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FEATURE SPRINGS & SHOCK ABSORBERS


are not an option. The cost of factory downtime is so high that minimising the risk of failure is essential, which rules out using cheaper, lower quality components.” The specification is key for providing the right intent and the products to be used, but it does not cover design. “If you have a duct run, for example, it will tell you what you need to isolate and will specify spring mounts of a certain deflection. It will not tell you which ones to use, where to put them or, critically, what the load is. Details like this are left to the contractor to figure out,” he explained. Despite the scale of this project, Mason took on significant responsibility for the design. This allowed the contractor to stick to those elements they knew best, while leaving the area of vibration control to Mason’s expertise. Although this arrangement is unusual, the extra engagement was an important factor in the contractor’s decision to work with Mason.


THE CHALLENGE OF SCALE Isolating against vibration involves a system of specialised products that interrupt and absorb the path for vibration transmission. For this project, the key product was spring mounts. These are usually used for applications where low frequency (sub 8Hz) vibrations are present. One of the unique features of this project was


the vast scale. In total, there were approximately 130 kilometres of piping and 3.2 kilometres of ductwork. The project therefore required a staggering 3,800 mounts. “I’ve worked on all sorts of projects at this stage of my career, but nothing can touch this one in terms of scale. Nothing is even close,” Fox commented. As well as the quantity of products supplied and the logistical challenge it presented, the size of some of these products is also worthy of mention. In general, larger pipes require a higher level of isolation. As some of the ducts were up to four meters in diameter, there were some unusually large spring mounts that were required. George Taylor, a project engineer who was heavily involved in the work, recalled his surprised when he first encountered the size of the mounts. “I knew the mounts needed to be large because of the load, but actually seeing them they appeared unusually large,” he said. In addition to the mounts, Mason supplied 1600


acoustic hangers, from which pipework and ducts were suspended, as well as 400 pipe connectors.


Many of the products were supplied bespoke, with housings designed specifically to deal with factors such as wind loading and thermal expansion.


ENGINEERING CHALLENGES There was an additional agreement with the contractors whereby Mason would assist with the installation as well as the design, given the critical importance of getting this right. The spring mounts and hangers are designed to be easy to install, and include features for this purpose, but attention to detail is key as even millimetres matter. Fox and his colleagues were


therefore on site regularly, assisting with installation, training staff and carrying out installation inspections. Adjusting a mount or a hanger incorrectly can lead to load in the wrong place and prevent the isolator from working, so the team’s experience was useful in ensuring everything would work as intended. Transporting and installing all


Isolating against vibration involves a system of specialised products such as spring mounts


of this equipment was a huge endeavour for logistics, planning and collaboration. Mason was assisted in this regard by Asgard Engineering. Having a local agent like this is key to ensuring success in these projects. Asgard was able to act as the conduit for Mason products into Ireland and, in addition to regular site visits from Mason’s team, they were able to provide the local support that was essential for the customer. As well as controlling vibration, Mason’s solutions also need to accommodate factors like wind loading and thermal expansion. Designing systems that can handle both the demands of vibration isolation and these additional factors is especially challenging. This problem was especially significant for a lot of the duct work, as this was mounted externally and therefore subject to wind loading and sun loading. If a duct wants to expand, you cannot stop it doing that. So if you constrain it, something is going to break. Many of the mounts supplied were therefore bespoke, designed specifically to accommodate the additional loads and movement the ducts would be subject to, and to allow for this movement but within limits. These mounts are therefore restrained mounts, with customised housing that is more robust than you would expect with an off the shelf product. Once the mounts were


48 DESIGN SOLUTIONS DECEMBER/JANUARY 2024


customised to allow for factors like wind loading, it was then necessary to ensure that each mount went to the correct location. A lot of work was done to deliver this level of detail and provide the assurance it was going to work. Once more, the assistance of Asgard was key in delivering this outcome. Every mount was provided with a unique label to identify it and the exact location it would be sent to.


ONGOING SUPPORT This project was complete without significantly overrunning the schedule, which might be surprising to many. All projects contain engineering challenges and setbacks, but those involved had the additional obstacle of completing this work in the middle of a global pandemic. “It’s a testimony to all involved that we


were able to complete it within the schedule,” reflected Marc Power, engineering manager at Asgard Engineering. Although the fab may be up and running,


regular site inspections and adjustments will continue, and both Mason and Asgard will continue to provide ongoing support. In fact, at the time of writing, Taylor is currently attending the site to carry out inspections and Fox is due to return the following month. Working under the radar, they are part of a specialised group of engineers whose work is essential in ensuring the world continues to receive its supply of silicon chips.


Mason UK


T: 01252 716610 www.mason-uk.co.uk


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