Quad/Graphics, Inc. Stacked Press

Quad/Graphics is the largest privately held printer of magazines, catalogs, books, and commercial materials in North America. GRAEF recently designed Quad/Graphics’ first stacked press line, supporting four automated press units directly above four identical units to save valuable floor space in an existing printing plant. Special consideration was given to the design of the 36-foot by 24-foot cast-in-place concrete press mezzanine, the project’s key structural element. The overall depth of the mezzanine was restricted to just 24 inches to avoid costly modifications to existing roof framing members. This relatively shallow structure would need to exceed typical design requirements for rigidity to maintain the fine print clarity of the supported press units. The press manufacturer’s recommended allowable deflection is 0.0015 inch under normal operating loads. GRAEF designed the mezzanine using a waffle-type system to meet these stringent requirements.

Quad/Graphics’ initial goal of achieving maximum utilization of their existing space was met. The company also realized an unexpected production rate increase of nearly 20 percent over similar presses staged side-by-side. The success of this initial project has convinced Quad/Graphics to construct other stacked press lines in Sussex, Lomira, and Hartford, WI, and The Rock, GA.

Awards:
WACE Engineering Excellence Achievement Award