Specialist North East sheet metal fabrication company, Hydram Engineering, is proud to commemorate the 2025 bicentenary of the Stockton & Darlington Railway (S&DR) with a unique project. Our talented metal fabrication apprentices, supported by East Durham College, are designing and fabricating a half-size, stylized sculpture of the iconic Locomotion Number 1. This impressive artwork will be a permanent feature at the Hopetown Darlington, the award-winning railway-themed visitor attraction.
A Bicentenary Tribute
The initiative stemmed from a railway-enthusiast apprentice manager at Hydram, who envisioned a meaningful contribution to the S&DR200 celebrations. Leveraging Hydram’s fabrication expertise and commitment to developing young engineers, the Locomotion No.1 sculpture project was launched. Hydram’s apprentices are immersed in all stages of this unique undertaking, from the initial design concepts through to the welding and fabrication.
“We are really proud to be part of the S&DR200,” says Lee Bailey, Hydram’s Apprentice Liaison Officer and Systems & Software Engineer. “For me personally, this assignment is particularly special. Having volunteered at the Hopetown site as a teenager, witnessing its transformation and now seeing Hydram’s apprentices contribute to its future with this depiction of Locomotion No.1 is truly rewarding. It’s a fantastic showcase of their abilities, a lasting tribute to railway history, and a piece that will complement Hopetown Darlington’s design beautifully.”
Honouring a Pioneering Locomotive
Hydram’s Locomotion No.1 will offer an artistic interpretation of the pioneering steam locomotive that in September 1825, hauled the first passenger-carrying train over the S&DR, marking the dawn of public railway transport. Its prominent position at Hopetown Darlington, the site of an original S&DR station at Darlington North Road, will provide visitors with a tangible connection to the railway’s revolutionary heritage.
A significant and carefully considered detail is the choice of material: weathering steel (Corten). This is the same distinctive grade renowned for its iconic use in Antony Gormley’s Angel of the North, forging an interesting link between this new sculpture and the celebrated North East landmark. Corten steel possesses the unique property of developing a rust-like patina over time which acts as a protective layer, preventing further corrosion and ensuring the monument’s longevity without the need for additional coatings.
“We are thrilled to be the permanent home for Hydram Engineering’s Locomotion No.1 model,” says Leona White-Hannant, Development Director at Hopetown Darlington. “As a key historical site on the original Stockton & Darlington Railway, Hopetown Darlington provides the perfect backdrop for this artwork, creating a powerful and tangible connection with the railway’s groundbreaking legacy and Locomotion No.1’s pioneering involvement. The choice of weathering steel also ensures a striking visual harmony with our revitalised grounds, which feature this distinctive material.”
Investing in Future Engineers
This endeavour underscores Hydram’s commitment to community engagement and the development of future engineering skills through this, our first undertaking with a distinct heritage element. By entrusting this significant task to their apprentices, Hydram is providing them with exceptional experience and fostering pride in their input to a major historical milestone.
Follow the Progress
The exciting project is now underway at Hydram Engineering, brought to life by our dedicated team of apprentices. To follow their progress and see updates on the stylized Locomotion No.1’s sculpture, please visit Hydram Engineering’s LinkedIn page. www.linkedin.com
About Hydram Engineering: Sheet Metal Fabrications: Established in 1977, Hydram Engineering Ltd is a leading UK-based subcontract precision sheet metal fabrication company. It offers a comprehensive range of metalwork services, including laser cutting, CNC punching, metal forming, fabrication, machining, powder coating, and assembly. Hydram supplies high-quality components to various sectors, including the rail industry and actively supports the development of future talent through its apprenticeship programme.
About the Stockton & Darlington Railway Bicentenary (S&DR200): The 2025 bicentenary of the Stockton & Darlington Railway marks 200 years since the opening of the world’s first public railway to use steam locomotives. This momentous anniversary will be celebrated throughout the North East with the S&DR200 Festival, a 9-month international festival from March to November 2025 in County Durham and Tees Valley, featuring free large-scale outdoor spectacles, events, exhibitions, and new art commissions. This commemorates the S&DR’s pivotal role in shaping modern transportation and its enduring legacy. www.sdr200.co.uk
About Hopetown Darlington: Hopetown Darlington, a key historical site on the original Stockton & Darlington Railway, is at the heart of the 2025 bicentenary celebrations. Recent investment of £37 million into Darlington’s Rail Heritage Quarter, which includes Hopetown, has revitalised the former Head of Steam Museum, creating new visitor experiences, interactive exhibits, and improved infrastructure to enhance its role in presenting the S&DR’s story. This makes it a particularly fitting and prominent location for the permanent installation of Hydram Engineering’s Locomotion No.1 monument. www.hopetowndarlington.co.uk
Impressive Improvements in Metal Profiling
Hydram Engineering, a leading name in sheet metal fabrication, has significantly enhanced its manufacturing capabilities with the acquisition of the Trumpf TruLaser 3030, a cutting-edge 10kW fibre laser cutting system, complete with integrated automation systems. This investment marks a substantial upgrade in Hydram’s precision, efficiency, and commitment to sustainability, reinforcing its dedication to delivering quality products to its diverse customer base.
This new machine replaces an older 4kW CO2 laser system, representing a significant leap forward in technology and performance for its laser cutting service. The investment represents the culmination of a 12-month project, involving significant modifications to the factory building, including raising a significant portion of the roof to accommodate the height of the TruStore tower – an impressive multi-shelf sheet storage and retrieval system. With the machine now in production, Hydram is fully assessing the improvements that the new technology offers.
Trumpf TruLaser 3030
The Trumpf TruLaser 3030 is a versatile, high-performance laser cutting machine designed to handle a wide range of materials with impressive speed, precision, and flexibility. Renowned for its reliability and superior cutting quality, this machine empowers Hydram to optimise production processes and meet the growing demands of its customers. Some of the standout features of the TruLaser 3030, further enhanced by integrated automation systems, include:
- Speed and Efficiency: One of the key benefits of the TruLaser 3030 is its rapid cutting speed, significantly improving turnaround times. This is especially advantageous for Hydram Engineering’s customers who require quick delivery of complex components without compromising on quality. Compared to the older CO2 laser system it replaces, the TruLaser 3030 offers dramatically faster cutting speeds, leading to increased throughput and reduced lead times. The increased power output allows oxide-free cutting of mild steel with nitrogen at thicknesses up to 10mm, which can be a significant benefit compared to cutting with oxygen. The TruLaser 3030’s efficiency, boosted by automated material handling, also limits the effect of increasing production costs across the business, maintaining Hydram’s competitive edge in the market.
