The imagery above shows the damaged column. A concrete decorative trim surrounding this column top was originally installed. Over time, the structure deteriorated and the concrete trim was lost to the river below. Multiple concrete columns exist in the bridge structure, and to maintain the existing aesthetic a replacement was required.

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The concrete trim was heavy, and given short time-frames and safety concerns an alternate solution was deemed necessary.

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Armstrong Manufacturing was asked to devise a solution. We developed a plan with the following items being our major deliverable items to achieve with the client.

 

• Manufacturing methodology consulting

• Reverse engineering and 3D modelling

• Final design conceptualisation

• Part prototyping

• Detailed design

• Develop a customised manufacturing process

• Batch manufacture and supply of multiple similar parts

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We determined that we were able to build the replacement trim in a modular methodology i.e. Multiple interlocking parts built using polymer based cold-casting manufacturing methods. This would mean that each individual part was a fraction of the original part weight and could be assembled around the column with minimal effort. 

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Initially, we used supplied original drawings and a sample of the original concrete part to design the prototype. We digitised the original part using our 3D scanning hardware. This allowed us to directly compare the original part to the modelled part created using the original drawings within modern software. We then 3D printed the model to display to the client. They were able to hold and see the form of the part first-hand as a complimentary component to the detailed design data and drawings.

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Due to our refined process we were able to produce the concept prototype as the final part,  and we could progress to developing the final pieces. 

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The final part manufacturing process consisted of:

• A 3D printed and CNC processed mould manufacturing system

• The manufacture of a cold-cast two-part interlocking silicone mould shell system for moulding multiple parts

• Design of a two-part polymer structure that consisted of a hard-wearing outer polymer skin and an internal polymer fill structure

• Use of a polymer mixing station to cast and demould efficiently

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We produced 14 parts, two of which were offered to the client as spare parts. Our moulding system was also entirely re-useable and could be used to manufacture many more components.

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The final parts were delivered to the client and installed on site promptly. We were able to deliver a high-end modular component that solved issues the client was experiencing with procurement of a bespoke component. The end result was aesthetically similar to the existing columns, and Armstrong Manufacturing developed a reproduceable part for it any future repairs were required.