At HawkeyePedershaab we deliver more than machines. We deliver solutions.

The Americas506 S. Wapello StreetMediapolis, Iowa 52637 USAPhone: +1 (319) 394-3197Telefax +1 (319) 394-3977

Africa, Asia, Australia, Oceania, EuropeSaltumvej 259700 Bronderslev – DenmarkPhone: +45 9645 4000Telefax: +45 9645 4040

info@hawkeyepedershaab.comwww.hawkeyepedershaab.com

Spec ia l i zed base p roduc t i on made s imp le .S M A R T C A S T

Smartcast shatters the mold of the old ways and introduces a new era in monolithic manhole base production. More than

just a machine, Smartcast embodies a concept, a whole-plant forming and production system for the

production of wet-cast base sections with an infinite number of channel possibilities.

The Smartcast system mills channel-forming molds out of a single piece of industry-standard

EPS (Expanded Polystrene) with a program-mable industrial robot. There’s no need to tape, glue, or use proprietary-shaped foam sections. A user-friendly PC-Human inter-face is used to create the world’s easiest system for manufacturing monolithic bases of the highest-quality.

Smartcast form equipment can be used as a simple, stand-alone forming system or

integrated into an automated production system featuring robotic filling, demolding,

and handling. Smartcast forming equipment is available for manufacturing manhole bases up

to 1500mm (60”) diameter.System Benefits

Software. Innovative, web-based software allows base sections to be designed from anywhere – the office, the job site, and even from home.

Infinite flow channel possibilities. With Smartcast software and an integrated six-axis computer-controlled robot, flow channel configurations are virtually unlimited.

Smooth flow channel surfaces. Specialized tooling and an optional sprayer allows the EPS to be shaped with an incredibly smooth casting surface – resulting in flow channels with glass-like finishes.

Quick and easy set-up. A single piece EPS former is simply fixed to the permanent steel mold top. No hot-wire cutting, gluing, or taping is required.

Locally available EPS. The Smartcast system utilizes EPS blanks available from competitive sources. There’s no requirement to pur-chase formed EPS components solely from the equipment supplier.

System Components and FeaturesFor maximum performance, every element of the Smartcast system has been designed with a purpose - to interact seamlessly and flawlessly in the production of high-quality bases. From engineering the EPS former, casting the product, and removing the finished product, no aspect of production has been overlooked.

Design SoftwareUsing the intuitive Smartcast Designer software, the base is designed by inputting key variables, including the number of inlets, the diameter of the inlets, the height of the inlets, the amount of fall in the flow channel, the type of connections, the angle of the banquette, etc. It’s all done with a user-friendly, cloud-based interface that can be run as a stand-alone system or

Coating ApplicationAfter milling, a smoothing agent is applied to the surface of the milled EPS channel formers. This coating hardens into an ex-tremely smooth casting surface to form flow

Milling RobotA multi-axis, high-speed KUKA robot equipped with a precision grinding head mills expanded polystyrene (EPS) “pucks” quickly, precisely and efficiently into a reverse-mold of the base flow channels. Depending on the size of the base and the

integrated into existing manhole design software. Web-based, Smartcast Designer software allows bases to be designed from any computer station, including the job site or from home. After the base has been designed, a full manufacturing drawing can be emailed to the end user for final approval. After approval, the base design is automatically placed into queue at the Smartcast’s robotic milling center.

channels with a glass-like finish. The hard-ened shell also makes possible the removal of the EPS former from the hardened bases in a single piece to allow reuse.

configuration of its flow channels, the robot is able to mill up to 5 EPS core tops per hour. The robot runs without supervision and is extremely reliable. Also included is a suction/bagging system that accumu-lates the milled EPS so that residue can be returned to the EPS supplier for recycling.

High-Performance MoldsSpecialized wet-cast molds with split, roll-back jackets allow for easy placement of the EPS core tops and permit clearance for a manipulator to grip and remove the

hardened product from the mold. The mold features a special rigid core that retracts to break the bond of the hardened manhole base for quick and streamlined demolding.

EPS Extraction/Compacting System:For quick removal of the EPS formers, a special tool removes the side cores that form the inlet and outlet connections, and a vacuum removal device lifts the main EPS channel former in a single piece from the hardened base. Any excess EPS can be compressed 50:1 into small blocks with an available compaction device.

The compressed blocks can be palletized and discarded in a number of ways to reduce waste.

The Smartcast components can be set up as a traditional wet-cast operation with the molds stationed on the floor and filled with a conventional bucket; or the components can be integrated with a robotic feeding/handling system for fully automatic production.