- Automation for Enhanced Productivity: Hydram Engineering has maximised the productivity of the TruLaser 3030 by integrating advanced automation systems. The seven-shelf TruStore tower system provides automated loading and unloading of materials, ensuring a continuous and efficient workflow. This minimises downtime and maximises the machine’s cutting time. Furthermore, the PartMaster conveyor system streamlines the unloading process, making it safer and more efficient for operators to handle finished parts. These integrated automation solutions improve productivity and reduce manual handling.
- Sustainability Features: The TruLaser 3030, employing solid-state TruDisk fibre laser technology, is significantly more energy-efficient than the older CO2 laser system it replaces. This translates to a reduction in Hydram Engineering’s energy consumption and associated carbon footprint, despite the increased power output. The precise cutting capabilities also minimise material waste, further enhancing its environmental benefits. This focus on sustainability aligns with Hydram’s commitment to adopting green technologies and improving the sustainability of its operations. The machine’s optimised beam delivery and efficient use of consumables also contribute to a smaller environmental footprint.
Game-Changers
“Investing in the TruLaser 3030, along with the associated automation systems, represents a significant step forward for Hydram Engineering,” says Operations Director Stephen Beacham. “Replacing our older CO2 laser with this cutting-edge fibre laser machine has resulted in considerable energy savings and a faster, more efficient production process. The TruStore and PartMaster systems have been game-changers, allowing us to run the machine more efficiently and safely. This machine not only boosts our production capacity and precision but also reinforces our commitment to sustainable manufacturing practices.”
Senior Account Manager Neil Bell adds, “From a commercial perspective, the increased efficiency and versatility, combined with faster turnaround times due to automation, allows us to continue offering customers competitive pricing and strengthens our position in the market.”
Comprehensive Capabilities
Over the past 47 years, Hydram has established an enviable reputation in the sheet metal fabrication marketplace, providing finished metal products to customers in industries ranging from heavy construction equipment and public transportation solutions, through to electrical cabinets and HVAC systems.
The investment in the Trumpf TruLaser 3030 is just one example of Hydram Engineering’s ongoing commitment to staying at the forefront of the sheet metal fabrication industry. Based in County Durham in the North of England, the company has grown over the last 48 years to become the premier UK precision subcontractor, fully equipped to supply complete metal fabrications direct to tier-one manufacturers.
With continuous upgrades to its machinery and technology, Hydram ensures that it is equipped to meet evolving customer needs, and maintains its reputation as a leader in manufacturing quality and customer service. Hydram’s capabilities now include laser cutting (both sheet and tube), CNC punch profiling, folding, panel bending, welding, assembly, CNC machining and powder coating, boasting considerable capacity on its 135,000 square foot site. These facilities are backed up with a comprehensive suite of quality certifications and a workforce committed to customer service.
Continuous Improvement
“Our success is founded on customer satisfaction – we aim to achieve maximum productivity, quality and service whilst maintaining competitive prices,” Neil Bell concludes. “We work closely with customers to establish long-term partnerships and strive to continuously improve how we do things. The new Trumpf 3030 is just one example of how we embrace improvements – and it is a pretty impressive one.”
UK Sheet Metal Fabrication Experts Achieve Prestigious DIN 2303 Certification, Forging Leadership in Military-Grade Welding
Hydram Engineering, a leading provider of high-quality sheet metalwork and fabricated metal products, has achieved the highly coveted DIN 2303 certification following a rigorous audit conducted by TÜV Nord. This milestone further strengthens the company’s already impressive portfolio of welding certifications, including EN ISO 3834-2, BS EN 15085 CL1, and ECWRV, and opens new avenues for serving the defence sector.
DIN 2303 is a stringent German standard specifically designed for welding and allied processes in the production and maintenance of military equipment. Achieving this certification demonstrates Hydram’s unwavering commitment to quality and its ability to meet the most demanding requirements of the defence industry.
“This certification is a testament to our team’s dedication and expertise,” said Alan Bailey, Welding Co-Ordinator at Hydram. “DIN 2303 sets the bar incredibly high, and achieving it on our first audit reflects our meticulous attention to detail and our ability to consistently deliver exceptional welding quality.”
The addition of DIN 2303 enhances Hydram’s existing certifications, providing established customers in the rail, earth moving and transportation sectors with even greater confidence in the company’s capabilities. While ISO 3834 and other standards ensure general welding quality, DIN 2303 specifically addresses the unique and critical requirements of military applications, where high stress, varying temperatures, and potential combat situations necessitates welding of the highest integrity.
“This achievement underscores our continuous improvement ethos,” stated Hydram’s Quality Manager, Barry Edgar. “We are constantly striving to enhance our processes and qualifications to provide our customers with the highest level of service and quality. DIN 2303 certification allows us to offer specialized welding services for critical military projects, further solidifying our position as a trusted partner in the sheet metal fabrication industry.”
Benefits for Customers:
- Enhanced Reliability: DIN 2303 ensures that welding processes meet the most rigorous military standards, guaranteeing the reliability and durability of critical components.
- Expanded Capabilities: This certification enables Hydram to undertake complex military projects, providing a wider range of services to both existing and new clients.
- Increased Confidence: Customers can have complete confidence in the quality and traceability of welding work performed by Hydram.
- Access to Defence Contracts: DIN 2303 certification is often a prerequisite for participation in defence-related projects, opening doors to new commercial opportunities.
- Demonstrated Commitment: This certification showcases Hydram’s commitment to excellence and its ability to meet the highest industry standards.
The audit was conducted by TÜV Nord, a globally recognized certification body with extensive experience in the defence sector. Their rigorous assessment process ensured that Hydram met all the requirements of DIN 2303.
“We are immensely proud of our team’s achievement,” said Managing Director, David Greatorex. “Gaining DIN 2303 certification on our first audit is a testament to the hard work, dedication, and expertise of our employees. This attainment reinforces our commitment to providing our customers with the highest quality welding services, particularly within the demanding defence sector.”
