ridgistorm-xl technical guide - polypipe · ridgistorm-xl storage capacities table 3.5-1 33 typical...

Uniclass EPICL2172 B524CI/SfB

(52.5) X

August 2009

Ridgistorm-XL

Technical guide

WMS

Design, planning, specification and installation guidelines

Water Management Solutions

Polypipe Water Management

Solutions the UK’s leading supplier of

sustainable urban drainage solutions

for commercial, infrastructure and

residential applications.

Ridgistorm-XL is the latest introduction

to the WMS portfolio and provides a

full range of large diameter pipes and

fittings for use within attenuation and

pipeline projects. This manual outlines the

features and benefits of the Ridgistorm-XL

system and provides advice and guidance

regarding the design, installation and

general properties of the system.

WMS

2

3

Contents

Section 1 Introduction to Polypipe WMS 6 - 11

Section 2 Introduction to Ridgistorm-XL 12 - 21

Section 3 Design 22 - 41

Section 4 Handling and Installation 42 - 57

Section 5 General Properties 58 - 61

Section 6 Project Solutions ?62 - 65

Section 7 Associated Products ?66 - 69

Section 8 The Company ?70 - 74

Notes for technical drawings

The following notes apply for the technical drawings in this document:

• Alldimensionsareinmillimetresunlessotherwisestated

• Alltemporaryandenablingworksbyothers

• RefertoPolypipeWaterManagementSolutionsforunitdetails

• Allpipeconnectionsandinspectionpointsareassumedunlessotherwisespecified

• Alldimensionsoffabricateditemsarenominalandmayvarywithinmanufacturingtolerances

• Adrawingisintendedforguidanceonly.Confirmationoftheinformationcontainedinadrawing

shouldbesoughtfromtheconsultingengineersbeforeconstructionactivitiestakeplace

Index - Pages

4

How this document is organised Thedocumentispresentedinclearlymarkedsectionstohelpyounavigateandfindtheinformationyourequirequicklyandeasily.

Section 1 - IntroductiontoPolypipeWMS.

Section 2 - Introduction to Ridgistorm-XL.

Section 3 - Design.

Section 4 - HandlingandInstallation.

Section 5 - GeneralProperties.

Section 6 - ProjectSolutions.

Section 7 - AssociatedProducts.

Section 8 - TheCompany.

Section 1 - Introduction to Polypipe WMS

SUDSBestPractice 9BuildingRegulations 10SustainableDrainagePlanning 11

Section 2 - Introduction to Ridgistorm-XL

BespokeProjectDesign 14Applications 14Jointing 14BespokePipeProfileProvidingIndividual

StiffnessClass14

ExceptionalLeakTightness 15Ridgistorm-XLversusRigidMaterials 15PipeLength 15StandardsandApprovals 15MultipleJointingOptions 16WRcApproval 17ApplicationsforRidgistorm-XL 17BenefitsofPlasticPipes 19

Section 3 - Design

PipeStructuralPerformance 24UniquePipeStiffnessTechnologyProvidingFlexible

andVariableLoadingSpecifications25

Value Engineering 27Ridgistorm-XLGeneralArrangements 28BespokeFabrications 32Hydraulic Design 40HydraulicPerformances 41AbrasionResistance 41

Section 4 - Handling and Installation

HealthandSafety 44Handling 45

Installation 46Typical Installation Details 47Electro-fusion Jointing 50Testing 56Maintenance 57

Section 5 - General Properties

UVLightResistance 60ChemicalResistance 60Durability 61

Section 6 - Project Solutions

RiverDiversionProjectusingRidgistorm-XL 64Ridgistorm-XLElectro-fusionJointDelivers

StormwaterDiversionforGatwickAirportScheme64

BespokeLargeDiameterAttenuationandRainwater

HarvestingSolutionforNewLivestockMarket65

Ridgistorm-XLLargeDiameterPipeSystemProvides

theSolutionforLandfillProject65

Section 7 - Associated Products

Stormcheck‘Vortex’FlowControlChamber 67Storm-X4 68Polystorm 69BespokeFabricatedProducts 69TechnicalInformationOnline 69

Section 8 - The Company

Innovation 72Manufacturing 72EnvironmentalCommitments 72PolypipeHealthandSafetyPolicy 73PolypipeEnvironmentalPolicy 74EnergyManagementandConservationPolicy 74

5

Description Tables Illustrations* Page

Section 2 - Introduction to Ridgistorm-XL

ComparisonofCO2 emissions Table2.12-1 19

Section 3 - Design

Performancemechanisms Fig3.1.1 24

Overloadingeffect Fig3.1.2 24

Ridgistorm-XL dimensions Table3.4-1 28

Standardpipelength Fig3.4.1 28

Generalarrangement1 Fig3.4.3 29

General arrangement 2 Fig3.4.4 29



FabricatedCunit Fig3.5.1 32

FabricatedTunit Fig3.5.2 32

FabricatedBunit Fig3.5.3 32

FabricatedFunit Fig3.5.4 33

Ridgistorm-XL storage capacities Table3.5-1 33

Typical manhole installation detail Fig3.5.5 34

Typical manhole plan Fig3.5.6 34

Typical off-set manhole installation detail

Fig3.5.7 35

Typical off-set manhole plan Fig3.5.8 35

Typicaloff-setmanholesectionA-A Fig3.5.9 35

End termination Fig3.5.10 36

Pipewithlateralconnection Fig3.5.11 36

Pipewithlateralconnection Table3.5-2 36

Inspection point Fig3.5.12 37

Inspection points Table3.5-3 37

Manaccess Fig3.5.13 38

Manaccess Table3.5-4 38

Stepiron/ladder Fig3.5.14 39

Selectedroughnesscoefficientvalues(Ks)

