13 August 2024

When a local Rugby signage company needed some specialist metal work for signs it was producing for Cancer Research UK’s Race for Life, it turned to its long-standing local customer, TS Metals, to step-up to the design and fabrication challenge.

At the start of 2024, specialists in signage, design and branding, ID Genie was awarded a prestigious contract to match a new theme, across all CRUK products, as part of its rebrand. This was needed to help promote its ambitious UK wide awareness and fundraising activities at events including its high profile 3k, 5k, 10k & Pretty Muddy Races, taking place from the beginning of April until late July 2024.

“There was an initial concept to consider but ID Genie were looking to us for guidance and our metal working experience to create the technical designs, prototype for approval by CRUK and then manufacture a practical and long-lasting solution,” explained Ian Addison, TS Metals’ Business Manager. “In addition to aesthetic looks and functionality we also had to ensure longevity and practicality. This meant keeping the weight down to ensure they could be handled, transported and erected by just two people. They also had to remain ridged in use plus stand up to the expected hard knocks they would invariably receive being transported, set-up and then moved to multiple locations.”

The solution for the 40 off new ‘Group Photo Moment’ structures (each 2m wide x 900mm deep x 1480mm high) was to fabricate them using mild steel bases,ensuring that they were able to safely hold the weight of a ‘crowd of people’ and then use aluminium half crescent moon graphic header boards. They also had to incorporate the ability to be secured down safely in windy environments and avoid any chance of tipping over.

TS Metals designed a ‘groove’ system underneath each unit into which the half-moon shape was affixed to prevent flex and a lattice work underneath the base prevents it sinking into mud. Different thicknesses of material were tested to optimise strength whilst keeping the overall weight down to under 75Kg. A commissioned prototype was first developed as proof of concept, and once this was signed off by CRUK and ID Genie, the design went into full production, with the full order being completed in just four weeks.

The eventual solution uses 2mm mild steel while the back and struts use 1.5mm and the half-moon being fabricated in 3mm aluminium. Pegging down lugs and integral lifting handles were also incorporated so that plinths would not trip up passers‑by.

TS Metals fabricated all the parts, first using its Trumpf 4kW laser to cut out the various elements which were then folded, assembled, tacked and welded before being finished to ensure that no weld marks would be visible through the powder coating, which would need to colour match CRUK’s specific colour scheme. Following graphic application by our client, each structure was inspected and wrapped using special PVC bags from Jumbo Inflatables, ready for delivery.

Amanda Williams, Owner of ID Genie added: “We have had the pleasure of working alongside CRUK ‘Race for Life’ for many years with their branding, but this year’s rebrand brought us new challenges! One element of the contract was to design and produce a steel structure to stand in front of the existing ‘reflection area’ banners and we turned to locally based TS Metals, for whom we had previously provided site signage, as we knew about their capabilities and expertise when it came to working in metal. They effortlessly took the initial concepts through to full technical drawings and a prototype in a matter of weeks, then producing all structures within one month.”

Ian concluded “It was fantastic to receive feedback from Amanda at ID Genie that the CRUK team were over the moon with the finished signage and the effect. This has been an extremely interesting challenge, and we were happy to work as a team with our client’s other suppliers to help deliver a finished product on time and within budget with stunning results as you can see from the photos! It’s been a pleasure to support this amazing cause.”

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