AT BAHRAIN prism GLASS FACTORY WE ARE COMMITTED TO your vision

AT BAHRAIN prism GLASS FACTORY WE ARE COMMITTED TO your vision 4. IN CONTROL OF YOUR VISION 2. GLASS factfile 1. vISiON AND MISSION Contents 4 R...
Author: Sandra Logan
0 downloads 0 Views 1MB Size
AT BAHRAIN prism GLASS FACTORY WE ARE COMMITTED TO your vision

4. IN CONTROL OF YOUR VISION 2. GLASS factfile

1. vISiON AND MISSION

Contents

4 Reflect your Vision

3. A CLEAR VISION

Vision and mission Origin of glass Raw materials to shape your vision A clear vision Cutting edge solutions Standards of perfection

6 9 9 10 11 11

In control of your vision Glass selection guidelines Inside the PRO E furnace Heat treatment Tempered glass Heat strengthened glass

12 15 16 16 16 17

6. THE RIGHT PROCESS

5. GLASS SELECTION

8. SMOOTH WORKFLOW

9. CUTTING EDGE EQUIPMENT

7. OPTIMISED

PRODUCTION

LINE

Heat soaked test Tempered glass properties Glass preparation Insulating glass production line Structural glazing Laminated glass

17 17 17 18 21 23

Cutting edge equipment Factory firsts Contacts

24 25 26

Bahrain Prism Glass Factory 5

1. VISION AND MISSION

Vision: Our confidence thrives on honesty, on honor, on the sacredness of obligations, on faithful protection and on selfless performance.

Mission: To be a market-focused, process centered organisation that develops innovative solutions. To consistently outperform peers and provide a dynamic environment for employees. To be a one-stop address that delivers the challenging needs of our esteemed clientele.

Goal: To be recognised in the industry as a leading provider of high quality architectural, design and decorative glass wall systems, along with a host of other glass solutions, ably supported by quick and responsive service.

6 Reflect your Vision

Bahrain Prism Glass Factory 7

As a creator, glass is raw material in your hands. To be moulded and shaped according to your vision.

8 Reflect your Vision

2. GLASS FACTFILE

ORIGIN OF GLASS Glass is said to have originated in the medieval Islamic world during the 9th century, when Abbas Ibn Firnas (810-887) invented Silica glass and high-purity clear glass from sand and stones. In the 8th century, an Arab chemist Jabir ibn Hayyan (Geber) scientifically described 46 original recipes for producing coloured glass in Kitab al-Durra al-Maknuna (The Book of the Hidden Pearl). During the 11th century, clear glass mirrors were being produced in Islamic Spain. The first glass factories were built by Muslim craftsmen in the Islamic world.

Raw materials to shape your vision As a creator, glass is raw material in your hands. You can heat treat it, insulate it or shape it according to your needs. Glass gives structural solidity in your work, adds an aesthetic texture and brings an emotional appeal to your architectural design.

Precious, precise and premium glass From Bahrain Prism GLASS FACTORY Look no further. Now you can access glass fabricated to your choice, right here, in Bahrain that matches your most challenging designs and stringent specifications. A one stop shop for all your requirements in glass, be it exterior/interior, architectural/decorative, commercial or digital-design printing, etc.

Bahrain Prism Glass Factory 9

3. A CLEAR VISION

A clear vision If you are looking for high performance insulated glass units, multiple laminated units, glass wall systems, point fixed assemblies, glazed floorings or more, rest assured that you have come to the right place. The first of its kind, Bahrain Prism Glass Factory (BPGF) provides innovative glass solutions that meet diverse architectural needs from a 35000 square meter state-of-the-art, fully automatic glass fabrication plant at Hidd in the Kingdom of Bahrain. Years of experience in the real estate and construction sector has given us an insight into the special architectural and structural requirements of the region. This allows us to offer high grade products and efficient services that match your unique projects, including advice on making the right selection, be it aesthetic choices or solar and thermal performance. You will always find the collective experience of our representatives ready to assist you.

10 Reflect your Vision

IN OUR relentless pursuit of perfection, we are committed to your vision.

