Projects

How Tuned Mass Dampers can cure torsional vibration problems on large milling machines

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.

torsional vibration problems
torsional vibration problems graph

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

Resolving torsional vibration problems Tuned Mass Damper

Industrial Vibration Isolation – a showcase of our latest projects

In our latest project showcase below, we share a few of our recent Industrial Vibration Control projects, which highlight how our expert vibration control systems are being used to maximise accuracy, efficiency, and ensure the health & safety of production employees across can making and power generation industries.

The Lakeside EfW facility, UK

Based near Slough, this energy from waste power plant processes over 450,000 tonnes of residual waste per year, whilst generating 306GWh of power. It led the way in terms of environmental impact back in 2017, by becoming the first in the country to achieve the zero waste to landfill target by recycling all the residues left behind from waste processing and turning it into sustainable energy.

An education centre is located adjacent to the facility, where schools and other groups can learn about sustainable waste management and energy from waste to promote the switch to zero waste in the future.

Farrat have designed and manufactured a bespoke vibration control system, which is currently being installed on critical overhead machinery within the facility, to maximise efficiency and minimise the effects of vibration on the surrounding structure.

Lakeside facility Industrial Vibration Isolation

Farrat NR62 Hybrid Bearings and bespoke Shear Key Bearings form part of the overall solution to support the crane structure.

Cylon Cans Isolated Foundations

Ceylon Beverage Can, Sri Lanka

This is the most advanced facility in the region with state-of-the-art technology in metal forming and printing. The plant is equipped with the latest machinery and quality gauges with the capacity of producing 720 million cans and 2 billion ends per year. With cans as a highly recyclable liquid packaging option on the increase due to their sustainability credentials, the efficient running of this facility is essential to meet demand.

Farrat recently completed a machine foundation isolation project for a cupper press and bodymaker that was installed on site. The vibration isolation system comprised of Farrat Isomat , which is made from Nitrile rubber, and Vidam, which is made of cork composite.

Farrat Isomat offers excellent damping characteristics for impact applications such as presses, while Vidam works well to damp lateral loads coming onto the foundation walls. Together the anti-vibration materials work to mitigate the impact of vibration on the machinery, and ensure high levels of productivity and efficiency.

Pomini Tenova, Italy

Pomini Tenova is a global leader in the production of roll grinders, for rolls belonging to flat products mills such as steel and other non-ferrous metals such as copper and aluminum, processed in beverage can manufacturing plants and paper mills. Pomini Tenova also delivers special machines for the grinding of heavy components across the industrial sector.

A bespoke Farrat Isolated Foundation system was recently supplied for two roll grinding machines, that went on to be installed at a sheet metal plant in the United States.

This form of precision equipment should be protected from all sources of external vibrations, to avoid chatter marks on the finished rolls (reducing wastage), and also to ensure the health & safety of both the machinery and employees.

Pomini Tenova Isolated Foundations

The Farrat industrial vibration isolation solution was engineered from a combination of Farrat Isomat base isolators and Farrat Isofoam Wall isolators. This solution effectively isolates all incoming frequencies from the base, as well as walls of the foundation, and improves the overall efficiency of the machine.

On a mission across the globe

The growth of the can-making industry means that with the right incentives, liquid packaging using cans could become 100% recyclable, and our vibration isolation solutions ensure that the manufacturing of these cans and tops can be done at optimal levels of productivity and efficiency.

Where businesses are committing to zero waste, onsite recycling, and energy generation through original approaches, Farrat is equally committed to using our specialist knowledge and bespoke vibration isolation solutions to optimise these innovative solutions.

 

For more information on Farrat Industrial Vibration Isolation solutions including Isolated Foundations take a look at our Industrial Vibration Control centre, or our  Can Making Hub.

 

#onamission

Structural Thermal Breaks – a showcase of energy efficiency projects

We are pleased to share a few of our recent and upcoming projects, which highlight where Structural Thermal Breaks are commonly utilised across the building  construction industry to maximise energy efficiency.

