Copywriting for Technical Literature
User Manual for Ashgrid Support System
ASHGRID. FOR NEW BUILD AND REFURB APPLICATIONS.
The advanced Ashgrid support system offers many benefits over conventional systems. Its technical superiority has been proved in thousands of applications worldwide.
For the metal cladding of walls and roofs, whether new or refurbished, Ashgrid provides the complete energy efficient solution. It is stronger and more stable, but also easier to install - leading to significant savings in labour costs, less site disruption and faster completion.
All in all, this is a quality product engineered for high performance and surpassing the latest building regulations. Fully supported by Ash & Lacy’s technical advice and assistance, Ashgrid is the surest specification for any double skin, over-roofing or cladding project.
THE BENEFITS
Strong and simple to assemble
Fast, cost effective and safe fixing
Reduces fixing time by 50%
Quality product, engineered for high performance
Full design and technical back-up service available
Enhances performance of structural purlins
Built in thermal check zone
Reduction of construction time and on site costs
Less supervision time and administration
Aids completion of project to time
Superbly efficient fixing technology
Strong support bars
Bar end spigot for easy alignment
Vapour seal pad acts as thermal insulator and cushions against fastener
stress
Saves on fastener costs
(Caption to Ashgrid cutaway)
Variable 60 - 200mm
Bracket
Support Bar
Insulation
Twin fixing
(Cutaway diagrams of new build and refurb)
FIXING PROCEDURE
a. Lining panels are tacked onto the structural purlins/rails with stitch
fasteners as a preliminary hold prior to the fixing of spacer and support
assembly.
b. Brackets are positioned and locked into the support bar at recommended
intervals and fixed with standard self drive hexagonal headed fasteners.
Note: a bracket should be positioned within 100mm of the leading edge of the
support bar so that the joint is subject to a shear load action.
c. Insulation may be laid, cut and tucked under the support bar for
continuity or laid continuously under the support bracket if preferred.
d. Optional breather membrane may be laid if specified.
e. Subsequently the specified weathering sheet may be laid and fixed in
accordance with manufacturers recommendation.
f. Standard assemblies are available to accept 60mm and 100mm fibreglass
insulation quilts, or greater if required.
(Captions to fixing procedure diagram)
Direction of lay
External weathering sheet to specification
Spigot joint
Stitch fasten liner panel prior to fixing brackets
Liner panel
Bracket
Support Bar
(Illustrated for new work - similar for refurbishment.)
(Captions to specific fixing diagrams)
ROOFING
Twin fixing gives max stability. Orientation reduces load eccentricity on purlin. Brackets at 1.0m crs.
On slopes above 100 and in some instances a single fix may be preferred. Reduce bracket centres to 750mm max.
WALLING
VERTICAL FIX
Normal application with weather sheeting fixed vertically.
Single or twin fix to suit load and purlin/rail type.
Check bracket spacing if sheeting rails are at 2m crs.
Sheeting rails up to 2.0m centres
HORIZONTAL FIX
Where the weather sheet is laid horizontally, the AG 40 is fixed in a
vertical position and at up to 1.5m crs depending on loading.
The rail spacing will dictate the centres of the vertical Ashgrid bars. The
performance guide indicates 1.2m crs for 1.25knm2 wind load with sheeting
rails at 2m crs. All vertical bars require an AGB support cleat fixed to the
bottom sheeting rail and the AG 40.
Plan on A.A.
REFURB APPLICATIONS
Existing asbestos cement sheeting
Existing steel/aluminium sheeting
Existing joist board and felt
Existing built up steel/aluminium decking
Brackets are located in the AG 40 bar section to suit the centres of the existing cladding. The bracket base pad moulds to the corrugation shape and forms a fixing cushion and seal.
Bracket centres 900mm nominal. Vary to suit cladding profiles.