Table3.6-1 40

Hydraulic performances graph Fig3.7.1 41

Abrasionresistancegraph Fig3.8.1 41

Section 4 - Installation

Numberofpipesdeliveredpervehicle

Table4.2-1 45

StandardRidgistorm-XLtrenchinstallation-detail1

Fig4.4.1 48

StandardRidgistorm-XLtrench installation - detail 2

Fig4.4.2 48


Fig4.4.3 49


Fig4.4.4 49

Electro-fusion welding parameters for preheating

Table4.5-1 52

Digram showing the position of tools during electro-fusion process

Fig4.5.2 55

Weldingparametersforelectro-fusionsocket

Table4.5-3 55

Visiblesignofweldingcompletion

Fig4.5.4 55

Section 5 - General Properties

Chemicalresistanceof Ridgistorm-XL

Table5.2-1 60

For updates and a pdf of this document go to

www.polypipewms.co.uk/downloads

*Please note: Illustrations shown

withinthispublicationareavailable

asdownloadableCADdrawingsfrom:

www.polypipewms.co.uk

Index - Illustrations & Tables

Polypipe WMS provides a full range

of Water Management Solutions and

are able to offer you unbiased advice

and guidance as to the appropriate

solution for your specific project.

Introduction

6

7

Intended Audience• CivilEngineersandArchitectswhodesign

andspecifyattenuationandinfiltrationsystems.

• ContractorswhoinstallRidgistorm-XL

largediameterpipes.

Purpose of this documentThisdocumentprovidesfulltechnicaldetailson

PolypipeWMSRidgistorm-XLproductsandexplainshowto:

• Selectproductstoprovidethebestsolutionforyour

specificstormwaterrequirements.

• Incorporateproductsintoyourproject’sdesign.

• Installproductson-site.

Health and Safety at WorkTheHealthandSafetyatWorkActandtheregulations

underitapplytoSUDSschemes.AllPolypipeWMS

productsshouldbetransported,handledandinstalledin

accordancewiththerequirementsofBS5955:Part6:1980

and,forapplicablecontracts,theHighwaysAgency’s

ManualofContractDocumentsforHighwayWorks

andSewersforAdoption.

Construction (Design and Management) Regulations 2007Apartfromverysmallprojects,wheretheclientsare

typicallyhouseholders,theConstruction(Designand

Management)Regulations2007applytotheplanning,

design,constructionandmaintenanceofSUDSschemes.

The Regulations emphasise the importance of considering

healthandsafetyforaconstructionprojectduringthe

project’sdesignphase.

1section

Holistic Solutions

8

Our ApproachPolypipeWMSistheonlymanufacturerofwatermanagement

products to offer a complete range of solutions from large

diameterpipestomodularcellsystems,flowcontroldevices

andfiltrationunits.Thisapproachenablesyoutotake

advantageofbespokesolutionsdesignedforaspecificproject

andvalueengineeredtoyourexactrequirements.

Dedicated SupportOurteamoffullyqualifiedDrainageSpecialists,Civil

EngineersandTechnicalSupportexpertsalsoprovide

invaluableexperienceandknowledgethrougheach

stageofaproject.

ContactourTechnicalTeamon01509 615100 or go to

www.polypipewms.co.uk/technical-support/.

Holistic solutions from the market leaders in surface water management

POLYPIPE WMSVALUE ENGINEERED

CYCLE

PRODUCTPERFORMANCE CALCULATIONS

Specificdesigncalculationscanbeprovidedto

support our solutions andensureeffective

long-termperformance.

PRODUCT SOLUTION

Utilisingbestpracticecombinedwiththelatest

software to specify the most appropriateproduct.

BESPOKE FABRICATIONS

Off-sitemanufacture using modern methods

ofconstruction. Awiderangeof

bespokeproductsandfittings from our in-house

FabricationsTeam.

HEALTH & SAFETY

Productsaredesignedwithhealth and safety in mind

and full guidance for the safe handling and

storage of our products isavailable.

INSTALLATION SERVICES

Detailed installation guides offer contractors and

groundworkersdefinedparameters to help when installingourproducts. Weworkwithpreferredsupply & fit partners to

deliveracompleteinstallationservice.

ON-SITE GUIDANCE

Dedicated technical support experts on-hand to offer

adviceandsupporton-site.

MAINTENANCE GUIDANCE

FullmaintenanceguidanceavailablefromthePolypipe

WMSTechnicalTeam.

LONG TERM ALLOWANCES

Sustainablesolutionsdesignedtoprovidethe

appropriateprojectsolution.

PLANNING

CivilEngineersandDrainageSpecialistson-handtooffer

guidance on appropriate projectsolutions.

DESIGN

Design assistance utilising CAD,microdrainageanddeformation calculations availableateverystage

oftheproject.

9

1section

Sustainable Drainage Systems (SUDS)

1. SUDS Best Practice TheSUDSManual,publishedbyCIRIA2007(CIRIAC697)definesthatasustainableurbandrainage

systemshouldconsidercertainbasicrequirements,including:

• Run-offfromadevelopedareashouldbenogreaterthantherun-offpriortodevelopment.

• Run-offfromadevelopedareashouldnotresultinanydown-gradingofdownstream

watercoursesorhabitat.

• Considerationshouldbegivenatthedevelopmentfeasibilitystagetowaterresourcemanagement

andcontrolinthedevelopedarea.

• Runoffshouldreplicateasfaraspossiblethenaturalresponseofthesitetorainfall.

