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ROBAR INDUSTRIES LTD.
is Canada’s lowest cost source of logging fittings. These fittings are currently exported to eight countries worldwide.
ROBAR continues to accept new distributors for its global sales.
ROBAR's main plant is a 50,000 sq. ft. facility employing 80 people in Surrey, BC, Canada, just 30 minutes from the Vancouver International Airport, the Port of Vancouver and the US border. To better serve the Eastern market,
LES PRODUITS INDUSTRIELS ROBAR INC. was opened in Boucherville (near Montreal), Quebec in 1994. This facility manufactures, assembles and stocks our full waterworks line. Both facilities handle standard waterworks products up to 24" in diameter. Through an association with Baker Coupling, a California-based company,
ROBAR offers special application couplings up to 216" (5.5m) in diameter and segmented products up to 408" (10.5m) in diameter.
ROBAR INDUSTRIES LTD. is a privately owned company which prides itself on quality, value and service. We are
dedicated to expanding our product, customer and distributor base worldwide.
HISTORY
ROBAR was founded in 1958 by Mr. Vern Barr who, with a partner, Alex Robertson, gave the new company its name Ro-Bar. Vern patented the first “all stainless steel” pipe repair clamp, now a standard in the industry.
Vern Barr purchased property at the present location on Anvil Way to build a small foundry and a manufacturing shop. Vern passed away shortly after completing the first building on the site. His wife, Mrs. Sheila Barr successfully operated
ROBAR until she retired in 1989.
At that time, ROBAR was purchased by the present owner, Mrs.
Michelle Charleston.
The Waterworks line includes Repair
Clamps, Couplings, Saddles,
Tapping Sleeves, Flange Coupling
Adapters, Restrainers, and many other products.
In addition to our location in Surrey, we opened
LES PRODUITS INDUSTRIELS ROBAR INC., a warehouse and fabrication/assembly plant in Boucherville, a suburb of Montreal, Quebec in 1994.
ROBAR is allied with Baker Coupling of California, to distribute and exclusively market their line of large fabricated steel Couplings, Expansion Joints and Flange Coupling Adapters, in Canada.
ROBAR employs around 80 people in Surrey and up to 20 more in Boucherville. In addition there are staff sales representatives in each area of Canada.
Over the last forty years, ROBAR’s Foundry has expanded to become one of the largest and most modern in British Columbia. Along the way
ROBAR has become a supplier of high quality castings for many other manufacturers.
At the same time, ROBAR has developed other cast product lines of its own, like
ROLOG logging fittings. ROLOG fittings include a variety of wire rope fittings used in conventional and helicopter logging. ROBAR operates what is called a “Green Sand Foundry”. The castings produced are created from an impression made by a pattern in a compacted sand medium.
We are also classed as a “High Production Foundry” specializing in the efficient manufacture of large numbers of relatively small castings. The operations of the foundry and manufacturing plant are briefly described on this page. At the beginning of each project, the Foundry Salesman in conjunction with the Methods Engineer discusses the requirements with the
customer and then they decide on the best way to make the casting.
Once the decisions have been made, a Pattern Maker (either an independent contractor or a
ROBAR tradesman) builds the equipment according to ROBAR’s specifications. When the new pattern equipment has been received, it goes into the foundry where initial trials and final production occurs. Patterns typically cost from $1000 to $10,000.
The casting process begins with patterns. ROBAR
has around 2000 patterns at any one time. Some patterns are owned by our customers while others are owned by
ROBAR. Patterns are used to create an “impression” in the molding sand. The impression will later be filled with molten metal. The pattern is the exact size and shape as the outside areas of the metal casting to be produced.
Some patterns produce single castings while others can create multiple castings from each molding cycle. Patterns are commonly made from wood, aluminum or plastics.
To create more complicated shapes, special details, holes or hollows in castings, foundries use cores. Cores are placed in the sand mold after the pattern impression is made. Cores are produced from bonded sand in special molds called “Core Boxes”. The pattern provides for the cores by having places for the cores built into the pattern. When the pattern is removed from the sand, it leaves indentations called “core prints”. When the cores are set into these places they are correctly positioned and supported.
ROBAR has equipment designed to produce castings with the maximum efficiency, highest quality and lowest unit cost. The next process in the production of iron, steel and brass castings begins with making the cores required for the job. Many castings do not require cores, but when cores are required, they must be made before the sand molds are made. The Molding Operator needs the cores ready at hand when he is making the molds.
Cores are made from bonded sand. There are several methods for doing this, each has certain advantages and disadvantages.
ROBAR has chosen just three systems for our operations.
The first is a “Pep-Set” process in which the silica sand grains are bonded when two resins (mixed together with the sand) “set” or harden over time. This process is also called a “Cold-Box” process since no external heat is required. The Pep-Set is mixed in the ‘Bepex” machine. This process is quite versatile, it’s good for small runs or large volumes.
