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Customer Case Study

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Corey- ‘Steeling’ The Market in Mexico!

EXECUTIVE SUMMARY Where They Got Their StartCorey, based in Guadalajara, Mexico was established 1981 specializing in the design, manufacturing and erection of steel structures. Corey is a subsidiary of Aceros Corey, founded in 1979. Aceros Corey is a distributor of structural steel and wide plate; together (Corey & Aceros Corey) they make Grupo Corcal Acero VGS.

Corey really thrived and became a big industry player after the construction of Torre Mayor, a skyscraper in Mexico City. Towering at 225 meters (740 ft) high, Torre Mayor became a turning point for structural steel in Mexico.

Corey began construction of Torre Mayor in 2000 and completed the structure in late 2002. What makes this skyscraper such an important structure for Corey is the January 2003 earthquake in Mexico City. The 7.6 tremor shook the entire city relentlessly. Not only did the building survive undamaged, but occupants inside at the time did not even know a quake occurred. The nearly finished steel structure was able to withstand the devastating effects of the earthquake, while the concrete buildings around it crumbled to the ground.

What is Going On Now?Since 2003, Corey has flourished to become the leading steel provider,

CUSTOMER NAME: Corey

INDUSTRY: Structural Steel Provider, Fabricator, and Erector

LOCATION: Guadalajara, Mexico

NUMBER OF EMPLOYEES: 800 employees on three shifts

CHALLENGE: Increase capacity and quality

SOLUTION: Installed the TDK drill, PCD-1100, FDB, BDL 1250, and ABCM coper

RESULTS: Large tonnage capacity because of the ability to process more in a shorter time

Marco Calderon (left) of Corey with Jose Cavazos (right), Director of Latin American Operations have worked together to design the expansive Corey fabrication facility in Guadelejara, Mexico.

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fabricator and erector in Mexico. In 2010, Corey opened a new facility in Guadalajara, which merged three of their smaller locations (Guadalajara, Monterrey, and Mexico City). The new ‘college campus’ size facility includes 50,000 square meters (538,195 sq ft) of shop space; considerably surpassing the previous 15,000 square meters (161,458 sq ft) combined shop space of all three merged facilities.

“The new shop doubled our production capacity and tripled our storage capacity,” Javier Villa Torres, Director of Operations said. “No other company in Mexico can even come close to our production capacity!” With about 800 shop employees working on three shifts, Corey processes 72,000 metric tons (79,366 U.S. tons) of steel annually with Peddinghaus machines. The Game Changing DecisionCorey purchased their first Peddinghaus machines in 1994. The steel giant was referred to Peddinghaus by partners, Schuff Steel in the U.S. The purchase of a Peddinghaus TDK drill and an ABCM coper was the start of an advantageous relationship between Peddinghaus and Corey. Since then, Corey has procured several drills, plate machines, saws and iron workers.

“We needed efficient machines to help us keep up with demand,”Marco Calderón, Plant manager said. “Peddinghaus machines are strong, low maintenance, and effective machines for operation.”

High Efficiency Leads to Big PayoffCorey is a perfect example of a high efficiency shop. Currently Corey has two band saws to feed the BDL-1250 beam line, which then can feed into the coper if needed.

“We used to have the drill and saw in tandem, which was working great,” Calderón said. “However, we were not keeping the drill busy enough that way. Our set-up with two saws feeding into the drill allows us to process much more in the same or less time, and keeps the drill busy.”

Setting up a shop of this size can be tricky. To ensure maximum efficiency Peddinghaus Layout engineers assisted Corey with their shop layout. Currently Corey is running two different layout systems. Previously mentioned, one system has two saws feeding into a BDL drill and the drill feeding the ABCM coper if needed. This set-up also has a third saw feeding the coper directly for special applications.

A small portion of the facility at Corey

The view from atop of the entire Corey facility

Large, complex assemblies are “just another day in the office” at Corey

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Corey’s second system is a PCD-1100 feeding an additional coper. Separate from the lines, Corey has three FDB plate machines opposite of the PCD/coper line, and 4 iron workers at the end of the triple saw/BDL/coper line.

“The layout engineers were really helpful,” Calderón said. “The Peddinghaus representative put us in contact with the right people at the Peddinghaus headquarters. With a shop as large as ours, and with as many machines as we have, it was important to for us to maximize space and efficiency. We wanted the upgrade to the facility to payoff. Our shop layout definitely helps improve our efficiency.”

Large Tonnage for a Large ShopAlthough Torre Mayor was a great triumph, it is not the only great accomplishment from Corey. The BBVA Bancomer headquarters is to be completed in 2013 and will tip the scale at 22,000 metric tons (24,250 U.S. tons) of fabricated steel. Baluarte Bridge is the 3rd highest (390 meters/1,280 ft) bridge in the world and the longest span in Latin America (580 meters/1,903 ft). When completed in early 2012, Baluarte Bridge will equal 5,000 metric tons (5,511 U.S. tons) of fabricated steel. The most challenging project for Corey was the Arena Ciudad de Mexico. Erectors had to use 1,000 metric ton cranes to lift each 450 metric ton piece. Completed in 2011, the arena measures at a lofty 140 meters (459 ft) wide and 17 meters (55 ft) high, the Arena Ciudad de Mexico can hold up to 22,000 people!

“We contribute part of our great success to our Peddinghaus machines,” Calderón said. “Without our Peddinghaus machines, we would not be able to operate as efficiently and put out as much work as we do now. We are very pleased with the quality of Peddinghaus machines, employees and service. We have so many [machines]; we are like a showroom for Peddinghaus!”

ABCM-1250 Coping System

Large assemblies are no issue with the advanced automation employed at Corey

The ABCM-1250 uses Siemens electronics for production

BDL-1250/9B 9 spindle drill line handles the largest and heavies profiles available on the market today

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FOR MORE INFORMATION

To learn more about Peddinghaus Corporation visit:www.peddinghaus.com

PRODUCT LIST: ▪ Beam Drill Lines ▪ Angle Masters ▪ Plate Processing ▪ Coping Machines ▪ Thermal Cutting ▪ Automated Layout Marking ▪ Structural Band Saws ▪ Ironworkers ▪ Material Handling

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