Products

Farrat works with Production Engineers and OEM’s (Original Equipment Manufacturers) within high-capacity rolling mills around the world, to ensure the accuracy and efficiency of a wide range of machinery through vibration control.

A key role we play within the rolled metal and aluminum industry is preventing ‘chatter’.

Chatter refers to the inaccuracies and/or faults in the finish of a manufactured product as a result of vibration sources impacting machine accuracy.

In the recent case study below, we demonstrate how Tuned Mass Dampers can be used as an effective industrial vibrational solution for large milling machines.

The Scenario

Farrat was contacted by the Production Manager at a global aeronautics company, who had identified reporting issues with the performance of a large milling machine within a busy manufacturing plant.

The milling machine was used to machine titanium aero-engine components; therefore, accuracy was essential for the precision part.

On further inspection by Farrat Applications Engineers, the machine was noticeably severely hampered by chatter instability, occurring at the 64 Hz frequency.

The Investigation

Farrat Applications Engineers conducted modal analysis to measure the effects of vibrations on surrounding machinery, as well as activity on the milling machine. The data showed that torsional resonance of the spindle and drivetrain was causing the issue.

If left unresolved, the chatter disturbance would continue and potentially worsen as the effects of the vibration increasingly affected the milling accuracy.

The Conclusion

In order to reduce the effects of the surrounding vibration, a vibration Tuned Mass Damper was fitted to the rear face of the milling cutter. The damper was then carefully tuned to the specific frequency of the torsional resonance that was disrupting the performance of the milling machine, resolving the torsional vibration problems.

As a result of this damper being installed, the chatter was completely eliminated, and the milling machine has performed at the required level of accuracy ever since.

 

For more information on how we’re supporting manufacturers and machine refurbishers with our vibration consultancy, analysis, and troubleshooting services, take a look at our Industrial Vibration Isolation hub or contact our Industrial Applications team.

 

#onamission

It has been widely shared that buildings and construction are responsible for almost 40% of global carbon emissions driving rapid climate change.

But, did you know that at the current rate of construction, the world is forecast to build more than 2 trillion square feet of floor space in the next 40 years? In their current form, a considerable proportion of these buildings will be constructed out of concrete, with cement as its main ingredient (a notorious greenhouse gas emitter).

A simple route to reducing carbon emissions in the race to net-zero is to design and build smarter. By this, we mean reducing the volume of materials required in construction, reusing/repurposing where possible, and opting for high-performance materials with superior efficiency credentials at the point of the specification.

This sentiment is echoed in a recent report published by the Royal Academy of Engineering on ‘Decarbonising Construction’, which notes that the following aspects will be vital in achieving net-zero transformation in the construction sector:

• availability and specification of low-carbon materials,
• reusing materials as standard,
• and low-carbon procurement.

In our latest insight below, we further explore the role of sustainable building materials in the built environment to understand how our Structural Thermal Break solutions align with the agenda.

Utilising sustainable building materials in construction

Reduce, recycle and reuse

Structural steelwork and lightweight gauge steel can be recycled and reused multiple times. As a result, steel is increasingly selected as a reliable material for constructing robust structures that meet the low carbon demands of the future without compromising on design, practicality, or cost-efficiency.

The recovery rates from demolition sites in the UK are 99% for structural steelwork and 96% for all steel construction products – figures that far exceed those for any other construction material. And the superior strength-to-weight ratio of steel as a construction material, also means that a little goes a long way. This unique characteristic gives steel a high economic value at all stages of its life cycle.

By utilising more recyclable building materials, the industry contributes to more sustainable development by reducing waste and by saving primary resources. Recycling materials such as steel and other metals also save energy and reduce carbon emissions, since it requires less energy to re-melt scrap than it does to produce new metal from primary resources, i.e., iron ore.

The primary benefits of recycling sustainable building materials are well understood and include:

• Reducing waste, i.e., diverting waste from landfill
• Saving primary resources, i.e., substituting primary production
• Saving energy and associated greenhouse gas emissions through less energy-intensive reprocessing.

Although these benefits apply to many commonly recycled materials, there are some significant differences in the properties of materials that influence the environmental benefit of recycling and particularly how these benefits are quantified.

