PypeServer Makes it Easy to Prefabricate Pipe Hanger Assemblies Using Existing Tools
November 13, 2023
Written by PypeServer

Accurate and efficient pipe hanger fabrication is critical in mechanical, electrical, and plumbing (MEP) construction. The integrity of these systems directly impacts the safety and performance of mechanical and plumbing systems.

Hanger assemblies have traditionally been fabricated on the jobsite, which is time-consuming, labor-intensive, and costly. As a result, fabricators are increasingly looking toward prefabrication for pipe hangers. However, the large volume of hangers on most jobs, combined with the fact that the final hanger length is typically determined in the field complicates efforts to fully prefabricate hangers.

PypeServer is changing the game by simplifying the hanger prefabrication process with smart approaches that maximize the degree of hanger prefabrication while ensuring the work that’s best left to the field is still done there but in the most efficient way possible. To understand precisely how PypeServer works, let’s explore its innovative approach through a five-step process streamlining pipe hanger assembly fabrication.

Step 1: Select Hangers in the Model using PypeServer Connect Plug-in

PypeServer’s free Connect plug-ins for Revit, AutoCAD MEP and Fabrication CADmep, Plant 3D, and Inventor let you select ITM or family hangers directly within the design model. In the process, Connect can calculate strut lengths from model parameters, round rod and strut lengths up in increments that you choose, and use custom rules you define to generate correct strut counts.

Step 2: Send Hangers to the Fab Shop using PypeServer Cloud

Once the hanger assemblies have been selected, the next step is to send the hanger cut list to the fabrication shop. PypeServer offers a free Cloud service that simplifies this task. You send your cut lists to our Cloud right from within our Connect plug-ins. Once in our Cloud they can go straight to a tool driven by PypeServer Lyte with just a few mouse clicks and an internet connection.

PypeServer Lyte is our software for automated saws, linear positioners, and manual tools. Lyte can fully control any automated positioner or saw from TigerStop as well as Scotchman autosaws and any Windows-based RazorGage. Lyte also turbocharges manual tools. With manual tools, Lyte is run on a small tablet next to the tool and lets the operator know the best order in which to measure and cut the materials. This inexpensive upgrade dramatically enhances the productivity of manual tools, enabling project stakeholders to access and review the cut lists from anywhere with an internet connection. This saves time and reduces the likelihood of errors introduced during manual data transfer. PypeServer’s Cloud service makes the entire process more streamlined, accurate, and cost-effective.

Step 3: Nest Parts to Reduce Waste

Once you have your cut lists, it’s time to improve material utilization with Lyte’s nesting algorithms, which find the optimal cut order to minimize waste. Lyte’s nesting takes into account the exact length of your stock (or previous drop), kerf, trim cuts, cutter and clamp clearance distances and even material defects to squeeze as many parts as possible out of your valuable materials.

With relatively thin stock like hanger rod, it’s often possible to bundle and cut more than one piece of stock at a time. This is especially helpful when your cut list contains lots of parts of the same length, as is often the case with hanger rod. Lyte goes well beyond cutting whatever bundle size you give it, it can actually analyze your cut list and recommend the optimal bundling scheme, including automatically changing the bundle size as you work through the cut list.

Compared to manual nesting, Lyte’s algorithms are far faster, more efficient, and actually improve as your cut lists get larger. In short, Lyte’s powerful nesting capabilities save substantial amounts of material and contribute to a more sustainable and environmentally friendly fabrication process.

Step 4: Label Parts with QR Codes for Better Project Management

PypeServer Lyte further enhances pipe hanger fabrication with advanced labeling, making it easy to track parts, re-use drops, and speed up assembly. Lyte’s part labels can include any text or numerical parameter from your model (alone or in combination), QR codes, graphics, and other information. PypeServer’s graphical label designer is the best in the business, giving you an intuitive, what-you-see-is-what-you-get way to design, modify, and share label templates.

With each cut, Lyte will print a label for the cut part and update the Cloud with its fabrication status. The QR codes Lyte prints on labels can be scanned using smartphones or tablets, allowing construction and installation teams to quickly access drawings and other information they may need for prefabrication in the shop or installation in the field.

Step 5: Assemble in the Field or Shop Using PypeServer’s 3D Assembly Viewer

The final step of the process involves assembling the fabricated parts, either in the field or the shop. PypeServer’s 3D Assembly Viewer provides a user-friendly web-based platform for viewing and verifying assembly instructions in 3D on any platform: computer, tablet, or phone.

The 3D Assembly Viewer reduces errors by offering a clear visual representation of how the parts should come together and where in the structure they’ll be installed. This is especially valuable when dealing with complex pipe hanger assemblies that require precise positioning and alignment.

Bottom Line: PypeServer can dramatically simplify your hanger fabrication process 

PypeServer’s software integrates seamlessly with popular design software, includes a cloud-based service for cut list transmission and status tracking, optimizes material utilization, offers QR coded labels for better project management, and includes a 3D Assembly Viewer to assure quality. With all these capabilities, offered at a breakthrough price, PypeServer empowers professionals to make the most of their existing tools and resources while improving the efficiency, accuracy, and overall quality of their pipe hanger assembly projects.

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