ABOUT INFO
THE CLIENT: Sulzer is a global engineering leader, delivering high-performance solutions across mission-critical infrastructure and industrial processes. Operating in more than 150 locations worldwide, Sulzer supports vital sectors including energy, water, manufacturing, and transportation.
THE PROJECT: To develop and implement a lightweight, non-conductive alternative to the existing cast iron panels used within Sulzer’s infrastructure. The solution needed to match structural integrity while enhancing safety and ease of handling.
SCOPE OF WORK: To engineer, manufacture, and deliver a precision GRP panel system, designed to meet strict dimensional tolerances, weight restrictions, and mechanical performance standards, fully supported by structural calculations.
INTRODUCTION IN BRIEF
The client: Sulzer engaged Hayward GRP to support the upgrade of a key electrical access infrastructure system. The existing cast iron covers, each weighing approximate 52 kg, required two-person handling and specialised lifting equipment to safely remove and reinstall.
The objective: to develop a direct-replacement GRP panel with a maximum weight of 10 kg, non-conductive, corrosion-resistant, and engineered to match the exact dimensions and load-bearing capabilities of the originals.
OUR SOLUTION AND OBJECTIVES
Hayward GRP’s engineering team conducted a detailed site consultation with Sulzer to fully assess the legacy covers and clarify all dimensional, mechanical, and performance requirements.
A bespoke, four-part, heavy-duty mould was fabricated from an original cast iron panel, capturing all critical geometry, fastener locations, and surface datum points. This enabled precise replication of the legacy covers using high-strength, glass-reinforced polyester, each GRP panel was manufactured to a final weight of just 8 kg.
Prior to delivery, a full in-house test build was completed to verify geometric accuracy, ensure load conformity, and guarantee a seamless site installation.
THE RESULT IN CONCLUSION
The replacement GRP panels met every objective of Sulzer’s brief, reducing individual panel weight by over 80%, simplifying handling, and eliminating the need for lifting apparatus.
A single technician can safely and efficiently install the new modular covers, improving site safety, operational turnaround, and reducing costs. This project stands as a clear example of Hayward GRP’s ability to deliver technically precise, custom-engineered composite solutions for legacy system replacement.
WHY CHOOSE HAYWARD GRP KNOWLEDGE. EXPERTISE. COMMITMENT.
Hayward GRP is recognised as a complete solution provider with decades of experience delivering complex, bespoke GRP moulding solutions. Our comprehensive approach encompasses every aspect of your project, from initial consultation and design assistance to tooling, precision manufacturing, flawless finishing, and seamless installation, providing clients with an exceptional service that consistently exceeds expectation.
We forge enduring partnerships through clear communication, technical precision, and consistent reliability. Our industry-leading reputation for quality and compliance is built upon strict adherence to internationally accredited standards, ensuring every project meets the highest benchmarks.
READY TO START YOUR PROJECT LET’S MAKE IT HAPPEN
Are you ready to turn your project vision into reality? Our extensive portfolio reflects our expertise and capabilities in delivering world-class GRP solutions. We’re here to bring your ideas to life, reach out to us today, and let’s collaborate to transform your concepts into tangible, stunning realities.
Whether you’re in the UK or anywhere else around the globe, we are eager to discuss how our tailored GRP solutions can elevate your project to new heights, let’s explore the feasibility together.
Contact our team today to start the conversation.
Call us on 01323 679555 or Email: info@haywardgrp.co.uk
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