Cutting edge solutions

Production values that meet your standards of perfection

You can expect more from Bahrain Prism Glass Factory, through value additions such as double vision panels, tile textures, digitally etched designs and wood textures, making it the first factory of its kind to offer these product lines in the MENA region.

In our relentless pursuit of perfection, we are committed to retaining quality and ethical practice in all aspects of our business. Stringent quality checks are in place to ensure that materials are processed according to the best international standards of practice.

You can also expect a wide range of surface decoration tools that include sandblasting, bevel clusters, air brushing, leaded stained glass, translucent fiberglass art panels, carved glass, glue chipped glass, 3 dimensional glass, fused and slumped glass.

Today, Bahrain Prism Glass Factory can deliver high performance insulated glass units to a maximum of 2800 square meters a day.

Our factory is equipped with state-of-the-art machineries acquired from ISO certified manufacturers and our strict production standards are fully capable of meeting your vast and specific demands.

After extensive market studies conducted in the MENA/East Europe region and Asia we are all set to enhance our capacity to reach a minimum of 4000 square meters of processed high performance insulated glass units per day supported by a host of value added functionalities using lamination, ceramic frit, silk screen printing, and CNC machines.

Bahrain Prism Glass Factory 11

4. IN CONTROL OF YOUR VISION

IN CONTROL OF YOUR VISION At Bahrain Prism Glass Factory, we approach manufacturing in line with modern manufacturing practices. The product control, process controls and sampling frequency required at various stages are derived after a detailed study using FMEA guidelines. Process control starts right from the time of selection of all raw materials that match detailed specifications in all aspects of quality. A detailed control plan indicates the control methods and mistake-proofing at all stages of the operation. Absolute clarity is documented in defining reaction plans and preventive action is necessary at all stages. Each stage has a clear pictorial standard for all operating procedures and essential steps that should be undertaken at every step in the process. The focus is to control the process first and the product by verification at every stage. Practices of first-off inspection, in process inspection, control charts and statistical process controls are used at all stages. The responsibility, authority and interrelation of all personnel who manage, perform and verify work effecting quality is clearly defined, particularly for personnel who need organisational freedom and authority to: a) Initiate action to prevent the occurrence of product non-conformity b) Identify and record any product quality problems

12 Reflect your Vision

Additionally the quality assurance department is actively engaged in conducting process audits to ensure adherence to systems and in identifying areas with the scope for strengthening. The in-process rejection PPM level performance versus targets is a key aspect in quality assurance. All machines at Bahrain Prism Glass Factory are top of the range, state-of-the-art glass machineries from world leaders such as LISEC and TAM GLASS. All key personnel at all organisation levels are highly skilled individuals with extensive experience and expertise working in the Glass field. To maintain the machines in an optimum working condition all operators are trained for autonomous maintenance and are an integral part of the team that performs planned machine maintenance activities along with the maintenance department. To continuously upgrade technical skills, the HR department is actively involved in competency mapping at all the levels of the organisation. The department heads prepare a skill matrix for their operators and have individual plans for upgrading the skill and multi-skills of all staff. The training programme for operators covers both soft skills and functional on-job training. The team is trained in practicing the essentials of the manufacturing practices of 5S and TPM. Other skills such as use of statistical tools (SPC/ SQC), ISO 9000, ISO 14000 are given as per the training needs identified by the functional head.

CHOOSE THE RIGHT GLASS TO REFLECT your vision

5. GLASS SELECTION

Glass selection guidelines Glass is a key element of any architectural design. Hence, its properties have to be evaluated to make a suitable choice. Here are some of the points to keep in mind while selecting the right glass for your project. Sun Control Solar rays can cause overheating or disturbing glares. This can be countered by using solar control glass, either body-tinted (absorbing) or coated (reflecting). This greatly reduces the transmission of solar radiant light and heat energy. Sound proofing To sound proof a building effectively, the type of glass used should have the properties to shield and insulate the internal spaces of a building. Laminated and insulating glass (double glazed) are the most popular choices. Thermal insulation The U value is a measure of the rate of heat loss of a building component. It is expressed as watts per square metre, per degree Kelvin, W/m2K. Lower U-Values are achieved by multiple glazing layers, gases and the use of low-e coatings. Solidity Glass is subjected to different types of environmental and human loads, which can cause glazed surfaces to malfunction or break. Since each load has a specific impact on glass, it is important to understand and study the special characteristics of the project to choose the right glass. Visual appearance The latest manufacturing processes allow glass to be created in myriad colors. Glass color is also subject to environmental factors such as sunlight reflected by sky or clouds. Lamination Laminated glass is ideal for maximum safety and security. It has excellent anti-accident, anti-burglary properties and more. It is also highly effective in reducing noise and ultra-violet rays. It provides excellent protection against natural disasters such as hurricanes and earthquakes, making it the highest rated multifunctional glass available in the market.

