Bespoke Fabrication Systems
SEPTEMBER 2008FB-V1
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Polypipe Civilsunique solutions in fabrication
The UK Market Leader
Polypipe Civils is the UK’s leading
manufacturer of cable protection, drainage,
sewerage and water management systems,
serving the utilities, construction and civil
engineering markets.
Polypipe is one of Europe’s largest and fastest
growing manufacturers of piping and sanitary
systems for the residential, commercial and
infrastructure sectors. Supported by this
established foundation, Polypipe Civils is able
to make significant investment in its
manufacturing processes and now operates
over three sites in Loughborough, Horncastle
and Glasgow, employing over 300 people.
Unique In-house
Fabrications Department
Polypipe Civils is the only plastic pipe
manufacturer in the UK with its own in-house
fabrications department. This unique service
enables Polypipe Civils to overcome the most
difficult site constraints to create truly bespoke
solutions to meet the needs of customers.
Our in-house fabrications department, which
includes a 30,000 square foot facility, allows
us to work in partnership with our clients to
provide bespoke, pre-fabricated solutions
designed to reduce time and installation
costs on-site.
With the fabrications department located
within the Polypipe Civils business it
provides direct access to the raw materials
for the fabricated items. This not only
results in reduced lead times, but also gives
the fabrications department access to the
extensive knowledge, experience and
resource of the wider Polypipe Civils team.
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Tailor made solutionsfrom Polypipe Civils’ highly skilled in-house fabrications team
Tailor Made Solutions
As part of the unique fabrications service
offered by Polypipe Civils, fully qualified
design engineers work in partnership with
our customers to create a bespoke solution
to match individual specifications and site
requirements. Our fabrications team does not
only include a team of highly experienced
welders, but also calls upon the resource and
capabilities of the wider Polypipe Civils team,
including Civils Specialists, Design Engineers
and technical support to ensure our
customers receive the very best service.
Off-site Construction
Polypipe Civils is unique in its position of being
able to offer pre-fabricated, bespoke solutions
constructed off-site. This approach to modern
methods of construction reduces time and
installation costs on-site as well as minimising
health and safety risks in handling, storage
and installation. The strong, yet lightweight
properties of plastic pipes also enables further
reduction in the use of heavy plant on-site.
Seamless Integration
Fabricated solutions from Polypipe Civils are
designed to integrate into an overall drainage
application, with the fabricated element
designed specifically to meet the requirements
of the scheme. Polypipe Civils offers a value-
engineered approach to bespoke fabrications
and is supported by a technical department
that provides sound advice and design
experience. Our products can be designed
and manufactured to suit any project timeline,
without the need for lengthy lead times that
often limit more traditional materials.
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The Rangefabricated products from standard applications to one-off bespoke solutions
The range
Years of experience has enabled Polypipe
Civils to produce a core range of products
that although bespoke to each site, form part
of a standard stable of fabricated products.
Manholes
Fittings
Catchpits
TanksFilters
Flow Controls
Accessories
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Catchpitsour structured wall catchpits are manufactured to exact customer requirements
Our range of catchpits are designed to be
used in conjunction with our attenuation
and soakaway products. They provide easily
accessible maintenance points before the
attenuation or soakaway structure.
Benefits• Lightweight chamber design
• Tough and durable product
• Pre-fabricated off-site and delivered
ready to install
• Choice of chamber sizes from
1050mm, 1200mm, 1500mm, 1800mm
and 2100mm
• Inlets and outlets supplied with integral
sockets as standard
• Provides easy access maintenance
points for silt collection prior to the
attenuation structure
• Catchpits are also available perforated for
use as a lightweight soakaway chamber
Specification Requirements what we need to know:
Internal diameter of chamber (mm)
Base required
Step irons/ladder access required
Number of inlets
Orientation of inlets
Depth to invert level of inlets
Specification Requirements what we need to know:
Internal diameter of chamber
Base required
Step irons/ladder access required
Number of inlets
Orientation of inlets
Depth to invert level of inlets
Full Range of Options
Manholessurface water and sewer manholes manufactured to adoptable standards
Associated Products
Ridgidrain is the first structured wall surface
water drainage system to achieve the HAPAS
specification issued by the BBA. Ridgisewer is
the largest range of integrally socketed pipes
for use in gravity sewers.