Medius House, central London

As part of the redevelopment and refurbishment of Castlewood House and Medius House on New Oxford Street, this scheme will deliver 20 new affordable homes built over retail units in a central location, without losing the Grade II-listed façade of the existing building.

Farrat are working with Skanska to achieve the highest standard of structural and thermal insulation, with the supply of our high-strength, fire-rated Structural Thermal Break material Farrat TBF.  In a densely populated area such as central London, energy efficiency and fire safety are both vital considerations. Using an A2 Non-combustible thermal break not only achieved energy reducing thermal performance at the structural penetrations but also ensured the highest levels of building envelope fire safety.

The £83M design and build project is still in progress and we look forward to it’s completion in the future.

Medius House Farrrat FTB
Millford Green
Millford Green - image from Open Doors Construction

Millford Green

Farrat are supporting Willmott Dixon to deliver their first net-zero carbon project, with the supply of our low thermal conductivity and high compressive strength Structural Thermal Break material: Farrat TBK. Farrat TBK is the optimum balance of thermal and structural performance being as strong as steel but with over 100% better insulation performance.

The state-of-the-art carbon-neutral retirement living village will compromise of 80 apartments and one assisted living block at the centre of a sustainable village complex. Additional facilities will include a restaurant, swimming pool, yoga deck, library, craft room, and bike and buggy stores.

Gorton Community Hub

Gorton Community Hub is a new £22m community hub recently approved by Manchester Council for construction on a brownfield site in the previous location of a suburban pub.

Farrat is supplying A2 fire-rated Structural Thermal Breaks for integration into the steel-to-steel connections, to ensure structural integrity whilst assisting in achieving the highest levels of thermal performance.

The facility is set to be a ‘one-stop shop’ at the heart of the local community, which will enable residents to access much-needed services – bringing together doctor’s surgeries, mental health care services, and a library in one centre.

Farrat will supply A2 fire-rated Structural Thermal Breaks for integration between steel connections, to ensure structural integrity and provide high-performance thermal insulation.

Gorton Community Hub - image from Manchester Council

Travel Lodge Est Docklands

Farrat are supporting PTSG Access to deliver a new build contemporary Travelodge in the East India Dock area of London Docklands, on an undeveloped nearby brownfield site.

As well as allowing solid structural connections between external elements and the main structure, Farrat Structural Thermal Breaks reduce the heat sapping effects of thermal bridges making it possible for designs to meet the stringent energy performance requirements of a modern building.

The design is further reflective of the hospitality industry’s new focus on reducing their impact on the environment, with 40 percent of all parking spaces assigned as electric charging points. The hotel will also feature a ‘pocket park’ with enhanced landscaping to the perimeter with planting designed to mitigate air pollution.

Engineers on a mission for 2022

Farrat supports clients to deliver a wide range of projects across the world, with an increasing focus on social usefulness, energy efficiency, and sustainability. This might include bringing integrated services to regions that need them, working around issues surrounding utilising brownfield sites over greenfield, the promotion of the most reusable and recyclable materials such as steel, and superior insulation.

We are dedicated to continuing to work alongside forward-thinking partners and clients in 2022 to create the most energy-efficient and sustainable buildings, without compromising on design.

#onamission

Farrat celebrate six years of engineering innovation with Clancy Consulting

Over the last 62 years, Farrat have successfully partnered with a range of local, national, and international organisations that share a passion for solving complex engineering innovation challenges in a bid to make lives better. This has included research partnerships with education authorities, collaborations with leading industry institutions as professional members, supporting and engaging with STEM organisations to offer work placements, and submitting Farrat products and services to the scrutiny of 3rd party testing and accreditation.

However, the ongoing partnership with multi-discipline engineering firm Clancy Consulting stands out as one of the most successful series of collaborations that have contributed to Farrat’s advanced engineering achievements in UK construction to date.