Note: Hi-thread fasteners are recommended to maintain the balanced state after fixing. Depending on cavity make up it is generally recommended to pre-drill clearance hole 5.8mm dia through the layers of existing sheeting and battens etc. to prevent jacking and cracking of the existing roof. In final fixed position the Hi-threads engage in bracket for firm independent support.
Calculating bracket height for refurb of existing roofs.
Existing profile
Big six - 48mm profile - 146mm pitch
85mm bracket min at 900 crs
Double six - 78mm profile - 305mm pitch
130mm bracket min at 900 crs
COMPONENTS
BRACKET
Material - HDG Mild Steel. Z2/1.5mm
Incorporates vapour seal pad.
Standard Bracket Heights (mm)
60, 8?, 85, 90, 100, 120, 130, 140, 150, 160, 180, 200.
Other heights can be produced by arrangement.
SUPPORT BAR
HDG Mild Steel. Z2/1.5mm - 1.5mm fixing pull out rating.
1xx 26434mm 1xx 32860mm MRP (Plastic) 0.5knm
GENERAL PERFORMANCE GUIDE
The simple guide formula is based on the proven safe working load of 3kN per
bracket and base fastener assembly with 2 fixings per bracket base.
W = wind load kN/m2
P = main purlin centres in metres
S = bracket spacing in metres
L = safe bracket assembly load in kN
W = L/PxS and S = L/PxW
Based upon purlins spaced at 2.00m the following loads can be
accommodated with brackets at 1.000m centres.
Super load - 1.3kn/m2 Wind load - 1.5kn/m2
Foot traffic - 1.35kn at midpoint of bar and bracket 1m. By reducing the
spacing of brackets increased loads can be accommodated..
GENERAL GUIDE FOR LOADING
Bar - 3kn with brackets at 1m centres. Brackets - 3kn equates to above.
eg Wind load = 2kn/m2
Purlins at 2m
Load/metre of bar = 2x2 = 4kn and hence bracket spacing should be adjusted
to ¾ = 750mm centres
(Captions to illustration of assembled and fixed Ashgrid unit.)
17mm
40mm
40mm
Range 60 - 200mm
Self drill fixing & washer
Weather sheet
Bracket
Support bar
Twin screw fixing for maximum stability
Vapour seal pad (also acts as thermal insulator and stress absorber)
Insulation*
Breather membrane*
*Optional features
ASSEMBLY GUIDE
1.Insert required number of brackets per bar from non-spigoted end at
approx 450 angle.
2.Slide to required position and simply bring brackets upright to lock into
place. (For speed, bars and brackets can be batch assembled.)
3.Use self-drill screws for steel purlins up to 3.5mm thickness and HS
fasteners into Hot Rolled Sections. (For refurbishment please seek advice)
4.Use upper fixing hole first. For maximum stability use two screws.
5.Align bars using spigoted joint. A bracket should be within 100mm from end
of bar.
THERMAL PERFORMANCE
Ashgrid is a spacer bar system which allows the insulation quilt to be laid with minimal compression under the bar and includes a thermal break on the base of the bracket.
The Building Research Establishment have advised that the traditional zed spacer and ferrule requires an increased thickness of insulation to meet the minimum requirement of 0.45Wm2K compared with the Ashgrid system using 83mm brackets spaced at 1.0m crs. which meets the required standard.
AG 40 PERFORMANCE TABLE
AshgridTM firewall 4hr resistance certified
A fire test has been conducted on a fire wall comprising PMF sheeting and the Instaloc support system (similar to Ashgrid) report J 88627/3 and WFRC. C54109 to provide a 4 hour fire rating to satisfy the criteria of BS 476 Part 22 1987. For the following period - insulation 19min , integrity 240min the wall construction will comprise the following elements:
LINER
0.4mm laps stitched at 300mm crs with steel rivets.
ASHGRID BRACKETS
1.0mm crs max 120mm bp fixed with 2 No. 5.5 bia carbon S/D screws.