Benefits
• Designed to integrate with the extensive
range of systems from Polypipe Civils
• Choice of chamber sizes from 1050mm,
1200mm, 1500mm, 1800mm and 2100mm
• One piece shaft
• Fully welded water tight solution
• Depth of manhole bespoke to customer
requirements
• Fully bespoke option of inlets and outlets
• Double step irons to BS 1247 as standard,
with orientation set to customer
requirements
Foul or Surface Water ManholesG
Stormwater manhole Foul manhole
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Flow Control Chambers
Specification Requirements what we need to know:
Number of inlets
Pipe diameter of inlets (mm)
Design head of water (m)
Available flow rate (litres/sec)
Specification Requirements what we need to know:
Roof area (m²)
Pipe diameter of inlets and outlets (mm)
Depth to invert of tank inlet (m)
Stormcheck Chambers
The Stormcheck ‘Vortex Flow Control
Chamber’ comprises of a pre-fabricated
plastic chamber in a range of diameters.
Supplied pre-installed with an integral Vortex
Flow Control device which allows precise
control of site discharge rates from an
attenuation storage system. Vortex Flow
Control devices are widely recognised as the
most hydraulically efficient means of flow
regulation. The unique design utilises no
moving parts, meaning they are virtually
maintenance free.
Benefits• Vortex Flow Control housed within sealed
chamber for ‘plug and play’ installation
• Integral sump for silt catchment with
optional drain down system to ease
maintenance and silt removal
• Choice of depth up to maximum invert
level of six metres
• Factory-fitted pre-installed Vortex Control
device saves time and expense on-site
• Available as manual, bypass and
non-bypass system
Eco-Vat Tanks
Eco-Vat tanks are designed for both
residential and commercial projects to
collect rainwater from roof areas for
re-use in non-potable applications, such
as toilet flushing, washing machine use
and wash down areas. Constructed from
either structured-wall pipe for shallower
burial depth or GRP for larger capacity
requirements, the Eco-Vat rainwater
harvesting solution can typically reduce
mains water demand by as much as 50%.
Polypipe Civils can also supply tanks for use
in foul water or surface water applications.
Benefits• Designed specifically for the UK market
• Robust as well as quick and easy
to install
• Can sustain high water tables without
the need for concrete surround
• Comes pre-assembled, ready for
installation
• Based on a proven and tested product
Associated Products
Polypipe offers a range of modular attenuation
and soakaway solutions. Polystorm Xtra has a
load bearing of 80 tonnes, with Polystorm and
Polystorm Lite offering 40 and 20 tonne load
bearing capability respectively. Each variety of
Polystorm unit is light enough to carry and
installations can be built up to form a load
bearing tank structure. Polypipe also offers
a large diameter pipeline and attenuation
system, Ridgistorm-XL. Various tank sizes
can be offered to suit specific sites.
Tanks
Associated Products
To accompany our structured-wall or GRP tanks
in rainwater harvesting applications, Polypipe
Civils supplies a range of leaf filters which
prevent the ingress of leaves, silt and other
debris from entering and contaminating any
run-off water in the tank.
Stormcheck Vortex Flow Controls Stormcheck Vortex Flow Controls
Rainwater Harvesting Tanks
Surface Water & Foul Water Tanks
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Storm X4
Utilising the latest four stage upward filtration
technology, Storm X4 reduces surface water
run-off contamination from road and roof
areas to enable clean water to enter the
watercourse or soakaway structure.
Storm X4 is delivered to site within a
pre-fabricated chamber, reducing installation
time dramatically and providing an innovative
solution to the issue of surface water quality.
Benefits• Treated surface water run-off can be
discharged directly to watercourse
• Delivered to site within a chamber for
quicker, easier and safer installation
• Low maintenance - filter lasts for 2 years
on average
• Designed specifically for project
requirements
• Compliant with Water Framework Directive
Filters within Chambersquicker, easier and safer installation with off-site construction
Specification Requirements what we need to know:
Roof area (m²)/Traffic flow
Pipe diameter of inlets and outlets (mm)
Depth to invert of tank inlet (m)
Filters within Chambers
Polypipe Civils provides sediment and leaf filters
pre-fabricated within chambers and delivered
to site ready to install. Used in conjunction
with the Eco-Vat Rainwater Harvesting system
to eliminate siltation within the system,
Polypipe Civils is the only supplier of rainwater
harvesting products with the capability to offer
such a service. Utilising no moving parts, they
are virtually maintenance free.