SUDSbestpracticelimitstheflowofrainwaterwhichrunsoffasiteorispipedaway,protectslocal

watercoursesfromcontaminationcarriedinsurfacerun-off,encouragesnaturalgroundwaterrecharge

(whereappropriate)andreducesthelikelihoodofdownstreamflooding.

Sustainable Drainage Systems (SUDS) is the alternative to the traditional approach of collecting stormwater in pipes and discharging it into sewers or watercourses.

10

1.1 Building RegulationsTheBuildingRegulationsApprovedDocumentH3,RainwaterDrainage,whichcameintoeffect

on1stApril2002,prioritisesdrainagerequirements.Inshort,itrequiresthatrainwaterfromtheroof

ofabuildingorfromapavedareamayeitherbegatheredforre-useinarainwaterstoragetankorbe

dischargedintooneofthefollowing,listedinorder:

(a) anadequatesoakawayorsomeotheradequateinfiltrationsystem;or,wherethatis

notreasonablypractical,

(b) awatercourse;or,wherethatisnotreasonablypractical,

(c) asewer.

SUDSincorporatevariouscost-effectivetechniquesthatareapplicabletoawiderangeofschemes,from

smalldevelopmentstomajorcommercial,industrial,residentialorleisureoperationswithlargeroof

spacesandlargehardstandingareas.Theycanalsobesuccessfullyretrofittedtoexistingdevelopments.

PlanningpolicyguidanceondevelopmentandfloodriskemphasisestheroleofSUDSandintroducesa

generalpresumptionthattheywillbeused.Aswithotherkeyconsiderationsintheplanningprocess-

transport,landscape,heritageandnatureconservation-incorporatingSUDSneedstobeconsideredearly

inthesiteevaluationandplanningprocess,aswellasatthedetaileddesignstage.

Inotherwords,thetraditionallypreferredmethodofrainwaterdisposal,i.e.totallydischargingtoa

sewer,maynowonlybeconsideredafterotherformsofre-useordrainagehavebeenconsideredand

showntobeimpracticalforagivensite.

TheBuildingRegulationsalsoprovideguidanceontheconstructionofrainwaterharvestingsystemsfor

thefirsttime.TheCodeforSustainableHomesindicatestheGovernment’sintentionstofurtherdrive

developerstowardsbuildingsustainablehomes.Aswellascoveringenergyefficiency,waterusageand

waste,thecodealsoproposesaminimumstandardforsurfacewatermanagement.Thisminimum

standardwillrequirepeakrun-offratesorannualrun-offvolumesofsurfacewatertobenomorethan

theoriginalconditionsofthesite.Thechallengeeachdeveloperfacesonbothgreenfieldandbrownfield

developmentsiswhattodowiththeexcessrun-offgeneratedbydevelopmentwhichhastoberetained

inandaroundthesite.SoftSUDSalonemaynotprovidesufficientstorageoncertainsitesduetospace

constraints,particularlydrivenbythehousingdensityrequirementsinPPS3:housing.Inthesesituations

engineeredsolutionsprovidedbyPolypipecanbeusedorcombinedwiththesoftsolutionstoprovidean

effectiveandintegratedwatermanagementsystem.

PolypipeWaterManagementSolutionsprovidestoboththelargeandsmalldeveloper,flexiblesolutions

whichcaterforalmostanysiteconditionsandrestraints.

11

1section

1.2 Sustainable Drainage PlanningManyauthoritieswillexpectplanningapplications,whetheroutlineordetailed,todemonstratehowa

moresustainableapproachtodrainageistobeincorporatedintodevelopmentproposals.

1.2.1 PlanningTheEnvironmentAgencywillsetalimittotherateandvolumeofstormwaterflowfromasiteviasewers

asaconditionofplanningconsent.Inrecognitionofthis,LocalPlannersincreasinglystatethatall

applicationsshould,inthefirstinstance,aimtoincorporateSUDSintodevelopmentproposals.SUDSare

alsoconsideredsuitableformitigatingadverseimpactsandsupportingwaterconservationobjectives.

1.2.2 Adoption and Future MaintenanceIntheearlystagesofdesign,considerationshouldbegiventothearrangementsforadoptionandfuture

maintenanceofthesystem.Thisislikelytoinfluencethedesignjustasmuchastechnicalconsiderations.

Forprivate,ornon-adoptedsystems,maintenancewillbetheresponsibilityoftheownerandfuture

developmentsmaybeaffectedbycovenants.

Forsystemsservingmorethanoneresidentialpropertyitisrecommendedthatmaintenance

shouldbetheresponsibilityofapubliclyaccountablebody,whichwilloftennecessitatethepaymentof

acommutedsumoralegalagreement,possiblybackedbythedepositofafinancialbond.

Theadoptingorganisationshouldapprovethedesignbeforeconstruction.

12

Introducing Ridgistorm-XL

13

2section

Ridgistorm-XL

Advanced technology from Polypipe

Ridgistorm-XL is the latest innovative

solution to SUDS and stormwater

management requirements.

Combined with the technical expertise,

knowledge and support of Polypipe

Water Management Solutions (WMS),

Ridgistorm-XL is designed as a bespoke

application for each project and offers

the most advanced large diameter plastic

pipe solution available in the UK.

14

900mm 1200mm1050mm

from750mm diameter

6 metres (typical)

Ridgistorm-XL*

Ridgistorm-XL

2.1 Bespoke Project DesignRidgistorm-XLisdesignedasabespoke

solutiontosuiteachindividualproject.

OurteamofDesignEngineersand

DrainageSpecialistsutilisethelatest

designandmanufacturingtechniques

to engineer a drainage system to your

exactrequirements.Thisflexibility

enablesustodesign-inrequired

elements such as inspection

chambersandmanholeaccess

atdeterminedintervals.

