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A Year on With Hythe HOSMU Storage and Distribution Solutions

HOSMU airport winter resilience storage and distribution solutions

One year after Hythe HOSMU was formed, we take a look at the companies storage and distribution solutions projects, the challenges faced, and goals for the future. 

storage and distribution solutions by HOSMU at heathrow airport airside winter resilience

In their first year, Hythe HOSMU installed a modular self-help system at Heathrow Airport. This system allows for the distribution, deployment and return of equipment, coupled with the safe, measured and effective dispensing of de-icing media. We discuss the challenges and wins of this crucial winter resilience project at one of the world’s busiest airports.

But before we get into it, what exactly does Hythe HOSMU do?

 

An Introduction to Hythe HOSMU

Back in 2019, HOSMU was formed to support the mass production of bespoke modular units. These units enable the efficient storage, distribution and deployment of self-help tools, plus aircraft stand and roadway clearing equipment. 

HOSMU is part of the Hythe Group. What sets it apart from the other companies within the group is its capability to design, develop and install bespoke and tailored storage and distribution solutions specific to clients’ operational requirements. 

Specialising in Aviation and Rail projects, HOSMU compliments the group’s proven strength and experience in providing Marine and Building Services. 

 

Storage and Distribution Solutions for Heathrow’s Winter Resilience

Previous winters had seen the deterioration of the pre-existing winter resilience solution at Heathrow, coupled with inadequate storage for grit and de-icer. 

Hythe HOSMU provided Heathrow’s Winter Operations team with a one-stop location for important tools and necessary equipment. The project aided the safe and efficient turnaround of aircraft on stands, while keeping airside roads and pathways clear.

The innovative HOSMU self-help solution we manufactured provides the consolidated and organised storage of essential winter resilience tools and stand clearing equipment. De-icing products are now distributed safely and with precision.

“We’re delighted to report that following the recent snowy conditions our HOSMU custom made modular units have successfully improved operational effectiveness during a ‘snow event’ airside at Heathrow Airport.” – Neil Robinson 

storage and distribution solutions by HOSMU at heathrow airport airside winter resilience

What Did the Project Involve? 

Following a period of consultancy and development of the project brief, the HOSMU system installation provided an innovative four-part solution.

This included a consolidated single collection point for essential winter resilience operating equipment and the management of stand waste, combined with winter media storage and distribution. 

Forty-eight key airside locations were identified across the terminals, including aircraft stands, pathways, roadways and control posts. These key locations were provided with the requisite modular parts to provide winter resilience tool storage and effective, consolidated housing and distribution for snow and ice clearing media in use across the entire site.

Each custom made component features an RFID asset management and inspection system. The system regularly records inspections and reduces the need for maintenance and equipment replenishment commonly associated with winter operational use.

During an intensive period of prototyping and feedback, HOSMU presented Heathrow with nine client-driven revised prototypes. To ensure quality throughout the project, each step incorporated feedback gathered from presentation and review at airside events and consultations with the winter operations team.

 

What Was the Biggest Challenge HOSMU Faced and How Was it Overcome?

In addition to understanding, overcoming and changing behavioural and methodological operational airside practices in Winter, perhaps the biggest challenge faced by the HOSMU team was providing a solution to safely store and dispense the winter de-icing media commonly known as ‘Prill’.

Prill is a pelletised form of de-icing media formed by the congealing of a liquid and it provides a safe and effective way to rapidly de-ice and melt ice and snow. It robustly stays in place when deployed ahead of a ‘snow event.’ Prill is packaged in 25-kilogram bags which, once opened and left exposed to the elements or moisture, hardens and is wasted. Hundreds of kilos of prill were often squandered during winter due to bags being partially used or stored ineffectively in grit bins or left exposed to the elements. 

The key was to develop a modular unit capable of being able to receive an entire bag of prill at a safe lifting height and then dispense a specified amount determined by the user, depending on the surface to be treated.

Nine concept prototypes were developed by the HOSMU team offering a range of solutions. After a sustained period of testing the final ‘media Hopper’ design was approved by Airfield operations and following two winters has proven a success. It uses a unique mechanism to ensure the prill is dispensed in its pelletised form, even if it has solidified within the hopper, or has been added to the hopper in a solidified form. 

 

How Has the Installation Changed Life for the Winter Resilience Team?

“HOSMU’s custom solution has taken our outdated self-help tools and media storage and provided airfield operations with an innovative and robust concept ready to tackle the snow events we manage each winter, helping to keep the airport fully operational…” 

– Winter Operations Manager at Heathrow 

For the first time airside at any airport, all winter self-help equipment is in one easy to use modular system at key locations.

Winter operational efficiencies were vastly improved during the recent snow events at Heathrow. Notifiable asset management and inspection systems are in place with each component. As a result, the need for maintenance and equipment replenishment associated with winter operational use is reduced. 

The HOSMU now provides a clearly identifiable, branded focal point for the organisation and storage of the equipment and winter media. It also ensures operational equipment is returned, reducing the likelihood of trip hazards and lowering the need for tool replenishment. The units are also used as a mechanism to promote safety messages, like the ‘safety 6’, to the airside community.

storage and distribution solutions by HOSMU at heathrow airport airside winter resilience

What’s next for Hythe HOSMU?