Low Invert Drop Leaf Filters
In situations where the existing drain run
dictates the invert level, low invert drop filters
may need to be considered. Polypipe Civils is
unique in its ability to offer bespoke low invert
drop filters within a pre-fabricated chamber.
Designed to exact customer specifications the
low invert drop filters and chambers allow a
minimum head loss of only 66mm, enabling
connection to an existing drain run.
Benefits• All filters are fabricated within a sealed
chamber, built to exacting standards
and customer specifications
• Low maintenance-filter
• Lightweight chamber design
• Tough and durable product
• Designed specifically to meet project
requirements
• Range of filters available for roof sizes
up to 9,000 square metres
Specification Requirements what we need to know:
Roof area (m2)
Pipe diameter of inlets and outlets (mm)
Depth to invert of tank inlet (m)
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Fittings & Accessoriesto accompany our range of bespoke and fabricated products
Covers and Frames
We offer a range of covers and frames
in a variety of materials:
• Steel
• Plastic
• DuctileIron
• Composite
• Bespokefabricatedtosuitsite
Fittings Accessories
Gully Riser Pieces
Channel
Benching
Loading
Chamber
Step irons or ladder
Concrete cover slabs
Manhole cover & frame
Non-standard Ts and Bends for Sewer
Split Duct
Riser Pieces
Step Irons or ladders
Tank/Turret Riser Pieces
Bespoke Gullies
Drain and Duct
Installationquicker, safer and robust installations for pedestrian, light load and traffic applications
Quick and easy installation
Polypipe Civils chambers and manholes
can be installed in a fraction of the time of
traditional concrete or brick construction with
reduced health and safety risks. These time
and cost savings are passed directly to the
contractor on-site.
Gravel surrounds are suitable for pedestrian
or light field loading. Concrete surrounds
should be used in carriageways or locations
subject to heavy loads or frequent trafficking,
or where a high water table is present.
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The Fabrications Teamskill and commitment throughout the design and fabrication process
Technical Expertise
Our qualified Civils Specialists provide
exceptional standards of customer service
and operate as the link between the site
and the technical office. By working with
a dedicated representative, our customers
can take advantage of our detailed
knowledge to ensure the solution meets
their exact requirements.
Technical Department
The calibre of people and technical expertise
within Polypipe Civils provides an enviable
standard of technical service and customer
support. The technical services team includes
fully qualified Design engineers who provide
detailed specification right through to
installation and guidance.
Our technical department are able to take
existing drawings and employ the principles
of value-engineering to design a more cost
effective solution. We also work closely with
our customers to design a specific element of
an overall project plan as part of our design
take-off service.
Profile: Andy Cullum age 30
Position: Commercial Manager
for Polypipe WMS
Qualifications: BEng Civil Engineering
from Nottingham University
Polypipe Civils Service: 8 years
Achievements: Being a Civil Engineer
allows me to understand both the
needs of the project and the technical
data requirements for our technical
team. As the link between the
technical department and site this
knowledge is invaluable.
Profile: Satnam Johal age 40
Position: Fabrications Manager
at Polypipe Civils
Qualifications: City & Guilds
(Brickwork) and IOSH – Managing Safely
Polypipe Civils Service: 19 years
Achievements: As the only UK plastic
pipe manufacturer to offer a dedicated
fabrications service, we are very proud
of the work carried out by the team.
There is often a lot of work that goes
into the jobs we undertake and we
operate strict controls to ensure that
we supply products that are the
highest quality to our customers.
Profile: Pal Johal
Qualifications: TWI certification
Polypipe Civils Service: 15 years
Achievements: The fabrications
department is a rewarding place to work
as I get to work on some of the most
high profile projects within the business.
We’ve recently completed work on over
40 bespoke manholes for the CJL project
which I’m very proud to have been
involved with.
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Fabrications processin-house fabrication for every site specific application
Justifiably Proud
Our team of highly experienced welders
have all successfully completed The Welding
Institutes Certification Scheme for Welding
and Inspection Personnel, a tailored training
course which is carried out in accordance
with the British and European Standard.
Working together with technical support,
our Fabrications Team ensure that we can
respond efficiently to customers’ needs to
design and provide solutions to pipeline
problems. As part of our continuous
improvement plan, our fabrications operatives
undergo continued training and development
to ensure the service we offer our customers
is the very best available. The Fabrications Process
As part of our unique fabrications service,
we undertake full problem analysis to
identify the initial issue on-site and the most
appropriate fabrication solution. In situations
where standard products are not the
preferred option, Polypipe Civils can
fabricate a complete and bespoke solution
to meet specific site requirements.