2.3 Jointing Ridgistorm-XLcanbedesignedtosuitany

jointingrequirementson-site.

• Electro-fusion. • Extrusionwelding.

• Rubberseals. • Flangeconnection.

(Seepage16fordetails).

2.2 Applications Witharangeofdiametersfrom

750mmto2100mm,Ridgistorm-XL

offersadurableandengineered

solution to large-scale attenuation

andpipelinerequirementsforusein:

• Surfacewaterdrainage.

• Large-scaleattenuationstructures.

• Specialistpipelineapplications.

• Foulsewers.

• Bespokelargediametermanholes

andchambers.

(Seepage17fordetails).

2.4 Bespoke Pipe Profile Providing Individual Stiffness Class Ridgistorm-XLcanbeengineeredto

suitanyapplication.Byanalysing

the site conditions and installation

parameters,ourDesignEngineers

can create a solution with the

appropriate profile strength and

stiffnessthatisneitherovernor

underengineered.Ourproduction

flexibilityallowspipestrengthtobe

producedatvaryingstiffnessclasses

tomeetthedesignrequirementsof

aproject.Thisremovestheneedto

step-uppipespecification.

(Seesection3forfulldetails).

2.5 Exceptional Leak Tightness Ridgistorm-XLisdesignedasaflexible

structure to minimise the effects of

groundmovementanddeformation

andpreventleakagefromthepipeline

orattenuationstructure.Exceptional

pipelineintegrityisachievedwith

Ridgistorm-XL due to the reduced

numberofjoints,thereforeminimising

thenumberofpotentialleakage

pointsandremovingtheriskof

groundwaterpollution.

* Based on standard 6m length, other lengths available on request

Concrete**

2.8 Standards and Approvals Ridgistorm-XLisapprovedby

WRc(seepage17fordetails)

and is designed to meet the

performancerequirementsof

theEuropeanSewerPipe

standardBSEN13476.

Ridgistorm-XL also meets the

requirementsofDIN16961.

Astheapprovalprocessis

ongoingpleasevisitourwebsite

for the latest information


or call 01509 615100.

• Able to withstand ground

movement without leakage

• Strong yet flexible design

• Superior hydraulic performance achieved through smooth bore

• Durable materials

• Excellent resist

ance

to sulphate and

chemical atta

ck

• 100% recyclable

up to 2100mm diameter

• Longer

pip

e len

gths f

or

impro

ved p

ipeli

ne

inte

grity a

nd fewer

join

ts

• Ex

celle

nt lo

ad b

earin

g

ca

pabi

lity

• Ideal for use as large-scale

attenuation system

15

1500mm 1800mm

**Based on 2.5m length concrete pipe

2section

2.6 Ridgistorm-XL versus Rigid Materials Ridgistorm-XLoffersarobust,durableandadaptablesolution

incomparisontorigidmaterialssuchasconcreteandsteel.

Duetoitslongerlengthsandlighterweight,Ridgistorm-XL

canbe70%cheapertotransportthanequivalentsize

concretepipesandcanbehandledand

storedmuchmoresafelyon-site.

(seepage19forfurtherdetailson

thebenefitsofplasticpipes).

2.7 Pipe Length Ridgistorm-XLcanbesuppliedin

anythingfrom1-6masstandard.

Longerlengthsmaybeavailable

onrequest.

PT/284/0609

2.9.2 Extrusion Welding

Pipesand/orfittingsarejointedwithanextrusionweldingdevice.Thejointingmethodcanbecarriedout

insideand/oroutsidethepipe.Thisjointingismostsuitableforlow-pressuregravitypipesandmanholes.

AccordingtoDVS2207part4.

16

Jointing

2.9 Multiple Jointing Options

Ridgistorm-XLcanbedesignedandmanufacturedtosuitanyjointingrequirementon-site.Electro-fusion

welding,extrusionwelding,flangeconnectionsandrubbersealconnectionscanallbeachievedwiththe

Ridgistorm-XLsystem,dependingontheinstallationandapplicationrequirementsoftheproject.

2.9.1 Electro-fusion

Thissystemisthepreferredjointsystemasthewholepipesystemeffectivelybecomesahomogeneousunit

and100%sealtightnesscanbeachievedtoguaranteeexceptionaljointandpipeperformance.Electro-fusion

wireisconnectedtothesocketendofthepipeduringmanufacture.Seefulldetailsinsection4.

Elecro-fusion wire

Extrusion weld

2.9.3 Rubber Seals

ThisconnectionusesthesocketandspigotjointingwithtwoSBRrubbersealswhichareinstalledintothe

spigotendofthepipeorfitting.Thismethodallowspipestobeseparatedinthefutureifneccessary.

Availablefor750-1200mmdiameterpipes.MeetstherequirementsofBSEN1277.

Nitratesealsareavailable,butaresubjecttoleadtimes.

Rubberseals

Flangeconnection

2.9.4 Flange Connection

Theendsofpipesandfittingsaremanufacturedwithcircularflanges,jointedwiththehelpofasteelflange

andrubbergasket.Thisisaspecialconnection,pleasecontactthetechnicaldepartmentforfurther

details on 01509 615100.

17

2section

2.10 WRc Approval

Ridgistorm-XLandallpipeprofileoptions,stiffnessclassesuptoSN2toSN8anddiametersfrom750

to2100mmareapprovedbyWRc.TheapprovalalsoextendstoallworkcarriedoutbyPolypipe’s

in-houseFabricationsDepartment,thedesignsoftwareusedtoengineertheproduct(forSN1-SN8)

andRidgistorm-XL’suniqueandpatentedelectro-fusionjointingmethod,whichcoversthetensile

strengthofeachjoint,thejointingmethodandPolypipe’sinstallationmanualandguidance.Asthe

approvalprocessisongoingpleasecontactusforthelatestinformationon01509 615100.