Uniting to deliver world-class engineering projects

Farrat and Clancy have collaborated on 35 commissions across a range of construction projects within the last six years.

An early notable project was back in 2016 at ADF (Anthology Deptford Foundry) in London, where a specialist building vibration isolation solution was required to provide lateral movement restraint and vertical acoustic isolation. The solution was essential to achieving the ambitions of the client and the wider project design team, due to the proximity of railway tracks on two sides of the site generating prominent levels of disturbing noise and vibration.

Farrat worked with Clancy to design bespoke high-performance Shear Keys that would provide high vertical load capacity capable of eradicating tension in the walls and high shear loads to minimise the number of assemblies required.

Farrat Ashley Road East

Read more about the Building Vibration Isolation developed for Ashley Road East by downloading the Case Study.

More recently in 2020, Farrat and Clancy worked together to deliver Ashley Road East, a new 183-unit mixed-use development located in Tottenham Hale.

A key challenge when building in London is the surrounding network of the London Underground, railway lines, high traffic roads and activity from the busy city life each causing significant noise and vibration disturbance. Vibration generated from the London Underground Victoria Line would cause significant structural problems to the proposed Ashley Road East development site and without building vibration isolation there would be a substantial risk of disruption from structure-borne noise.

Clancy bought Farrat into the project at the pre-construction stage, to assist in developing a variety of isolation solutions to mitigate against both structural and thermal disturbances impacting on building performance.

Together, the team designed a Base Vibration Isolation system as the most efficient long-term solution to ensure a comfortable and safe environment for the entire lifetime of the building. The assemblies within the system were designed, manufactured, and then supplied directly to the ARE site and throughout the construction phase Farrat supported the project team with regular on-site installation guidance and post-installation inspection.

Another complex project was Regents Crescent, a super prime residential development located in London. Following a vibration survey undertaken by Hilson Moran Architects during design stage, it was discovered that the new buildings would be subject to re-radiated noise generated by existing underground train movements beneath the development across Hammersmith & City, Circle, Metropolitan, Jubilee and Bakerloo lines.

Farrat and Clancy worked together to re-engineer the basic shear key design created for 20 Grosvenor Square and tuned it to the different load cases present at Regents Crescent.

The project has since been shortlisted at a finalist for Building Magazine’s Project of the Year award 2021.

 

Additional structural, acoustic, and thermal isolation projects in the engineering innovation partnership portfolio include:

  • 2015: MIHP (Manchester Institute of Health and Performance) part of the Etihad complex
  • 2015: Grosvenor Square
  • 2016: ADF Anthology
  • 2017: 60 Curzon Street
  • 2018: AHW Anthology Tottenham Hale Works
  • 2018-Ongoing: The Factory
  • 2019: 21 Moorfields
  • 2020: Lewisham Exchange
  • 2020: Ashley Road East
  • 2019-21: Thermal Break innovation project
Regents Crescent, London
20 Grosvenor Square, London

Multi-faceted collaboration, trust & respect

In a recently published post-pandemic construction insight released earlier this year, Farrat and Clancy both discussed the impact of recent societal and legislative events on client expectations, best practice, technology utilisation, and subsequent evolution of ‘smarter & more collaborative’ working.

Clancy’s Civil and Structural Associate, Paul Fleming, has also recently reflected on how the relationship with Farrat has evolved:

“Since 2015, Clancy Consulting has been working with Farrat to deliver innovative solutions for whole building isolation. Over several years, there has been an increasing expectation on new developments to deliver the highest standards of acoustic and vibration performance. Whether that is preventing noise and vibration from passing from one area of a building to another or preventing external influences from disturbing the comfort of the internal environment, Farrat and Clancy work together to find the solution.

