GRP Bells – Replicating Cast Iron

Client: Engineering Services Company Specialising in Design and Build

Project Overview

In mid-2022, Harviglass Fibre was asked to create replica metal bells for a unique project at the Barclays Technology Centre in Knutsford. The client, an engineering services company with whom Harviglass Fibre had a prior working relationship, required a creative solution for a new extension that included a conference centre. Central to this project was the need for a bell feature, but traditional materials posed significant challenges.

GRP Bells – The Challenge

The primary challenge was the weight of the bells. Traditional cast iron bells would weigh over 200kg each, raising concerns about structural integrity, installation logistics, and cost. Not only did the client require us to create imitation bells, but they also needed a metallic finish. . Harviglass Fibre had completed for Marks & Spencer in 2012.  This rekindled the idea to employ GRP/Fibreglass for its lightweight properties.

Solution Development
Harviglass Fibre quickly set to work, transforming the designer’s concept of the non metal bells into a practical design. Utilising SolidWorks software, the team created both 2D shop floor drawings and a 3D model for tooling. Following customer approval of these plans, a female mould was CNC machined from MDF – a strategy best suited for low-volume production like this project.

Manufacturing The Bells

The creation of five GRP bells ensued, each embodying a cast iron look to the finish that not only looked authentic but actually contained iron particles, enabling natural weathering and oxidisation. An option to seal the bells with lacquer was available, offering flexibility in the final appearance. Weighing just 10kg each, these GRP/Fibreglass bells represented a significant reduction from the original 200kg estimate.

Installation and Outcome

Upon completion, the GRP bells were delivered and installed at the Barclays Technology Centre using a suspended hanging arrangement. The end result was not only visually striking but also practically sound, fulfilling the client’s vision while overcoming the initial challenges.  As you can see from the images below, the overall final effect is stunning.  We helped create an outcome that would have been almost impossible with real cast metal bells.

This project exemplifies Harviglass Fibre’s ability to provide innovative, bespoke glass fibre solutions that meet specific client needs. The successful implementation of the Fibreglass bells at the Barclays Technology Centre is a testament to the company’s commitment to quality, innovation, and customer satisfaction.

Contact Harviglass Fibre

For bespoke GRP/Fibreglass solutions that blend creativity with practicality, reach out to Harviglass Fibre. Whether it’s replicating traditional materials or innovating new designs, our team is ready to bring your vision to life.

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