Construction + Civil Engineering

The research, development and testing carried out at EJOT UK’s Applitec Centre is key to helping the roofing and façades sector to raise the bar in terms of optimising performance and installation processes.

One of the main reasons why the facility is so valuable is that it allows systems manufacturers, envelope designers and installers to consult with the fastener manufacturer at an early design stage to ensure the most suitable fastening approach can be tested and confirmed.

This ‘new product development’ (NPD) area of the Applitec team’s work largely goes on under the radar. It is, however, crucially important to support the industry as it seeks to continuously improve building performance standards, safety and longevity, as well as respond to architectural trends.

EJOT UK’s fastener NPD facilitates technical innovation in roofing and façade systems, membranes and other elements of the building envelope. This is because – without EJOT pushing these boundaries – any progress made in terms of new designs and materials for roofing and cladding sheets, systems, panels, etc. may never realise their long term potential long term if they cannot be effectively fixed into position.

This is why EJOT UK supports the UK construction markets with a dedicated technical team, who use state of the art machinery and technology within the Applitec Centre to develop tomorrow’s fastening solutions. This facility is a key part of the company’s Yorkshire site, which is integral to its UK manufacturing operations and makes a contribution to the success of the EJOT Group globally.

The Applitec team work in virtual tandem with their engineering counterparts based at EJOT in Germany, who are involved in their own extensive research, development and testing programmes within the EJOT TEC ACADEMY. In addition to collaborating with EJOT divisions around the world, this facility allows the team to support customers via a digital training portal, mirroring the UK team’s goal to provide best practice in construction projects when using EJOT fasteners.

Fastener insights to transform concepts into reality

Technology is reshaping the construction industry, and that includes the development of new building products. That is why the Applitec Team is increasingly utilising innovative technology to drive better performance of fasteners and increase the value of their contribution to the built environment.

The team’s Technical Advisor, Dylan Roe, plays a key role by leading on EJOT UK’s product design developments. Dylan utilises CAD (Computer Aided Design), including SolidWorks software for designing new products and modifying existing fasteners to achieve new design and performance goals.

Dylan’s work is initially completed almost entirely in a digital environment, meaning that physical resources are not required until much later in the NPD process. After securing approval on the virtual design, the team is then able to progress it to rapid prototyping. At this stage, 3D printing technology within Applitec is used which delivers significant time and cost savings compared to traditional prototyping processes.

Dylan says: “SolidWorks is an important tool for us as it enables us to generate the files required for prototyping. We also use it to assist with CAM (Computer Aided Manufacturing) and there are other elements within the software that will be increasingly important in future.

“For example, it will enable us to unlock the power of FEA (finite element analysis), which allows us to see where the stress points are digitally, and where the forces are localised using colour gradients. This makes it possible to predict how the product will perform in-situ with a high degree of accuracy to further streamline the NPD process.”

3D printing technology also supports EJOT UK’s testing and analysis processes. It helps the team to create elements for equipment within the Applitec Centre, including as part of the process to create critically important jigs for its extensometer, which is used to measure the extension of materials under load. Another use is for producing devices used with torque transducers that fit into the end of a screw gun to measure torque.

Both these applications illustrate how 3D printing integrates with other parts of the business, not just for NPD, but to expand the standard Applitec kit to deliver even more.

Rigorous analysis of installation processes and techniques

Another dimension to the product development work undertaken at EJOT UK’s Applitec Centre is installation analysis. This is really important to evaluate the specified performance of fasteners versus the actual performance. The team uses a state of the art Kistler machine as part of their analysis and the test data it generates also feeds in to quality control.

By replicating processes being used on site, the Applitec team can provide the equivalent values to installers who will actually be using screw guns on-site. Hence why this is not only key to NPD, but also important for when investigating issues that customers may be facing with non-standard applications.

Installation analysis is also important in maintaining quality processesor example, it helps to confirm the consistency of products arriving at EJOT UK from other manufacturing subsidiaries in the EJOT Group. In addition, the process is also utilised by OEMs who may turn to EJOT during the development of their new products for specialist assistance regarding which fasteners to use for optimum installation.

Benefits of early consultation

The complexity of fastening for the building envelope means that the technical team’s work goes way beyond the design and application of the fastener. It is important that they take time to understand the entire system in which the fasteners are being used, which EJOT UK’s Technical Services Team Leader, Stephen Holl, factors into the Applitec schedule.

The team assists OEMs test their products, such as to confirm performance figures, using numerous different types of testing including tensile testing, pullover testing and installation testing.

Stephen and the Applitec team can draw on a huge number of fasteners within the EJOT portfolio to meet the needs of new applications, as well as those which may have changed. In addition, EJOT UK has a close relationship with many OEM customers who consult with the company first when they are considering making changes, particularly with systems.

This kind of early consultation with EJOT UK, along with a collaborative design approach, has the potential to pay huge dividends given the savings that can be achieved overall in the development process for a new system or product. It may enable new products to be launched to the market earlier due to a shorter development period, thus enabling a faster return on investment, as well as achieving an overall reduction in the design, prototyping and testing processes – all of which come with a cost.

Collaboration with EJOT Group colleagues in Germany

EJOT is a global brand with a reputation for technical excellence that goes far beyond the UK’s shores. What this means for EJOT UK’s technical team is that they are not only part of a highly skilled and experienced technical team here in the UK, but supported by colleagues at EJOT Group based in Germany, as and when required.

And it is also a two-way relationship. In certain projects, Dylan is able to make minor modifications to an established EJOT fastener for his design and manufacturing colleagues in Germany to develop further and progress into production.