Clancy has supported Farrat on some significantly challenging projects during this time. Building isolation from ground vibration due to below-ground rail networks often leads to full building isolation being considered as the highest standard of protection. The brief is often simple, ‘we need a break between these two points to carry X Load.’ It is only when you drill into the detail that the challenges of geometry, load path, movement, shear load transfer, collapse tie provision, to name a few, become apparent.”

Bespoke engineered and manufacturred 'Big Bertha' by Farrat & Clancy Consulting

“At the extreme end of things, our affectionately named “Big Bertha”, could deliver 2400kN of shear across the isolation joint as well as a sizable 8400kN vertically. The product is supplied by Farrat to the highest standard of manufacturing and installation support. With our team providing guidance and support through the design and installation stages so that it can be integrated into the construction.

This is a true example of a successful partnership that we are both delighted to be a part of.”

Oliver Farrell, CEO at Farrat agreed with Clancy’s evaluation of the working relationship:

“One of our goals at Farrat is to maximise the return on investment for our clients, which generally means maximising the space available out of already challenging plots of land. To achieve this, like Olympic athletes, we are constantly challenging ourselves to push the boundaries.

Clancy have helped us to achieve this in a wide range of projects to create successful outcomes either by providing the intricate detailed design to get our creative ideas to work or bringing their own creativity to find solutions to impossible challenges. Always with the comfort that the final design will be robust and buildable. They are a pleasure to work with.”

 


For more information on bespoke engineered Building Vibration Isolation solutions, visit our hub here or contact our Technical Team here.

 

#onamission

Working with an international design team to achieve the highest energy efficiency & sustainability standards, for an exciting new high-rise tower located in Morocco’s City of Light

Set to be the tallest building in Africa at 250-metres with 55 stories, Mohammed Tower IV is a new high-rise tower designed by Rafael de la Hoz & Hakim Benjelloun to resemble a rocket on its launch pad. The striking development will be visible from 50km in all directions and forms the centre piece in the Bouregreg Valley Development Project, which plays a leading role in the development programme for Rabat, ‘the City of Light,’ in the Moroccan Capital of Culture. Once complete, the project will provide a luxury hotel, commercial offices, high-end residential apartments, and a viewing sky terrace.

The Challenge

Sustainability and energy efficiency are both primary design considerations in this project, with the client aiming to achieve LEED Gold and HQE quality standards. LEED certification provides an independent guarantee of a building’s green features, with a LEED Gold rating representing first-class leadership in resource-efficient building design, construction, operations, and maintenance.

Farrat were contacted via our export partner in the GCC region, UniGroup, to supply a high-performance, robust, and certified fire-resistant thermal break solution to mitigate against thermal bridging across façade connections for contemporary facade design company Glassline Abu Dhabi. Farrat Structural Thermal Breaks are favoured across the construction industry, as the most efficient & responsible way to thermally separate structural connections and prevent heat loss in the building envelope.

The thermal breaks would form part of a wider sustainable construction program, alongside smart energy efficiency systems such as 3350 m² of photovoltaic solar panels on the South façade, rainwater recovery and wastewater recycling systems and an internal energy recovery system to produce hot water.

Mohammed Tower image
TBF_cut

The Solution

Following a review of the connection designs, Farrat TBF was selected as the optimal structural thermal break material for extensive use across the façade connections of Mohammed Tower, to prevent heat transfer through steel beams where the external building aspects meet the interior.

Farrat TBF is an A2 rated non-combustible structural thermal break material capable of maintaining superior structural performance at temperatures more than 1000°C. Farrat TBF also provides high-level thermal performance to solve structural thermal bridge issues and exceeds all current fire regulatory requirements for buildings above (and below) 18m.

Following several high-rise fire tragedies across the globe, increasing numbers of building designers are looking to go beyond the standard when it comes to fire safety.

The Design

The inherent non-combustible composition of Farrat TBF was the solution to the fire element of the design, allowing unrestricted use in the high-rise construction. Use of the material’s remarkably high compressive force resistance allowed Farrat to assess the transmission of loads through the structural connection, sufficient to maintain performance under influence from weather stresses.

