Race Rock Elevates Their Cut Quality, Efficiency, and Operator Confidence with Hypertherm Powermax SYNC
Race Rock is a fabrication partner behind some of the most visible structures on American highways. From guardrails to the thousands of steel posts used in solar fields, the company handles a wide range of heavy-duty steel components that require cutting, processing, and galvanizing before installation. With its own galvanizing operation and a steady flow of incoming and outgoing steel, Race Rock depends on reliable cutting technology to keep production moving.
For Production Planner Matthew Martin, who has spent 15 years at the company, plasma cutting is at the heart of nearly every job. “I do everything here with plasma,” he explains. “Incoming steel, outgoing steel, meeting demands.” The shop processes Grade 50 and A36 steel in thicknesses ranging from 1/4 inch to 5/8 inch, cutting everything from I‑beams and plate to channel and angle. Approximately 95% of all cutting is done with plasma, making system performance and uptime critical to operations.
A Needed Upgrade After 15 Years of Service
Race Rock’s previous Powermax plasma system had served the company well for fifteen years, but as production demands grew, it became clear that an upgrade was needed. Their supplier recommended Hypertherm Powermax SYNC®, and the team decided to put the new system to the test. They kept their original Powermax in service for ad hoc jobs around the shop.
The results with the Powermax SYNC were immediate.
I was very impressed with the quality of the cut without changing any parameters. The quality of the cut was 75% better.
Matthew Martin
Production Planner, Race Rock
That improvement alone made a strong case for upgrading, but the benefits didn’t stop there.
Powermax SYNC: A Dramatic Change in Simplicity and Consistency
When Race Rock adopted Powermax SYNC®, the impact on day-to-day operations was even more dramatic. The system’s single-piece cartridge consumables replaced the multi-piece setup they had used for years, eliminating a major source of operator error.
“The Powermax SYNC is ten times better than what we were using before,” Martin says. “It takes the operator error out of any of the products that we have to do.”
Operators quickly embraced the new system. Instead of managing multiple consumable parts, they now install a single cartridge with a simple quarter‑turn. Training became easier, setup became faster, and the risk of incorrect assembly disappeared.
“It’s a quarter turn on and a quarter turn off, and we’re good to go,” Martin explains. “Even ordering is so much easier. You’re ordering one instead of five pieces.”
Longer Life, Less Downtime
Consumable life also improved significantly. With their previous system, operators changed consumables twice a day. With Powermax SYNC, they now change cartridges once a week.
That reduction in downtime directly impacts throughput, especially in a shop where plasma cutting is the starting point for nearly every job. Fewer interruptions mean smoother workflow, more predictable scheduling, and less frustration for operators.
There’s no reason to be skeptical of the one‑piece. It took all the operator problems out of the equation. The one-piece setup is the way to go.
Matthew Martin
Production Planner, Race Rock
A System That Supports the Way Race Rock Works
For a company that cuts such a wide range of structural steel components, consistency and ease of use matter just as much as cut quality. Powermax SYNC provides Race Rock with a system that supports both experienced operators and new team members, helping the company maintain productivity as workloads shift.
The improved cut quality reduces secondary operations, the simplified consumable system reduces training time, and the longer cartridge life reduces interruptions. Together, these advantages help Race Rock keep pace with demanding production schedules while delivering the high-quality parts their customers expect.
A Smarter Way Forward
Race Rock’s experience reflects what many fabricators discover when upgrading to Powermax SYNC: better cut quality is only the beginning. The real value lies in the system’s ability to simplify work, reduce variability, and provide operators with tools that help them succeed.
For Martin and his team, the upgrade has been transformative.
“We love it,” he says—a fitting summary of a system that has made their work easier, faster, and more consistent.