Hanley Plant Hanley Plant LOCATION: LOCATION: Route 28 Route 28 Summerville, Jefferson Summerville, Jefferson County, PA County, PA (approx. 80 miles NE of (approx. 80 miles NE of Pittsburgh) Pittsburgh) Plant Manager: Plant Manager: Terry Bullers Terry Bullers General Manager: General Manager: Phil Raub Phil Raub Distribution Manager: Distribution Manager: Craig Wonderling Craig Wonderling Hanley Hanley Plant Plant
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Hanley Plant LOCATION: Route 28 Summerville, Jefferson County, PA (approx. 80 miles NE of Pittsburgh) Plant Manager: Terry Bullers General Manager: Phil.
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Hanley PlantHanley Plant
LOCATION:LOCATION:
Route 28Route 28
Summerville, Jefferson County, PASummerville, Jefferson County, PA(approx. 80 miles NE of Pittsburgh)(approx. 80 miles NE of Pittsburgh)
General Manager:General Manager:Phil RaubPhil Raub
Distribution Manager:Distribution Manager:Craig WonderlingCraig Wonderling
Hanley Hanley PlantPlant
HistoryHistory• The original Hanley plant was built in 1893 in Bradford, PA, and ran until The original Hanley plant was built in 1893 in Bradford, PA, and ran until
1983, when it was sold to an unknown buyer.1983, when it was sold to an unknown buyer.
• The Hanley Plant in Summerville was builtThe Hanley Plant in Summerville was builtin 1925.in 1925.
• Hanley Plant was built by Lee Hanley,Hanley Plant was built by Lee Hanley,brickmaker and celebrated tunnel kiln designer.brickmaker and celebrated tunnel kiln designer.Considered “visionary” in his approach to brick-Considered “visionary” in his approach to brick-making, Hanley was also famous for building notoriously quirky kilns. making, Hanley was also famous for building notoriously quirky kilns.
• The two Hanley kilns present at the timeThe two Hanley kilns present at the timeof our purchase were the last Hanleyof our purchase were the last Hanleytunnel kilns in the world. They were builttunnel kilns in the world. They were builtaround 1960 and razed for thearound 1960 and razed for theModernization project that began inModernization project that began inthe fall of 2001.the fall of 2001.
Hanley Hanley PlantPlant
Hanley ModernizationHanley Modernization
$18 million upgrade$18 million upgrade
• Improve availabilityImprove availability• Improve product qualityImprove product quality• Broaden range of product Broaden range of product offeringsofferings
REASON FOR UPGRADEREASON FOR UPGRADE
Hanley Hanley PlantPlant
Hanley ModernizationHanley Modernization
• AVAILABILITYAVAILABILITY
– – the plant’s capacity is increased 32% fromthe plant’s capacity is increased 32% from 35 million (former) units to 50 million (new) 35 million (former) units to 50 million (new)
SpecificallySpecifically . . . . . .
• QUALITYQUALITY
– – consistent color, tighter color ranges consistent color, tighter color ranges (3 vs. 5 shades)(3 vs. 5 shades)
– products conform consistently to FBX specs– products conform consistently to FBX specs
• SELECTIONSELECTION
– – addition of flashed brick addition of flashed brick (vs. clearburn only)(vs. clearburn only)
Hanley ModernizationHanley Modernization$18 million upgrade began in Nov. 2001 and was completed – on time $18 million upgrade began in Nov. 2001 and was completed – on time and within budget – in 18 monthsand within budget – in 18 months
• 1 280 ft. Ceric, air-tight tunnel kiln and attached dryer (total length 503 ft.) 1 280 ft. Ceric, air-tight tunnel kiln and attached dryer (total length 503 ft.) replace 2 old Hanley kilnsreplace 2 old Hanley kilns
• Robotic dehacker (new to Hanley – carousel in use prior)Robotic dehacker (new to Hanley – carousel in use prior)
• New robotic setting equipmentNew robotic setting equipment
6.6. The Thomas Brick Co.The Thomas Brick Co.(Cleveland, OH)(Cleveland, OH) 1,151,9531,151,953
Top customers / brick shipmentsTop customers / brick shipments
Hanley Hanley PlantPlant
Hanley Product OverviewHanley Product Overview
First and most importantly . . . First and most importantly . . . ALLALL Hanley brick is Hanley brick is FBXFBX..
FBX brick conforms to a “higher degree of precision and FBX brick conforms to a “higher degree of precision and lower permissible variation in size than permitted forlower permissible variation in size than permitted forType FBS (general use masonry).” Type FBS (general use masonry).” Cf. ASTM C216-99Cf. ASTM C216-99
Basically, that means a superior, Basically, that means a superior, precision-smooth face (and not precision-smooth face (and not necessarily the edge!) that shows little necessarily the edge!) that shows little or no chips, bumps or cracks. Hanley or no chips, bumps or cracks. Hanley attributes the quality of its FBX brick to attributes the quality of its FBX brick to find grind that they use on their raw find grind that they use on their raw materials.materials.
Hanley Hanley PlantPlant
Tawny Beige – S32
Dolomite Grey – S181
Smoky Quartz – S72
Hanley Hanley PlantPlant
Example of Hanley shape that conforms to Example of Hanley shape that conforms to FBXFBX standards. standards.
