CA invests in robotics in response to HSE demand
The new CA gutter robot in action
New robot systems solve problem of manual handling risk
CA specialises in metal building products, particularly for commercial and industrial buildings, which are being built on an ever increasingly large scale. One detail of these buildings is high-capacity guttering, which is often formed from sections of sheet metal of up to 200kg – significantly over the 25kg per person recommended maximum lift allowed for manual handling.
Approximately two years ago, the HSE visited CA’s manufacturing headquarters in Evenwood, County Durham, and observed that in the process of manufacturing these single skin and insulated gutter sections, a considerable element of manual lifting was required and could not be avoided.
To manipulate sheet metal through the shaping and bonding process, two operatives were required to lift and move it, but in order to comply with regulations and to minimise risk, the HSE demanded that this practice be abolished. At the time, however, no machinery or solution was available, so CA made a commitment to the HSE to invest in devising and implementing its own means of solving the problem at the earliest opportunity.
Two years and a substantial investment later, CA has unveiled its solution. Its technical team, working in conjunction with a robotics manufacturer, has devised a new system that completely eliminates manual handling from the entire process. First, sheet metal is lifted by forklift into a robotic cell, where it is automatically shaped in a computerised press. It is then manoeuvred to two articulated manipulators, which use suction cups to lift and rotate the gutter sections into position for the bonding process. Sections of gutter of up to 7.2 metres are lifted into position via internal cranes for welding and bonding, then transported to site and craned into position at roof level.
Peter Donohue, CA Group’s Safety, Health and Environment manager, explains: “Not only have we eliminated manual handling and associated risk from our end-to-end manufacturing process, but we have also minimised our clients’ exposure to risk by ensuring that contractors on site can work more easily with the product. Furthermore, we reduce specifiers’ CDM risk exposure, as they can now design ever larger guttering systems without being limited by workability.
“Where a roofing contractor might have been tempted to cut corners by manually lifting and positioning gutter sections, we have now made this impossible by producing much larger sections. Our new 7.2 metre guttering sections mean less on-site assembly, so crane hire for the lifting process is more cost effective as half as many lifts are required as with a traditional 3 metre section.”
Brian Watson, CA Group commercial director, is delighted with the new robotics systems. “We have always supported the delivery of the highest standards where health and safety are concerned, and our new system is testament to our commitment to the HSE,” he says. “We are now determined to spread the word that a solution exists, so no metal roofing manufacturer should ever be exposed to manual handling risks from now on.”
As a consequence of this new technology, manufacturers with similar processes should expect to receive visits by the HSE to assess how this technology can be implemented into their process systems to ensure the elimination of manual handling associated risks. It is likely, now that there exists a solution, that any manufacturers who choose to ignore the risks will face further action by the HSE.
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