Another type of cores is made in the “Shell-Core” process. It is a “Hot-Box” process. Cores in this process are made by mixing thermo-set (heat set) resins with sand and applying heat. They are made in iron core boxes. Core boxes are molds for the cores. The steel core boxes are heated with natural gas flames and the sand is injected into the box where it cures. This process is ideal for high production and detail work.
ROBAR is also using the “Ecolotek” system. It runs on a Shalco U-180 machine that
ROBAR has adapted for this purpose. It is another “Cold-Box” process that is both environmentally friendly as well as being suitable for high production. This process is good for high production runs or where fine detail is not required.
The sand molds are made by both automatic and jolt-squeeze machines. The molding sand is supplied to the machines by an overhead belt conveyor. Excess and spilled sand is removed by conveyors under the floor and returned to the “Sand Reclamation System”.
ROBAR has two fully automatic molding machines, the B&P 1620 (small) and the B&P 2026 (large).
The operator may need to place cores into the molds but otherwise, he monitors the machine and works at handling mold cars and distributing the completed molds. This is a high production process used for making large numbers of castings.
These machines use expensive aluminum matchplate patterns. The machine moves the pattern into the forming area and special flasks (boxes) close around it. Sand is then injected by air under high pressure. The sand is compacted around the pattern. The flasks are separated vertically by the machine and the finished mold is ejected. The whole process can take as little as 30 seconds. If cores are required a few seconds are added when the Molding Operator places the cores in position.
Two other machines are manual jolt-squeeze machines, the BMM CT-3 (small) and the BMM CT-5 (large)
The operators of these machines have a more active role. These machines do compact the sand, but moving mold flasks and placing sand is a manual operation. They are good for smaller production runs or for larger jobs with more detailed core work.
These machines can use less expensive patterns than the automatic machines. The operator makes a mold by indexing (exactly positioning) a molding box over the pattern. He places sand into the box (flask) by opening a chute above the mold and then uses the machine to compact the sand. The operator first makes the bottom half of a mold (Drag), then makes the top part (Cope). If cores are used, they are placed into the Drag, then the Cope is located onto the Drag and the mold is clamped together for pouring. The Cope is accurately registered onto the Drag by means of “Locating Pins”. The parts of the mold are clamped securely together to prevent molten metal from escaping when the mold is poured.
This process is slower than the automatic machines. It takes from 7-12 minutes on the CT-3 and up to 20-30 minutes on the CT-5 to make a mold.
As mentioned earlier, ROBAR uses a "Green Sand” process. The sand is not “green” but “black”. Green Sand is a foundry name for this type of sand. It is not dirty. It is basically silica sand that has some clay, a little water and some organic binders in it. The silica sand starts out white, but the binders (ordinary wood and cereal flour) “carbonize” or turn black when exposed to the molten metal during the pouring process. This gives the sand its distinct color and smell.
The molding sand is recycled through the Sand Reclamation System. The sand is cleaned and refreshed in this process. The final mixing and wetting preparation is in the Sand Muller.
The sand muller used is a Beardsley & Piper 85-B Speedmullor. It can deliver up to 2000 pounds of prepared sand in a minute. Current production rates require about 1600 pounds per minute. That’s equal to 3800 wheelbarrow loads per day. In
the future, demand will increase when an automatic mold handler is installed for the B&P 2026.
The molding sand is recycled and reused. In a typical day the whole system is rotated about once per shift (twice per shift before the new Sand Reclamation System was installed).
The sand grains are worn down in the process so
ROBAR currently purchases about 1200 tons of new sand each year. ROBAR uses Induction Furnaces to convert Steel Scrap, Pig Iron, Returns and alloying materials into any one of the 36 standard metallurgical materials.
ROBAR has five melting furnaces. They are all “Induction Furnaces”. They do not use flame heat or heat from an electric arc. Induction Furnaces use electrical energy to melt solid metal into its molten form at temperatures up to 1677 C (3050 F). The “Power Packs” behind the furnaces convert alternating current to direct current which is used to create an intense magnetic field inside the coils which surround each furnace. This magnetic field creates powerful “Eddy Currents” in the metal “charge” placed in the furnace and causes the metal to melt.
About 85% of all the electrical energy used by
ROBAR is consumed by the furnaces. This is equivalent to the power consumed by 500 average houses.
As the melt progresses, alloying materials are added in order to modify the metal’s chemistry. There are about 30 materials commonly specified for use in our “recipes” at
ROBAR.
In addition to carefully controlling the materials and conditions in the melting operation, extensive quality checks are made throughout the process.
ROBAR uses a “Baird” Spectrometer as well as other sophisticated instruments like “Electronite” Pyrometers and a “Leeds-Northrup” Digilab for these tests.
