VERTICALLY INTEGRATED & MADE IN THE USA
Formulation design is only one side of the equation. How the material is cast, cured, and processed ultimately determines the success of every project. We design the mix, we design the manufacturing, and we have complete traceability through every step of the process.
TAKTL manufactures its products just outside of Pittsburgh, in Turtle Creek, PA, and sources 91% of its raw materials from within a 500-mile radius. TAKTL’s 240,000 square foot facility is located in a historic Westinghouse plant built in the 1880’s that has been completely renovated by the Regional Industrial Development Corporation of Southwestern PA (RIDC) into a high-tech, flexible and energy efficient manufacturing space that addresses the needs of TAKTL’s manufacturing operations and research center: climate control, high efficiency lighting, water filtration system, linear layout, and additional storage.
The TAKTL production line has been custom designed to control every aspect of manufacturing – quality, energy consumption, air and water emissions and waste – with a high level of precision at every step. By viewing the manufacturing process as an integral part of the overall design challenge, our team of engineers, designers and manufacturing experts has created a model that is resource-efficient, scalable, automated and exportable, with the modularity to expand into new applications, design ideas and geographies.
Dosing + Mixing The automated dosing system transfers raw materials for each batch from storage silos to precision scales, accurate to within 50 grams for high volume ingredients, and 1 gram for pigments and lower volume ingredients. Materials continue directly into a high intensity mixer, where they are combined according to an exacting mixing regimen.
Mold Preparation Mold sets are pulled from TAKTL’s extensive inventory, prepared with mold release calibrated to each unique texture, and then transferred to the beginning of the casting line. In the case of custom textures, the required tooling, master molds, and custom molds are manufactured in-house.
Casting + Demold TAKTL has been formulated to flow efficiently into a variety of mold types with a strength development curve that minimizes shrinkage, produces high quality surfaces upon de-mold, and allows cost-efficient cycling of molds. From the casting line, panels proceed to a climate controlled initial curing chamber to develop enough strength to de-mold. After de-mold the molds return to production (or inventory) and the panels proceed to large, climate-controlled chambers, where they cure for several weeks.
Finishing TAKTL products have an intrinsic texture and finish created by the mold surface. Depending upon the aesthetic objective, all standard textures can be media blasted to achieve a matte finish. TAKTL has also developed a technique to incorporate decorative aggregates in the surface layer of each panel that are then exposed through the media blasting process. Our high-speed Media Blast equipment was custom designed for UHPC finishing, using a vertical panel orientation to create even surfaces of subtly exposed aggregate. Media is cleaned and re-circulated in a dust-free and resource efficient cycle.
Cutting Panel sizes are transferred digitally from the approved manufacturing drawings to 5-axis CNC Bridge Saws, where panel optimization ensures efficient material utilization. TAKTL operates four bridge saws to process multiple projects concurrently. The machine pictured above can perform linear and curved cuts along any angle by interpolating all 5 axes. The equipment can also automatically reposition the components on the working surface via integral vacuum. This maximizes throughput while delivering straight, beveled and curved panel edges without operator intervention.
Drilling After cutting, TAKTL parts are prepped for anchors as required. Pictured here is a Keil drilling machine capable of performing the cylindrical and undercut drilling for the Keil concealed stainless anchors in a patented process requiring only one tool. Anchor preparation is also accomplished using a CNC machine with Keil end mills. Undercut anchor holes are checked for accurate depth using a Keil depth checking tool. Drilling for exposed anchors can be accomplished automatically by any of our CNC saws as an integrated step in the sawing/drilling process.
Final Barcode + Wash/Dry Inline barcode printers automatically print a final barcode on the edge of each panel as it exits the drilling area, identifying the Project, Lot, Part Number, and Serial Number. Panels proceed through a final wash/dry step to remove any surface residue created in the cutting and drilling operations after which they are inspected for surface and edge quality before proceeding to Finishing.
Final Inspection + Crating All panels and corners are inspected a final time, and their lot clearances (flexural and anchor pullout strength) are verified. Each panel barcode is scanned and recorded onto the crate manifest. The final manifest is affixed to the sealed crate and also emailed to the customer upon shipment.