Hydram thanks and congratulates its employees for their continued efforts and commitment in achieving this significant milestone. The company looks forward to taking advantage of this new certification to further enhance its services and expand its reach within the defence industry.
About Hydram:
With excellent customer service as its founding principle since 1977, Hydram has earned the trust of its customers to grow to be one of the UK’s largest sheet metal manufacturing companies. It has also gained and maintained certifications from numerous bodies including ISO, BS, EN and DIN, which evidence its continued dedication to standards, compliance, and improvement. Based in North East England, the business is proud to support multinational customers in a wide range of industries including HVAC, rolling stock, earth-moving equipment, industrial metal cabinets, and many others. Hydram offers the full range of sheet metal and tube fabrication process capacities, including laser cutting, CNC punching, forming, robotic welding, CNC machining, presswork, powder coating and assembly.
About TÜV Nord:
TÜV Nord is a leading provider of testing, inspection, and certification services. With a long history of expertise in the defence sector, TÜV Nord is recognized for its rigorous and impartial assessments.
Hydram Achieves Prestigious ECWRV Certification in Metal Fabrication and Welding
Hydram Sheet Metalwork, a leading name in the metal fabrication industry, has proudly achieved ECWRV (European Certification for Welding of Railway Vehicles and Components) certification. This attainment underscores Hydram’s commitment to excellence and quality in metal fabrication and welding, specifically in the rail rolling stock sector.
What Is ECWRV certification?
The ECWRV certification, also known as EN 15085-2, is a rigorous standard ensuring harmonisation across Europe of the highest levels of welding quality for railway vehicles and components. Hydram’s achievement of this certification places it among a select group of companies in the UK that have met the stringent requirements of Class 1, covering welded parts with high safety relevance – the top level of accreditation.
Quality Commitment
Hydram’s journey to this certification began with their accreditation to the prerequisite welding standard ISO3834-2 in May 2016, followed by initial approval to BS EN 15085-2 Class 2 in June 2017, then by Class 1 certification in August 2018, and finally recognised by the pan-European ECWRV standard in July 2024. This progression highlights Hydram’s dedication to continuous improvement and adherence to the highest industry standards.
The certification process involved a thorough evaluation of Hydram’s welding quality management system, including welding procedure specifications, welder qualifications, material control, and inspection and testing processes. By meeting these rigorous standards, Hydram has demonstrated its capability to consistently produce high-quality welded products, ensuring safety and reliability in the railway industry.
European Rail Industry Supplier
On Hydram’s achievement, Business Development Manager, Joanne Farms commented, “This certification is a testament to the hard work and dedication of our welding and quality teams. It reflects our commitment to quality and our ability to meet the demanding standards of the railway industry across Europe. We are excited about the opportunities this certification brings and look forward to continuing to deliver exceptional products to our customers.”
With this certification, Hydram is well-positioned to expand its presence in the railway sector, providing high-quality, reliable components that meet the exacting safety standards of the industry. This achievement not only enhances Hydram’s reputation but also reinforces its commitment to excellence and customer satisfaction.
ECWRV Accredited Fabricator
ECWRV accreditation reflects Hydram’s commitment to the highest levels of welded fabrication quality as it continues to provide accredited metal fabrications and precision sheet metalwork for the European railway vehicle sector. For enquiries or further information, please contact our ECWRV accredited team.
You can find out more details about ECWRV EN 15085-2 here: TWI Certification – ECWRV
More About Hydram Sheet Metalwork
Established in 1977, and employing over 200 people in its 135,000 square foot facility, Hydram Sheet Metalwork is one of the largest sheet metal fabrication companies in Europe. With excellent customer service as its founding principle, over more than 45 years, Hydram has earned the trust of its customers to grow to be one of the UK’s largest sheet metal manufacturing companies. It has also gained and maintained accreditation from numerous bodies including ISO, BS, EN and DIN, which evidence its continued dedication to standards, compliance, and improvement.
Hydram Sheet Metalwork adhears to the stringent quality requirements of the railway vehicle sector, supplying EN 15085-2 accreditated precision sheet metal fabrications on a subcontract basis.
Precision sheet metal EN 15085-2 accredited fabricator
Rail sector metal fabrication supplier Hydram provides prime contractors with sub-assemblies and precision metal fabrications for various railway vehicles used in the UK and Europe.
EN 15085-2 accredited sheet metal fabricator Hydram also supplies metal products, metal components and precision sheet metal fabrication services to market leading companies in industry sectors such as defence, bus, lighting, furniture, earth-moving machinery and white goods within the UK and Europe.
With customers in such a range of industries, Hydram has a wealth of experience and expertise to offer.
Hydram Achieves Silver EcoVadis Rating
North East metal fabrication company Hydram Sheet Metalwork has been rated Silver in its 2024 EcoVadis sustainability assessment, placing it among the top 15% of rated companies. EcoVadis is the World‘s most trusted business sustainability rating and is regarded as a global standard for business sustainability. It screens more than 2 million companies, and rates more than 130,000 companies in over 180 countries across more than 220 industries.
Sustainability in Metal Fabrications
Hydram’s Environment, Health and Safety Manager, Lewis Dartnall spearheaded the initiative to obtain EcoVadis recognition. “Sustainability is a word that everyone is familiar with, but it can be hard for companies to get to grips with it, and turn the concept into tangible actions,” says Lewis. “That’s where a framework like EcoVadis can help put structure around it and drive motivation to deliver improvements.”
What is EcoVadis?
The objective of the EcoVadis Corporate Social Responsibility (CSR) rating methodology is to measure the quality of a company’s CSR management system through its policies, actions and results. The assessment evaluates 21 sustainability criteria across four core themes:
- Environment
- Labour & Human Rights
- Ethics
- Sustainable Procurement
EcoVadis’ business sustainability ratings are based on international sustainability standards such as the Ten Principles of the UN Global Compact, and the ISO 26000 guidance on social responsibility, among others. The ratings provide an evidenced-based analysis on performance and an actionable roadmap for continuous improvement.