Bahrain Prism Glass Factory 15

6. THE RIGHT PROCESS

Processes and applications Inside the PRO E-Furnace A Tamglass product, the PRO E Magnum 2860-CS-20L Furnace deals with Low-e and the Super Low-e glass. Typically, alongside Low-e and Super Low-e, most glass processors need to produce traditional glass in large as well as small sizes. To achieve the required production flexibility, Tamglass has used its unique understanding of temperature and convection profiled heating to create a top of the line furnace ideal for optimised glass production runs.

must have a surface compression between 3500 psi and 10000 psi or an edge compression between 5500 and 9700 psi. In the heat treatment process, glass is heated first and then cooled rapidly to create surface and edge compression. This leaves the thickness of the center glass relatively hot compared to the surfaces. As the center thickness cools, it forces the surfaces and edges into compression.

Tempered glass Fast and efficient The key difference in the PRO E-Furnace is the placement of the convection system in the direction of the process, individual heating element control, individual operation of the furnace modules and a new highly efficient quench system for the quenching and cooling section. At Bahrain Prism Glass Factory, the PRO E-Furnace has been customised with CGSB, a new capacity booster option which gives more flexibility in the tempering of advanced architectural glass products such as those with a hard coating on the roller side of the glass sheet and an enameled or silk screen printed surface on the upper side. These innovations allow us to handle glass types with varying emissivity.

Heat Treatment Heat treated glasses are classified as either fully tempered or heat strengthened. According to Federal Specifications DD-G-1403B, fully tempered glass must have a surface compression of 10000 psi or more, or an edge compression of 9700 psi or more. Heat strengthened glass

16 Reflect your Vision

The glass tempered at Bahrain Prism Glass Factory can resist temperature differences (200 degree F to 300 degree F) which would cause annealed glass to crack. Tempered glass, also called toughened glass, makes the glass four to five times stronger than annealed glass of the same thickness. This process gives the glass greater resistance to thermally induced stress than annealed glass. Tempered glass typically breaks into small granules which is considered harmless. This process conforms to ASTM C 1048, American Standard and is best suited to be used as safety glass. Areas of application Tempered glass can be used on windows, glass facades, shopfronts, structural glass, shower screens, bathtub enclosures, sliding or swing doors, showcases, balustrades, squash court walls, glazed flooring, wall claddings, etc.

Heat strengthened glass Bahrain Prism Glass Factory's heat strengthened glass, with its lower processing temperature gives the façade less optical distortion.

inconvenience caused. That is why we advice heat soaked testing for all fully tempered glass in our oven.

This process makes the glass approximately twice as strong as annealed glass of the same thickness and also exhibits greater resistance to thermal stress when compared to normal glass or annealed glass.

Heat soaked testing allows us to transfer the potential on-site breakage of tempered glass to breakage under a controlled process in our factory.

According to BSI standards, unless this type of processed glass is laminated it cannot be construed as a safety glass. This process which conforms to ASTM C 1048, enables glass to break into larger pieces and remain in the window frame. Areas of application Heat strengthened glass can be used for high rise buildings, commercial complexes, building facades, insulating glass units, spandrel glass, windows etc.