PT/284/0609

2.11 Applications for Ridgistorm-XL

Ridgistorm-XLpipescanbeengineeredtosuitawiderangeofapplications,frompipelinesforsurface

waterdrainageandfoulsewerschemes,toattenuationstructuresandlargediametermanholesand

chambers.Asavalueengineeredproduct,eachRidgistorm-XLpipeisdesignedtominimisematerialand

providecostsavingstotheclient.Ridgistorm-XLislightweightcomparedtotraditional,rigidmaterialsand

istypically6%oftheweightofanequivalentconcretepipe,makingiteasier,saferandquickertohandle

andinstall.Seecasestudiesofthefollowingapplicationsonpages64&65andfurtherrecentstories

at www.polypipewms.co.uk/projects/.

2.11.1 Surface Water and Foul Drainage Systems

Ridgistorm-XLpipescanbeusedinfoul,CSOapplicationsandsurfacewatersewersystemsforuse

underSection104AdoptionAgreement.Adoptionofthesystemshouldbecheckedwiththe

appropriatewatercompany.

18

2.11.2 Attenuation Structures

PolypipeWMScansupplybothsmallandlargescaleattenuationsystemstomeettheexactrequirements

ofaproject.Ridgistorm-XLattenuationsolutionsfeatureatankstructureengineeredandmanufactured

fromlargediameterpipeinarangeofsizesfrom750to2100mm.Theproductcanalsobepre-fabricated

withtheoptionofweldedendplatesorbespokemanifoldsbyPolypipe’sin-houseFabricationsDepartment.

Surfacewaterrun-offfromroofs,roadsorcarparkscanbestoredinbelowground,engineeredstructures,

readytoreleasewithinasetdischargelimit.TheStormcheck‘Vortex’FlowControlChamber(seepage67)

comprisesapre-fabricatedplasticchamberinarangeofdiameters,withanintegralvortexflowcontrol

devicetoallowprecisecontrolofsurfacewaterdischargeratesfromsite.Theingressofdebrisandsiltwithin

theattenuationstructureispreventedbyPolypipeSiltTrapswhichcanbedesignedandfabricatedfrom

Ridgistorm-XLlargediameterpipetosuitanydrainagescheme.

2.11.3 Soakaway/Infiltration

TheBuildingRegulationsApprovedDocumentH3,RainwaterDrainage,prioritisesanadequatesoakaway

asthefirstconsiderationforrainwaterdischarge(seepage10).Ridgistorm-XLpipescanbeperforatedto

suittherequirementsofanysoakawayorinfiltrationproject.

2.11.4 Rainwater Harvesting

Rainwaterharvestingtankscanbepre-fabricatedfromRidgistorm-XLindiametersfrom750to2100mm

todeliverarangeoftanksizes.Theseareidealforrainwaterre-useapplications,includingeducationand

commercialprojectsandbenefitfromoff-siteconstructionandarrivingon-sitereadyforinstallation.

2.11.5 Sea Outfalls

Ridgistorm-XLpipesareresistanttoseawater.Thismaterialstrengthcombinedwithitsuniqueandpatented

electro-fusionjointingsystemmakesRidgistorm-XLidealforseaoutfallprojectsasahomogenouspipeline

canbeachieved,guaranteeinganexceptionaljoint.

Applications

19

2section

2.12 Benefits of Plastic Pipes

2.12.1 Environmental BenefitsPlastics,whichfeatureamongthemostresearchedmaterialsintheworld,areanintegralpartof

sustainabledevelopments.Thinner,lighterandmorerobustthanmostrigidmaterialsthankstocontinuous

technologicalinnovation,plasticpipestypically weigh 94% less than their concrete equivalent.

Duetotheirlightweightnature,plasticpipesandfittingshelptoreduce energy use and therefore

greenhousegasemissions.

Usingplasticalsoreducestheneedforquarryingactivities,andbecauseoftheirlightweightnature,

plasticpipescanbetransported in greater volumesthantheirconcreteequivalents.Forexample,

1kmof900mmplasticdrainagepipesfromPolypipewillonlyrequire17 deliveries compared to concrete

pipeswhichwouldrequire29 deliveriestosite.Notonlywillthereducednumberofdeliveriesprovide

environmentalbenefits,suchasreduced CO2 emissionsbutthereductioninvehiclemovementson-site

also ensure that the associated Health and Safety risks are reduced.

Polypipeproducespipesandfittingsutilisingrecycledmaterialswhereappropriate,evenwhenthe

integrityofthesystemrequiresproductstobemanufacturedfromprimematerialstheproductsare

100% recyclableattheendoftheirusefullife.

ThetablebelowshowsacomparisonofCO2emissionsforplastics,concreteandmetalpipesfromcradle

(manufacture)togate(beforetransportationtotheconsumer).Forexample,theCO2 emissions for

1500mmdiameterconcretepipesat287.49/ftisoverthreetimesthatoftheplasticpipesevenbefore

deliverytotheconsumer.

