Projects

The imaginative, multi skilled, creative and professional approach of ASF stands out when working on bespoke coordinated projects. With attention to detail held as a key ideal and a knowledge of the combined importance of durability alongside finish, texture and form, ASF has the savvy to take an idea from concept to completion.





Projects




From Concept to Completion



PROJECT:
Bespoke Cast Iron Ground Compass
CLIENT:
Leeds City Council
INFO:

Leeds City Council were constructing a new 'South' entrance for Leeds Central Station and requested a bespoke cast iron ground compass as a centrepiece. The compass was to be embossed with selected international, national and local place names, cities and points of interest, as well as key historical facts.

The requirement was that the compass be supplied in SG (Ductile) Cast Iron and left in a bare metal state to patina and weather over time.

ASF were approached with drawings already completed, to interpret and turn into the finished product.

PRODUCTS
& SOLUTIONS:

As a bespoke product in cast iron, the first task was to produce a pattern.

The compass was planned in base sections - themselves totalling 17 parts, comprising a central rose pattern, 8 central surrounds, and 8 large outer spokes which housed the directional feature arms. In addition to this, a pattern for each directional arm had to be produced, which took the pattern sections to over 70 in all and included 1786 individual letters - all produced and mounted by hand by ASF's own in house pattern making specialists.

The manufacturing process then requires sand moulds to be taken from the patterns. For this to happen the pattern is mounted in a box which is then rammed with sand mixed with furane resin (a setting agent) - this leaves an inverted imprint of the pattern that is ready to take the molten iron.

Each of the 17 base patterns - mounted with the directional feature arms, were cast individually on a 'one casting a day' basis, quality checked and the next section boxed and set for moulding.

The castings are then shot blasted and dremelled by hand by the pattern makers to ensure they are exactly as per the original drawings supplied.

The ground compass is set into feature paving at the new south entrance of Leeds Station, where it expected to last many lifetimes.


PROJECT:
St Michaels Church Communal Area, Mytholmroyd
CLIENT:
Calderdale Council
INFO:

Calderdale Council invited ASF to a planning meeting regarding the public area adjacent to St Michaels Church, Mytholmroyd.

An area was undergoing re-paving and renovation that would require a number of street furniture elements - the specification at this stage was pretty open with a general thought towards polished stainless steel combined with timber.

There was a need for seating, tree grilles, cycle stands, a step handrail unit and a length of quayside post and rail to core fix to a knee high retaining wall along the river bank

ASF was given a fixed fee and asked to offer some design solutions

PRODUCTS:

Firstly, ASF produced a range of product drawings - some from standard range items and some completely bespoke. These were accepted in theory by the client. ASF conducted a number of site visits, some with and some without the client. Once the site was surveyed, measured and drawn a final specification was developed:

SEATING
The stylish ASF 6012 seat was used, 6 in total. Manufactured in grade 316 stainless steel from recycled sources with timbers in non tropical, non endangered hardwood.

QUAYSIDE POST AND RAIL
This was designed as a modified ¾ height version of the usual ASF 211 quayside post. Manufactured in grade 316 stainless steel from recycled sources the design core fixes into the retaining wall and has a permanent cover plate to over the fixing area. The rail sections are a combination of stainless steel tubing and tension cables. Installation required a fair amount of onsite welding, so ASF brought in a mobile polishing company to finish the job to a high standard after installation.

POST AND GLASS PANEL
Abutting to one end of the quayside post and rail is an area of cantilevered stone paving overlooking the river. ASF custom manufactured a section of stainless steel and glass feature post and panel to connect cleverly into the curved profile of the quayside post. Again, manufactured from grade 316 stainless steel from recycled sources.

TREE GRILLES
There was simply not enough in the budget for stainless steel tree grilles, so ASF manufactured ASF 327 cast iron tree grilles in our own on site foundry. These are manufactured in 100% recycled cast iron and to follow the polished metal theme of the other products, were finished in a slow heated clear lacquer, preserving the gun metal effect of the newly poured cast iron.

