Scroll down to see the process from start to finish.
The workshop where all the manufacturing took place.
Step 1
Artists Maquette showing lines which would eventually be the metalwork.
Step 2
The full size polystyrene former in its basic form - this was used as a base to build the framework around.
Step 3
The polystyrene former first had to be covered in plaster to reduce fire risk when welding.
Step 4
Artist's maquette next to polystyrene former to give idea of scale.
Step 5
The artist transferred all the lines from the maquette using string onto the full size former.
Step 6
Initial stages of metalwork being fitted around former
Step 7
Close up detail of metalwork. You can see from the measurements written on the plaster how much detail each piece required. Every length of tube or bar was a different measurement and each section was joined using a metal sphere which had been specially manufactured from solid bar. The welding for each joint had to be Tig Welding to enable NDT testing to be undertaken with confidence once the structure was complete. Each joint involved at least 9 runs of weld making this a very time consuming process and meant that over 3000 welded joints were required. Each welder undertaking the work had to be tested on each particular joint he was welding and on each type of weld eg fillet weld, butt weld etc. Samples of each welded joints from every welder were also sent away to be tested before manufacture could take place and a welding procedure written up for every size of material and type of weld.
Step 8
The figures on the sculpture were based on some of the craftsmen who undertook the work. The artist photographed them whilst working and then enlarged the shapes which were cut out in metal and welded to the finished structure. Once again the welds used to join the figures to the structure had to be tested and the complete work NDT tested.
Step 9
Once the metalwork on the former was complete we had to remove the polystyrene from inside the sculpture leaving only the metal framework.
Step 10
The sculpture was manufactured in three sections, the head, shoulders and legs. This picture shows the shoulder framework which had been brought outside in order to be lifted into he outdoor workspace and then joined to the head section.
Step 11
The shoulder framework being lifted into the outdoor workspace. We used local company Ross & Wright for all the lifting during the construction phase.
Step 12
The head framework outside ready to be lifted into the outdoor workspace.
Step 13
The head framework being lifted into the covered workspace where it was joined onto the shoulders using welding procedures which had been tested both on the joints and the welders carrying out the work.
Step 14
The head and shoulders are now joined together and ready to be lifted onto the transport to be moved to site and joined to the legs which have already been manufactured and installed.
Step 15
Families and friends gathered to watch the initial lift at our factory.
Step 15a
Head and shoulders lowered onto transport. We used specialist transport company GCS Johnson who gave us total confidence in their ability to transport such an unusual load.
Step 16
Safely on the transport being secured ready for the journey.
Step 17
And we're off - a momentous occasion after all the months of hard work to finally see this huge sculpture being transported to its new home.
Step 18
The view from the new site as the sculpture makes it's way along the road.
Step 19
Now getting ready to be lifted from the transport and secured to the lifting frame which was manufactured by Aycliffe Fabrications. We used Hewdens Crane Hire for the site lift.
Step 20
Now for the real test - lowering the head and shoulders onto the legs which have already been concreted into place.
Step 21
Colin Henderson (Estimating & Technical Manager), John Flanagan & Chris Parkin (Senior Tradesmen) and Dave Mann (Production Manager) watching their months of hard work being lifted into place on site.
Step 21a
Colin Henderson (Estimating & Technical Manager) John Flanagan & Chris Parkin (Senior Tradesmen) waiting patiently for the lift to be completed so they can finalise the installation.
Step 21b
David Mann (Production Manager) and Christine Bewley (Director) watching apprehensively as months of work is in the hands of others being lifted into place.
Step 21c
Of course it fits perfectly - we are experts after all.
Step 22
David Mann (Production Manager) and Christine Bewley (Director) delighted that finally all the months of work are in one place successfully.
Step 22a
A view from the top of the cherry picker - this is the view the 'Head' watches over at the entrance to Aycliffe Business Park.
Step 23
Finally in place 'In our Image' settles into its new home at the entrance to Aycliffe Business Park.
Step 24
It was a real family event as all our familes and friends gathered to watch the final installation.
Step 24a
As the trees grow around the sculpture only the head and shoulders are visible which was exactly as the artist intended.
Step 25
Artist Joseph Hillier presenting Christine Bewley (Director) with 3D model of 'In Our Image'.
Step 26
Aycliffe Fabrications have been supplying high quality tanks to Oberlin Filter Ltd for 13 years. Oberlin recognize the importance of developing a good business relationship with suppliers to achieve a constant high quality service. All the personnel at Aycliffe Fabrications provide a comprehensive quality service.
Having known of the reliability and quality of Aycliffe Fabrications work by previously consulting with them on various projects I was more than happy on this occasion to ask them to undertake the fabrication of my sculpture. It was a pleasure to work with them in every detail of the work, where they provided a quality service and I look forward to working with them again in the future.
I've used Aycliffe Fabrications on several occasions over the past 8 years. I cannot fault the entire service, ranging from design to execution and installation. The workmanship is of the highest order and whether the job has been to fit bars to windows or create an entire new gateway I have always been 100% happy with the work carried out. The finished work is always of the highest quality and will undoubtedly last for decades.
Aycliffe Fabrications are proud to be certified in the above.
