We are ready and able to meet your challenge!

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