Bahrain Prism Glass Factory’s heat soaked test Although fully tempered glass offers a certain degree of resistance to breakage, it is potentially at the risk of spontaneous breakage due to the formation of nickel sulphides (NIS) during glass production. As it stands, the formation of NIS in glass cannot be totally eliminated. Since nickel rich contaminants such as stainless steel are present in the glass melt materials, the nickel combines with sulphur in the batch or furnace fuels to form an impurity called nickel sulphide (NIS)

This method has proven to be an invaluable test for identifying batches that have a high occurrence of nickel sulphide inclusions. • This is a quality control test conducted on fully tempered glass • All glass panes fully tempered heat soaked tested by Bahrain Prism Glass Factory carry a warranty for a period of 10 years from the date of the process

Tempered glass properties • Heat treated glass cannot be cut, drilled or chamfered after treatment, as it will shatter into pieces • Holes, notches and edge work have to be conformed before tempering

Glass preparation • Hole size limitations: The diameter of circular holes should not be less than that of the thickness of the glass. The distance from the edge of a hole to the edge of the glass should be twice the thickness of the glass itself.

At Bahrain Prism Glass Factory, we understand the implications of spontaneous tempered glass fracture and the related

Bahrain Prism Glass Factory 17

6. THE RIGHT PROCESS

Glass preparation CONTINUED • If the total area of the holes exceeds 1/6th of the plate area, then technical advice would be necessary to prevent breakage during the tempering process • The distance between the edges of the holes should be in excess of the distance from the edge of the glass to the edge of the hole itself or else it is always recommended to create a slit on the edge of the glass • The distance between the edges of two holes should not be less than twice the nominal glass thickness, on the same surface

Insulating glass production line Currently, Bahrain Prism Glass Factory is the only factory in the Kingdom of Bahrain with a dual insulating line. A state of the art, 3500mm x 2500mm, fully automatic with dual robotic sealant options along with a fully automatic, robotised insulating line, 5000 x 2500 from LISEC, Austria, the biggest glass insulating line in Middle East has been installed. This ensures that customer requirement in terms of sealant application will be done with ease when it comes to polyeurathane, polysulphide and silicone simultaneously. Double glazed or insulated units are manufactured by encapsulating two distinctive lites of glass separated by a desiccant filled aluminum spacer and sealed with inorganic sealant. The property of the desiccant is to absorb the residual moisture that remains in the encapsulated unit. The primary seal is polyisobutylene, which provides protection against the moisture vapor transmittance. It also helps reduce thermal edge conductance between spacer and glass, thereby increasing energy savings.

18 Reflect your Vision

7. OPTIMISED

PRODUCTION

LINE

Insulating glass production line CONTINUED We also provide a host of secondary sealants depending on the type of application and installation, providing versatility in product application, giving maximum strength and protection from stress and extreme temperature. Our insulated glass units can be used to significantly save energy costs, and is highly recommended for its acoustic values, structural integrity and protection against moisture vapor transmittance.

Areas of application: Insulated glass can be used in office buildings, residential towers, hospitals and commercial complexes which require high cooling, in buildings that require temperature and humidity control, such as a telephone exchange or labs, and in airport buildings or buildings close to the airport, railway station, and highways for its acoustic properties. Specifications

The encapsulated layer of air increases the insulation capability of the double glazed glass units produced by Bahrain Prism Glass Factory, reducing the air conditioning load significantly. The use of normal reflective, high performance reflective glass, solar controlled coated glass or Low-e glass used in our double glazed units further reduces the load on the cooling system. Further advantages of the insulated glass units can also be found in moisture formation. In double glazed units produced by Bahrain Prism Glass Factory, the insulating effect of the air layer makes it difficult for the glass to cool and consequently there is no dew condensation.

20 Reflect your Vision

• Insulated units should not be exposed with secondary sealant type polyurethane or any other secondary sealant to continuous sunlight. This reduces the efficiency of the insulated unit, its sealant and service life • Our insulated units are manufactured by sealing a layer of air. However, changes in temperature may cause some distortion in glass and this could be more obvious in reflective tempered glass used for external facades

Structural Glazing •

We don’t recommend the insertion of Victorian profiles or Georgian bars, including golden stripes within the encapsulated units because of the additional energy this invites from external sources

• If the altitudes are higher than the ones where the insulated units are manufactured, an internal pressure regulator is essential • Providing accurate particulars is very important while placing orders as rework is not cost effective and will involve further costs • Insulated units for skylights and green house applications need proper technical advice. Here, usage of laminated glass is recommended • We recommend face 2 as the reflective coated surface in order to avoid erosion of the coated surface due to climatic conditions prevalent in the Middle East