HOSMU are ready to present their winter resilience solution to the wider airport community and other industries with a winter resilience requirement. 

The team have also been developing four additional components. These allow for totally consolidated equipment storage on stands and airside at airports. Including; bollard bin clamps, cone and trolley storage, sawdust storage for minor spills and a tiered approach to chock storage. 

HOSMU‘s storage and distribution solutions will give ramp users a one-stop location for all equipment associated with the safe and efficient turnaround of aircraft. It also provides stakeholders with the necessary self-help tools to carry out their roles.

The HOSMU modular concept can be tailored to any industrial operational requirement

Contact our team to discuss HOSMU’s storage and distribution solutions capabilities for your upcoming projects. 

Hythe Group Introduce a New Joinery and Carpentry Workshop

Meet Peter Barker and Mike Budd

Hythe Group have opened up a brand new workshop specifically for woodworking projects. To find out more we spoke to experienced carpenters Peter Barker and Mike Budd, who recently joined the Hythe team.

Peter and Mike first worked with Hythe Marine Services (HMS) in May 2019, as contractors on a project for the Royal Navy’s Hunt Class minesweepers. After seeing their skill and work ethic, HMS offered them permanent roles within Hythe Group and in September 2019 they joined the team full-time.

The new joinery workshop

Hythe Marine Services’ shop floor previously focused solely on metalwork and fabrication. Metal welders and fabricators often work in cold environments, whereas woodwork requires a warm, dry workshop. Combining these two crafts under the same roof would have posed a potential fire hazard (between the sparks of welding and the wood shavings of joinery work) and so the decision was made to keep the two workshops apart. 

As a result, Hythe Group built a brand new workshop designed especially for woodwork, which is spacious, warm, clean and well-lit.

New team members Peter Barker and Mike Budd

Both Peter and Mike obtained their NVQ Levels 1,2, and 3 in Carpentry and Joinery whilst completing apprenticeships at shipyard companies. Throughout their careers, they have worked for numerous businesses within the marine engineering industry. 

Since his apprenticeship, Mike built a wealth of experience and skill working for A&P Shipcare, Sunseekers, Harris Pye Marine, Trimline, and BSA building and maintenance. During Mike’s time at A&P Shipcare, he worked on deck heads and bulkheads, built cradles for the ships

 to sit on, was part of the team dry docking ships and was involved in stripping out cabins.

Whilst working with various businesses, such as BAE Systems, Peter gained invaluable industry knowledge which he brought to HMS. Peter also spent time working for luxury yacht companies like Oyster and Compass Tenders. Throughout his time at Compass Tenders, Peter built and moulded high-end superyacht tenders from scratch, such as the Jupiter tender for their superyacht ‘Alisail’.

Prior to joining Hythe Group, Peter and Mike were working at the same company. Peter told us about a fantastic antique yacht he worked on during his time there. “I worked at a classic boatyard in Germany where we re-planked an antique boat from scratch. We used American cedar inboard plank and mahogany exterior plank, and the joinery consisted of old school scarf joints or for oak frames we used brass screws. It was traditional boat building in a very prestigious boatyard. A great project to be a part of.”

Through their previous company, Mike and Peter worked for Sunseekers on interior subfloors, roofing and decking. Interior fit-outs were always to an impeccably high standard. They recalled being in awe at the sheer size of the superyachts, and their unbelievable features like gyms and even cinemas! 

“The work that we do is really rewarding because ultimately, the end result is on display for everyone to see. Having worked with superyachts and other high-end clients, the standards are extremely high and the finishes must be top-notch. It’s great to finish a project and see all that hard work on display,” Mike Budd.

What does this mean for Hythe Marine Services? 

With the new workshop, Hythe Marine Services can now provide custom high-quality joinery and carpentry services to the marine industry. This is a new in-house capability for Hythe Group, and they look forward to the different nature of projects it will bring. 

Since starting with HMS in September, Pete and Mike have been busy working on some exciting woodwork projects. These will usually begin with a drawing, cutting list and edging and finish with bespoke, handmade items that meet customer’s exact requirements. These projects include custom wardrobes with built-in beds, radiator covers and bathroom utility units. After drawing up designs for one customer, they built a bespoke kitchen suite using tongue and groove vertical lines. 

Mike commented: “Hythe Marine Services do exceptional work but it’s usually behind the scenes and hidden once the end product is completed. Our work is the final product, minus the finish, so it has to be perfect before leaving the workshop.” 

In the future, Pete and Mike are looking to do more woodwork for Royal Navy carriers, such as their cabin refits, bar tops and workspaces and are also hoping to expand within the building side of the business. Their diverse careers have given them a wide-ranging skillset which enables them to adapt to anything. Their skills go beyond woodwork to mechanical fitting and installations, with Mike and Pete often helping out with bulkheads, tracks and deckheads. They also spent a lot of time last year working on the HMS Queen Elizabeth adding hinges to fire doors. 

The new joinery workshop is now up and running within Hythe Marine Services. A great benefit to Hythe Group is the new workshop can also assist Building services on their projects where required. The new team with Peter and Mike is there to support the turnkey solutions HMS require. This gives customers the added ease of a one-stop-shop for their projects.