Corporate Social Responsibility
Hydram Sheet Metalwork is committed to sustainability across all areas of the business whilst remaining an ethical and responsible organisation. “We’ve always considered ourselves to be a responsible organisation – focusing on customer service, quality, health and safety and the environment, and you can see that in the number of ISO standards that we maintain,” enthuses Lewis.
“Having a CSR policy or sustainability policy is fine, but when you get a third party involved to drill into all aspects, and provide a list of criteria you can benchmark against, it focuses people and drives positive change,” Lewis continues. “Thanks to the efforts of my colleagues, particularly in HR and purchasing, we can now prove our sustainability credentials with an internationally recognised award.”
A Sustainable Metal Fabricator
Hydram’s Silver rating is a significant achievement in its second assessment year, as the company’s rating increased from a Bronze rating in the previous year, and the company is now in the 86th percentile across all industries. “Continuous improvement has been embedded in the company long before I started,” says Lewis, “and the fact that we have made an improvement on sustainability is something we should be proud of, and I think customers will see that and want to talk to us about it.”
Hydram works with a surprising number of industry sectors, and has always been committed to sustainability across all areas of the business whilst remaining an ethical and responsible organisation. Now, Hydram’s customers can benefit from association with an accredited sustainable sheet metal supplier. From power generation equipment to bus and coachbuilding, earth-moving vehicles to trains and HVAC systems, Hydram’s customers can be assured that they are working with a responsible, professional, experienced, supply chain partner – one that takes corporate social responsibility seriously.
You can find out more about EcoVadis here: https://ecovadis.com and here: EcoVadis at Hydram
More About Hydram Sheet Metalwork
Established in 1977, and employing over 200 people in its 135,000 square foot facility, Hydram Sheet Metalwork has gone from strength to strength following its acquisition by Don Nystrom in 2018, and is now one of the largest sheet metal fabrication companies in the UK.
Hydram supplies metal products, metal components and precision sheet metal fabrication services to market leading companies in industry sectors such as rail, bus, lighting, furniture, earth-moving machinery and white goods within the UK and Europe.
Hydram Sheet Metalwork provides the full range of subcontract metal fabrication services, from sheet metal profiling, metal forming, metal fabrication and welding, CNC machining, assembly and powder coating.
Complete with a comprehensive array of industry accreditations and international standards, Hydram provides customers with a dependable, professional, experienced, supply chain partner – and an expert in Sheet Metal Fabrication.
Hydram – Your Preferred Manufacturing Partner.
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Ensuring Excellence in Defence and Aerospace Supply Chains
North East sheet metal fabricator Hydram Engineering is proud to announce the achievement of JOSCAR accreditation for a second year, and continues as a JOSCAR accredited fabricator.
Hydram was established in 1977 with excellent customer service as its founding principle, and over more than 40 years it has earned the trust of its customers to grow to be one of the UK’s largest sheet metal manufacturing companies. It has also gained and maintained accreditation from numerous bodies including ISO, BS EN and DIN which evidence its continued dedication to standards, compliance, and improvement.
What Is JOSCAR?
Recognition by JOSCAR underscores Hydram’s commitment to excellence, transparency, and reliability, specifically in the defence, aerospace, and security sectors. JOSCAR, the Joint Supply Chain Accreditation Register, is a database of companies maintained by Hellios Information Ltd, designed to streamline supplier qualification and enhance transparency within those critical industries. As a robust accreditation system, it serves as a single source of information for buyers and suppliers, and provides comprehensive insights into third-party risk.
Why JOSCAR Matters
On Hydram’s achievement, Business Development Manager, Joanne Farms commented, “We do a lot of supplier audits for our customers, in addition to the regular ISO renewals, and we have identified that sectors, such as defence and the rail industry, have started to use the likes of the JOSCAR and IRIS schemes respectively to make the audit process more efficient.”
As buyers from major defence organisations recognise JOSCAR as a reliable benchmark, covering a whole gamut of metrics from financial status to legal compliance, the procurement process is simplified, shortening the timescales involved.
“Instead of navigating multiple questionnaires and compliance checks, buyers can now access our pre-qualified profile instantly. With JOSCAR accreditation, we’ve demonstrated our compliance with stringent standards, and made it easier for prime contractors to deal with us with confidence,” finishes Joanne.
JOSCAR Customer Benefits
To summarise, there are three direct benefits to Hydram’s JOSCAR supplier accreditation:
• Assured Quality: Customers can rely on the products and services Hydram provide, knowing they come from a JOSCAR-accredited supplier.
• Faster Transactions: Procurement processes are streamlined, resulting in quicker transactions.
• Risk Mitigation: JOSCAR accreditation minimizes supply chain risks, safeguarding project timelines.
JOSCAR Accredited Fabricator
JOSCAR accreditation reflects Hydram’s commitment to excellence, transparency, and customer satisfaction as it continues to provide accredited metal fabrications and precision sheet metalwork for the defence sector. For enquiries or further information, please contact our JOSCAR-accredited team.
You can find out more details about JOSCAR here https://hellios.com/joscar/
More About Hydram Sheet Metalwork
Established in 1977, and employing over 200 people in its 135,000 square foot facility, Hydram Sheet Metalwork is one of the largest sheet metal fabrication companies in Europe.
Hydram supplies metal products, metal components and precision sheet metal fabrication services to market leading companies in industry sectors such as rail, bus, lighting, furniture, earth-moving machinery and white goods within the UK and Europe.
Hydram Sheet Metalwork adhears to the stringent quality requirements of the defence engineering sector, supplying JOSCAR accreditated precision sheet metal fabrications on a subcontract basis.
With customers in such a range of industries, Hydram has a wealth of experience and expertise to offer.
Precision sheet metal JOSCAR accredited fabricator
Defence fabrication supplier Hydram provides prime contractors with sub-assemblies and precision metal fabrications for various military vehicles, military HVAC systems and heat shield products.
JOSCAR accredited sheet metal fabricator Hydram also supplies metal products, components, and fabrications to world leaders in the aerospace sector and in the manufacture of components for commercial and civil projects, aircraft and vehicles.
Approved suppliers are used to provide quality raw materials and full material traceability is maintained throughout manufacture.
Hydram can be found in The British Defence Industry Directory (BDID).