Structural glazing has a very high self cleaning capacity and a very long service life. The economics of the system allows you to keep maintenance costs significantly low. Primarily structural glazing is economical. Factory manufactured glazing units can easily be assembled at the site and replacements can be undertaken. Savings on account of thermal insulation due to the properties of glass facades using high performance solar controlled coated glass types from world class manufacturers save tremendous amount of money in energy costs. Glass and silicones naturally have lower thermal conductivity than metals. As the energy consumption is high in extremely hot countries like the Middle East, this could save a lot in energy costs. Improved sound insulation and reduced thermal stress are added features of structural glazing.

• We consider and follow edge deletion on all low emissive glass types used in phase 2 or 3 applications

Bahrain Prism Glass Factory 21

LAMINATED GLASS LINE U-LAYOUT 1. Loading tilt table 2. Washing machine 3. Glass picking zone 4. Aerial transfer suction bridge 5. Interlayer unwinding system 6. Laying/Assembling station 7. Interlayer trimming section 8. Primary heating station 9. Primary roller press 10. Secondary heating stations 11. Secondary roller press 12. Unloading title table 13. Climatised room

06

07

08 09 10

11

12

01

22 Reflect your Vision

05

13

8. SMOOTH WORK FLOW

Laminated Glass Laminated glass is a combination of two or more glass sheets with one or more interlayers of PVB. In case of breakage, the interlayer holds the fragments together and continues to provide resistance to the passage of persons or objects. The performance of laminated glasses can be varied by changing the number and thickness of each of the panes of glass, and the PVB interlayers. This provides the designer or architect, a wide choice of products depending on application, whether it be for safety or security, noise control, solar control, UV screening, blast resistance or privacy. Bullet resistant & Triple laminated glass Bullet resistant glass is a multi-layered product with three or more sheets of glass of specific thickness combined with PVB interlayers offering greater resistance. To satisfy the needs for special protection requirements, sheets of glass and PVB are fused together to absorb the tremendous energy that needs to be dissipated when a bullet strikes. Shatter proof The benefit of laminated glass is that it offers a very high level of protection. When broken due to a blast, laminated glass doesn’t shatter around but reduces the risk of injury by remaining in place.

04

Noise control Efficient noise control is a challenge in today’s world. Noise is an environmental factor, hazardous to human beings. Laminated glass provides excellent sound insulation, encouraging designers and architects to use it to meet their acoustic protection requirements. Key applications include building entrances, internal doors, overhead glazing, swimming pools and shop display windows. 03

02

Bahrain Prism Glass Factory 23

9. CUTTING EDGE EQUIPMENT

list of equipments: LISEC Mobile Overhead with Rotating Double Section Frame - 1 Line

LISEC Automatic Plant for Endless Bent Spacer Bender BSV 45 A along with A 2RL/M Automatic - 1 Unit

Completely automatic PKL line serving 2 jumbo cutting lines, supported by a multi compartment glass rack LBR which is a movable compartment construction to store jumbo sized glass sheets. This is also enabled with a laminated glass cutting table with a combined thermo mechanic cutting process. LISEC Fully Automatic Vertical Insulation Glass Line LV FPLN 3500/2500 - 1 Unit

A desiccant filling machine for bent spacer equipped with a 6 slot spacer automatic magazine.

A fully automatic combined machine with integrated controlled function sequence for assembling and pressing insulated units. This ensures a short cycle time by a process optimised function sequence and enables production of stepped units. LISEC Fully Automatic Vertical Insulation Glass Line LV FPLN/S 5000/2500 - 1 Unit A fully automatic combined machine with an integrated controlled function sequence for assembling and pressing insulated units. This machine ensures a short cycle time by process optimised function sequence, production of stepped units and double sided vacuum suction bridge Type LAS 8 and overhead spacer frame conveyor. Vertical Edge Deletion Machine for Low-E Glass Type AKL - 2 Units With a selectable grinding width of up to 50 mm this machine allows automatic dressing of the grinding wheel. It also allows automatic adjustment to different glass thicknesses. Its electronically controlled drives with suction pad movement of glass sheets are ideal for accurate positioning in the deletion center. Its working sequence is reverse to washing machine in order that both the grinding station and washing machine can be loaded from one position.