Metals, for example, are infinitely recyclable, i.e., they can be recycled repeatedly into functionally equivalent products – this is the most environmentally beneficial form of recycling.

Other products are ‘down-cycled’ into new products that are only suitable for lower grade applications because the recycled product has different, usually lower, material properties. Although waste is diverted from landfills by down-cycling, only lower-grade primary resources are saved.

For example, crushing bricks and concrete for hardcore, sub-base, or general fill saves aggregates but does not save the resources required to make new bricks or new concrete.

BHC steelwork erection at Cineworld Hounslow in 2019

For recycling to be sustainable in the long term, it is important that the recycling process is financially viable. This is frequently the biggest hurdle to recycling, particularly for products and materials that are downcycled into lower grade, low-value applications.

Current end-of-life scenarios for three of the most common construction materials; concrete, timber and steel are shown below. The illustration describes the end-of-life outcomes of these materials against the established UK Waste Hierarchy:

Moving towards more sustainable procurement

Steel production is currently a source of greenhouse gas emissions (7% in 2020); however, the good news is that a revolution in steel production is now within reach.

The amount of energy used in steel manufacture has fallen by some 61% since the 1960s, according to World Steel Association data (2020), and further improvements are being sought from steel sector research and development investments.

In 2020, 1.8 gigatons (GT) of steel were produced, accounting for 90% of all metals globally. Major steel-producing countries, including China, Japan, the EU, and now the US, have set ambitious targets to reach net-zero economies. Achieving these demands will further advance the material efficiency of steel and the greater recycling of scrap steel.

In 2005, the British Constructional Steelwork Association (BCSA) became the first steel representative organisation in the UK to launch a Sustainability Charter. This was updated and strengthened in 2021 in response to the climate emergency. The objective of the Charter is to further advance steel as a sustainable form of construction in terms of carbon reduction, reuse and efficiency, economic viability, social progress, and environmental responsibility.

Similarly, leading manufacturers and suppliers of structural steel in the UK, British Steel, and Tata Steel, are certified under the BRE Environmental & Sustainability Standard BES 6001, a responsible sourcing certification for the UK construction market.

For these companies, sustainable procurement is part of wider corporate responsibility.

Severfield installing steel connections with Farrat TBK Structural Thermal Breaks at 22 Bishopsgate, London

Thermal efficiency in modern steel design

In respect of the energy efficiency of buildings constructed with steel, low and zero-carbon buildings, and buildings with high BREEAM ratings are readily achievable using steel construction.

Structural Thermal Breaks are commonly integrated into primary and secondary steel connections as high-performance thermal insulators that provide a robust solution to minimising energy loss in steel construction.

Performance characteristics of Farrat thermal break materials include low thermal conductivity, high compressive strength, and limited creep under load, which provides Steel Contractors and Structural Engineers with complete flexibility to modify typical structural steel details with confidence, without compromising thermal efficiency or conformance.

And unlike general thermal insulation materials on the market, Farrat Structural Thermal Breaks are suitable to mitigate against planar, linear, and point load thermal bridging whilst carrying structural loads, which means that they can be used anywhere a penetration or transition exists in a building envelope, helping Architects and designers to achieve the highest levels of building performance and energy standards.

Thermal efficiency credentials

Passive House is one of the highest standards for energy efficiency, granting certification to structures, components, and professionals who have achieved and designed the best in quality, efficiency, and sustainability. The criteria to gain the title of ‘Certified Passive House Component’ is based on two categories: living health and comfort (‘Comfort criteria’) and energy balance during practical application (‘Energy criteria’).

In 2019, Farrat’s high-strength Structural Thermal Break material Farrat TBK, was listed as a Certified Passive House Component by the Passive House Institute in recognition of its low thermal conductivity and superior energy efficiency performance.

Following this in 2020, Farrat’s A2 non-combustible fire-rated Structural Thermal Break material, Farrat TBF, was entered as an approved product into the BRE (Building Research Establishment) Certified Thermal Details and Products Scheme and was also awarded BBA (British Board of Agreement) certification.

The BRE is an international independent certification body, operating with the highest standards in the certification of fire, security, and environmental products and services, management processes, and other products and systems. Details provided within the BRE scheme are invaluable to building design professionals committed to creating energy-efficient structures and are especially useful for architects and structural engineers at the specification stage.