To find out more about how our bespoke woodworking services can help your next project, contact us here!

HYTHE HOSMU PROVIDES STORAGE & DISTRIBUTION SOLUTIONS FOR HEATHROW AIRPORT

Who and what is HOSMU?

HOSMU is a Hythe Group company which was introduced to support the mass production of custom metal fabrication projects, providing innovative solutions to customers’ storage and distribution challenges.

The HOSMU concept was developed in partnership with Heathrow Airfield Operations, the safety and workplace supplier, Our Soles Ltd. and proven engineering specialists, Hythe Marine Services (HMS).

The resulting turnkey solution is a concept driven, manufacturing business capable of designing, delivering and implementing consolidated and organised storage of essential resilience equipment.

This process has been designed to give customers the highest quality solutions, based on Hythe Marine Services knowledge and experience from the marine sector, including cost efficiencies and speed of a production line.

 

The Heathrow Airport project

Hythe HOSMU was installed airside at Heathrow Airport in readiness for winter 2019/20. The installation provided a new solution for a consolidated, single point of collection, for essential winter resilience operating equipment.

Operational efficiencies are instantly improved by placing all equipment into one modular system (situated in multiple locations airside) which ensure self-help snow and ice clearance equipment is organised and readily available. By providing a clear focal point for organistaion and storage HOSMU ensures operational equipment is returned, reducing the likelihood of trip hazards whilst lowering the need for tool replenishment.

The HOSMU for each stand or airside location is assembled depending upon the footprint and operational requirements of the area. Each unit can contain a number of functions such as:

  • Winter operations locker
  • Winter media distribution hopper
  • FOD (Foreign Object Debris) and POL (Polluted waste) wheelie bin storage

What was the problem Heathrow Airport’s winter resilience team faced?

You might be wondering what winter resilience really means? Heathrow has a team specifically dedicated to winter operations and they are entrusted to plan, prepare and manage robust strategies and resources for effective winter resilience. This may concern the shocks and stresses of winter weather, such as snow and ice, which impact airport operations.

Heathrow provides a number of useful tools and consumables which are kept in strategic areas of the airport for use by stakeholders and contractors as ‘self-help’. This ensures the safe passage of working areas in the event of ice or snow.

Heathrow had previously been using open mesh steel cages to house self-help equipment (brooms, shovels, scoops and buckets) and HDPE bins for the storage of winter media (grit and prilled de-icer) for in-situ distribution when required.

The open mesh steel cages offered no protection from the elements, nor did they provide any dedicated space for each of the self-help items to be kept in an organised fashion. Items were routinely being tarnished by exposure to the elements or lost in use.

In addition the HDPE bins were proving inadequate to store bags of prilled de-icer, especially when they had been partially used due to the products requirement to be kept dry at all times. Therefore a solution was required to enable safe, dry storage of the prill and grit allowing for accessible dispensing without any deterioration of the media or risk of manual handling issues – as grit or prill were lifted out of the bins in bulk, or scooped out from the bin whilst bending.

During a routine meeting with the Heathrow Winter Operations team to discuss the provision of PPE and safety workplace supplies (specifically related to the self-help clearance of Snow) Neil Robinson, managing director of Our Soles, was asked to provide concepts for robust self-help equipment that could develop innovative solutions to enable the safe storage and distribution of the items.

 

Why was Hythe Marine chosen to solve the problem?

Neil has been servicing Hythe Marine with safety kit and uniforms for almost a decade. During this time his relationship with key personnel within Hythe Marine Services has grown, as has his understanding of their capabilities related to turnkey projects. Neil’s experience watching HMS work made Hythe Group the perfect partner for this task. The project was reliant upon Hythes Marine’s metal fabrication and engineering skill set, and familiarity with bespoke problem solving, to ensure delivery of a robust, elegant and effective solution.

 

How did HMS solve the problem?

The brief was as follows:

  1. Manufacture a storage unit whereby all self-help tools could be safely stored and easily accessed.
  2. Design a hopper capable of dispensing prilled de-icer and grit without jamming whilst ensuring the disposal of media doesn’t involve any unnecessary bending or lifting
  3. Design a bin clamping mechanism to keep wheelie bins located airside and locked into one location
  4. Make the component parts modular

Following a number of meetings between key personnel the requisite self-help products to be housed in the locker were decided upon and each of the media. Prilled De-Icer and Aviation Grit were analysed for their mechanical properties to enable prototype hoppers to be developed. A shadow-boarded ‘locker’ was quickly developed that would effectively, safely and securely keep the tools shielded from the adverse weather conditions and ready for use when required.

The ‘Hopper’ was more of a challenge. After multiple trials of the media (particularly the prilled de-icer) in cold, wet, warm and dry simulated environments, and experimenting with numerous dispensing mechanisms, HMS Technical Director Luke Fitgerald and Operations Manager Greg Strange finally developed a solution. This is now in effective operation at Heathrow, dispensing media reliably, safely and accurately.

Following multiple prototypes, client led revisions and design developments the final HOSMU locker prototype was produced in time for presentation at the Summer Airside safety event in May 2019. At the event it was presented to the airside community for feedback as well as the winter operations team for approval.