The Outcome

“In designing and securing this high-performance project, Farrat utilised the full extent of our material research & development skills and harnessed our extensive experience of thermal bridging projects in all climates and circumstances around the globe,” states Chris Lister, Commercial Manager of Structural Thermal Breaks at Farrat.

“The resulting construction details are to the highest levels of structural and fire safety performance whilst also being beautiful in their simplicity.”

Structural Thermal Breaks with Farrat

Farrat Structural Thermal Breaks are favored across the construction industry, as the most efficient & responsible way to thermally separate structural connections and prevent heat loss in the building envelope. For more information on using thermal breaks in steel construction, visit our thermal break hub.

#onamission

Farrat reduces spoilage and increases productivity of a Cupper Press within a £115M can making facility in Europe

A Cupper Press was recently installed in a new can making factory in Europe, which was built near to commercial and office buildings in the surrounding area. Following recommendations from a consultancy specialising in vibration and structural dynamics, the Cupper Press was installed on top of an inertia block supported by spring elements and visco-dampers, offering a system natural frequency of 1.25 Hz. However, high movements were reported on the machines Spring Foundation during production and as a result the vibrations were emitting outwards to the neighboring buildings.

The impact of this movement was premature wear on the machine and increased spoilage, reducing the overall productivity of the plant. 

The Challenge

Farrat were contacted to provide a replacement solution that would reduce the excessive movement of the Cupper Press and create a quieter environment for the neighbouring buildings. 

Cupper Presses are commonly used in can manufacturing to produce cylindrical cups from rolls of aluminium or metal. The primary action of this type of machine is to punch discs from sheets at high speeds. This action generates vertical excitations at frequencies determined by the speed of the machine, also known as ‘shocks’.  

These heavy vibrations have damaging effects on the functionality of the machine installation, its systems and components, and the machines overall productivity. Shock induced vibrations can also damage the building by generating waves and noises that propagate out into the environment. It is therefore crucial to ensure that Cupper Presses are installed on suitable vibration control systems to mitigate against these effects. 

The primary element of this challenge was to stiffen the overall system, while preventing excessive vibrations being transmitted around. 

Existing isolation in place: Springs & Visco-dampers
Replacement vibration isolation system - Bearing with Farrat Isomat on steel base
Replacement vibration isolation system - Bearing with Farrat Isomat on steel base

The Solution

Farrat’s application engineers considered several system criteria during the design phase, such as the mass, dimensions, and operating speed of the machine, as well as system stability and the isolation performance required to meet the clients challenging requirements.

To resolve both of the clients issues, Farrat engineered a replacement vibration isolation system configured with bespoke bearings made of a steel base and 2 layers of Isomat isolators.

Learn more about the material properties of Farrat Isomat here.

Performance Results 

A vibration investigation was conducted by Farrat to measure the level of vibration emitted before and after replacement of the spring packs, to assess the efficiency of the Farrat Isomat System.  The results of the survey are presented in the adjacent plot, showing the vertical accelerations measured before replacement with the blue curves, and after installation of the Farrat Isomat Bearing with the orange curves.

Vibrations measured at the feet of the machine are shown on top, on the inertia block in the middle, and on the surrounding factory floor at the bottom. The results were observed at all measured operational machine speeds, between 110 and 170 RPM.  

A significant vibration reduction can be seen in each part of the system, particularly at the operational speed of the Cupper Press at slightly below 2 Hz. This is the frequency where the machine is most likely to be moving & rocking, impacting the process quality. The pre-existing system of springs with visco-dampers has proven unsuitable because of its extremely low natural frequency, which is excessively close to the disturbing frequencies generated by the Cupper Press – increasing the risk of resonance issues. 

