Gulf Construction Online - BPGF acquires hi-tech CNC unit

Glass & Aluminium

The new CNC machine ... can perform movement about five different axes simultaneously.

BPGF acquires hi-tech CNC unit

Bahrain Prism Glass Factory has installed a new five-axis CNC machine, which will give it multi-dimensional capabilities and boost its competitive edge in the market.

01 October 2010

WITH innovation being at the heart of its growth strategy, Bahrain Prism Glass Factory (BPGF) continues to roll out new glass solutions and install sophisticated machinery to ensure the quality of its products and the precision of its manufacturing technology.

Among the latest equipment installed at its facility is an advanced version of CNC (computerised numerical control) machining – a Digit Glass five-axis CNC machining work station from Denver of San Marino – which was procured as part of stage two of the current expansion under way at BPGF.

Elaborating on the advantages of using the system, BPGF general manager T Mani says: “Five-axis CNC machining refers to the ability of the CNC machine to perform movement about five different axes simultaneously. Its benefits include the ability to produce complex shapes in a single arrangement, reducing the set-up time for the machinist and increasing production rates; as well as swifter production and a reduction in errors. In addition, feature-to-feature accuracy is improved as the same zero or datum reference frame is used throughout the manufacturing process.”
The machine can carry out countersink drilling, side writing, 3D processing, routing, grinding, polishing, grooving, bevelling, flat edge grinding and polishing with a cup wheel in a single arrangement on glass with a minimum thickness of 3 mm and a maximum size of 4,100 by 2,350 mm.

A tempering flat bed ... BPGF has innovative glass solutions.

The five-axis work centre installed at Bahrain Prism is a jumbo version with an extra-large working bed. It features extra security with software switches; mechanical security with a ‘Geneva wheel’ system; a self-adjusting bed, which ensures maximum flatness; and automatic tooling changes with 28 positions. The work centre also has an optical fibre device to copy and store templates and is capable of producing standard shower doors in 12 minutes, says Mani.

Launched just under a year ago to cater to the demands of the GCC market and beyond, BPGF is the first factory of its kind in the Middle East and North Africa (Mena) region to provide innovative glass solutions that meet diverse architectural needs, from its 35,000 sq m fully-automated glass fabrication plant at the Bahrain International Investment Park in Hidd.

It is the only factory in Bahrain with a dual robotic insulation line, automated cutting and loading and a Pro E Magnum tempering furnace and an automated lamination line with autoclave.

BPGF is also the only factory in Bahrain to manufacture laminated glass, which is produced using a PVB (polyvinyl butyral) interlayer. The company can offer pane sizes ranging from 300 by 600 mm to 2,600 by 5,100 mm. It handles panes with thicknesses ranging from 6.38 to 80 mm and has a capacity of 1,800 sq m cut pieces and 1,000 sq m of stock sheets per day.

Detailing the advantages of using the PVB interlayer, Mani says: “PVB laminated glass is manufactured by combining two or more glass sheets bonded with one or more PVB (polyvinyl butyral) interlayer and subjected to heat and pressure, in order to ensure perfect adhesion between the constituent elements. If the glass is broken, fragments tend to adhere to the PVB interlayer, thereby reducing the risk of injury from falling glass and helping to resist further impact or weather damage.

“The PVB membrane has good tenacity and when the laminated glass breaks due to high impact, the PVB will absorb a large amount of the impact energy and disperse it rapidly. Therefore, it is hard to break the laminated glass and the shape of the glass may be retained, even if broken. Furthermore, people inside or outside the buildings will not be injured by flying glass fragments.”

Laminated glass provides durability, high performance and multi-functional benefits and at the same time preserves the aesthetic appearance. It provides architectural solutions and offers increased protection from disasters such as hurricanes, earthquakes and bomb blasts, if suitably designed, he says.

A lamination unit at BPGF.

In addition, BPGF is certified to produce bullet-resistant glass conforming to Classes BR3, BR4 and BR6. The bullet make-up velocity and type for the three types of test categories are:

• BR3 – 0.357 Magnum (handgun), full metal jacket, coned bullet, soft core, velocity 430 m per sec;

• BR4 – 0.44 Rem Magnum (handgun), full metal jacket, flat nose, soft core, velocity 440 m per sec; and

• BR6 – 7.62 X 51 (rifle round), full metal jacket, pointed bullet, soft core (lead), velocity 830 m per sec.

The security glass produced by the company was recently tested by a leading consulting company at the UK-based DGA (DJ Goode & Associates) Testing Centre to meet the requirements of EN 1063.

The test, commissioned by BPGF, was undertaken to prove the design performance and protection level of the security glass designed, in strict compliance with the preliminary standards in the CEN for glass (EN 1063) and for doors, windows and shutters (ENV 1522/1523).

“The BS EN1063 2000 standard specifies performance requirements and test methods for the classification of the bullet-resistance of glass (consisting of one or more layer of glass) and glass/plastic composites,” Mani explains. “The main requirement for bullet-resistant glazing is to prevent the passage of projectiles from various types of weapon. The technical classification of bullet-resistance of glazing in this standard is based on common weapons and ammunition, depending on the intensity of the attack. As the variety of weapons and ammunition does not allow them all to be taken into account, a selection had to be made that covers most types. The choice of bullet-resistant glazing is established by the user for each individual case.”

The $25-million BPGF was recently awarded three key internationally-recognised certifications for its integrated management system in quality, environment and health and safety, further underscoring its status as a world-class glass processor. The three certifications for its integrated management system, which covers these areas of operations, were issued by Eurocert, a management systems certifying authority headquartered in Greece.

They covered the ISO (International Organization for Standardization) standards for Quality (ISO 9001:2008); Environment (ISO 14001:2004); and OHSAS (Occupational Health and Safety Advisory Services) international occupational health and safety management system standard OHSAS 18001:2007.

BPGF offers a wide portfolio of architectural products and services including:

• Insulated solar-controlled high-performance glass units for the horizontal and vertical market, with thicknesses varying from 12 mm to 60 mm, providing optimal thermal arid optical performance, thereby reducing power requirements. The company produces an average of 2,200 sq m of high-performance insulated glass per day;

• Multiple laminated glass units, which are utilised for acoustic, safety, bulletproof, shatterproof and heat-resistant applications;

• Frameless shopfronts, internal glazing/partitions, and shower enclosures;

• Spider wall system, glass wall systems and various types of point-fixed glass wall systems; and

• Glazed flooring, skylight, roof glazing, inclined glazing and walkways.

Following the successful operation of its initial phase of development, the company has embarked on Phase Two of its expansion. This phase is being implemented in two stages with a total investment of $4 million.

Civil work is in progress on the second stage with machinery arriving on site ready for installation. Apart from the five-axis CNC machining centre, the second stage also includes a fusing kiln – a high-value, low-volume line catering to the high-end of the market – and another tempering furnace, which will enable the company to produce super low-e glass.
The second stage is scheduled to be commissioned by the first week of November. This stage includes an integrated fully-automatic ceramic roller coater and silk screen printer, which will produce high-value ceramic-coated glass. It will have the capability to handle 2.6-m-wide by 3.6-m-long glass that can be coated as per customer requirements in an initial choice of 16 colours. This decorative glass can be used in diverse applications, ranging from office partitions, lifts and shower enclosures to spandrel area application.

BPGF is highly committed to providing top-quality products to specialised firms. “Our services have been recognised by industry experts as being one of the most dependable and professional in the market,” says Mani.