Hanley Hanley PlantPlant
Hanley’s 6 Price List ProductsHanley’s 6 Price List Products
• Engobe Engobe (aka “claycoat”)(aka “claycoat”)
• MattMatt• Coarse Coarse (Canyon Series exclusively)(Canyon Series exclusively)
Hanley also makes:Hanley also makes:-- “Stylo,” aka 8-square, in certain textures . . . but it is not a Price List item-- “Stylo,” aka 8-square, in certain textures . . . but it is not a Price List item-- Complete assortment of shapes to complement product line-- Complete assortment of shapes to complement product line
Hanley Hanley PlantPlant
• GlazedGlazed• Wire cutWire cut• SmoothSmooth
Hanley’s Product Line OverviewHanley’s Product Line Overview
• GlazedGlazed• EngobeEngobe• SmoothSmooth
PRODUCTS:PRODUCTS:
• TuscanTuscan (smooth face brick)(smooth face brick)• CanyonCanyon (coarse face brick)(coarse face brick)
SERIES:SERIES:
STOCK SIZES:STOCK SIZES:thickness x height x lengththickness x height x length
Note: All of Hanley’s 6 Price List products are made in the above sizes.Note: All of Hanley’s 6 Price List products are made in the above sizes.
The plant also makes a “jumbo norman” (3-5/8 x 2-3/4 x 11-5/8), The plant also makes a “jumbo norman” (3-5/8 x 2-3/4 x 11-5/8), but it is only as a special order.but it is only as a special order.
Hanley Hanley PlantPlant
• MattMatt• Wire CutWire Cut• CoarseCoarse
• ModularModular 3-5/8 x 2-1/4 x 7-5/83-5/8 x 2-1/4 x 7-5/8• JumboJumbo 3-5/8 x 2-3/4 x 83-5/8 x 2-3/4 x 8• EconoEcono 3-5/8 x 3-5/8 x 7-5/83-5/8 x 3-5/8 x 7-5/8• UtilityUtility 3-5/8 x 3-5/8 x 11-5/83-5/8 x 3-5/8 x 11-5/8 • NormanNorman 3-5/8 x 2-1/4 x 11-5/83-5/8 x 2-1/4 x 11-5/8
Spice White Blue Grey Black
Maroon Evergreen Bermuda Blue
Spice WhiteOyster White/
Speck White/Speck
Current stock glazed colors. Hanley also makes Current stock glazed colors. Hanley also makes custom colors.custom colors.
GlazedGlazed
Glazed brick are extruded brick to Glazed brick are extruded brick to which a non-permeable, smooth which a non-permeable, smooth coating has been applied.coating has been applied.
EngobeEngobe
Engobe brick are extruded brick to Engobe brick are extruded brick to which a water vapor-permeable, which a water vapor-permeable, coating has been applied.coating has been applied.
The manufacturing process for both The manufacturing process for both glazed and engobe brick is the glazed and engobe brick is the same: A coating is sprayed on the same: A coating is sprayed on the green column of clay on the green column of clay on the extrusion line. The coating is dry to extrusion line. The coating is dry to the touch by the time it gets to the the touch by the time it gets to the setting stage. setting stage.
Hanley’s face brick products are all Hanley’s face brick products are all extruded and, at this time, all clay-based extruded and, at this time, all clay-based materials.materials.
At left is an example of “Smoky Quartz” (72) in At left is an example of “Smoky Quartz” (72) in smooth texture (top) and wire cut texture smooth texture (top) and wire cut texture (bottom).(bottom).
*Rome Grey (utility) is the brick used on the *Rome Grey (utility) is the brick used on the outside of the new kiln. It serves only a cosmetic outside of the new kiln. It serves only a cosmetic
purpose and offers little insulating value.purpose and offers little insulating value.
Hanley Hanley PlantPlant
HanleyHanleyProduct DevelopmentProduct Development
PlannedPlanned for 2003, is the for 2003, is the introduction of Hanley introduction of Hanley RedRed (S/W15), a 100% shale,(S/W15), a 100% shale,authentic red brick.authentic red brick.
Hanley Hanley PlantPlant
Interesting Facts . . .Interesting Facts . . .
• New kiln normal operating temperature is 2100 – 2200New kiln normal operating temperature is 2100 – 2200°°FF
• Kiln-dryer combo holds 45 cars (1 car in pre-dryer stage,Kiln-dryer combo holds 45 cars (1 car in pre-dryer stage, 17 cars in dryer, 27 cars in kiln) 17 cars in dryer, 27 cars in kiln)
• New kiln cars hold about 5,200 modular size brick.New kiln cars hold about 5,200 modular size brick. Old cars, about 2,000 Old cars, about 2,000
• New kiln cars measure 10 ft x 15 ft. wide. Old cars, 61 inchesNew kiln cars measure 10 ft x 15 ft. wide. Old cars, 61 inches wide x 9 ft. long wide x 9 ft. long
• New kiln push rate is 54 min. Old kiln rate was 36 min.New kiln push rate is 54 min. Old kiln rate was 36 min. Push rate refers to the amount of time it takes to move a carPush rate refers to the amount of time it takes to move a car one car length. Basically, a car is removed every 54 min. one car length. Basically, a car is removed every 54 min.
• “ “Firing curves” from the old kiln are programmed into the newFiring curves” from the old kiln are programmed into the new kiln to minimize the adjustment time needed to zero in those kiln to minimize the adjustment time needed to zero in those temperatures that produce the desired effect. “Firing curves” temperatures that produce the desired effect. “Firing curves” refer to those temperatures for individual products known to refer to those temperatures for individual products known to produce quality brick. produce quality brick.
• “ “Pre-dryer” stage is where moisture content is reduced to,Pre-dryer” stage is where moisture content is reduced to, normally, below ½% in brick. It’s important to take out as normally, below ½% in brick. It’s important to take out as much moisture prior to entering the higher temperatures. much moisture prior to entering the higher temperatures. Excess moisture can vaporize and explode brick. Excess moisture can vaporize and explode brick.
““Deck blocks” Deck blocks” on kiln caron kiln car