Graph plotting the vertical accelerations measured before replacement with the blue curves, and after installation of the Farrat Isomat Bearing with the orange curves.
Graph plotting the vertical accelerations measured in the can making factory, before replacement with the blue curves, and after installation of the Farrat Isomat Bearing with the orange curves.

Conclusion

The client’s requirements have been met by the Farrat Isolated Foundation solution, which has significantly lowered the movements of the machine while maintaining a quiet environment for nearby buildings. This demonstrates the efficiency of Farrat Isomat systems for Cupper Press machine applications, where bespoke design solutions are needed to solve complex engineering challenges.

For more information on how our application engineers can work with your design teams, production managers and OEM partners to integrate industrial vibration control and Isomat System, contact our team here.

 

#onamission

Farrat creates holistic solutions for new London residential scheme Ashley Road East

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.

Challenge 01: Low frequency ground-borne noise and vibration

Farrat Solution: Building Vibration Isolation System

A key challenge when building in London is the surrounding network of the London Underground, railway lines, high traffic roads and activity from the busy city life, and this development is no exception. Vibration generated from the London Underground Victoria Line would cause significant structural problems and without building vibration isolation there would be a high risk of disruption from structure-borne noise.

Farrat designed a Base Vibration Isolation system as the most efficient long-term solution for ARE, to ensure a comfortable and safe environment for the entire lifetime of the building. The Farrat assemblies within the system were designed,  manufactured and then supplied by Farrat directly to the ARE site. Throughout the construction phase, Farrat supported the project team with regular on-site installation guidance and post-installation inspection.

Read more about the Building Vibration Isolation developed for Ashley Road East by downloading the Case Study.

Farrat Ashley Road East

Challenge 2: Thermal bridging in high-rise balcony connections

Farrat Solution: Fire-rated Structural Thermal Breaks (Farrat TBF)

Balconies are a great way of introducing an outside space to apartments and are becoming an increasingly attractive feature to developers, designers and end users alike.  Even before COVID-19, a balcony could add up to 12% to the price of a home without a garden and this rises to as much as 25% in Chelsea. With balconies however, comes another leading consideration for designers of apartment buildings – fire safety. It is becoming increasingly critical that all building materials used above 18m are certified as fire safe and that this consideration is worked in at early design stage, to ensure they meet safe buildings standards.

With this is mind, our A2 certified fire resistant Structural Thermal Break, Farrat TBF, was selected for use between balcony connections on this new London development. The high rigidity of Farrat TBF will effectively impose stiffness on potentially flexible connections in balconies, avoiding bounce and making for a more reassuring and safe experience.

Learn how Farrat TBF was designed into the Ashley Road East scheme in the case study below.

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

A look ahead at 2021 Projects with Farrat

As we enter February, we are pleased that 2021 looks set to be another busy year for Farrat solving some of our industries most exciting engineering challenges. Our team are currently ‘on mission’, working hard with project teams across construction and industrial to deliver high-performing acoustic and vibration isolation, structural thermal breaks and industrial vibration control solutions into key markets. Take a look at a few of our current projects below.

Acoustic Isolation

East Square Cinema in Basildon

A new 10-screen cinema located on East Square in Basildon is currently under construction as part of the towns master regeneration project, which is due to be completed in the summer of 2021. This new multiplex is set to contain the largest cinema screen in Essex and is being delivered by McLaren Construction.

The steel frame was completed at the end of 2020 and we have already manufactured and supplied solutions from within Farrat’s Cine range, with CineSTEEL and CineWALL beginning the acoustic isolation. In 2021 we will be providing Farrat Installation Services with our CineFLOOR system to build on our work so far and ensure the project is completed on schedule.

Vibration Isolation

The Factory in Manchester

The Factory has featured heavily on our construction agenda in 2020 and is now rolling into 2021, as the development rises into the Manchester skyline. The new multi-million pound arts centre will be the permanent home of Manchester International Festival and is expected to deliver a £1.1bn boost to the city’s economy over a decade.