Once a bespoke solution has been designed,
our Technical Department work closely with
the Fabrications Team to produce the desired
product, which is then quality checked and
tested to ensure a fit for purpose solution is
delivered to site.
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Our commitmentto the environment
Environmental Commitments
Polypipe Civils has made significant
investment in its commitment to the
environment throughout the business.
One key element of this commitment is our
use of recycled product. For the past 15 years
it has been our policy to use as much
recycled material as possible, either from
other industries or post consumer waste.
In the overall production of our plastic pipe
we use over 45% recycled plastic, enabling
us to maintain the exacting standards of
quality and durability to help protect
the environment.
Reducing Waste
The use of pre-fabricated solutions
manufactured off-site reduces the amount
of traffic to and from site, whilst also
dramatically reducing the amount of wastage.
This offers contractors and developers a
significant step in improving their green
credentials. Any waste which occurs during
manufacture is under our control and is fed
back into our manufacturing process to be
recycled. As many of our products arrive
on-site ready to be installed, no excess work
is required which reduces any waste
occurring on-site.
Our Future Commitments
Sustainability is not just about manufacturing
products from recycled material or helping
to reduce energy consumption, there are
many elements to consider. Polypipe Civils
makes a conscious effort to ensure as much is
being done to help the external environment
as possible, whether it be through improved
transport policies to reduce fuel consumption,
machinery which uses less energy or
recovering site waste. Our commitment to the
environment is inherent throughout the
business and we take pride in our position as
a responsible manufacturer.
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Case studiesour proven track record of providing tailored solutions for specific projects
Knowles Transport
Polypipe Civils worked closely with
groundworker DJE Construction to supply
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at the redevelopment of a transport depot
in Wisbech, Cambridgeshire. A concrete
drainage solution was originally specified
on the project. This was re-engineered to
incorporate plastic chambers which offered
quicker and more efficient installation, as
well as improved health and safety benefits
on-site. The bespoke solution designed by
Polypipe Civils included catchpits in 1500mm
and 1800mm diameters alongside more
than 100 metres of Ridgidrain structured
wall pipe in varying sizes. Polypipe Civils’
Fabrication Department played a key role in
determining the specific catchpit design to
meet the objectives of DJE on-site.
CJL
Sub-contractor CJL Construction required
over 70 manholes for a foul water scheme
on a new housing development in
Weston-Super-Mare. The project suffered
from particularly challenging site constraints
due to the high water table, which resulted
in Polypipe Civils designing and supplying a
bespoke sealed manhole solution.
The unique design incorporates a pre-formed
and pre-benched manhole with a complete
shaft, which significantly reduced the number
of leakage points within the structure.
Each manhole was also installed with a
concrete bed and surround to resist flotation
caused by the high water table.
Geo Post
Polypipe Civils were approached by Barnfield
Construction to supply technical advice for
the most appropriate drainage system during
the construction of a new 30,000 sq feet
depot and car park for Geo Post; an
international delivery company based in
Warrington. To collect excess rainwater and
surface water run-off from the large roof
and hard standing car park areas, Polypipe
Civils supplied its large diameter Ridgidrain
pipe in 900 and 1050mm diameters to
attenuate excess stormwater. Over 220
metres of pipe was installed in total.
To enable the surface water run-off to be
discharged safely to the local drainage
network, Polypipe Civils’ installed its
Stormcheck flow control products, which
were constructed off-site in prefabricated
chambers, enabling quicker and easier
installation on-site.
All descriptions and illustrations in this publication are intended for guidance only and shall not constitute a “sale by description”. All dimensions given are nominal and Polypipe Civils Limited may modify and change the information, products and specifications from time to time for a variety of reasons, without prior notice. The information in this brochure is provided ‘as is’ on 1st September 2008. Updates will not be issued automatically. This information is not intended to have any legal effect, whether by way of advice, representation or warranty (express or implied). We accept no liability whatsoever (to the extent permitted by law) if you place any reliance on this brochure and you must do so at your own risk.
Polypipe Civils
Head Office
Charnwood Business Park
North Road
Loughborough
Leicestershire LE11 1LE
Tel: 01509 615100
Fax: 01509 610215
Email: [email protected]
www.polypipecivils.co.uk
Bespoke Fabrications Systems