24 Reflect your Vision

LISEC Fully Automatic Dual Adapter Robotic Sealing Machine: Polyurethane and Silicone - 1 Line This machine allows easy change over to different types of sealant, along with volume and feed rate controlled. It also allows precise corner filling by using spatula device and roller system and is recommended for highly accurate mixing and metering. LISEC Fully Automatic Compact Vertical Glass Washing and Arising Machine KSR 25 -1 Unit This machine enables the arising of shaped and profiled glass units automatically, along with a capability of arising multiple laminated edges. It allows an integrated high pressure water spraying mechanism to rinse all the grinding residues. LISEC Laminating Glass Line, 5100 x 2600 - 1 Unit This machine is specially designed to laminate tempered glass panels, customized sizes, shapes and Low E coated glasses or painted glasses in mixed production of PVB unwinding stations up to 16 rollers. It allows simultaneous laminating of two small sized panels side by side for increased output. It also features a self diagnosis and tele-assistance control system, along with hybrid furnace with forced air convection for thick lamination, especially to save energy. LISEC Auto Clave 3000 mm x 6000 mm - 1 Unit This machine consists of hyperbaric chambers where temperatures and pressure are controlled by a special air recirculation system consisting of a fan with suitable air recycling and distributing channels where conditions of temperature and pressure homogeneity are obtained.

Factory firsts Tamglass, Pro E Magnum Horizontal Tempering 6000 x 2800 - 1 Unit Specially designed for advanced heating process with Coating Glass System and Over Heat Protection System using Modular Technology. It allows upgrading with various options including new capacity ad capability booster CGSB. CNC Five Axis Machine - 1 Unit This machine is designed to meet the requirements of the building and furniture sectors, interiors and designers. It has the capability to process any size and thickness. Digital operation and control system of the machine enables a dynamic prompt response of the axis and a precise check of speed. This machine allows processes such as drilling, milling, notching, edging (inside and outside) grooving and writing, artistic engraving, shaped cutting, polishing and internal and external bevels.

• First in the Kingdom of Bahrain to install Pro E Magnum tempering equipment from Tamglass, capable of processing glass units of dimensions 6000 mm x 2800 mm • First to procure and install 2 units of fully automatic robotic sealing apparatus with dual sealing heads, capable of serving multiple choices of complex clients • First in the Kingdom of Bahrain to install a jumbo cutting with automatic loader, capable of loading either side of the suction to feed twin tables simultaneously • First in the Kingdom of Bahrain and the Eastern Province to operate a lamination equipment with an autoclave apparatus, of process dimensions 5100 mm x 2600 mm • First in the Kingdom of Bahrain to process ceramic frit printing with the help of heterogeneous/homogeneous roller coater and silk screen printing machines

Heat Soak Testing Machine 5100 x 2800 - 1 Unit Silk Screen Printing Machine and Roller Coater Machine - 1 Unit

• The only architectural glass fabricator in the Kingdom of Bahrain with a decorative glass division, supported by an installation team to cover glazed flooring, glass wall systems and fused glass

Truilzi Horizontal Washing Machine, 5000 mm x 2800 mm - 1 Unit Schiatti Angelo, Edging and Polishing Machine - 1 Unit Lovati Edge Preparation Machine - 1 Unit Sandblasting & Decorative Equipments - 3 units A host of manual cutting tables and decorative glass equipments Automatic Gas Filling Station for Insulating glass-filling through Air Gap FPS/US - 1 Unit This machine allows high precision assembly with integrated and continuous gas filling, without holes in the spacer bar for optimised gas flow in order to achieve the desired filling. It also checks and controls the volume.

Bahrain Prism Glass Factory 25

CONTACT INFORMATION

Bahrain Prism Glass Factory PO Box: 50769, Al-Hidd Kingdom of Bahrain Tel.: +973 17 464000 Fax: +973 17 464040 Email: [email protected]

26 Reflect your Vision

Suggest Documents