BRE Certified Thermal Details for both Farrat TBK and Farrat TBF thermal breaks are available online here.

“We have always placed a strong emphasis on impartial assessment and certification for our structural thermal break materials,” says Chris Lister, Commercial Manager of Structural Thermal Breaks at Farrat.

“It enables us to back up our commitment to creating cutting edge materials with practical value and sustainability, for buildings and structures of the future.”

Summary

Specifiers and contractors are responsible for addressing some of the biggest challenges facing the building construction industry in the race to net-zero.

Meeting these challenges head-on in terms of innovative energy efficiency, intelligent building design, and responsible sustainable building materials choices will be a key driver in reaching sustainability targets and safeguarding the future of the world.

For more information on integrating thermal break solutions into typical, or bespoke, structural steel connections, visit our Structural Thermal Break hub or one of our dedicated portals:

• Architects Portal
• Structural Engineers Portal
• Buyers Portal

 

#onamission

A simple guide to the Farrat Chatter_Detect system

 

What is Chatter_Detect?

Chatter_Detect is a stand-alone PC-based post-process roll surface inspection system, used for the detection of regular undulations that might grind into the surface of a finish-ground metal roll. These imperfections are caused by vibrations generated during the grinding process.

The hardware is contained in a Chatter_Detect enclosure which is normally mounted on the wheel head of the machine, as shown in Figure 1.

When is it used and why?

Vibration generated by the grinding process may cause undulations to grind into the surface of the metal roll. The degree of which depends on the type of vibration and its frequency relative to the speed of rotation of the roll.

The undulations can be parallel with the roll axis or can lie at an oblique angle to the roll axis.

If they are of sufficient depth, they may appear as “chatter marks”, as shown in Figure 2.

However, most often they are either difficult, or impossible to see by eye, but are significant enough to affect the rolling process. The Chatter_Detect system is designed to detect these invisible marks and to measure their pitch and depth.

How does it work?

The system uses a non-contacting displacement sensor to measure the topography of a finished roll circumference. The test results are displayed as shown in Figure 3 below.

There are two main windows:

The upper window shows a graphical plot of the roll surface to provide an exact visual representation of the topography of the roll circumference, “unpeeled” and laid out flat. The undulations in the surface are the chatter marks. This window shows whether the marks are continuous or localised – in the example above they can be seen to be continuous.

The lower window shows a histogram in which the circumference of the roll is split into equal sectors. The depth of any regular marks detected in each sector is represented by the height of the bars (coloured green or red depending on whether the detected marks exceed a user-settable threshold or not). The actual marking pitch is displayed numerically above each bar. The position of the marks around the circumference of the roll relative to the trigger point is also displayed.

What are the benefits?

The Chatter_Detect software is proving successful in helping several Aluminium producers ensure that all ground rolls sent to the mill are free from chatter marks, resulting in almost complete eradication of strip chatter and increased throughput.

---

 

Testimonials from Farrat Chatter_Detect users:

Andy Wilkes, TSM2 Mill Start Up & Roll Grinding Manager at Bridgnorth Aluminium, UK

“Since our acquisition of the Chatter_Detect system, we have not had a single issue of strip chatter, as the system ensures that all rolls sent to the mill are free from chatter. Because of the success of the system an additional system has recently been acquired by Bridgnorth Aluminium”.

 

Francis RINGLER, General Manager at Rhenaroll, France

”Chatter_Detect and AVAS Monitoring Systems are proving to be very useful on our grinding machine, helping our operators find the best grinding conditions that minimise vibrations and ensure chatter free rolls”.

 

---

Further development

Recently, at the request of several customers, a vibration monitoring module has been integrated within the Chatter_Detect software (using the same enclosure as above, but with additional hardware including 2 accelerometers and signal conditioning hardware).

This monitors the vibration of the machine during grinding and warns the operator when the levels of vibration exceed a threshold level, turning the green bar graph into red, as illustrated in Figure 4.

The operator normally reacts to this by changing his grinding conditions (feeds and speeds) in a way that the alarm level reduces and turns to green colour.