STEP UNIT
One end of the site has a set of steps to a footpath and bridge over the river. ASF produced a bespoke stainless steel handrail for this.

CYCLE PARKING
The ASF 8000 stainless steel cycle stand was used to provide secure cycle parking on the site


PROJECT:
Ruthin Art Trail - Bespoke Laser Cut Tree Guards
CLIENT:
Lucy Strachan - Artist
Fred Baier - Artist
INFO:

The Ruthin Art Trail is a partnership between Cadwyn Clwyd, Denbighshire County Council, Ruthin Town Council, with support from Bro Rhuthun Funded by Arts & Business Cymru, Arts Council of Wales Lottery and Cadwyn Clwyd

The Ruthin Art Trail was designed to encourage visitiors to the centre of Ruthin and develop community links with the craft centre.

Part of this programme was the restoration of an avenue of trees along Market Street.

Artists Lucy Strachan and Fred Baier approached ASF with conceptual drawings of bespoke tree guards for this part of the project, with a view to using them in conjunction with the ASF 303 tree grille - with a brief to not only produce the guard, but find a method to invisible fix the guards and grilles together.

PRODUCTS:

The guards were manufactured in 275 carbon steel from recycled sources (a structural grade of steel). These were laser cut and rolled in two halves, to the correct diameter. The halves were then put together as bare metal and hand blended so that each section flowed perfectly, and the pattern was continuous through the full 360 degrees.

At the same point a bespoke frame was manufactured to house the ASF 303 tree grille and offer a shoe type guard fixing with all bolts hidden - so the attachment between grille and guard was not visible once the unit was installed.

The frames were finished galvanised and powder coated, and the grilles finished in metal primer and metal-shield top coat. The guards were hot dip galvanised, then acid etched and hand finished in a grey matt undercoat and pearlescent top coat as specified by artists Fred and Lucy.

ASF 5006 Steel bollards were manufactured form the same 275 carbon steel as the guards, and finished powder coated in a semi metallic grey.


PROJECT:
Widening, strengthening and refurbishment of Cleggford Bridge, Dewsbury - 2010
CLIENT:
CR Reynolds / Kirklees MBC
INFO:
The Grade II listed Cleggford Bridge is a 5 span arch bridge originally built in 1778 using stone masonry ashlar dressings. It was widened in 1889 at which point a cast iron parapet was fitted. ASF worked alongside CR Reynolds, the main contractor, Civil Engineers from Kirklees MBC and English Heritage in the renovation, refurbishment and re-strengthening of this cast iron parapet.
PRODUCTS / SERVICES:
Following extensive site surveys and test excavations the parapet needed to be delicately uplifted. This required the smelting out of Victorian leaded fixings and careful removal of hot rivets - a fixing method that was never meant to be removed! At this point careful attention was paid to numbering and ordering of bridge sections (over 100 in all, each one a different size, extending to over 200 metres in total length) to ensure they could be replaced in exactly the same order.

The whole bridge parapet was then brought to ASF's factory site in Brighouse for refurbishment. Firstly, a full metallurgists report was completed giving the chemical analysis of the Victorian iron, this meant that replacement parts could be manufactured to match as near as possible the original product.

The refurbishment began with shot blasting, by hand, the whole parapet followed by a survey of work to be done. The value of having our own skilled casting engineers, pattern makers and a metallurgist became invaluable as ASF managed to rescue 100% of the original panels. This was done by manufacturing individual cast iron sections and spindles to retro fit into the Victorian panels. A number of the older, weaker, and damaged spindles were also saved by the internal fixing of bright bar in a machined hole through the centre of the spindles. ASF saved around 50% of the posts using similar methods and employing a modular system for post sections, so that only those parts of the bridge parapet that were absolutely beyond rescue needed to be fully replaced.

The parapet was then re-fitted and returned to its former glory on the newly widened and strengthened Cleggford Bridge.