 

What was difficult about the bespoke requirements of this project?

This project was different to others Hythe Marine Services is used to due to the requirement for airside stand locations and proximity to aircraft. Numerous operational safety considerations needed to be adhered to in order to enable a safe and robust solution to exist airside. The most tricky element was the design and mechanism of the hopper, specifically for prill which is a notoriously difficult media to work with.

This is what led to the pioneering bespoke hopper design. All modular component parts have been bespokely manufactured to the original brief.

 

What is difficult to adhere to airport regulations?

Numerous operational safety instructions exist for contractors working airside at Heathrow of which HOSMU are proud to have complied with in delivering this project.

Specific safety management systems were built to assist the project in complying with HOSMU’s obligations to the project Risk and Method Statements, control and procedures for aerodrome works.

Adherence to ground operations in terms of use of personal protective equipment, airside cleanliness and FOD management in accordance with the airport operations plan, alongside our commitment to environmental management and sustainability, all featured as part of the project delivery.

 

Future Development Plans for HOSMU?

To provide additional operational resource and further reduce hazards in operational areas, we are proposing the following additional equipment storage:

  • Cone and Cone trolley storage
  • Sawdust storage for minor spills
  • A tiered approach to chock storage

This will give ramp users a one-stop location for all equipment associated with the safe and efficient turnaround of aircraft, as well as providing our stakeholders with the necessary tools to carry out their role.

University of Portsmouth Installation

Hythe Building Services designed and delivered the Mechanical services for this prestigious project with Kier Construction for Portsmouth University.

The Hythe Building Services team stripped out all existing Domestic, Heating, Ventilation and Air Conditioning Services and installed a completely new system that included new wash hand basins within the new Consultant rooms, a VAV system complete with heating coils to control the optimum environment within the teaching spaces, intricate BMS modifications to incorporate the new systems onto the existing BMS Schnieder infrastructure. 

The project was a great success and Hythe went on to secure and deliver two other extremely time sensitive projects with Kier for The University of Portsmouth, our relationship with Kier and the University continues to flourish.

Hythe Group – Where it all began

Today, Hythe Group specialise in the provision of premium design and engineering services. The Group operates globally within a variety of industries such as building, commercial, marine as well as the storage and distribution sector.

But where did Hythe Group begin?

 

A little history

The original business, Hythe Marine Services (HMS), are renowned worldwide for their work on bespoke design and engineering services. As HMS developed a strong reputation within the marine sector, demand for their design and engineering services started to diversify beyond that of the marine market. 

At this time the company’s sole focus was not on growth, or being the biggest company within the industry, speak with Hythe Group Director Josh Mathias and he will tell you it’s all about being the best at what you do, that reputation for delivering unrivaled quality and service is far more valuable than purely chasing market domination. 

Having said that, in 2016 a highly motivated team within HMS pitched the idea of separating the company into two entities. One side would continue operating within the marine sector and the other would focus wholly on the building industry to meet growing demand. They saw a requirement to take on small prefabrication and installation packages for larger companies, who held a major part of contracts. The demand was clear, these larger companies were over stretched and needed a reliable, flexible and motivated team to take care of the problem. Josh Mathias commented that, “funnily enough this attitude towards work was how Hythe Marine Services was built and is what continues to ensure its growth today.”

Anyone who’s done it will tell you that the thought of starting a new business is daunting. However when it became clear there was an opportunity for slow, controlled growth, and high demand for quality labour within the commercial sector, expansion seemed to be a good and progressive option. And so in 2016, the team took the leap and Hythe Pipe Services was born, which later got rebranded as Hythe Building Services in 2019. 

“It’s largely because of that team that the idea became a reality. Today the foundations have become even stronger by bringing in like minded people to help drive the company in the correct direction at a controllable rate.” Josh Mathias | Director |Hythe Group 

Today Hythe Building Services (HBS) specialise in bespoke pipework, welding, fabrication and design services within the industrial, commercial and public sectors. For HBS to succeed, in this new and extremely competitive market, the team focused predominantly on controlled growth and the maintenance of Hythe Group’s reputation with solid client relationships and outstanding project deliverance. 

Three years later, in 2019, Hythe HOSMU was formed. This division within Hythe Group is a concept driven manufacturing business capable of designing, manufacturing and implementing consolidated and organised mass storage and distribution solutions. The team specialise in providing bespoke solutions to unique storage and distribution challenges, access limitations and/or functional hurdles. 

Hythe HOSMU was developed in partnership with Our Soles Ltd. and Heathrow Airport, to provide bespoke storage and distribution solutions to Heathrow’s winter resilience team. Although this is the youngest company within Hythe Group, HOSMU will soon begin to take on larger projects of mass-produced and bespoke items, using its knowledge from the marine fabrication sector to fast track its quality and set up. 

“Hythe Group were the perfect team to choose for the Heathrow project. I had seen how diverse their skills in metal fabrication and engineering really were, skills that were essential for the bespoke nature of the Heathrow Airport project.” Neil Robinson | Managing Director | Our Soles Ltd.

After the creation of Hythe HOSMU Josh decided it was time to group the companies together and link them all under one umbrella. The overarching Hythe Group brand now allows for the promotion of each company’s diverse skill set through one single platform. 