High density polyethelene

Reinforced concrete pipe

Corrugated metal pipe

Pipe size (mm) WT/foot CO2/ft WT/foot CO2/ft WT/foot CO2/ft

300 3.34 6.69 93 20.65 10 28.20

375 4.74 9.49 127 28.19 12 33.84

450 6.59 13.19 168 37.30 15 42.30

600 11.30 22.59 264 58.61 19 53.58

750 15.83 31.65 384 85.25 24 67.68

900 20.35 40.70 524 116.33 36 101.52

1050 29.24 58.47 686 152.29 42 118.44

1200 32.05 64.10 867 192.47 65 183.30

1500 46.36 92.72 1295 287.49 103 290.46

Note: AllCO2productionislistedas‘cradletogate’.CO2Perunitdataobtainedfrom‘inventoryofCarbon&Energy(ICE)’,UniversityofBath,UK.ProjectwasfundedbytheCarbonTrust&EPSRC(Engineering&PhysicalSciencesResearchCouncil),theUKgovernment’sleadingfundingagencyforscienceandengineering.

Table 2.12-1ComparisonofCO2 emmissions

Benefits of Plastic Pipes

20

2.12.2 On-site BenefitsAsplasticpipesareinherentlylightweight they are quicker and easier to install than when

utilisingrigidmaterialssuchasclayorconcrete.Lighterplanthireisrequiredthereforeproviding

cost savings on-site.Furthercostsavingsareachievedaslighterplantremovestheneedfortemporary

accessworksandpreventsdamagetoroadsurfaces.Plasticpipescanbe70% cheaper to transport

thanequivalentconcretepipesduetotheirlongerlengthsandlightweight.Thelightweightnaturealso

providesexcellent Health and Safety benefitswhenconsideringthestorageandhandlingofpipes,

makingthembeneficialtoCDMcompliance,seepage44.

PolypipeWMSbenefitsfromitsownin-housefabricationsfacilitywhichallowsustoworkinpartnership

withourcustomerstoprovidebespokedrainagesolutions.Wearecommittedtodesigningoutcostand

thereforetimeon-site,throughtheeffectiveuseofpre-fabricatedsolutionsmanufacturedoff-siteand

deliveredreadyforinstallation.

2.12.3 Performance BenefitsTypically,Ridgistorm-XLpipesaresuppliedin1-6mlengths,althoughlongerlengthsarepossible.

Concretepipesareusuallysuppliedin1mor3mlengths.Usingplasticpipesensuresthat fewer joints

arerequiredalongthepipeline,thereforeminimising any potential leakage points.Theflexiblenature

of plastic pipes ensures that they are more tolerant to deformation and movement of the

surroundingsoilthanrigidpipes,furtherminimisingtheriskofleakage,akeyfactorwhenconsidering

theWaterFrameworkDirectiveEuropeanlegislationandthenewGroundwaterDirectivewhichputsa

reductionindiffusepollutionofgroundwaterasacriticalobjective.

21

2section

2.12.4 Plastic Pipe Solutions Benefits at a Glance

• Lowerdensityandweightthanrigidmaterials,solowertransportand installationcosts.

• Strongyetflexiblewithreducedriskofbreakage.

• StrongandlightweightprovidingexcellentHealthandSafetybenefits.

• Plasticpipeinstallationshavereducedleakagecomparedto rigidmaterialsbecauseoflongerpipelengthsandhigh-integrity jointsystems.

• Canbemanufacturedfromrecycledmaterials.

• Provensecondlife-100%recyclable.

• Abilitytouseas-dugmaterialsincertainapplications.

• Abilitytouseoff-siteconstructiontechniquestominimisecost andtimeon-site.

• Noncorrosive.

• Chemicallyresistant.

• Flexiblepipeprovidingincreasedabilitytowithstandgroundmovement.

• Highresistancetositedamageundernormalusageconditions.

• Structuredwallengineereddesignwithmaximumsystemstrengthbut minimumproductweightandcost.

Design

22

23

Our team of fully qualified Drainage

Specialists, Civil Engineers and

Technical Support experts provide

invaluable experience and knowledge

at design stage.

3section

24

Design

Fig. 3.1.1 Performancemechanisms

3.1.2 Comparedwithrigidpipes,flexiblepipesare

versatileandhaveimportantstructural

performanceadvantages.Unlikerigidpipes,

flexiblepipeshaveexcellentresistanceto

differentialsettlement.Plasticpipes,when

overloaded,willsimplydeform(figure3.1.2A)

furthertogenerategreaterpassiveearthpressures

untilthesystemregainsequilibrium.

Fig. 3.1.2 Overloadingeffect

B. RigidA. Flexible

B. RigidA. Flexible

B. RigidA. Flexible

B. RigidA. Flexible

As a consequence of the differing performance mechanisms, flexible pipes have structural

performance advantages over rigid pipe systems.

• Flexiblepipesofferexcellentresistancetodifferentialsettlement.

• Whenoverloaded,rigidpipesaresubjecttofractureandfailureofthesystem.Plasticpipes,

when overloaded, will deflect further to generate greater passive earth pressures until the

system regains equilibrium.

3.1.1 Failureofrigidpipesoccurswhenthevertical

loading exceeds its load capacity and causes

fractureofthepipewall(figure3.1.2B).In

order to perform satisfactorily the pipe must

thereforebestrongenoughtosupportthe

designloading,inadditiontobeinglaidona

stiffbeddingmaterial,whichmustultimately

support the loads transmitted through the

pipes.Thebeddingmustnotallowdifferential

settlementofthepipelinetooccur,sincethis

would result in stress concentrations in the

pipewallandresultinfailure.

3. Design Thissectionexplainsthestructuralperformanceofflexiblepipescomparedtorigidpipesanddetails

howRidgistorm-XLcanbevalueengineeredtositespecificrequirementsanddemonstratesgeneral

arrangementsoftheRidgistorm-XLsystemalongwiththeavailableunitsandfittings.