INSULATION
83mm glass fibre 10kg/m trapped between AG 40 rail and the outer sheet to
provide 40mm air space.
WEATHER SHEET
Trapezoidal profile steel sheet PVC coated 0.55mm thick. Fixed at 300mm crs
to the rail. Side laps stitched with steel rivets at 400mm crs
(Captions to firewall diagrams)
120mm
40mm
80mm
Fibreglass 10kg
80mm
Rockwool 23kg
Please consult Ash & Lacy Building Products technical department for an approved list of weatherskin and lining panel profiles
TECHNICAL SERVICE
Ash & Lacy has been an innovator in the cladding industry for many years.
Quality of product and design ranks high with that of a quick efficient service to all customers.
Technical advice and assistance of the highest standard is available during the project - and back-up support after completion can be provided.
All materials used are co-ordinated and selected for compatibility in use.
Quality is high and consistent to promote good performance and long life.
TECHNICAL DEPARTMENT HOTLINE: 0121 556 0444
NOTES
(Space for any additional info)
AshfixTM Fasteners
Framework assembly
The quality wide flange headed Ashfix LS 25 is the standard fastener for
final fixing.
Framework base to existing deck/structure
Use fasteners from the Ashfix range as laid down in the design specification
to suit the nature and condition of the existing deck/structure.
Weathersheet to Ashgrid support bar
Use fasteners from the Ashfix range as laid down in the design specification
to suit angle of slope and sheet profile, with coloured heads or caps as
required.
Ash & Lacy Building Products Ltd. (logo)
LEADING THE WAY IN CLADDING TECHNOLOGY
WEST MIDLANDS
PO Box 58, Alma Street, Warley, West Midlands B66 2RP.
Tel: 0121 952 3300 Fax: 0121 555 6234
Unit 4 Shaw Street, Hill Top Industrial Estate, Hill Top, West Bromwich,
West Midlands B70 0TX.
Tel: 0121 556 1444 Fax: 0121 556 0444
GLASGOW
Unit 10 New Albion Industrial Estate, Halley Street, Yoker, Glasgow, G13
4DT.
Tel: 0141 952 3300 Fax: 0141 952 8800
Literature for Glynwed Pipe Systems
A WORLD POWER IN HIGH PERFORMANCE PIPEWORK SYSTEMS
Glynwed Pipe Systems are internationally renowned for manufacturing and distributing some of the most advanced pipework systems available, and have achieved the pre-eminence of being the world’s largest integrated supplier.
With manufacturing facilities in the UK, Germany, Spain, Italy, the Netherlands, Monaco, USA, Australia and South Africa, together with a distribution network which spans the globe, the group is in an unrivalled position to provide effective answers to pipework problems almost anywhere in the world.
The strength of GPS is in the multiplicity of skills held by individual companies, backed by the resources and knowledge of a leading international group: Glynwed International plc.
There is scarcely a material or a component of pipework that does not feature somewhere in the GPS portfolio – from pipes to pumps, from traditional cast iron to the latest performance plastics, and it is this comprehensive approach which attracts customers wanting to find best solutions.
Indeed, there are few areas of industry, construction, processing or utilities where a GPS system has not found its niche, and the group is respected for its unsurpassed design engineering skills and capability in product development, often responsible for pioneering solutions to specific needs in pipework.
The customer who turns to GPS will be directed to the company in the group best equipped to serve their exact needs, or in many cases benefit from two or more companies working together to reach a customised solution which no singular organisation could have achieved.
In fact, few businesses are as customer-driven as GPS. It is our intention always to provide the most cost-effective solution, the highest standards of technical support and the most effective system design. We are world leaders and we intend to stay that way the only way we know how – through the quality of our products and service.
A WEALTH OF WORKING EXPERIENCE WITH INDUSTRY.
The comprehensive range of pipe products manufactured and marketed by GPS, represents a considerable advantage for specifiers in the industrial sector. As leaders in the production of high-performance pipework systems, the aim is to ensure quality and availability across the full scope of industrial applications.
