When you have several customers knocking at your door with a thousand count order of different-sized anchor bolts, you better be sure you have everything covered down to the nuts and bolts. At Madden Bolt, we’re continuously finding ways to be faster, safer, and better so we can rise to the occasion when engineers, designers, and all of our other customers need us the most.
So what’s the secret to staying ahead in the steel industry? At Madden Bolt, much goes into becoming the best at what we do. Just recently, we debuted a one-piece flow program that uses a highly customized version of an assembly line to get products out the door faster and safer. Though this is one of the more notable parts of our continuous improvement program, we cannot neglect one tangible operational component that has allowed us to deliver on a wide variety of bolting specifications for customers over many years:
Madden Bolt Bending Machines: All Sizes. All Radiuses.
Madden Bolt has sustained growth despite the instability of the US steel market primarily due to two key advantages: our ability to consistently meet tight timeframes for customers, and our ability to deliver on customized bolting specs for a variety of applications in the energy, transportation, telecommunications, and petrochemical industries.
Our orders range anywhere from fifty ½” through 2-1/4” L Bolts used on commercial buildings, roadways for illumination and traffic signal poles, and cell towers all the way up to 1500 anchor bolts, U Bolts, and L Bolts of 30 to 40 different sizes for petrochemical and power plant construction.
Customers know they can come to us for anchor bolts of all sizes and radiuses and still get it done faster, thanks to our most prized possessions: our six in-house bending machines.
Here’s what they do.
Manual Bending Machines
Madden Bolt receives a wide range of orders for flat bar, round bar, and rebar, but a majority of what we bend are round bar for u-bolts, anchor bolts, and eyebolts. Our machines will even link the tail and bolt together to fabricate an eyebolt.
Madden Bolt’s hand-operated bending machines can be set up in different ways to accommodate different specs that are requested by engineers, designers, and general contractors from various industries. These machines are used to bend bars as small as ¼ inch to ¾ inch. Our fabricator bends one end of the bar around a center pin using a movable arm and the bending process is completed in the matter of seconds.
To optimize our process, our in-house bending machine experts have implemented established proprietary processes to produce the highest quality bend for almost any measurement or dimension.
At times, a customer will call in a special bend order request like v-bolts for use on telecom towers. When we receive customized requests like this, Madden Bolt is able to meet those requests about 99.9% of the time by employing different bending machines for different materials. For example, although 90 degrees is the typical radius requested for an L-Bolt, we can fabricate tighter, sharper radiuses by applying heat to the material.
Pedrick Machines (Small to Large)
We have three different-sized Pedrick machines that allow Madden Bolt to fabricate a wide variety of bolt sizes for customers. The automation that these machines provide reduces the probability of human error in the bend. As part of our commitment to quality control standards, we set up the die for a specific radius that has been ordered and will run a test piece. We’ll also use a gauge to ensure the radius is produced accurately.
How our machines work
All of our machines are designed with a stop-reverse mechanism. The fabricator will set the reverse mechanism at the correct position to ensure the bending process will stop automatically at the correct radius. The vice pushes the material against the die and the roller on the arm forces the material around the die until it hits the stopping point (usually around 90 degrees or so). Once the arm hits the stopping point, the roller will reverse to ensure it doesn’t hit the other end of the machine and cause a safety hazard.
All of our Pedrick machines can be set up from right to left or left to right for operator ease. Madden Bolt fabricators can even add parts to the machines to get closer, tighter tolerances to meet customers’ unique requirements.
For special bend requests that may entail a 12-inch die, Madden Bolt’s fabrication facility carries a plate burner on site to fabricate center pins of different sizes. While other fabricators have to wait on an order for a special die size, we can cut it right here on site and prevent delays in the fulfillment process.
D10 Pedrick Machine
As our powerhouse bender, Madden Bolt’s largest Pedrick machine will bend 1 inch to 3 ½ inch bars (and even 4-inch bars for truly unique orders). This machine is used mostly to bend large solid bar stock for anchor bolts and U-bolts. It is ideal for wider radiuses that yield increased strength.
A3 and A6 Pedrick Machines:
Madden Bolt has two smaller Pedrick Machines for smaller diameter bars. Our smallest machine, the A3, can bend a ½ inch diameter up to a 1 ¼ diameter. It produces 9,000 IN pounds of bending moment.
Our slightly bigger Pedrick machine, the A6, can bend ½ inch to 1 ¾ inch which produces 25,000 inch-pounds of bending moment.
All of the Pedrick machines are rotary head compression benders that are driven with a mechanical drive. While our bending machines and new operational processes give Madden Bolt an edge on speed and versatility, it is our entire operational approach, quality standards, and local US presence that keeps us competitive in this ever-changing steel market.
⇒ Experience the Madden Bolt difference for yourself. Call today.