bespoke fabrication systems - find the...

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


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


Number of inlets

Pipe diameter of inlets (mm)

Design head of water (m)

Available flow rate (litres/sec)


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


Roof area (m²)/Traffic flow



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


Roof area (m2)



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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


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


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

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