Several monitoring screens are available, for example on the spectrum screen (Figure 5) it is possible to link each frequency component with a marking pitch, by simply moving the cursor along the frequency axis. This helps in identifying which frequency component is responsible for chatter on the roll, which is invaluable information for the maintenance engineer.

This monitoring option is proving to be very useful for the operators, as explained in the testimonials above.

Most of the systems sold by Farrat in the last couple of years include this option.

Did you find this Farrat 101 Article useful?

For more information on Chatter_Detect and to explore how Farrat can support manufacturers and machine refurbishers with rapid on-site services, please visit our Vibration & Chatter Control of Machinery page.

Ashley Road East (ARE) is a new 183-unit mixed-use development located in Tottenham Hale, set to play an important role in defining the area’s regeneration with the construction of two residential blocks, retail and office space.

Due to the developments prime London location, Farrat were contacted at pre-construction phase to help develop a variety of isolation solutions to mitigate against both structural and thermal disturbances impacting building performance.

Farrat in London redevelopment

Ashley Road East is just one of many projects currently underway in the country’s capital with the help of Farrat. If you take a walk through London you will see evidence of our teams hard work across a large number of redevelopments and projects.

For more information on how our engineers can work with your design teams, fabricators and on-site contractors to integrate building vibration isolation and fire resistant structural thermal break solutions, contact our team here.

 

#OnAMission

As part of our recent winter fundraising campaign – during which Farrat employees collectively covered over 3,000km from our office in Altrincham to reach Santa’s village in Lapland raising funds for 5 charities – Senior Project Delivery Manager, Neil Wilson, completed a jog around London to take in some of our recent projects whilst clocking up his distance.  

Setting out from the Everyman Cinema near Kings Cross (where Farrat CineWALL PRO provides the acoustic isolation for auditorium screens), Neil finished up at the new sustainable Google HQ which is currently under construction and integrates Farrat high-performance bridge bearings. 

On his tour, Neil passed a dozen other Farrat projects, including:  

• The former Royal Mail location, which was recently converted into 681 high class residential spaces and utilises bespoke Farrat acoustic floating floors to overcome the vibration control challenges that the busy location generates.  
• A theatre project on St Giles Circus junction in the West End of London, which is surrounded by a tangle of underground tunnels and features another bespoke Farrat floating floor to mitigate noise disturbance. 

• Ilona Rose House, a mixed-use commercial development comprising of retail, restaurants, roof terraces and pedestrian walkways, which are set to generate much needed employment into the area.  Here Farrat supplied Structural Thermal Breaks to reduce heat loss and mitigate against thermal bridging.
• VUE Cinema in Leicester Square, which has originally built in 1938, but re-opened in 2017 following a major refurbishment complete with leather reclining seats, Sony 4K digital projection and Dolby Atmos sound.  Farrat cinema isolation materials were engineered into the IMAX screen to ensure optimal acoustic isolation and the best possible viewing experience.
• Queen Street, a residential property that utilises the Farrat CineFLOOR system to isolate vibrations from the busy surrounding environment. 
• Just down the road, another residential project – 60 Curzon Street – where Farrat designed, engineered and manufactured the structural bearings that hold the weight of the load bearing walls above.
• Claridge’s (a building that needs no introduction in London), which underwent a major extension between 2019 and 2020 and where Farrat supplied acoustic pads within a CineFLOOR LITE system to ensure that surrounding hustle and bustle does not interfere with the guest’s comfort.

• 20 Grosvenor Square, a super prime residential development built between 2014 and 2018.  Farrat worked closely with the project team to not only provided the Structural Thermal Breaks to insulate the building efficiently, but a full building vibration isolation system incorporating the Farrat CineFLOOR PRO range to isolate the building from surrounding vibrations, which became an integral part of the entire project.  
• Neil then passed by the award-winning Royal Academy of Music, where Farrat developed a bespoke acoustic isolation system.  And just a little further along, Regents Crescent, another super prime residential centre where Farrat provided the Structural Thermal Breaks as well as structural bearings and Farrat CineFLOOR PRO for vibration isolation.  

 His last two stops before finishing at the new Google Headquarters were the Royal College of General Practitioners – a 290 seat auditorium with the added complication of being a Grade 2 listed building, with strict regulations to work around – and Cartwright Gardens – central London student accommodation.   