Farrat have supplied 1,001 individually designed, engineered and manufactured acoustic bearings to date, with another 1,000 predicted for 2021.

The Factory Manchester at night

Industrial Vibration Control

Global supply into the Canning Industry

Farrat have supported the global canning industry consistently over the last decade, consulting, engineering and manufacturing a range of industrial vibration control solutions that enable plant operators to achieve improved OEE and reduce spoilage.

Following the success of 2020, in 2021 we are set to be working to deliver a canning factory in South America and two more in Europe.

Improving quality and production for rolling plants

In addition to the canning industry, Farrat have projects lined up in steel and aluminium rolling plants. Rolling is the metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness or make the thickness of the metal consistent.

In 2021, we will be supporting steel and aluminium rolling plants in Turkey and South America to achieve better quality and production rates.

industrial Farrat

Structural Thermal Breaks

Continued growth and material development

For Farrat Structural Thermal Breaks, 2021 brings the much-anticipated conclusion of Joe Pemberton’s Farrat sponsored 3-year PhD study in association with University of Salford and their construction of the world acclaimed Energy House 2 project. 2021 will also see the continuation of Projects at London’s Chelsea Barracks and Battersea, as well as the redevelopment of Birmingham’s city centre and Manchester’s residential quarters.

Growing through challenges

No doubt 2021 will bring with it a host of challenges, as we work around restrictions and attempt to get back to some assemblance of ‘normal’, but with so many exciting projects and plans for the year, we are looking forward to seeing changing skylines and construction technology developments.

#onamission

On a Mission: to acoustically engineer a world-class arts venue in the heart of bustling Manchester

The Factory

 

Currently underway on the site of the old Granada Studio in Manchester, ‘The Factory’ is a £130 million world-class cultural development set to be the new home of the Manchester International Festival. Designed by renowned architects OMA and being delivered by Laing O’Rourke, the new arts venue will host one of Europe’s most ambitious and adventurous year-round creative programs, inspired by the city’s unmatched history of innovation.

Once complete, The Factory is expected to deliver a £1.1bn boost to the city’s economy over a decade.

Its central location is a key attraction; in close proximity to the Museum of Science and Industry, within walking distance of the nearest train, tram, and bus stop, and bordered by busy restaurants and nightlife. However, with this desirable location comes significant vibration and acoustic engineering challenges.

Surrounded by eight railways lines, two high rise towers and two major ‘A’ roads the new venue requires high-performance acoustic and structural vibration isolation on all sides to minimise two-way disturbance.

The Factory Manchester - Location and Noise Sources

Following Farrat’s instruction to design and manufacture bespoke acoustic and vibration isolation solutions for the scheme, Technical Director Ryan Arbabi, describes how there has never been a more significant project for Farrat. 

“The acoustic isolation requirement on The Factory is exceptionally high, the load conditions are varied and complex, and the tolerance is tight.  We are proud to be designing acoustically isolated assemblies that will connect the structural steel frame to a 200mm thick pre-cast concrete acoustic ‘shell’ – something that has never been attempted before”. 

Farrat have supplied 600 individually designed, engineered and manufactured acoustic bearings to date, with another 2,000 predicted to be needed over the course of 2021 for the Warehouse and Theatre – the two key areas of the project.  

 

The Factory Manchester daytime
The Factory Manchester at night
The Factory Manchester - Farrat Bearing Design
The Factory Manchester - Construction Progress

Farrat’s Building Acoustics Team are also working closely with Structural Engineering Specialists from Clancy Consulting to address some of the schemes most complex engineering challenges.  

“Working with Clancy Consulting on The Factory has taken the acoustic isolation system design to the level of engineering and accuracy required to successfully deliver a project of this magnitude,” comments Adriana Leotta, Project Delivery Manager of The Factory at Farrat.   

