Norco Composites & GRP partnered with Patterns and Moulds (P&M) to undertake a time-sensitive project for the Ellison Institute of Transformative Medicine (EITM). This project involved providing cast concrete mould tools to create six 20-metre-long architectural beams for a new interdisciplinary research and development facility in Oxford. Impressively, these moulds were completed within a five-month window, highlighting Norco’s ability to deliver large-scale, complex projects on tight schedules.
Project Challenges and Solutions
Faced with a tight production schedule and a significant build size, the P&M team sought Norco’s expertise in large composite specialist builds. Despite a busy order book, Norco successfully integrated this project, demonstrating our commitment to supporting trusted suppliers and meeting client demands.
Execution Process
The project employed traditional wet lay-up techniques, incorporating complex locating features for precise concrete pouring applications. Heavy lifting, exceeding 23 tonnes, was required for both the pattern and mould. The integration of heavy metallic supporting structures with composites and welding showcased our technical proficiency.
- Preparation: Initial planning and integration into the schedule.
- Wet Lay-Up Techniques: Utilised for detailed and complex mould features.
- Composite to Metallic Joining: Combined metallic structures with composites and welding.
- Heavy Lifting: Managed significant weights with external support.
P&M were responsible for the master pattern design and manufacture, mould design and engineering, and supplying the steel fabrications for Norco to bond into the laminate.
Key Benefits
This project not only highlighted Norco’s unique expertise but also demonstrated effective collaboration within the composites industry. The successful execution leveraged our existing skillsets and reinforced our position as a leader in delivering complex composite solutions.
Watch the video to see the team in action and learn more about this project. Cast Concrete Mould Tools (youtube.com)