Severfield ‘T & I’ Line: "Innovative Automation"

Innovation is at the heart of all fabrication, production, and installation processes at Severfield, and nowhere is this clearer than in our world-class, automated ‘T & I Plate’ girder line at our facility in Lostock, Bolton.

By definition, a ‘T & I’ plate girder line assembles flat plates into the distinctive ‘T’ sections and ‘I’ sections often seen in large steel structures around the world. And yet, the fabrication process is a complicated one, with the sheer size and weight of the girders adding further logistical demands. Our ‘T & I’ line, which was installed in 2018, rises to the occasion, and, as Andy Smedley, Factory General Manager at Lostock, tells us:

“The ‘T & I’ line at our Lostock facility has the capability of manufacturing plate girder carcasses, ranging from 300mm to 3500mm high and 150mm to 1500mm wide, and welding a range of fillet welds up to 12mm in a single pass, all whilst utilising the latest power wave technology.” [1]

Indeed, this is globally recognised as some of the most advanced steel fabrication parameters for any girder line in production today – whilst ensuring high quality and productivity.

Bolstered by a ￡2 million investment in recent years, our ‘T & I’ line at Lostock stands out when it comes to versatility and growth in the steel fabrication industry. ?Andy adds:

“The lines throughout display exceptional efficiency compared to manual build and weld, and is an improvement of four times, thereby giving Severfield the ability to reduce our project durations and enabling delivery to the end user in shorter timeframes. The line integrates not only plate girder fabrication, but also the ability to radius all four flange corners, a requirement for the application of protective treatments, and removing downstream manual activities. This automation improves productivity whilst removing a potentially hazardous activity.”

As Andy explains above, the line expertly facilitates pre-fabrication activities, niche triangle welding, and even complicated energy transition from the main source to the welding head itself.[2] In light of this, all Severfield’s bridge projects in recent years have been built using the T&I Line, the largest of which remains Barking Riverside, the scale of which is immense: it spans 1, 500 metres and weigh 3, 200 tonnes. From steel sections as deep as 3500mm, all the way through to girders 300mm deep and intricate square box columns, our ‘T & I’ line boasts an incredible array of adaptability.

It is clear to see that streamlining the fabrication process in order to improve productivity and increase safety across the site is a fundamental part of Severfield as a whole. The automated and efficient ‘T & I’ Line at Lostock underscores our commitment to quality steel fabrication, as well as our dedication to utilising innovative technology and developing new production techniques across the industry.

As we look towards an ever-changing landscape in steel fabrication, pioneering approaches such as these means that Severfield remains at the cutting edge of the industry.

[1] Power Wave Technology is a registered product name of Lincoln Electric; see e9181.pdf: lincolnelectric.com.

[2] Examples of niche welding include “Submerged Arc Welding”, that is, enhanced deposition using digital wave forms and tandem large diameter filler wires to produce high quality welds.