 

The role of the team

A unique advantage for Hythe Group businesses is the ability to create brand new companies using existing team members. Hythe Marine employee capabilities are recognised globally for their quality service, high standards, unique skills and attention to detail. These characteristics have carried through to the newer companies and employees.

Many team members have worked together for decades, harking back to when HMS was under previous titles Avrotech Design and Mathon Engineering. These long term employees of Hythe Group are known by name with industry-leading organisations, such as the Royal Navy, Babcock, BAE systems and the Ministry of Defence.

The small team who came up with the idea to split HMS into marine and building divisions are a great example of the Hythe Group mentality. It was because of their knowledge and dedication that the idea became a reality. Since then, the foundations have become even stronger by bringing in like-minded people to help drive the company in the correct direction.

We asked Josh Mathias about the team dynamic at Hythe Group: “The entire group at all levels enjoy improving themselves. The senior workforce is happy to pass on their knowledge to our apprentices and it’s great to watch them support the younger generation by passing on their knowledge within specific trades. In years to come, these apprentices are going to be highly skilled in multiple disciplines, making them the future must-haves hybrid traders of the industry.”

 

Group diversity

The staff turnover at Hythe Group is almost non-existent. Because of this, there are ever-growing amounts of in-house knowledge to continue the overall goal of upskilling and developing the workforce throughout the group.

Creating Hythe Group has made the company extremely versatile in applying their core skill sets. The workforce are able to comfortably move around to meet demand due to their wide-ranging experience. Despite being standalone companies, Hythe Group’s integrated teams ensure they are able to assist each other in periods of high or low demand. 

Team members are used to following incredibly strict policies and procedures. As a result the group is renowned for their ability to complete demanding turnkey projects in what are usually very short time scales.

 

What comes next?

An inevitable result of carrying out quality work and building strong relationships is an increase in demand. Hythe Group predicts the continued natural growth of each business for the coming years. This will be managed by selecting the right companies to work with, by taking on turnkey projects and supporting a growing workforce. 

Hythe Group’s immediate focus is the development of each business within the group, working to solidify their foundations, maintain the Hythe brand reputation and grow at a controllable rate. But most importantly, Hythe Group will ensure both the workforce and their clients are being looked after. 

To discuss how Hythe Group can assist with your next project?

Hythe Marine Services Achieves CE Accreditation for Structural Steelwork

The CE accreditation marking of construction products became mandatory in the summer of 2014 at which time fabricators were legally required to demonstrate compliance with BS EN 1090, a required European standard for the execution of steel and aluminium structures and construction products. The associated accreditation falls under the UK Construction Products Regulations (CPR).

Driven by customer demands and a commitment to continuous improvement, Hythe Marine Services (HMS) set CE marking accreditation as a primary strategic target to attain in 2020.

 

Value for our Customers

As of March 2020 HMS is now approved to fabricate steel and aluminium structures to an Execution Level of Class 2 as classified within the UK Construction Products Regulations. HMS level of accreditation comprises all supporting structures made of steel up to strength class S700 and structural components made of aluminium alloys. This typically includes buildings with between 2 and 15 floors.

Each product produced by Hythe Marine Services will follow a regulated process. The European Commission website explains, “It is the manufacturer’s responsibility to carry out the conformity assessment, set up the technical file, issue the declaration of conformity if requested by the customer, and affix the CE marking to the fabrication. Only then can this product be traded on the EEA market.”

We spoke to Hythe Marine Services, Compliance Manager, Paul Lessiter, who told us, “Just having the CE marking shows your prospective customers that you have gone through very stringent process controls in your production process. It shows that you’re checking things like materials, consumables, whether machines used are calibrated, that welders are qualified, that you’re putting the right people on the right jobs at the right time, and that you can certify all of this with full traceability.”

 

Responsibilities of Manufacturers using CE marking

As a CE accredited manufacturer, Hythe Marine Services has an obligation in ensuring its structural steel fabrications are safe and maintain the high standard required by BS EN 1090, ISO 3834 and the EEA market.

All components that comprise the fabrication are strictly controlled and audited. Line Managers in conjunction with an appointed Responsible Welding Coordinator, are responsible for the quality of the supply chain, the qualification of the fabricators, the traceability of materials, the approval of weld processes, the contractual and technical approvals. Auditing programmes are maintained and implemented through Paul Lessiter the Compliance Manager for HMS.

 

Looking to the future

HMS has embarked on a clear strategy of improvement, setting objectives from within the company that drive best kaizen practices across all of its functions, engaging with the marketplace and looking at potential future demands. The Company looks to demonstrate its achievements through an ongoing commitment to associated ISO Certifications.

Would you like to discuss a project?

Turnkey Belzona Solutions with Hythe Marine Services

 

Discover the processes and training behind Belzona applications.

Hythe Marine Services (HMS) is a highly competent applicator of all Belzona Polymeric Engineering Composites and Protective Coatings. Belzona marine coatings and metal repair composites are ideal solutions for the marine industry due to its ability to withstand extreme weather and long-term wear.

“Our products are specifically designed to cope with harsh offshore conditions and have exceptional resistance against erosion and corrosion.” – Belzona

 

What is Belzona?

