JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 30

inside the factory

requirements of regulators
such as Lloyds Register.
The company's capabilities
include robotic tape laying,
vacuum infusion, autoclave and controlled curing
of laminates at elevated
temperatures. The company
also boasts a major in-house
test facility, fibre optic
strain expertise and structural monitoring systems
and data analysis.
Due to the scope of its
projects, Magna Structures
requires secure procurement sources. It also needs
to be absolutely sure of the
feasibility and durability
of the structures it builds.
Therefore, the company has
entered into strategic partnerships with Gurit for the

composite raw materials,
with Toray for carbon fibre
(given the quantities of carbon used, it was absolutely
necessary to have a secure
supply).
Magma Structures' projects (and/or those of the
designers working on them)
have been opening new
horizons to the point where
there is support from the
academic world, in Magma's
partnerships with Aston
University (the Electronics department, for over 15
years with a clear focus on
fibre optic testing), Southampton University (for 25
years, with the Wolfson
Unit in the wind tunnel,
towing tank and Mechanical
and Ship Science departments) and Cambridge

University (Engineering department for over 3 years).
"We construct bespoke, oneoff, large-scale structures
using a range of advanced
manufacturing processes
and appropriate materials
to ensure the optimum build
method for each project,"
says Magma Structures
CEO Clive Johnson.
Two of the ongoing projects
are similar to the Maltese
Falcon one, although the
proportions are even more
gigantic, with rotatable
masts. In one project, these
are more than 60 metres
long and in the other, 90
metres long. The 90-metre masts are designed to
be mounted on a private
yacht 130 metres long. The
Magma Structures team carried out the initial project
appraisal and rig engineering and is now in the build
process, which will lead
to installation and commissioning. Magma Structures is responsible for the
project management and
supplying the rig (including
sails), control system and
automation.
These masts are made of
aerospace-grade carbon
fibre, and are probably the
largest structures ever created from carbon for the
civilian sector. They comprise several components,
including a shell weighing
12 metric tons that is oneshot cured over a period of
two days: it takes one day
to stabilize the temperature
over the entire length of
the part, and another for
the curing itself. Different
fabrication processes are

30 jec composites magazine / No92 October - November 2014

used for these masts as a
function of local constraints
or heating capacities. The
carbon production waste is
recycled offsite (this is still
fairly rare). The structures
are equipped with optic
fibres for monitoring their
structural health throughout their service life.

Future
development goals
While Magma Structures is
a specialist in extra-large,
highly stressed parts in oneoff production or in very
small series - and wishes to
continue as such - it does
not exclude the possibility
of series production for a
number of different sectors: yachts and rotating,
automated, free-standing
rigs and stayed mast rigs
of record heights for the
marine sector; non-flight
critical sections and unmanned aerial vehicles for
aerospace; trains, hovercraft
or cars for transportation;
pressure vessels; components for civil engineering
and architecture; and oil &
gas. n

More information:
www.magmastructures.com
www.magmaglobal.com
Contact:
info@magmastructures.com


http://www.mccleananderson.com http://www.magmastructures.com http://www.magmaglobal.com

JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014

Cover
Edito
Point of view: oil & gas
Contents
COMPANY & BUSINESS In Brief
Recycling
Biocomposites
Spin-off
Agenda of Events
APPLICATIONS
Sustainability
Defense
Automotive
MARKET
Biocomposites
Inside the factory
SPECIAL JEC AMERICAS - FALL EDITION
Gain insight into the JEC 2014 I.C.S. Americas Program
JEC Americas Innovation Awards Program
Maintenance - Certified composite repair system for pipelines
Carbon fabrics - Successful first flight test for the VX-1 KittyHawk C-PlyTM aircraft model
Design - Composite aerostructure development in high-performance enterprises
RESEARCH & DEVELOPMENT
Reinforcement
Process
TECHNOLOGY & INNOVATIONS
NDT
Tooling
Infusion
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Cover
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 2
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Edito
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Point of view: oil & gas
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 5
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Contents
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 7
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - COMPANY & BUSINESS In Brief
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Biocomposites
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Recycling
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Spin-off
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 12
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 13
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Ad1
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Ad2
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 15
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Sustainability
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 17
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 18
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 19
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Defense
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 21
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Automotive
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Biocomposites
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 24
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 25
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 26
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 27
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Inside the factory
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 29
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 30
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - SPECIAL JEC AMERICAS - FALL EDITION
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Gain insight into the JEC 2014 I.C.S. Americas Program
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 33
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 34
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 35
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 36
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - JEC Americas Innovation Awards Program
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 38
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 39
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 40
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 41
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Maintenance - Certified composite repair system for pipelines
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Carbon fabrics - Successful first flight test for the VX-1 KittyHawk C-PlyTM aircraft model
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Design - Composite aerostructure development in high-performance enterprises
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 45
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 46
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Reinforcement
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 48
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 49
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 50
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Process
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 52
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 53
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 54
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - NDT
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 56
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 57
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Tooling
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 59
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 60
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 61
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Infusion
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 63
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 64
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - Index
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - In the world
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 67
JEC COMPOSITES MAGAZINE - Issue #92 - October/November 2014 - 68
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