PROJECT:
Blackburn Town Hall, Blackburn
CLIENT:
Capita Symonds, Blackburn
INFO:
ASF worked closely with the client to develop a bench and seat which would be capable of withstanding the rigours of a busy city centre square. By using three different materials and their contrasting properties, a co-ordinated bench and seat design was developed. A co-ordinating granite bollard was used from our Cubist range which complimented the bespoke bench and seat designs.
PRODUCTS:
The Bespoke Seat and Bench were manufactured using flame finished Silver Grey Granite Pedestals, Iroko Hardwood Timber Slats (FSC Certification) and Steel Brackets. All fixings were made to be either invisible or anti tamper. The bollards used were our Cubist 150 in Silver Grey Granite, Flamed Finish

PROJECT:
Sale Town Hall, Sale
CLIENT:
HLM Design, Sheffield
INFO:
In order to modernise Sale Town Hall frontage and surrounding areas, ASF worked with the client to adapt established stainless steel range items to be used in a series of eye catching formats. Marine grade stainless steel was the chosen material as it is very low maintenance and offers the required contemporary look.
PRODUCTS:
Utilizing the ASF 5008/114 stainless steel bollard with satin brushed bases and highly polished machined tops, combined with the ASF 5050 stainless steel telescopic bollard to allow vehicular access, a coordinated scheme was developed. Chain barrier systems were also used to cordon off certain areas.
For permanent barrier areas, the ASF 5006 stainless steel bollard was chosen with 50mm diameter stainless steel rails as a complimentary scheme. At the front of the Town Hall perforated stainless steel panels were added to create an architecturally pleasing barrier. ASF 5006 step units were also used at the front of the building.



PROJECT:
Llanelli Seafront
CLIENT:
MacGregor Smith
INFO:
The ASF team was commissioned to help in the design of a range of modern cast iron posts for use both along the seafront and on top of a series of visually stunning look out towers. Three different but coordinated post styles were designed. In this extremely harsh environment a robust and high quality finish on the posts and rails was imperative.

ASF investigated the possibility of centrifugally galvanising the posts. Together with the use of marine grade stainless steel rails, separated from the cast iron posts via integral nylon sleeves in order to avoid any inter-metallic reaction, this proved extremely successful.
PRODUCTS:
The posts used were hybrids of our popular ASF211 post incorporating marine grade stainless steel rails. The cast iron was centrifugally galvanised to protect against both rusting and deterioration caused by the marine environment. The stainless steel rails were satin brush polished to a maximum RA value of 0.5 to reduce the risk of contamination.

This project was installed 8 years ago and is monitored regularly. The posts show absolutely no signs of deterioration and have dulled to a rich cast iron patina which together with the stainless steel looks superb. The system has required no maintenance during its eight years in this harsh salt water location.

PROJECT:
Llanelli Seafront - 14 years on
INFO:

ASF's sub-contract spin galvanising company (BE Wedge) revisited the Llanelli Millennium Park site after 14 years to take measurements on how the spin galvanising of cast iron posts had stood up to the harsh marine environment.

The Llanelli seafront site was visited on Friday 31st October 2014 for a full inspection.

The general appearance is remarkably good with absolutely no signs of distress from the galvanised coating on any of the posts. The surface colour remains a rich dulled grey patina. This is even more impressive when considering the position of some of the lower posts at the step access to the beach and their proximity to the continual sand and salt water spray.

Random coating readings were taken on the posts positioned on the towers, and on the posts backing on to the beach. The average thickness reading for the tower posts was 223 microns (with the lowest reading being 193 microns), the average for the beach posts was 208 microns (with the lowest being 183 microns).

These readings remain well above today's required standard and, based on their corrosion rate, should give a further 40 years of service before any maintenance is required. This is doubly impressive considering that even when the galvanised coating does begin to deteriorate, it will leave a cast iron post, a material that can be expected to last 100 years in normal use, with minimum maintenance.

These posts are also 100% recycled and 100% recyclable. Cast iron, although one of the oldest of engineering and architectural materials, remains one of the most practical, environmentally sound and in many ways modern materials there is.

ASF manufactures its castings in the UK and the products have only delivery miles on their carbon footprint. In ASF's Brighouse foundry the raw material travels 20 metres across the factory floor to be turned into finished product.