The 2022 Dynamic group residential experience for first-year apprentices from Hydram Engineering, and fellow Dynamic group company Dynamic Aerospace Fabrications took place between the 8th and 10th of November. This year the group stayed in the amazingly picturesque Featherstone Castle, a grand thirteenth Century castle in Northumberland.
The Grade 1 listed building was the ideal situation to develop apprentice team working, resilience and communication skills. This year’s activities were expertly carried out by John and Allister from “Big On Adventure”, a specialist company that Hydram Engineering has utilised over the years for residential and team-building activities, for apprentices and team members alike.
The Apprentices this year were not only challenged by the activities but the weather conditions, as they literally endured all four seasons in one day. This year the apprentices were supported by Neil (Training Manager), Lee (Systems and IT) and Andy (QC and Engineering) who were expected to support and guide the group through the activities.
Day One
Day one started gently with team activities, icebreakers and tasks designed to encourage the group to work together to achieve a common goal. As this was a mixed group with apprentices from both UK sites, these early activities are vital to the group getting to know each other, building bonds and above all letting them discover strengths and weaknesses within the team.
The day ended with a gorge walk along the turbulent Ashgill Force, located just outside Alston in the Cumbrian hills. Ashgill during the summer is a lovely walk, with the occasional waterfall to leap off, but in November this was a freezing cold torrent of water, battering all who entered.
The challenge with a gorge walk is to offer and accept support, you have to look out for your colleagues, guide them and above all help them along encouraging them to continue and experience the challenge head on.
Day Two
Day two was a new challenge for the Hydram and Dynamic teams, the ascent of Helvellyn, England’s second highest peak from Thirlmere, a short but steep climb, none of the apprentices had completed such a climb before in the conditions the group experienced.
This challenge did truly have the aforementioned four seasons, sun at the bottom, horizontal rain in the middle, followed by -6C and snowy at the top, a true mix. It has to be said that the whole group performed amazingly, helping and supporting each other with the climb.
Following a short lunch stop at the summit – under an emergency shelter for some, the descent began, in true Lake District fashion the sun came out half way down. Although only our second day the camaraderie between the group members was a pleasure to witness, considering they are from two sites separated by a couple of hundred miles, they supported and encouraged each other throughout the climb both up and down.
Day Three
The third and final day was a trip to Great Wanney Crag for Bouldering, Weaselling and finally a climb up and over the summit. Weaselling for those that may not know is the squeezing and squishing through gaps in rocks, similar to caving or potholing, but without being underground.
This is a test of personal perseverance and resilience, even the most confident get themselves stuck, as Harry demonstrated (photo below).
The support of peers is vital, as they can usually see more than the poor stuck person, and can then talk them out of the crevice. The beauty of this activity is the fact that it’s all carried out at ground level, with clear views of the route both in and out – nobody is stuck for long.
Final Thoughts
All in all the trip was a success, the seven apprentices and three staff had a wonderful experience, all gained skills and knowledge they previously did not have, and above all the team work skills were tested and stretched.
Special mention to Jenson from the Dynamic Aerospace team, his positive attitude and willingness to help and guide others is a credit to him as an individual, if he harnesses his energy he will be a powerful force, and an excellent team member, he gained the vote of the staff team regarding being the stand out apprentice of 2022. As Training Manager I have conducted trips like this for a few years now, first one was long before I even joined Hydram Engineering, and he is one of the best, if not the best performing team member I have seen to date.
This is the end goal of the Dynamic Group, Hydram Engineering and Dynamic Aerospace Apprentice programs, to discover and nurture raw talent into a productive and efficient individuals.
Neil Mawson – Training Manager, Hydram Engineering – November 22
Strong Customer Demand Sees Investment at Fabrication Company
North East-based engineering company Hydram, a leading specialist in precision sheet metal fabrications, has recently (September 2022) completed a significant programme of investments in an attempt to satisfy increasing demand from its customers.
From heating and ventilation, rail (both rolling stock and trackside), through to off-highway construction vehicles, Hydram’s customers cover a broad range of industries, and almost without exception, there has been a significant surge in requirements since the lifting of Covid restrictions.
Meeting increasing demand presents challenges at the best of times, and post-Covid, those challenges have multiplied and intensified, with both constrained labour and spiralling energy markets conspiring to make the task particularly difficult throughout the supply chain. Right now, it certainly cannot be described as the best of times, and the current responsibility for overcoming these challenges lies with Hydram’s Operations Director, Stephen Beacham.
Increasing the Tempo
“Over 45 years Hydram has always maintained a steady rhythm of investment and renewal to ensure we remain competitive and have capacity to grow with our customers,” says Stephen, “although there are times when you have to increase the tempo and do something exceptional to make the difference.” The difference in this case was a huge increase in the company’s powder coating and finishing capacity.
Hydram’s extensive capabilities range from laser cutting and punch profiling through to folding and forming, welding, coating (both wet and powder painting) and assembly. “Analysis proved that our most significant bottleneck was in painting, which is an area where floorspace and energy use are significant constraints,” Stephen explains, “which together made this a significant project to undertake, entailing a great deal of planning and preparation, and two new paint plants with a budget of over £1.2M.”
Auto Wash Pre-Treatment
With the acquisition of a vacant factory unit adjacent to the existing site, expansion of the floorspace was achieved without impacting the existing production area – which was already fully occupied by three paint plants. An order for the first new painting facility was then placed with North East-based Hogg Blasting and Finishing Ltd; a facility which includes both wet and powder spray booths, curing ovens and an auto-wash pre-treatment unit. “This new facility ultimately replaced one of our old plants in the main factory and it does so with a much smaller footprint thanks to the auto-wash,” says Stephen. “The old plant used several large dip tanks which took up a lot of space, were laborious to use, and inefficient in terms of energy usage – the auto-wash solves all these issues.”
Making Space
The Hoggs paint facility was commissioned in May 2022, and it handles the wet spraying and oversize powder-coated items, dealing with the smaller production volumes efficiently in a batch fashion. It offers many advantages over the older plant in the main building which, now redundant, was dismantled to make way for the second new investment. Stephen explains, “our real bottleneck was with the higher volume, smaller-sized parts, and for those, you need a continuous automated line, rather than a batch process. The old batch plant was decommissioned to allow us to use that floorspace for a new automated conveyor operated paint line.”