“Clancy have been extremely supportive during our long relationship. They have a strong sense of responsibility in providing the right solution and advice for the team they are working with.” 

Bringing together the unique strengths of both Clancy and Farrat has strengthened the long-term relationship and inspired collaborations on other projects. 

Our relationship with Clancy Consulting has developed from being a contractor to a trusted partner, engaged on a retained basis”, explains Ryan Arbabi. 

Together, we now regularly tackle hybrid acoustic isolation and structural engineering applications that are both novel and innovative. We know we can rely on Clancy’s breadth of structural engineering capabilities and mix them with our niche acoustics expertise to offer a service to our clients significantly greater than the sum of its parts. 

Clancy Consulting CEO, Martyn Headley, also affirms the collaborative relationship:  

The Farrat and Clancy teams work closely together to arrive at innovative solutions on each and every project, and over time we have seen an incredibly strong relationship develop which has yielded fantastic projects we are both incredibly proud of. The Factory is just one example of this. 

Acoustic Isolation Bearings for The Factory Project
Acoustic Isolation Bearings for The Factory Project close up

Sir Richard Leese, Leader of Manchester City Council, has also endorsed the complex engineering behind the scheme and notes the important role the arts venue will play in local economy 

“The Factory is a state-of-the-art, high-quality, multi-functional building, incomparable in nature to any other currently being constructed in the UK.  It’s fantastic to see the progress that has been made on site with the basic structure very much now visible. 

Our creative sector is already thriving, and Manchester is now recognised as the second largest creative city in Europe after London, with a GVA to the city’s economy of £1.4bn – all of which proves the soundness of our ongoing investment in culture and the arts, and our continuing belief in the power of culture and creativity, and The Factory, to transform lives.    

 

To work in partnership with these firms on such a ground-breaking scheme, so close to Farrat’s engineering and manufacturing facilitiesis a tremendous achievement. Our team look forward to enjoying the rewards of theiengineering feats in person, once The Factory project completes (set to open later this year).  

#OnAMission 

Farrat isolates first Dolby Atmos auditorium in Saudi Arabia

Muvi Cinemas – Saudi Arabia’s first home-grown cinema brand – have deployed the first Dolby Cinema screen in Saudi Arabia at the U-Walk Boulevard, Arabian Centres in Riyadh. Dolby Cinema sets out to offer a superior movie experience, made up of the ultra-vivid picture of Dolby Vision and the immersive sound of Dolby Atmos.

Farrat have been excited to be involved in such a ground-breaking project to the region. It was only in 2018 that Saudi Arabia opened its first cinema for 35 years and to see such technological advances in so relatively short a period of time is tremendous.

Farrat were brought on board as leading global experts in cinema acoustic isolation, having overseen the acoustic isolation of over 300 cinemas worldwide to date, including delivering more than 15 multiplexes in Saudi Arabia in the first 12 months following the lifting of the ban. Our experience operating in the Middle East as well as the full spectrum of products in the ‘Cine’ range means that we were able to provide a truly bespoke approach to this new technology in the region as well as meet the logistical challenges in supplying into Saudi Arabia.

Dolby Atmos represents a new challenge in the field of cinema acoustic isolation as there are far more speakers required to create the 3D sound field that is this next-generation advancement in cinema surround sound. Farrat’s Technical Director Ryan Arbabi described his excitement for these new acoustic technologies in a recent interview, “Immersive sound systems like Dolby Atmos are as profound to cinema acoustics as the shift to digital projection was to vision a few years ago. Where traditional surround-sound systems allow you to sense the sound happening around you, Dolby Atmos feels like the sound is inside your head – you are really ‘there’.

To Farrat this is represents a new challenge, but one that our huge experience in worldwide cinema acoustics and our advanced Cine range are more than capable of meeting. The products used included in this solution consisted of CineFLOOR PRO, CineWALL PRO and CineSTEEL LITE, so we thoroughly covered all aspects of the acoustic isolation”.