Historically, Ultraframe has used a wooden structure filled with insulation for its roof supports – making the manufacture very labour intensive and also making the final product heavy.
Ultraframe wanted to move to thin sheet steel to give a lightweight structure but ensuring it has the same strength requirements. Initial joining idea was to use 20 x rivets to join the sheet steel together.
Böllhoff’s engineering team suggested using the company’s RIVCLINCH® to give a fast, reliable and cost effective joint – this method would also eliminate the need for any consumable items bringing down the process cost.
Initially, Ultraframe wanted to use a variety of different sheet lengths to suit its different roof applications. By moving to a standardised 3m length and using RIVCLINCH® to join these sheets, Ultraframe saved £90.5k by not having to purchase specialist press brakes and guillotines to suit the maximum 6m sheet length initially required. By moving to RIVCLINCH® Ultraframe could reduce by almost one third its initial capital expenditure required.
By moving to a standardised length of sheet steel and implementing RIVCLINCH® into the process, this has reduced the total weight of the final assemble by 25%, allowing the end user to have a lighter system to work with. Shipping costs will also be reduced.
The initial method of screwing the wood used to require two people with a subsequent slow manufacture output – the RIVCLINCH® process will allow production to be increased by a projected 300% increase using just one person.
With the Böllhoff Technical sales engineering team working alongside Ultraframe, it was determined that a P35 PASS system on a custom made compliant mount would be the fastest and most efficient way to clinch the material.
Ultraframe intends to manufacture by connecting the 3m lengths of bent 0.9mm Galvanized mild steel and placing a 0.9mm galvanized steel joining plate across both sections of material. 20 joins will be used in total; 10 for each side of the joining plate.
Because of the total length of the final product, it was determined that the P35 PASS system would slide back and forth on a custom made mount to carry out the clinches – this means the 3m lengths of material can be readily slid together using a simple roller system thus making the joining process quicker.
Ultraframe intends manufacturing 20 of these beams per shift, totalling 400 clinch joints a week – annually this equates to 96,000 clinched joints.
Ultraframe also wanted to deploy Böllhoff’s expertise on the equipment and purchased an optional service package in which a Böllhoff engineer will service and maintain the equipment at regular intervals to ensure Ultraframe get the most efficient production possible.
Ultraframe (UK) Ltd has been established for over 30 years and is a high-end manufacturer of home extensions, conservatory systems and roof replacements.
The Ultraframe product range is to have high thermal efficiency coupled with a long life expectancy.
Ultraframe looks for continual improvement in all aspects of the business – constantly striving to improve product and process efficiency.
Manufacturing, design and testing is all carried out where the company began in Clitheroe.
With competition high and quality essential, Ultraframe was looking for a simplified and efficient manufacturing process without a compromise on quality
The brief was simple – cost effective, high quality joining, improved process efficiency and technical support.
