Kalzip has introduced an on-site production facility which uses a
portable roll-former suspended from a crane to manufacture aluminium
standing seam sheets where they’re wanted - up on the roof. This
creatively engineered midair manufacturing solution is fast,
efficient, extremely safe and very versatile as the roll-former can
be quickly repositioned to produce long sheets of Kalzip anywhere
around the building or site.
The new midair manufacturing facility is not attached to the
building in any way - the roll-former is mounted on a specially
designed carrying cradle which is suspended from a tower or crawler
crane. Powered by an integral generator, this self-sufficient
production unit is ‘stabilised’ in its midair manufacturing position
(about a metre away from the roof’s eaves) by virtue of Tirfor
winch-tensioned cables which run from its underside to large anchor
weights on the ground below.
Kalzip employs the highest standards of safety at all times and this
is exemplified by the fact that the roll-former unit’s positioning
in midair and all of the roof sheet production is managed and
remotely controlled by a highly experienced operator safely
positioned on the roof. There is also a large, clearly-marked
‘safety exclusion zone’ beneath the roll-former which comes into
operation whenever the machine is airborne and replenishing the coil
is done swiftly and easily by lowering the cradle down to ground
level.
Another safety factor is that roof level sheet handling activity is
significantly reduced with midair manufacturing as it’s the system
that’s moved to where the sheets are needed. On-site roll-forming is
a particularly convenient and cost-effective method of manufacturing
long sheets - and most appropriate where site access is restricted.
Kalzip can be produced in continuous sheet lengths in excess of 150
metres which virtually eliminates the need for end-lap joints and,
with aluminium being much lighter than steel, labour requirements
are further reduced.
On-site manufacturing is also environmentally beneficial as up to
5,000 sqm of coil can be delivered on a single trailer, which
reduces CO2 emissions as well as saving transport costs.
Administrative and organisational costs inevitably associated with
the movement of very long loads by road are also eliminated and so
perhaps it’s no real surprise that demand for the on-site
roll-forming of Kalzip is steadily increasing.
Kalzip has been manufactured on-site in the UK since 1997 - by
roll-forming at ground level, ground to eaves level using an angled
ramp up to eaves heights of 9 metres, and at eaves level where the
machine is mounted on a purpose built scaffolding tower. Whilst each
method has its own advantages, this new midair manufacturing
facility certainly provides the safest option of producing long
sheets of Kalzip at various roof level locations on buildings with
eaves heights ranging from 10 metres up to at least 30 metres.
Employing the best quality components and materials throughout, all
Kalzip’s site rolling equipment from ground level to crane hook has
been structurally engineered, fully tested and certified to achieve
the highest standards of safety, reliability and efficiency.
To view Kalzip’s midair manufacturing video, please visit:
www.kalzip.com
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