Three 1000 pound capacity furnaces are set up to melt Steel Alloys in batches. These are two Pillar Mark 8 furnaces and one Ajax Pacer LI.
Another two 4000 pound capacity furnaces are used to melt and hold Iron alloys. Both these furnaces are Pillar Mark 14’s. This metal is usually “tapped out”(poured) into 800 pound capacity ladles every twenty minutes.
When the molten metal has reached the right temperature and meets the required chemical and physical specifications, it is tapped into a pre-heated pouring ladle. Once the metal is tapped it immediately begins to cool.
After the castings cool, they are shaken out of the molds. The sand is recovered and recycled. Return Sand is conveyed through a series of magnets which removes all small castings, tramp metal and ferrous particles. The sand is then screened, cooled and transported to a pneumatic reclaimer which removes excess fine particles (sand and clay). Then, after a final screening, the sand is placed in a bin until needed at the Muller. The Finishing Room is where the castings are cleaned, ground and when required, heat treated. The castings are “finished” and readied for shipment.
The process begins at the “Shake-out” where the molding sand and hot castings are removed from the flasks (mold boxes). When the castings have solidified in the mold sufficiently to allow for handling, the molds are opened. Small castings can be shaken out as soon as 30 minutes after pouring. Larger castings must wait up to 4 hours in the mold. The castings are allowed to cool further and are then transported to the Finishing Room.
ROBAR uses a Pangborne 6LK-7 table-top shot-blast for large or fragile castings. For smaller and tougher castings, a Pangborne GT- 15 or a smaller 6GN3 Rotoblast machine is used. These machines tumble the casting load and effectively clean all the surfaces.
The “Runner” system (which is used to feed metal into the mold) and the “Risers” (which are used to compensate for “metal shrink”) are removed and
recycled into the melting process. The Cut-Off Machine Operator removes the Runner systems and Risers from castings by cutting through the metal, with high speed abrasive wheels. In some cases, Runner systems and Risers are removed by simply breaking them off when the metal is brittle cast iron. Where the metal is a tougher steel alloy we may use an Arc-Air process to do the same job.
After the Runners and the Risers have been removed, the castings are further processed to remove any excess material on the surface. This is done by manually chipping, grinding or sanding the casting.
ROBAR has Hand Grinding stations where large castings are cleaned by Operators with portable pneumatic and electric tools. Smaller castings may be cleaned by operators at the Pedestal Grinders or at the Belt Sanders. Some castings may be processed with little or no manual work by means of a Tumbler operation.
Layers of eye protection are required for operators in the Finishing Room. In addition, Finishing Room Operators must wear hearing protection, gloves and in some cases, leather aprons. Dust masks are worn to protect the Operators from grinding dusts.
Some metal alloys require Heat Treatment to achieve their maximum hardness, strength and wear resistance. These castings are raised to a high temperature in the Heat Treat Oven, then rapidly cooled either in Air, in a Water Quench or in an Oil Quench process.
The Annealing Oven has 4 burners (2,500,000 BTU’s) while the Heat Treat Oven has 6 burners (3,750,000 BTU’s). Together the ovens can provide heat
equivalent to the furnace output of about 65 average homes.
The castings to be Quenched (about 1500 pounds per load) are placed on the oven car which is placed into the oven. When the oven load is at about 1600 F (glowing red) the car is quickly withdrawn and the load is quenched in a 5000 gallon water bath.
WATERWORKS PRODUCTION The Fastener Area is a part of our Waterworks Division. Parts for the fasteners are made with the “Henry” Punch Press and the “Acme” Bolt Header.
The “Henry” Punch Press has a 200T capacity and is computer controlled. This machine is used to manufacture components for fabricated stainless steel Repair Clamps, Saddles and other products. In addition, it is used to cut rod to length for use in the Bolt Header.
The “Acme” Bolt Header and a Forge are used to make bolts. The rod is first cut to length on the “Henry” press. The bolt blanks are then heated and placed into the Bolt Header where the work piece is simultaneously clamped and pressed into shape by a “Heading Die”.
The Bolt Header is able to “hot-head” bolts up to 1 ‘in diameter although currently
ROBAR only requires 5/8” diameter Trackhead bolts. The Forge is used to heat the bolt blanks up to about 700 C (1300 F). These headed bolts are allowed to cool then they are taken to the Machine Shop where they undergo a “Thread-Rolling” process. Most of ROBAR’s waterworks products require some form of rubber gasket in order to seal to a pipe. The majority of the gaskets fall into two classes. They are either “flat-type” gaskets or “ring-type” gaskets. Flat gaskets are used for products like Repair Clamps and Ring gaskets are used for Couplings.