The expertise of the various specialised operations within the GPS framework covers the gamut of materials, both traditional and ultra-modern - metal and plastic – used in high performance pipe systems. This diversity of materials and design has resulted in an integrated source, which can fulfil the requirements of the vast majority of manufacturing and process industries.
Pressure and non-pressure systems, highly corrosive or toxic fluids, heavy and light applications, viscous fluids or gases, are all catered for by a uniquely extensive range of fittings, valves, pipe couplings, flowmeters and sensors, control equipment, jointing equipment, tools and accessories.
In providing products to industries as diverse as mining and biotechnology, the food industry and the oil industry, GPS has acquired an unsurpassed wealth of materials expertise, which includes cast iron and stainless steel as well as PVC, PVCc, PE, PP, ABS and PVDF.
It’s a truly global operation that is united in its determination to offer solutions that answer the design brief in every respect, so that over-specification, compromise and improvisation can be regarded as a thing of the past. Having worked hard to achieve their position of international eminence in industrial pipework, GPS will continue to be customer-driven, always striving to stay in the forefront of product development.
Process Industries
From concentrated acids to high purity water, slurries to compressed air – the demands of the process industry on pipework systems are highly diverse and often extreme.
GPS’s depth of experience in thermoplastics and stainless steel allows precise solutions to even the most difficult applications, ensuring efficiency and safety. It is a range of systems that is exceptionally broad, and is accompanied by an unrivalled degree of technical expertise.
A constantly evolving and expanding product range requires specialised knowledge for best usage. The advice available covers not only material selection and pipe sizing for effective performance, but also training where required to ensure a durable and safe installation.
Chemical Industry
The uniquely corrosive nature of the materials used in chemical industries leads to the need for optimum quality in the manufacture and design of pipework.
The response by GPS to this requirement has been the development of an extensive range of systems that overcome the problems of conventional materials, leading to longer service life, lower maintenance costs and drastically reduced downtime.
Acknowledging the serious consequences of inaccurate specification or installation in this industry, the highest levels of technical assistance are available. With this in-depth expertise allied to the most progressive products, GPS can provide uncompromising solutions to even the most testing applications.
Shipbuilding
The highly specialised nature of shipbuilding imposes a number of specific requirements for pipelines. Where there is limited space, for example, a method is required which permits fast, efficient installation, even in inaccessible areas.
The system will inevitably be subject to vibration, movement and water-hammer, and must be designed to endure these stresses whilst also offering weight reduction advantages.
GPS have a wealth of experience in the industry and over the years have developed pipework and couplings to meet the specific needs of major shipbuilders the world over. In an industry where reliability and durability are paramount, GPS can deliver.
Mining and Tunnelling
The heavy demands made on pipe systems in mining and tunnelling means the essential features of any system are strength and reliability. Few materials are more abrasive than sludge and slurry, whilst the likelihood of vibration and movement in the vicinity places further pressure on the system.
Through the combined expertise of GPS companies, systems have been developed to provide maximum durability combined with the ability to manage unusually high levels of movement. The key element is flexibility in the use of different materials to suit specific applications.
All the products have been tried and tested in some of the most demanding operations, and have the important added value of offering ease of installation with no specialised equipment required.
Pulp and Paper
In the production of pulp and paper, pipe systems play an indispensable role in the inward and outward transportation of fluids and compressed air. The most effective way to achieve minimal downtime and maintenance is through the quality of the original installation – which in turn depends upon the wide range of products only an organisation on GPS’s scale can provide.
From the supply of process water to the movement of aggressive chemicals for the bleach plant, GPS can provide exactly the right configuration of pipework, be it stainless steel or one of the comprehensive range of modern plastics.
Our technical expertise is a further vital component in the achievement of a thoroughly dependable and hard working system.