Increased Automation
With the floorspace in the main factory no longer a constraint, West Midlands-based TD Finishing was commissioned to supply a brand-new conveyor-operated paint line complete with an automated spray booth supplied by Gema. Installed over 6 weeks, the second new plant has a 145m overhead conveyor, a 20m-long five-stage pre-treatment plant with eco-friendly Oxsilan multi-metal pre-treatment solution, a 15m-long dry-off oven and a 38m-long curing oven. The Gema booth is equipped with the MagicCompact fast colour change facility, powder reclaim system and 10 auto guns on reciprocators complete with dynamic 3D contour tracking.
“The new conveyor plant was commissioned in July and it sits next to our two other conveyor plants,” Stephen says. “It has a higher throughput than our oldest plant, has more automation, a powder reclaim unit – which reduces the amount of powder wasted – and it uses less energy in the process. Overall, we have increased capacity by more than 50%, with the benefits of reduced labour requirements and increased energy efficiency, which are our two other constraints.” Now, with three conveyor paint plants for powder coating and a separate batch plant for wet and powder coating, Hydram has impressive capacity for metal coating and can rightly claim to offer a complete subcontract manufacturing solution.
Maintaining the Rhythm
With the bottleneck in painting alleviated thanks to the £1.2M budget, the underlying rhythm of investment involved in maintaining Hydram’s capacity was being addressed in other processing areas in the factory. Core to any sheet metal business are its profiling facilities and Hydram is proud to offer both high-speed laser and CNC punch profiling. On the punching side, the oldest of the two premium TruPunch 5000 punching machines from German-based Trumpf was beginning to show its age. “In a factory operating 24 hours per day, it’s imperative those hours are productive, and after 12 years of loyal service our older machine was beginning to cause us headaches,” admits Stephen. “In addition, the newer of the two machines benefitted from a tower storage system for automated sheet retrieval, and we wished to take the opportunity to upgrade, although again this was not without its own challenges!”
Packing a Punch
With an order placed for the new TruPunch and TruStore tower, the hard work began to prepare the factory for the new machine – it wasn’t simply a case of old-out, new-in. Two civil engineering tasks had to be undertaken long before the new machine was delivered, and in the meantime customer demand was still growing, making continuity of supply a major concern. “We had to move the 12-year-old machine to another part of the factory whilst we upgraded the concrete floor and raised the roof – literally – to accommodate the tower, which was not ideal,” Stephen recalls. “We only just had enough room to squeeze the old machine in a corner and that was without the automation systems for loading or unloading. In addition, punching is a noisy process that we try to segregate, but it was an essential compromise to keep our customers supplied whilst the necessary upgrade tasks took place.
The new TruPunch 5000 complete with its TruStore tower was commissioned in August 2021 at a project cost of £1M, providing a significant uplift in capacity both in terms of reliability and efficiency, as the automated sheet retrieval system means the machine spends less time waiting for material. The machine is fully equipped with a SheetMaster loading and unloading system, a TrumaTool for automated tool storage and a TrumaGrip scrap unloading facility, minimising the labour requirement and maximising its potential as a profiling maestro.
Maintaining the Lead
Hydram considers itself to be one of the UK’s leading sheet metal subcontractors and the effort required to maintain that position is considerable. With two big capital projects completed within 12 months, and a number of less significant, but no less important investments in three TruBend pressbrakes and a Haas VF-11 CNC milling machine in the same period, the evidence of that effort is compelling.
Those capital projects grab the headlines, but there are many other elements involved in increasing capacity, such as staff training and efficiency drives, and Hydram is working hard on these too. Hydram continues to run its own apprenticeship program – a number of former apprentices have continued studying to degree level – and it offers NVQ training to those who wish to gain additional qualifications. The workplace environment also gets a fair share of maintenance and renewal attention, with recent endeavours to improve shopfloor lighting and ventilation, health and safety projects to reduce manual handling, and regular low-tech deep cleaning, all benefitting the business, helping to ensure staff retention and improve their performance.
Stephen concludes, “Our business is built on customer satisfaction – and maintaining a high level of service in the current climate is challenging for all businesses in this sector. We can prove that Hydram is working exceptionally hard and investing significant sums to continue meeting demand.”
Well-established North-East subcontract sheet metal fabricator, Hydram Engineering, retains its existing ISO standards following an audit by SGS in September 2021.
This recertification was carried out to the requirements of ISO 9001 (quality standard), ISO 45001 (occupational health and safety standard) and ISO 14001 (environmental standard) in a combined audit. With COVID-19 precautions for visitors still in force at the time, the decision was made to make use of information technology to enable the entire audit to be conducted remotely.
“We were able to use web conferencing and the coverage of our CCTV system so that the auditor could fully engage and assess everything required,” says Hydram’s Safety Health and Environment Manager, Lewis Dartnall. “The feedback was very positive and there were no areas that were difficult to access so that all the objectives were met.”
The SGS auditor commented, “Hydram operates a well-established Integrated Management System that has been in place for many years – the IMS is well presented, implemented and managed. The audit covered all production processes (laser cutting, punching, inserting, painting, machining and welding), support activities, interviews with personnel, and checking of related management system documented information.”
After careful review of process records, testimonials and video evidence, re-certification to ISO 9001:2015, ISO 14001:2015 and ISO 45001:2018 was recommended. There were no non-conformances and four opportunities for improvement identified.
Hydram’s Quality Manager, Barry Edgar said, “Obviously I’m very pleased with the outcome of the audit and positive feedback from the auditor regarding the way in which we control our systems and processes. For me though, the professionalism of those who contributed during the audit really stood out, and the management team thanks everyone who was involved.”
About Hydram Engineering
Established in 1977 and employing over 250 people in its 115,000 square foot facility, Hydram Engineering is one of the largest sheet metal fabrication companies in Europe. It offers the full range of subcontract engineering services including laser cutting, CNC punching, panel bending and folding, tube laser cutting and tube bending, fabrication and welding, powder coating, wet painting and assembly from its site in Chilton, County Durham, UK.
