1The Challenge
A Tier 1 automotive supplier producing pressed steel components needed to segregate a new painting and coating line from their existing assembly operations. The painting process generated significant solvent vapour and overspray, creating both a fire risk and a contamination risk for the precision-assembled components on adjacent lines. A permanent brickwork wall was quoted but would require a 3-week production shutdown that was incompatible with their OEM supply commitments.
2Our Solution
Mercia Industrial installed a 45-metre run of RapidFireWall with anti-static PVC panels rated to LPS 1207, creating an ATEX zone boundary between the painting enclosure and the adjacent assembly area. Installation was completed over two weekends without halting weekday production. The system incorporated integrated strip curtain access points on the two forklift lanes connecting the areas, and the overhead track was designed to integrate with the facility's existing sprinkler system without requiring any modification.
3The Outcome
The installation was completed on schedule and within budget, with zero production days lost. The solvent vapour levels in the assembly area were reduced to below 10% of the LEV (Lower Explosive Limit) as measured by post-installation air monitoring. The client's insurers accepted the LPS 1207 certification in satisfaction of their fire safety requirements, reducing the facility's insurance premium by 12%.
“Mercia delivered exactly what they promised — an ATEX-compliant partition that we could install without shutting the line down. The weekend installation approach was their idea, and it saved us from a very difficult conversation with our OEM customer.”
— Facilities Director, Coventry Automotive Supplier
- Client
- Automotive Manufacturing Coventry
- Location
- Coventry, West Midlands
- Industry
- Automotive Manufacturing
- Product
- RapidFireWall