All gaskets are made from raw rubber that is placed into special molds.
ROBAR uses several types of rubber to satisfy the requirements of our customers.
Some gaskets require the rubber to be pre-formed in the “Extruder”. When placed in a mold, the raw rubber flows and “cures” under heat and high pressure in one of the rubber presses. The large hydraulic Rubber Press develops a force of one (1) million pounds on the rubber molds. In the machine shop, the basic manufacture of our “Trackhead” bolts is completed. Threads are placed onto the “headed” bolt-blank. The operator uses the Roll Threader to perform this task. Hydraulic pressure and special “Roll Dies” are used to “press” the threads onto the blank. The “Landis” Roll Threader uses different rolls for each thread form.
ROBAR uses four (4) standard thread forms and has Dies for 1/2, 5/8, 3/4” and 7/8” NC (National Coarse) threads.
ROBAR makes bolts and studs from two basic materials, corrosion resistant stainless steel (grades T-304 or T-316) and “Weathering” steel.
Another important task done in the Machine Shop is to “Drill and Tap” the cast saddles. The raw saddles from the Foundry are machined and put into stock once completed. The saddles are cast in either “Ductile Iron” or “Waterworks Brass” (85,5,5,5). In these stations, Couplings, Repair Clamps and Saddles are assembled and packaged for delivery.
Coupling components: castings from the Foundry; bolts formed and threaded from the Fastener Shop and gaskets, extruded, molded and cured from the Rubber Shop, come together for assembly. The metal components are either coated with an enamel paint or a fusion-bonded epoxy for corrosion resistance. The Couplings are then fully assembled at the Assembly Stations.
Couplings are used to join two pieces of "plain-end” pipe or to join two pipes of different outside diameters.
ROBAR’s cast couplings range from 4” diameter to 24” diameter. Through our association with Baker Coupling of California, we market “fabricated” steel couplings up to 240” diameter. (20 feet)
Repair Clamps are fabricated from Stainless Steel (T-304 or T-316). Repair Clamps are like a bandage for pipe. Cities, Municipalities, Mining companies and contractors use them to repair a hole, crack or break in a pipeline to stop a leak. Repair Clamps can be made for pipes from 2” diameter up to 48” diameter.
Saddles are used on a watermain to create a branchline in order to bring a “water service" into a house or business. The size of Saddle varies from a common house “service” at 3/4” diameter up to 3” diameter for a business.
Depending on soil conditions and the type of “mainline” pipe being used, Saddles are made from either “Ductile Iron”, “Waterworks Brass” complete with stainless steel straps or “All Stainless Steel”. Ductile and brass bodies are cast in the Foundry while the stainless steel Saddles are made in the Fabrication shop. ROBAR began by manufacturing Repair Clamps. The process of manufacturing Repair Clamps, Tapping Sleeves and stainless steel Saddles starts at the “Brown-Boggs” Shear where the “body” is cut to size from a sheet of stainless steel.
The stainless steel welded products are now “Passivated” before final assembly. Passivation means chemically treating stainless steel after welding, to return it to its original high corrosion resistance and appearance.
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ROBAR INDUSTRIES LTD.
was founded in 1958 to produce a line of patented cast and fabricated fittings. Due to the difficulty of purchasing quality castings for use in these products, a
Over the years, ROBAR’s 
SURREY
FOUNDRY OPERATIONS
CORE
MAKING AND MOLDING
MELTING
AND POURING
The metal is quickly poured into the molds, before it begins to solidify. The Metal Pourers move the full ladle to the waiting completed molds on a crane hook that travels on overhead railways or “tramways”. They use the crane to move the ladle to the correct height to start the pour. The Pourer tips the ladle with a wheel that is geared to the ladle pivot shaft. As the Pourer increases the angle of tip in the ladle he continuously adjusts the height with the crane to get a constant and smooth pour into the mold.
Machines are used to clean any remaining sand from the castings and to improve the finish. The function of the various shot-blast machines is to remove all excess sand from the surface of the raw casting and from pockets or core areas. In the shot-blast machines, impellers blast steel shot against the castings at a speed of 500 mph. All surface sand and scale is removed in this process.
Heat Treatment and Quenching are used to alter the Physical Characteristics of castings. Some cast metals tend to be brittle after the metal has rapidly cooled in the mold. This characteristic may be modified by Annealing the castings. Annealing requires raising the temperature of the casting to a certain point then very slowly cooling the casting.
RUBBER
SHOP
ASSEMBLY
STATIONS
In this area, welders manufacture the “closures” which are an integral part of these products. Closures consist of assemblies called “Finger-bars” or “Bolt-bars”. They are made to various sizes on the MIG jig stations. Later, these “closures” are welded to the “shell” and give the product its characteristic shape. This assembly is done at semi-automatic TIG welding stations.