3.1 Pipe Structural Performance

Pipesaretypicallycategorisedasrigidorflexible,dependinguponthematerialfromwhichtheyare

manufactured.Rigidpipes,suchasconcrete,haveahighinherentstrengthandresistappliedloadingbya

bendingactionwithinthepipewalls.Theyaregenerallystifferthanthepipesurroundmaterial,inparticular

thesidefillandconsequentlysupportahigherloadthanthesidefillmaterial.Fordesignpurposes,theyare

generallyassumedtosupporttheentireverticalloadtransmittedthroughthebackfillmaterialplacedabove

thelevelofthepipecrown.(SeeFigure3.1.1B).

25

3section

3.1.3 Pipe DeformationThedeformationofflexiblepipesunderloadresultsintheovalisationofthepipe(typicallya1-4%

reductionintheverticaldiameterandanincreaseinthehorizontaldiameter).Asthehorizontaldiameter

ofthepipeincreases,itderivessupportfromthesidefillandtrenchwall.Thispassiveearthpressure

increasesasthepipedeformsfurtheruntilthepipe-soilsystemcomesintoequilibrium.

Furtherdeformationwillnotoccurthereafterunlessahigherverticalloadisappliedtothepipe-soil

systemorconsolidation(orcreep)ofthematerialsoccursoveralongperiodoftime.Itisinternationally

recognisedthatwhenapipeisinstalledinaccordancewithanappropriatecodeofpractice,increasesin

deflectionvirtuallystopsafterashortperiodoftime.Thedurationoftimeisdependentonsoiland

installationconditionsbutgenerallylessthantwoyears.

3.1.4 Serviceability LimitsDeformationofflexiblepipesmustoccurifthepipe-soilsystemistoreachequilibrium.

Thereforedeformationisnotdetrimentalbutanaturalactionallowedforinflexiblepipedesign.

Europeantestingonflexiblepipeshasshownthatpipedeformationsofmorethan30%can

occurinpracticewithoutsignsofstructuralfailure.

However,itisacceptedthatalimitonverticaldeformationisnecessarytoensureadequatelongterm

pipeperformance.Appropriatedeflection(serviceability)limitsshouldbesetonacasebycasebasis.

Forexample,greaterlimitsmaybeallowableinadeeplandfillinstallationcomparedtoapipeburied

atshallowdepthunderaroad.

DeflectionlimitswithintheUKvaries,dependingontherelevantadoptingauthority.Fordesignpurposes

theHighwaysAgencyspecifiesamaximumallowabledeformationof5%forthermoplasticstructuredwall

pipes,whilethewaterindustrytendstospecify6%.

Polypipe WMS are able to perform calculations using the design protocol EN1295, to design and

check that the pipe deformation will not exceed individual project requirements.

PolypipeWMSisuniqueinitsabilitytoproduce

large diameter pipe and attenuation solutions

tomatchyourexactrequirementsandsite

conditions.Theflexibilityofourmanufacturing

processenablesyoutospecifyexactstiffness

requirementsandutiliseavalueengineered

solutionthatisneitherundernoroverspecified.

3.2 Unique Pipe Stiffness Technology Providing Flexible and Variable Loading Specifications

Design

26

ProfiletypeVWenablesthe

production of a solid pipe with a

smoothinnerandoutersurface.

Thesepipescanbeproducedwith

awallthicknessof5mmto80mm.

VW profile

PipesproducedwithaPRprofileachieve

highstiffnesswithrelativelylowweight.

This is a common pipe profile for use

in sewer and surface water drainage

applicationsandattenuation.

PR profile

InadditiontothePRprofile,the

Olympiaprofileoptioncanachieve

greater pipeline stiffness with a

comparativelylowweight.

Olympia profile

Thisprofileoptionhasasmoothinnerandoutersurface,

includinginternalprofiletoonelayer.Highstiffnessisachieved

throughtheSQprofile,makingitidealforextremelyhigh

loadsorlargerdiameters.

SQ2offersthesamebenefitsasthesingle-layerSQprofile,

yetitcanbeproducedwithadditionalprofilelayersforadded

ringstiffnessandexceptionalloadingfordeepburialand

specialistapplications.

SQ2 profileSQ profile

3.2.1 Individual Pipe Profiles Followingmanyyearsofdevelopment,structuredwallpipetechnologyhasbeendesignedandengineeredtomaximise

thestrengthofthepipeline.Utilisingthelatestmanufacturingtechnologyandunique,stateoftheartsoftwareenables

PolypipeWMStocreateuniqueprofiledesignstomatchcustomers’siterequirements.Pipeprofiledesignscanbe

adaptedtomaximisestrengthandminimiseuseofmaterialwithinthepipeline,whichimprovespipelineperformance

andprovidesavalueengineeredsolution.

Ourbespokerangeofprofilesareintegraltothestrengthandperformanceofthepipeline.Optimisedwallthicknessandpipe

profiledesignensuresthatthepipelinecancopewithbothexternalandinternalpressuresandanysubsequentdeformation.

Ridgistorm-XLisdesignedasaflexiblestructuretowithstandimposedloadingandgroundmovementonceinstalled.

27

3section

3.3 Value Engineering HistoricallytheringstiffnessofplasticstructuredwallpipeshavetypicallybeenSN8toallowforall

projectrequirements.Inmanyapplicationsthisisoverspecified.TheflexibilityoftheRidgistorm-XL

systemallowssitespecificassessmentstobecarriedouttodeterminetheexactringstiffnessrequired

withapotentialprojectsavingofupto35%*onmaterialcosts.

AgranularbedandsurrounddetailisstandardfortheinstallationoftheRidgistorm-XLsystem.