Hydram has put quality central to all its business activities since its inception, and has held internationally recognised standards since 1996 and has been certified to the ISO 9001 Quality Standard since 2002. Hydram also emphasises the importance of occupational health and safety (achieving ISO 45001 in 2018), and the environment (holding ISO 14001 since 2010). The three ISO standards have been brought into alignment so that they can be assessed in a combined audit, saving time and expense.
Hydram supplies metal products, components and precision sheet metal fabrications to market leading OEM companies in industries such as railway, bus, cabinets, furniture, earth-moving machinery and white goods. The company is committed to providing outstanding manufacturing services and working closely with customers to establish long-term partnerships.
Find out more about Hydram’s accreditations >
Engineering Apprenticeships at Hydram
Hydram Engineering welcomed the newest group of engineering technician apprentices to the business in September 2021. Six young people from across the region began their apprenticeships, bringing the number of current apprentices studying towards the nationally recognised Engineering Technician level 3 qualification to nine. Hydram has always had a strong ethos in workforce development and apprenticeships in particular, offering apprenticeships to the workforce at qualification levels ranging from level 2 up to master’s degree level 7.
Hydram Apprenticeship Centre
Hydram began delivering its own engineering apprenticeship programme in 2011 having previously worked closely with local colleges which supplied candidates and delivered training. Since bringing the whole process in house Hydram is now able to deliver full Apprenticeship Standards at Level 3, along with a range of other qualifications at various levels as an EAL recognised centre; EAL being one of the leading awarding bodies for manufacturing and technical qualifications.
In recent years the programme has expanded, with applications increasing rapidly along with the quality of the candidates, strengthening the Hydram team and securing a sustainable workforce for the future. It has also gained accreditation from the Institute of Mechanical Engineering (IMechE) allowing apprentices direct entry to EngTech status upon completion, and even gaining access the National Union of Students NUS Extra program. Hydram has a dedicated training centre equipped with all of the required technology apprentices need to achieve their individual learning goals.
“This is a great opportunity for young people with an interest in engineering. They are gaining knowledge and experience from an established team of engineers within Hydram, and from a company perspective they are learning exactly what this business needs to continue its expansion within the sheet metal sector,” said Neil Mawson, Hydram’s Training Manager.
About Hydram’s Apprenticeship Programme
A formalised training programme exists which has fixed training plans and progression routes for all apprentices. Apprentices develop practical skills in line with the core business of Hydram whilst completing their technical studies. Apprentices gain not only the technical knowledge which is delivered onsite by members of Hydram’s training team, but also the necessary practical skills on the latest production machinery: CNC laser cutting machines, punching machines, press brakes, milling machines and the paint and assembly facilities to name a few.
Hydram Engineering has obtained certification to Cyber Essentials demonstrating its commitment to protecting both its business and customers’ data against cyberattack.
The government backed Cyber Essentials scheme provides independent verification that cyber threats to the business have been understood and appropriate cyber security measures are in place. To achieve certification an assessment is made against five areas of IT security implementation and the information provided verified by an external auditor.
UK Group Director, David Greatorex says: “We are delighted to have been certified as meeting the standards of Cyber Essentials. It’s long been expected that we have the appropriate standards in place for quality, health and safety and environment, and we have maintained corresponding ISO compliance for many years. Increasingly new customers are enquiring about our IT resilience and policies, and the benchmark in the UK is Cyber Essentials. We are happy to say that we are now certified to Cyber Essentials which, along with our ISO standards, gives assurance to our customers.”
Hydram obtained certification at the end of August covering its complete IT environment including its workstations, servers, mobile devices, firewalls, anti-virus, software and network.
Find out about all our certifications HERE
Since 2013, Hitachi Rail has spent over £1.8bn with UK suppliers, including with local company Hydram Engineering.
Hitachi Rail’s success with the Intercity Express Programme (IEP) – supplying new fleets for the East Coast and Great Western Main Lines – has helped to create a supply chain of over 1,400 individual suppliers. This includes over 130 suppliers directly in the North East – close to the manufacturing facility in Newton Aycliffe, County Durham.
Hydram Engineering has worked successfully with Hitachi Rail to enter the rail market in 2016, winning a contract to supply over 1,500 components and assemblies.
Hydram’s employees are proud to experience the trains during both the production process and then again as passengers – seeing how the parts they are responsible for make a real difference to millions of people each year travelling on Hitachi rolling stock.
Find out more about how Hydram collaborated with Hitachi Rail as a partner and has supported business growth, whilst developing new talent through a successful apprentice scheme.
Hydram Chooses the Latest FaroArm Inspection Arm
Quality is central to Hydram’s business philosophy. In addition to holding an impressive list of customer specific approvals, the business is certified to the ISO 9001 Quality Standard, the ISO 3834-2 and EN 15085-2 Welding Standards and the DIN 6701 standard for adhesive bonding related to the rail industry.
The mainstay of Hydram’s inspection function is the company’s collection of FaroArm, portable measuring arms. Having acquired its first measuring arm 13 years ago, the transition to FARO was made in 2015. The outstanding performance of Hydram’s first FaroArm meant that, as the company grew further FARO models were purchased.
Prompted by an ever increasing volume of QC work and the further inspection activities that will be needed following the securing of a large contract, Hydram recently obtained the latest generation of FaroArm – the advanced QuantumM model. The company now boasts an impressive FARO collection that reflects the continuous evolution and technical development of the FaroArm range.
Hydram Quality Manager, Barry Edgar explained. “Since we bought our fist model, we have regarded our FaroArms as the ‘workhorses’ of our inspection department. Although, to ensure that we achieve best value and always obtain technically superior inspection equipment, before we made any of our FARO purchase, we carefully considered the alternatives.
“As with our previous FaroArm purchases, when judged against other makes and models of measuring arms, we considered our most recently installed FaroArm, a 2.5 meter capacity QuantumM with tactile probing, to be the superior option. In addition to its impressive accuracy specification, speed and ease of use, the QuantumM is extremely robust.
“When compared to previous generation FaroArms, we have been impressed by the range of enhancements made to the new QuantumM, that make it simpler to use and more productive. For instance, the QuantumM is easy to manoeuvre as it is 20% lighter in the hand than previous FARO models, also, unlike our earlier FaroArms, it is always immediately ready to use as it requires no warm up time. On completion of a FARO measuring routine it helps that we can instantly archive the achieved results or print detailed customer reports.