Belzona are an internationally renowned manufacturer of repair and refurbishment services as well as coating inspection and application training. Their unique technology provides solutions to wide ranging repair needs, from full turnkey systems to in-situ repairs. Their mission is to ensure customers have the correct materials and knowledge to protect against erosion, abrasion, corrosion and chemical attack.

“Our approach to refurbishment and protection avoids the need for replacement, reducing repair and maintenance costs, and above all, downtime.” – Belzona

Founded in 1952 by entrepreneur Jorgen Svendsen, Belzona is now a global leader in repair compounds and industrial coatings. Hythe Marine Services understand the importance of providing bespoke and effective solutions to every client and Belzona’s materials, applications and training help make that possible.

Belzona commented that, “In recent years the Hythe Group have invested extensively in team training which has resulted in qualified members of the Group reaching Belzona Certified Trained Contractor status.”

 

What is Belzona used for?

Hythe Marine Services works with Belzona to protect and repair common erosive forces such as cavitation, impingement and entrainment. This ensures long term solutions against the effects of water erosion and corrosion in marine equipment. From mechanical parts through to damaged ships or offshore structures, Hythe Marine applies Belzona processes and materials to ensure exceptional defence against harsh offshore conditions.

By utilising a wide range of rapid and cold-curing marine coatings and metal repair composites, repairs can be safely carried out in-situ, to reduce downtime and the need for hot work.

“When hot work isn’t achievable we use Belzona. Using this method we got the system back in action in a fraction of the time of conventional methods!” Hythe Marine Belzona Applicator

 

What makes Belzona special?

“It’s our mission to exceed customers’ needs and expectations by providing long-lasting, quality repair and maintenance solutions” – Belzona. With over six decades of experience, the Belzona specification consists of the highest standard of long-term repair and protection, with the team priding themselves on sourcing the best raw materials available, to enable the highest quality manufacturing.

The company also has a cycle of continuous improvement, working to improve the standard of Belzona material application through theoretical and practical training programs. These programs enable Belzona certified engineers at Hythe Marine Services to learn and perfect their application skills.

 

Verified Belzona training

Hythe Marine Services have various engineers that are extensively trained to eliminate the risks of incorrect application practices. Belzona commented that, “To enable our reputation to remain as world leaders in our field we acknowledge the need for providing training whilst working alongside contractors.”

Belzona has state of the art training facilities where courses have been developed following internationally recognised Engineering Standards. Each course enhances application skills and provides the technical and practical knowledge required to adapt to the ever-changing demands of the marine industry. After completing training at Belzona headquarters, applicators can earn their verified status.

 

What Belzona services does HMS provide?

Within Hythe Marine Services, Belzona materials and processes are used for a variety of projects including sea tube repairs and initial sea tube protection measurements, steel pitting repairs, cold plate bonding and rubber seals.

“It is comforting to know that when a Certified Trained Contractor such as Hythe are involved then the level of application will be of a very high standard.” Steven Stay, Independent Area Consultant, Belzona Polymerics Ltd.

Hythe’s verified applicators are trained in a vast range of Belzona services to match all project needs, such as Belzona’s ceramic erosion resistant coating, which prolongs the life of marine equipment against weathering and water wear.

Looking for Belzona solutions?

Alister O’Neill Appointed as Production Manager at Hythe Marine

An introduction to Hythe’s newest team member.

Alister O’Neill first came into contact with Hythe Marine Services (HMS) as a subcontracted welder whilst working for Elta Fans Ltd. After gaining years of experience working within the marine, automotive and military industries, Alister is now joining Hythe Marine as a Production Manager.

Under his new role, Alister will be taking the lead on project, team and production processes. His extensive background within the marine industry and with welding inspection will be a valuable addition to the workforce at Hythe Marine.

Hythe Marine Services’ support to customers has been continually growing at a manageable rate. Josh Mathias, Hythe Marine’s Managing Director, told us “we have been able to take our time employing the correct person to ensure the continuation of quality service and on-time delivery”.

To support this growth, a significant part of Alister’s new role will involve the Quality, Safety, Health & Environment (QSHE) side of the business. Some of his main focuses will be quality control, business and production efficiencies as well as health and safety. Alister will also have a direct line to the welding and compliance team, in order to improve and maintain high production standards.

From Apprentice to Production Manager

At the start of his working life, Alister was an apprentice at FBM Marine on the Isle of Wight. Skills gained during his apprenticeship included welding and making aluminium parts for ferries and lifeboats. After his apprenticeship, Alister worked as a chargehand, whilst continuing to provide welding services within the marine and automotive industries.

Alister’s next role was as a welder with Elta Fans Ltd., a leading manufacturer specialising in large bespoke fans. It was with Elta Fans that Alister continued to develop and obtain additional qualifications to become a Certified Welding Inspector. In this role, Alister was subcontracted to Hythe Marine where he spent a lot of time on-site working with, and getting to know, Hythe Marine Services.

Alister’s career has demonstrated the rewards of working hard and maintaining high standards. The move to Production Management was after a production-based Foreman role where Alister told us, “I worked my way up from the Foreman of a large factory to the Production Manager of a smaller site.”