Food and Beverage
In an industry where hygiene is an imperative, there can be no compromises made with the pipe systems. Since access to the interior of the system is inevitably restricted, there must be confidence in the design of valves, joints and tubes to resist corrosion and entrapment of bacteria. Another essential is fast, effective cleaning to sterile standards.
It’s significant that GPS companies have a proven track record in developing pipe fittings that meet the extremely stringent regulations for pharmaceutical applications. There is no higher test of their effectiveness in hygiene maintenance.
With an existing range that covers almost all requirements for processing and storage of food and beverages, together with the capacity to develop new products where necessary, GPS offer the ultimate assurance of reliability and efficiency.
A TOTALLY CONSTRUCTIVE APPROACH TO BUILDING SERVICES
For contractors and specifiers of building services the GPS range of pipe systems is a uniquely comprehensive one, providing unprecedented choice and technical capability. The structure of the group allows for genuine specialisation by individual companies to ensure the products meet or exceed current building regulations and are inherently suited to their specific application.
This results in an extremely wide range of materials being exploited, including the traditional options such as cast iron and carbon steel through to the full family of contemporary thermoplastics which have revolutionised building services over the past two decades.
Through GPS the total requirements of a pipework system can be sourced, including fittings, valves, couplings as well as the pipe itself. Their suitability for the building services applications also includes their ease of installation and cost effectiveness – a pre-requisite in an industry where precisely regulated timescales and budgetary constraints are the norm.
It is the level of GPS’s excellence in distribution, both local and worldwide, which also attracts customers. We are always ready to discuss the precise delivery needs of our customer, including JIT, and we can also offer an exceptional depth of technical support to aid with accuracy in product specification and quantity.
As leading suppliers of grooved and shouldered pipe jointing systems, GPS are the automatic choice for fast, secure installation, but in the final analysis we can meet virtually any requirement, whether for heating, ventilation, air conditioning, water, fire protection or drainage, no matter how straightforward or complex the project.
Heating
The capability of a heating system is dependent on the strength of its weakest constituents, which in the case of pipework are the joints. The more the temperature fluctuates, the more the integrity of the joints is tested.
Generally heating systems are designed for longevity and negligible maintenance, which is where the origination and development by GPS of new and more effective methods for joining pipe has led to significant benefits. These include time and cost savings plus a considerable increase in the range and magnitude of working temperatures.
Responding to the needs of contractors over many years, GPS have acquired the skills and products to ensure that simplicity of installation has been combined with enhanced performance.
Air Conditioning and Refrigeration
Not only the use, but also the quality, of air conditioning in modern buildings is a requirement that is ever increasing, as is the need for reliable refrigeration. In response to this GPS have developed a range of advanced systems which meet the current demands of building services, covering offices, homes, hotels, hospitals and retail buildings.
Safe containment of the cooling medium is of course a prior consideration, along with the service longevity of the system. High resistance to corrosion, for example, is essential owing to high levels of condensation, and in refrigeration applications temperatures can be as low as – 40°C testing the integrity of the joints.
Systems supplied by GPS allow ease of installation, minimal maintenance and reduced insulation – all factors that can contribute towards significant cost savings.
Hot and Cold Water
The wide spectrum of materials, valves, fittings and diameters available from GPS, enables the design consultant to specify the best solution to the distribution of hot and cold water in a comprehensive range of commercial, industrial and public building applications.
The long-term performance of the system can be assured since all GPS products are designed and manufactured to recognised standards. Hot water reaching temperatures up to 95°C is particularly testing of the joint integrity, and this is an area where GPS can offer the latest designs to ensure increased reliability.
In short, for the total answer to hot and cold water distribution, GPS is the only source the specifier needs.
Fire Protection
The pipework in a sprinkler system plays a unique role. Generally dormant it nevertheless has to perform with perfect efficiency in an emergency. Inevitably this is one area where the ability to resist deterioration yet withstand immediate and impromptu water pressures is an absolute essential.