It is amazing to be able to see such huge engineering achievements delivered by Farrat in this one – albeit long – run, and demonstrate how Farrat is playing a key role in developing our nation’s capital; working around networks of underground and overground trains, main roads and surrounding hospitality venues as well as nearby airports, to delight our customers.   

#onamission 

The massive renovation project at the Riverside Studios came to a close with the opening of the most modern TV studio in the whole of the UK. It also has two theatre spaces with 200 and 500 seat capacity, 2 cinemas and social facilities such as a café, coffee shop and bar.

Farrat were pleased to be a big part of this innovative building whose key aim was to have sound isolation so great that productions could run simultaneously without disrupting each other. The studios in particular were designed with a complete “box-in-box” design enabling maximum use at all times.

Farrat were involved with the sound insulation of the cinemas and studios one, two and three. A mix of bearings were used to ensure sound was isolated to the extent that it would not be heard or felt anywhere else in the building, including Farrat Acoustic Laminated Bearings and Farrat Hybrid Bearings. Other materials used to achieve this effect include Farrat ISOMAT and Farrat AWSTC Acoustic Washers.

Farrat were involved with the sound insulation of the cinemas and studios one, two and three. A mix of bearings were used to ensure sound was isolated to the extent that it would not be heard or felt anywhere else in the building, including Farrat Acoustic Laminated Bearings and Farrat Hybrid Bearings. Other materials used to achieve this effect include Farrat ISOMAT and Farrat AWSTC Acoustic Washers.

Artistic director of the space, William Burdett-Coutts, said: ‘To see Riverside Studios reopen its doors to the public is the culmination of a dream. Whilst the old building held an extremely fond place in the hearts of people across the arts, television and film worlds it had all the benefits and problems of a “found space”. Essentially it began life as a Victorian factory and through a number of different incarnations played a part in all these different worlds.

‘Today the new building combines all these interests into a fantastic new public facility which can realise the potential for this incredible site in London. The artists that have passed through the building are legendary and we look forward to welcoming many more in future and making this a place the public feel they can enjoy and cherish.’

Farrat has unveiled the markets first A2 Fire Rated Structural Thermal Break ‘Farrat TBF’ this week, following 12 months of research and development in consultation with Salford and Manchester Universities, material scientists and specialist raw material producers.

Farrat TBF is a very limited combustibility Structural Thermal Break material designed to maintain full structural integrity in the event of fire.

Alongside its limited combustibility, the new Farrat TBF material stands alongside the markets best performing thermal insulators, with very high compressive strength and low thermal conductivity – preventing thermal bridges from forming between structural connections and mitigating against the risk of condensation, mould or corrosion.

Farrat TBF has been independently tested and verified to the latest industry standards, with a limited combustible calorific rating achieved to EN 1716.

Farrat TBF is verified to maintain its very high structural performance and compressive strength to 500° under EN ISO 604 and is consequently compliant for use under Document B Building Regulations for buildings above 18m.

“The addition of Farrat TBF to our Structural Thermal break range is in response to several enquiries from our clients regarding a fire-safe thermal break product,” explains Chris Lister, Commercial Manager for Thermal Products.

“The intention is that Farrat TBF acts as a reliable, effective and readily-available material for fabricators and designers that are looking to meet multiple building regulations relating to fire, heat loss and energy performance with the one Structural Thermal Break product. We expected Farrat TBF to be favoured and especially suitable for thermally insulating structural connections on high-rise developments and buildings above 18m.”

Farrat TBF is available for procurement worldwide from November 1st 2019 and is already set to be used in products around the UK.

Farrat TBK Structural Thermal Break Plates have been granted a ‘Certified Passive House Component’ by the Passive House Institute.

Passive House is the standard for energy efficiency, granting certification to structures, components and professionals who have achieved the very best in quality, efficiency and sustainability.

The criteria to gain the title of ‘Certified Passive House Component’ is based on two categories:

• Living health and comfort (‘Comfort criteria’) and
• Energy balance during practical application (‘Energy criteria’)

Components that carry this certification have been tested according to these aforementioned criteria and are of a high standard regarding energy efficiency. This ensures that the specific use of the component meets the essential needs and functions of the professionals that require it (architects, structural engineers, technicians).