After Elta Fan’s Ltd, Alister moved to his new role as a Works Manager at Veotec (now part of the Woz Group). He stayed with Veotec for 5 years, making high-end separators, eliminators and filtration equipment for the oil, gas and marine market. The role at Veotec involved managing the majority of the production process – “After design, the entire production process was down to me, all the way through to packaging, shipping and transport.”

Due to company changes, Alister turned down a new position within the company which would involve a relocation. Because of this, he completely changed his role, company and industry and moved to Eberspächer UK. At this company, Alister was the Production Manager for a multi-million pound foreign military project. His main responsibility was setting up a lean production line to facilitate the production of 1,500 units at the lowest cost. “I was there to set up a 5S, lean manufacturing production line,” and it was after this project that Alister took on the role of Production Manager at Hythe Marine Services.

In a snapshot, Alister is “Very efficient, hard-working with a strong ability to multitask.”

Prioritising quality is always at the forefront of his work and projects, and he believes that nothing substandard should ever leave a site. Customers pay for a good product and the team should be proud of everything they produce.

Years of experience in welding and an inspection background has honed Alister’s strong attention to detail. He stated, “I’m very practical. Coming from a welding background and the marine industry I understand what it takes, from the ground up, to produce a product.”

The Role of a Production Manager

For Alister, the role of a Production Manager means being the central hub of a project to find and iron out any problems. Another key aspect of the role is collating and communicating information to make everybody aware of how the products will be produced, “I see the role of Production Manager as the main link or conduit between the workforce, project and design engineers.” 

Within a Production Manager role, it’s necessary to plan and react appropriately to external and internal factors. These may include changes in demand, the capacity of machine and floor and availability of skills. The overall responsibility is to ensure outputs are at the required quality, specification and within cost parameters.

As well as the Production side of the role there is a strong focus on people-management, creating a multifunctional workforce. Alister believes in investing time with people to develop their skills. In terms of allocating roles within projects, Alister said: “It’s about matching the right team to the right job based on reading people, their ways of working, and the work they turn out.” 

When asked what he’s most looking forward to in his new role Alister stated, “I have a strong understanding of the marine industry, particularly within the welding and fabrication services side of the business and am looking forward to getting more involved in these areas!”

The specialist knowledge of contracted structural engineers

 

An insight into the world of Structural Design

As well as in-house services, Hythe Marine also provides contracted talent to external large scale projects. Currently, a Hythe Marine Services (HMS) contracted Designer is working on a submarine design project over in Barrow-on-Furness with BAE Systems. We spoke with them to find out a bit more about what this involves.

 

How does the contracting process work at Hythe Marine? 

Within BAE Systems, Hythe Designers work on machinery seating as well as checking models and output drawings. These checks involve special expertise in order to feedback improvements or necessary re-works to the other Designers.

Alongside these tasks, this particular engineer provides services such as testing Foran (the CAD package) and providing CAD support to the Designers. CAD stands for computer-aided design, and in the case of BAE Systems will contribute to the production of precise and easily-modifiable designs.

“I first used Foran around 10 years ago, so I have a good working knowledge of the package. Already knowing my way around Foran also led to me being involved with the publishing side of things which sends the model data into the database.”

Completing an apprenticeship as a Structural Designer on the Trident project at Barrow meant this Hythe Designer had useful previous experience of working on submarines. Also, their knowledge of the Foran CAD package and how BAE use it means they are able to assist with ‘best practice’ processes.

 

The life of a shipbuilding Structural Designer

Being a Structural Designer covers a range of roles. Potential activities include creating the main structural elements such as the hull, decks and bulkheads, to the secondary structure like machinery seating, ladders and walkways. These jobs require expert knowledge and experience to provide the best design to complete the manufacture within a given timescale.

A BAE Designer may create designs from data provided by engineers, who do shock/stress calculations to the size and thicknesses of a plate. For smaller seats, designers will do all the design work themselves.

Part of this Structural Designers role is also as a design checker, which involves quality-assuring other Designers work to ensure it conforms to specification.

 

An average day at BAE Systems 

After an hour-long commute to BAE in Barrow, then begins the exciting day of troubleshooting and completing any tasks that arise. Other Designers will come to Hythe’s Structural Designer with various problems, such as with the CAD package or questions about the job and specifications. Often finding themselves doing several jobs at one time, it’s impossible to know what to expect from each day to the next. This way of working requires the ability to prioritise and multitask. Alongside all of that, they are also attending workshops and meetings regarding the software and processes.

A hectic day may not sound ideal to everyone, but this Structural Designer assured us, “My average day at work probably looks chaotic to some people because, unlike the other designers, I’m not really given specific tasks. I actually like this way of working because I’m always doing something different.”

 

Not just ships and submarines

When asked about past projects this Structural Designer found particularly interesting, they responded: “Possibly my most enjoyable contract was on a yacht called Mirabella V.” 

Mirabella V is a luxury superyacht with a 300 foot GRP hull. Within this project, this Structural Designer’s role was to accurately model surfaces to produce the moulds for things like the rudder, boom and even the Jacuzzi! This yacht also held a motorboat, for getting to and from shore, within its hull. “I had to model the motorboat to make sure it fit in the space provided.” 