For the specialist contractor, GPS offer a number of advantages, including an unrivalled range of products matched by experienced personnel who can work alongside those with fire protection expertise to reach a customised solution to any problem.
GPS companies have pioneered many of the features that are increasing the dependability of today’s sprinkler systems, but are never complacent. Increasing the high performance capabilities of the pipework and its accessories is an on-going priority.
Drainage
Recent environmental pressures make effective drainage an increasingly critical factor in a wide range of areas – including sewage, soil and waste systems, chemical and industrial drainage.
For example in the case of industrial sewage systems, more and more governments are insisting that the polluter pays, leading to a demand for ever more sophisticated systems including dual containment and leakage detection.
GPS can offer systems both technologically advanced and traditionally reliable depending on the application, from cast iron to PVC, concrete to PE. Added to which the group can boast an expertise in valve and coupling technology that’s second to none, giving GPS a reputation as a highly progressive supplier in this ever more complex market.
Swimming Pools and Irrigation
As a worldwide organisation, GPS have experience in the supply of pipework systems to areas where the climate makes irrigation an intrinsic component of farming, horticulture and recreational amenities.
The key advantage of GPS systems is that they are composed of premium products, designed to withstand the high operating pressures and surges inherent in this type of application. Where laterals are likely to be subjected to UV exposure or abuse by farming equipment, appropriate materials can help to maximise endurance.
But whether the environment is hostile or benign, GPS’s access to a wide range of products means the end result will be a properly specified irrigation system designed to perform consistently and reliably.
PVC is the principal material employed in the pipework for swimming pool installations, and GPS have unparalleled expertise in this area. In fact, it was a company now in the GPS group who produced Europe’s first 100% plastic valve.
Of course since then huge strides have been made in the development and design of PVC pipe systems, and specialisation is the key. GPS can offer valves that are dedicated to swimming pool applications, along with all fittings, controllers and pipe.
The aim is to achieve a balance between quality and value in order to
provide cost-effective solutions that can be relied on to perform with
minimal maintenance even when in constant use.
IN-DEPTH KNOWLEDGE OF UTILITIES
GPS’s expertise in high performance pipework systems for the global utilities market is built on a distinguished history of design and manufacture in this field which goes back as far as 1890.
Today there is no single group of companies who can offer such a
knowledge of the modern requirements of utilities, or invests so much in
anticipating the development of the market. Long established in large
diameter carbon steel systems, GPS has also grown into
Europe’s premier producer of polyethylene pressure pipework systems.
GPS customers benefit not only from currently prevalent materials, but also from innovations made possible by our input into product development, such as a new generation of systems capable of unprecedentedly high operating pressures.
Another area of excellence is that of mechanical couplings, for which GPS have acquired a worldwide reputation as being in the forefront of technical progress. It’s a product range which covers virtually every pipe material and size, from 15mm to 5m.
In fact whatever the requirement, with GPS the key word is flexibility. With a vast selection of products covering everything from fittings and valves to couplings and flow meters, together with a comprehensive range of specialist installation equipment, the group has the capacity to provide exactly the degree of service required.
Whether it’s simply a replacement valve or a total package that includes system design and project management the client is seeking – GPS can provide it. Professionalism and commitment to customer service permeates the group at every level of the workforce.
Water Utilities
With growing pressure on water suppliers around the world to minimise wastage through leaking, the quality of the pipe system has gained new importance and the highest levels of quality are sought.
Particularly at the pumping station, the pipework can be subjected to stress through vibration, whilst underground pipe systems may have to cope with inconsistent pressures. Corrosive materials, including salt water may also be a problem. Through rigorous testing procedures, GPS ensure the products maintain their integrity in these conditions and meet required international standards.
The depth of expertise in the GPS group when it comes to water utilities is vast. From the reservoir to the home, GPS have a range to answer all kinds of application and environmental conditions, including the latest concepts in rehabilitation.