Farrat Structural Thermal Break Plates have received multiple certifications in the past. However, this is the first Farrat solution that has received Passive House Certification, cementing Farrat’s committed to developing innovative high-performance building materials with proven performance.

Passive House certification also fits closely into Farrat’s core values of Customer Service Excellence, Responsibility, Ambition and Quality, by ensuring quality assurance, performance and trust in manufacturing excellence.

“Farrat are very proud to have achieved certification to such a highly regarded standard as Passive House. Achieving exemplar level performance with our TBK material confirms our belief in the merits of solid state structural thermal breaks and the benefits of their use throughout general construction detailing.”

Chris Lister, Commercial Manager, Thermal Products

---

Farrat’s Passive House certificated Structural Thermal Break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat Structural Thermal Breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

To contact us click here or get in touch on +44 (0) 161 924 1600.

Over the last few weeks, Farrat Production & Operations Teams have been busy working round the clock to manufacture and deliver a diverse range of high-performance isolation systems to some incredible projects located around the world.

Below we have highlighted just a few examples of the solutions that have been manufactured and dispatched in the last few weeks, by our hardworking and passionate team.

200x Farrat Isoblocs for installation under Presses in Taiwan to provide high-load shock isolation.

68x Laminated Natural Rubber (LNR) Bearings for a London Hotel being built next to a music venue.

14x pallets of Anti-Vibration Materials to configure Isolated Foundations for a Canning factory in France.

30x CineSTEEL MAX acoustic isolators for the raked seating in the new Cineworld 4DX in Cheltenham.

These particular isolation systems required Farrat resources across Engineering & Design, Rubber Moulding, Waterjet, Assembly and Dispatch to work together to produce a fit-for-purpose solution that met the client brief and could be delivered on time.

As with all Farrat products and solutions, they were manufactured under an ISO 9001:2015 Quality Assurance System and the international ISO 14001:2015 Environmental Management Standard.

These latest projects making their way out the door demonstrate a great effort by all involved and are a prime example of how teams at Farrat work together to flow customer value through the organisation and achieve great things.

Reflecting our ongoing, shared commitment to provide our customers – wherever they are in the world – with the best technical solutions to their engineering challenges.

For more information on our Manufacturing capabilities click here.

We are pleased to bring to market our highest-performance and most advanced grade of commercial floating floor yet: CineFLOOR MAX.

Engineered to meet the specific and rigorous acoustic demands of 4DX auditoria, the new CineFLOOR MAX system incorporates high damping isolators to control and constrain vibration, while still providing exceptionally high levels of sound insulation performance.

Development of the CineFLOOR MAX system began following Farrat’s role in the design, supply and installation of the new Cineworld Bracknell – one of the first purpose built 4DX Cinemas in the UK – as well as several years of research into cinema motion technology. 

MAX System Features:

CineFLOOR MAX is future-proofed using the most extreme calibration routines from 4DX suppliers.

The MAX system not only isolates the vibration from adjacent auditoria, but also controls the slab response that the 4DX seats are mounted to, offering superior motion feedback and a more immersive 4D experience.

CineFLOOR MAX floating slabs can be designed with a fully fibre reinforced concrete to allow easy seat installation without the risk of hitting the rebar and self-compacting concrete can also be used to ensure high flatness tolerance is achieved, to allow vinyl or carpet to be laid directly on top of it.

 

MAX Design Details:

• CineFLOOR MAX Design Details 
• Download CineFLOOR MAX Data Sheet

 

MAX Grade Suitability:

CineFLOOR MAX sits at the top end of the CineFLOOR range, engineered to provide the highest levels of acoustic isolation performance for the most demanding cinema applications – predominantly 4DX and multiplex cinemas. Our ultimate aim for CineFLOOR MAX is to enhance movie-goers’ 4DX experience and maximise value/impact for cinema developers.

To identify which grade of CineFLOOR is right for your auditorium, use our suitability table here.

---

Farrat has designed and delivered acoustic isolation solutions for many of the world’s largest and most striking multiplex cinema projects and the Building Acoustics team at Farrat has decades of experience creating state-of-the-art acoustic environments within cinemas.

For further information on CineFLOOR MAX, or to discuss a project, Contact Farrat Building Acoustics Team.