Also within the Mirabella V project, this Structural Designer designed the shape of the radar arch for the yacht. One benefit of this project is the ability to see their work and be proud of what they created. They told us, “On most contracts, you don’t really see your work in the finished product because it’s usually not visible from outside, in the case of Mirabella V, I can look at the yacht and see the work I did.”

In addition to ships, submarines and superyachts, this Structural Designer has also worked within the Aerospace industry. A common trend amongst all industries is quality-assurance and checking.

When asked about how this role relates to their current role with Hythe Marine they said that checking within Aerospace requires certification as a checker on specific aircraft, whereas checking in his current industry is more down to experience, “However, checking in both sectors does require a good attention to detail and the ability to stand your ground when others might not agree with you.”

 

Being part of the Hythe Marine Team 

Working for Hythe Marine on and off for over 20 years has allowed this Designer to see the company’s progression and development. From being a Mathon Engineering employee in 1998, they saw Mathon become Avrotech Design, which later became part of Hythe Marine Services. Reminiscing about their history with Hythe Marine, they told us, “I actually visited Hythe Marine with Avrotech when they first looked at getting involved, so I’ve seen Hythe grow into the great company it is today.”

As somebody who knows the ins and outs of Hythe Marine, it was great to get some insight into what makes them different from the rest.

“In my experience, Hythe Marine stands out because it always offers top quality personnel. From a design point of view, gathering personnel is done mostly by referral rather than advertising so the client always knows they will get good quality people. Hythe tend to offer the same team for each project so for a lot of contracts, the client already knows the core team they are getting.”

Bespoke machining services at Hythe Marine

Meet the man in the machine shop.

Being part of the Hythe Marine Services (HMS) team means working alongside highly skilled individuals who are leaders in their fields. Just within the machining side of the business alone there are a huge range of in-house abilities and specialist knowledge. Some of the services provided include bespoke Precision Machining and CNC Profiling for one-offs and small batch capabilities.

Every single project has rigorous quality checks, both throughout and after completion. As well as this, the company focuses on continuous improvement for procedures and staff development.

Imagine being given a piece of machinery you’ve never seen before and then being asked to recreate it within a couple of days. This is one of the common challenges faced by the Hythe Marine Machine Shop team.

 

The Man in the Machine Shop

Before joining Hythe Marine seven months ago one member of that team had been in the aircraft industry for twenty-one years. Straight out of school he began his apprenticeship with Highbury College and J M Automatics. During these four transformative years he developed skills he still uses on a daily basis. These years included his first experiences of tool-making, and learning how to replicate, in precision detail, a bespoke object.

Since the start of this young machinists career, he has worked hard to continually learn and perfect his skills, stating that, “The harder you work on a project, the more pride you have when you finally see the finished result!”

This drive and dedication meant it wasn’t long before he was on the production line where projects were varied and challenging, building parts for helicopters and aircraft as well as pretty much any other bespoke items requested by customers. After many great years at J M Automatics he felt it was time for new challenges and for the last 7 months has been a Mechanical Fitter/Machinist at Hythe Marine Services.

 

The Jump From Aircraft to Marine Engineering

Moving to a new industry and company after 21 years takes courage. Gone was the familiar environment and in its place were dockyards, boating terminology and Navy abbreviations. Initially, this change was a struggle but the welcoming atmosphere at Hythe Marine meant this machinist quickly settled in and became part of the team.

 

Daily Life at Hythe Marine

Even with years of experience in the tool making industry, there are always new problems to solve. Working at Hythe can be a high-pressure job with numerous teams working in tandem to get the job done. Much of the work is an internal process with raw materials coming in and leaving as high quality finished products.

“There are the welders who work with the Pipe Fitters, who work with the Fabricators, who work with the Machine Shop. There are so many trades coming together to create a great finished product. Every day is a learning curve, even to me who’s been doing this for 22 years.  A lot of the projects are bespoke one-offs that require reverse engineering to recreate an object. This process of working out the mechanics behind an item is something I’ve enjoyed since childhood.”

 

What goes on in the Machine Shop?

Being a Hythe Machinist involves a lot of work on the manual milling machine, which uses cutters to create horizontal and vertical profiles, and drill or tap holes.

“My previous company required me to work to extremely precise, millimetric accuracy measurements. Precision that is still present in my work at Hythe.” 

What the Hythe Marine machine shop is working on often depends on customer’s drawings, specifications and timeframes. The wide range of knowledge and skills within the team means Hythe Marine are able to manufacture and install all types of systems. This spans from complex pipe systems through to structural and non-structural fabrication.

Occasionally the team comes across parts that are unknown, so there are always opportunities to learn and improve.

“If the customer wants it, and Hythe is able to do it, we just get it done.”

 

What’s it like to work at Hythe Marine?

When asked what to say to someone considering working at Hythe Marine, they simply said, “If there’s an opportunity at Hythe Marine then grab it with both hands and don’t let go. Training and opportunities here are invaluable.” 

A clear theme from this chat was the familial atmosphere at Hythe. From his very first day, it was clear he felt like part of the team, with everybody always ready to help each other out. “If you’re ever struggling with something, somebody will always stop and help you out. From the apprentices to the experienced heads, they all have a minute to help. Everyone’s friendly and working together. It’s a really nice place to work.”