“Although our new QuantumM FaroArm is now mainly used in our dedicated Inspection Department, its ability to perform full digital analysis and review the data in less than perfect conditions, enables it to be used across our entire shop-floor. Also, as we ordered a 2.5 meter capacity model, our new FaroArm is capable of inspecting the vast majority of even the largest of our fabrications.
“As we anticipated, our recently installed FaroArm has already made a significant contribution to the efficiency of our Inspection Department. Given the ease and speed of use of our new QuantumM, not only is it able to handle our current throughput of inspection work, it will also be able to handle the anticipated increases in production related to our large new contract.”
Find out more about quality at Hydram here >
Hydram raises its game with 16-tonne Mercedes-Benz Atego from Bell Truck and Van
Metal fabrications specialist Hydram Engineering has responded to increased demand from customers by commissioning its biggest truck yet, a 16-tonner from the Mercedes-Benz Atego range which has been providing reliable service for upwards of 20 years.
Based in Chilton, County Durham, the company is a leading provider of subcontract services covering all aspects of precision sheet metal profiling, forming and fabrication, as well as powder coating and assembly.
The new rigid arrived, like the six other vehicles on the Hydram fleet, via North-East Dealer Bell Truck and Van. At 16 tonnes, its gross weight is the highest in the Atego portfolio.
The truck is smartly finished in the operator’s distinctive silver livery, with the ‘personalised’ registration plate P222 HYD. It has a ClassicSpace S-cab and, as a 1521 model, is powered by a 5.1-litre four-cylinder engine which produces 155 kW (211 hp) and is paired with a six-speed manual transmission. Its 26 ft curtainside body, meanwhile, is by Robinsons Truck Bodyworks, of Newcastle upon Tyne.
Acquired in 2018 by the US-owned Dynamic Aerospace and Defense Group, Hydram is committed to implementing world class standards across all of business functions, including its transport operation.
The fabricator has previously relied on 13.5-tonne trucks in its delivery fleet. Underlining the Atego’s unrivalled reliability and durability, Hydram is still running a 14-year-old example which has clocked-up 970,000 km, as well as others from 2010, 2013 and 2015. Completing the fleet are a pair of Mercedes-Benz Sprinters, a 4.6-tonne curtainsider and a 3.5-tonne panel van.
Purchasing Manager David Lowes explained: “We’re very busy and some of our products are heavy, so we felt a vehicle which offered a higher payload would beneficial in helping us to meet the rise in customer demand.
“The new truck’s footprint is no bigger than previous versions, but it has enabled us to increase efficiency and improve cost and other controls by reducing the extent to which we rely on third-party transport providers to support our in-house operation.”
He continued: “We like to run vehicles which stand out from the crowd, and feel the Mercedes-Benz brand complements our own company’s image and reputation for quality.
“We pride ourselves in going ‘above and beyond’ in terms of the service we provide to our customers. This means the avoidance of unplanned vehicle downtime is crucial. The Atego has proved over the years to be exceptionally reliable, and has given us the flexibility we need to respond quickly to changing requirements.”
Hydram’s trucks undertake nationwide deliveries so the round-the-clock support provided by members of Mercedes-Benz Trucks’ Dealer network is also key to the Atego’s appeal. “There have been very few occasions when we’ve needed to call on the manufacturer’s Service24h back-up, but when we’ve done so it’s performed well,” confirmed Mr Lowes.
Purpose-designed for light- and medium-duty distribution work, the Mercedes-Benz Atego range offers advanced truck technology for the 7.5 to 16 tonnes segment, with outstanding dynamics, comfort, safety and manoeuvrability, making it an outstanding choice for adding to Hydram’s delivery fleet.
On June 10th 2019, The Dynamic Metals Group confirmed its acquisition of the aerospace division of Paul Fabrications. The new company will begin trading as Dynamic Aerospace Fabrications Ltd (DAFL).
The Dynamic Metals Group (www.dynamicindustrial.com) is a privately-owned business with its main headquarters in Michigan, USA. The new acquisition will join its existing portfolio of companies: Hydram Engineering in the UK; Dynamic Industries (SG) in Singapore; and Gem City Metal Technologies, Dynamic Metals and Dexter Stamping, based in the American mid-west. All these companies have an established reputation, specialising in the supply of precision metal components for the aerospace, defence, automotive and rail sectors.
Paul Fabrications becomes Dynamic Aerospace Fabrications
Don Nystrom, the President of The Dynamic Metals Group said: “We are delighted that the aero division of Paul Fabrications has joined The Dynamic Metals Group. Aerospace engineering goes right back to Dynamic’s origins in the US and there is a great synergy between the two businesses in respect of skill sets and customer portfolio. It is natural that the new company inherits the Dynamic brand as it moves forward.”
David Greatorex, Managing Director of sister company Hydram Engineering, said: “It is great to see the expansion of Dynamic’s ambition in the UK. Hydram has been part of The Dynamic Group for 12 months and we have seen strong commitment to continued improvement and investment that has underpinned our success. The opportunities for Dynamic Aerospace Fabrications are considerable.”
Alistair Bools, Senior Supplier Management Executive Installations for Rolls Royce said: “The Dynamic Group is an important part of our supply chain, and following its acquisition of Paul Fabrications, we look forward to working with them even more closely in the future.”
About Dynamic Aerospace Fabrications
Dynamic Aerospace Fabrications, a former division of Paul Fabrications, has a long history supplying precision sheet metal and machined metal products and assemblies for the aerospace and power generation industries. Using advanced manufacturing and engineering expertise, Dynamic Aerospace Fabrications produces components for demanding applications such as aero gas turbines, aircraft structures and land-based turbines, and supplies to market-leading companies in these sectors.
www.dynamicaerofabs.com
About The Dynamic Group
The Dynamic Group has its main headquarters in Michigan, USA. It consists of a group of tightly coordinated companies particularly renowned for excellence in metal forming and fabrication, including roll forming, hydroforming, metal spinning and stamping. Its customers include aerospace, defence, automotive, rail and earthmoving equipment manufacturers. This is Dynamic’s second acquisition in the UK and is positioned to be the group’s platform for further growth in the aerospace sector in the UK and Europe.