As with gas utilities, re-lining is becoming an increasingly prevalent method of extending the working life of water mains and GPS are developing unique fittings which will make subsequent connections to such installations a much simpler operation.
But above all, GPS offer tried and tested products that have proved their reliability over time where it counts – in day to day usage. Though technically advanced, they are designed for ease of installation and many of the products are regarded as the industry standard.
Gas Utilities
The capability of GPS in the gas utilities sector is virtually unrivalled, and in a service where leaks present a high potential hazard the quality standards GPS maintain is paramount.
Throughout product development, stringent pressure and temperature tests are conducted to ensure the pipework is resilient to both interior and exterior problems – including corrosion and ground loading for underground pipes; light and weather-resistant for exposed products.
One of GPS’s notable strengths is in jointing systems, including specifications where the joints have to remain stronger than the pipe even after a projected fifty years lifespan.
With the increasing sophistication of pipe maintenance through re-lining, GPS have answered the need for specialised fittings with a range of time and cost saving products.
The GPS range is not only technically superior, it is also unusually extensive allowing the specifier to tailor a system very precisely to the needs of the supply and the nature of the installation.
Petrol Forecourts
New and forthcoming legislation combined with environmental concerns over ground water pollution, means that nothing less than a pipeline system dedicated to service-station installations is likely to suffice.
Systems available through GPS can provide zero rated permeation, exceeding all current and draft environmental standards. With a metallic barrier layer, a smooth bore, lightweight and non-corrodible structure, this thermoplastic system is designed to be future-proof and highly efficient in operation.
The jointing system is proven and patented, using welded electrofusion joints to ensure permanent system integrity. For fuel lines, off-set fill and vent vapour recovery this is the technically advanced option
Magazine article for Cummins
Taking the technology forward with Scania
July 2003 was an important milestone in the history of the manufacture of Variable Geometry Turbochargers (VGT) at the Huddersfield plant. It was the date that Scania, Europe’s most profitable truck manufacturer and a long and loyal customer of Cummins Turbo Technologies, commissioned us to develop and build a VGT that was actuated electronically rather than pneumatically.
Variable Geometry Turbochargers are used to counter turbo lag at low speeds, as well as helping to reduce exhaust emissions in diesel engines. We have been involved in developing this technology since 1996 when a modest 100 turbochargers per week were coming off the bench.
Today around 1,300 units are being produced weekly, and with the new Scania deal this is expected to increase significantly. That’s because the turbochargers are destined for Scania’s popular 9 and 12 litre Euro 5 engines, with Cummins Turbo Technologies supplying all the Electronic Variable Geometry Turbochargers (EVGT) required. In fact, it’s estimated that sales will be around 26,000 a year.
The new turbochargers are the result of extensive research and development involving Scania’s engineering department. The final agreed design was completed in April 2006 which gave the green light for developing, sourcing and manufacturing the new equipment and processes at Huddersfield. This resulted in a combined operation involving the in-house Maintenance department, Laboratory Operations, the Operations Engineering Group, Special Products and the Production Engineering Department.
So precisely what changes were involved?
First, extensive modifications had to be made to the assembly line producing the EVGT. This included two new stations to check how the electronic actuator is functioning before assembly as well as performing the hysteresis test on the turbo.
Another important change was that the line failsafes had to be re-positioned to accommodate the larger outline of the turbo, and a whole new bench had to be commissioned to make sure that the setting process for the bearing housing sub assembly, nozzle ring and sector gear was failsafed. This was to ensure the correct parts were built into the turbocharger.
Last but not least, all the new equipment had to be tested and implemented, but without losing any productivity for our other valued VGT customer, Iveco!
The launch of the very first EVGT was of course a special occasion, and the culmination of a huge amount of brainwork and engineering expertise. Scania were present and were very complimentary about the processes we were using to build their turbocharger. The next chapter in the story will be to provide new components for the smaller HE400Ve which will be in production from May of this year.