However,byusingtheuniqueEasypipesoftware,PolypipeWMSareabletoengineeralternative

trenchbedandsurrounddetailstoensurethemostcosteffectiveandoptimumconstructiontosuit

eachindividualproject.TheWMSTechnicalTeamisabletoassistinperformingdesignchecksto

ensurethattheproposedpipedesignissuitableforthesitespecificconditions.

Unliketraditionalrigidpipesystems,flexiblepipesdonothaveaspecificcrushingstrengthbutaring

stiffness.Thereforethelongtermperformanceofaflexiblepipesystemistypicallybasedonamaximum

allowablepipedeformation(i.e.serviceabilitylimitstatestyleanalysis,asopposedtoultimatelimitstate

analysis;(refertopage25).

TheflexibilityoftheRidgistorm-XLmanufacturingprocessallowsengineerstoderiveaminimumpipe

specificationforanygivensiteconditionsandspecifiedperformancelimit;therebyallowingthe

specificationofaRidgistorm-XLpipetobeoptimisedtogivethemostcosteffectivesolution.

PolypipeWMSutilisesEasypipe,aproprietarysoftwarepackagetoderivetheoptimumRidgistorm-XL

unitpropertiesforanyproposedinstallation.Inextensiveuseacrosstheworld,Easypipeisbasedonthe

GermanAssociationforWater,WastewaterandWastestandardATV-DVWK-A127;3rdEdition;

‘StaticCalculationofDrainsandSewers’.

ItshouldbenotedthatATV-DVWK-A127istheestablishedmethodofstructuraldesignofburied

pipelines,referencedwithintheGermannationalannexofEN1295.Thesoftwareenablesmultipleload

casestobeanalysedsimultaneously,alongwithrealtimeassessmentofvariationsininstallation

parameters.PolypipeWMSarethenabletosupplyaprint-outfromEasypipe,detailingtheassumed

installationconditionsandtheresultsfromthevariousstructuralassessmentproofs.PolypipeWMSare

alsoabletoassistinundertakingdesignchecksinaccordancewiththeUKannexofEN1295-1.

3.3.1 Information Required Thefollowingdetailsarerequiredinordertoofferourvalueengineeringservice:

• Nativegroundproperties(i.e.stiffnessofthesoilinwhichthetrenchiscut).

• Imposeddeadload(i.e.depthanddensityoftheoverburden).

• Imposedliveload(i.e.loadsduetovehicletrafficking).

• Hydrostaticloads.

• Pipebeddingdetail.

• Specifiedallowablemaximumlimitofdeflection.

PleasecontactthePolypipeWMSTechnicalTeamforfurtherinformationon01509 615100.

*BasedontheaveragedifferencebetweenRidgistorm-XLSN2andSN86metrepipe.

General Arrangements

28

3.4 Ridgistorm-XL General Arrangements

TheRidgistorm-XLsystemmaybeutilisedinstandardpiperuns(betweenmanholes),ortoform

dedicatedstoragestructures.Wherestoragestructuresarerequired,Polypipe’sexperiencedFabrications

Teamareabletoofferawiderangeoffittingoptionstomeetclients’requirements.Thefollowingsection

offersaninsightintotherangeofstandardandbespokefittingsthatareavailablefromPolypipeWMS.

PleasefeelfreetocontactthePolypipeWMSTechnicalTeam,whowillbehappytodiscussthevarious

optionsavailable.

3.4.1 Standard Pipe Run

Whereadditionalstorageneedstobeincorporatedintoaproposed(orexisting)drainagesystem,the

systemlayoutmayallowengineerstooversizecertainpiperunstoformwhatarecommonlyknownas

‘tanksewers’.Table3.4-1summarisesthestoragecapacitiesofthecurrentrangeofRidgistorm-XLpipes:

3.4.2 Attenuation Structures

TheRidgistorm-XLsystemmaybeusedinvariousarrangementstoprovideaspecifieddesignstorage

structure.Variousmanhole,inspectionturretandpipeworkconnectionsareavailable.Dueconsideration

shouldbegiventoventilationofattenuationstoragesystemswhetherthisisviamanholesordedicatedvents.

Joint 1 Socket

Joint 2 Socket

Ridgistorm-XL dimensions and storage capacities

Pipe Ø(mm)

Standard lengthdim ‘x’ (m) Nominal O.D. (mm) Nominal storage

volume (m3/m) Nominal I.D. (mm)

750 6 766 0.460 883

900 6 914 0.656 1040

1050 6 1065 0.890 1215

1200 6 1200 1.130 1320

1500 6 1500 1.767 1646

1800 6 1800 2.544 1954

2100 6 2100 3.463 2302

NOTE:Basedonapiperingstiffnessclassificationof2.0kN/m2.ODwillvaryifotherringstiffnessclassificationisused.Unitlengthsarefrom2-6min0.25msteps.

Table 3.4-1 Ridgistorm-XL dimensions storage capacities

Figure 3.4.1Standardpipelength

29

3section

Please note: IllustrationsshownareavailableasdownloadableCADdrawingsfromwww.polypipewms.co.uk/downloads/.

1200mm Ø 90°end termination

1200mm Ø90° end termination

Assumed FGL

Assumed FGL

1200mm Ø cruciform chamber


IL

20006000

PLAN

ELEVATION

1050mm ØRidgistorm-XL unit


Dim ‘Y’

1050mm ØRidgistorm-XL unitInspection point

90° bend(incl 600mm Ø inspection point)

600mm Ø inspection point

1500mm Ø fabricatedmanhole



1500mm Ø fabricated manhole

1050/1050mm Ø equal T-junction

Unit Type ‘E’1050mm Ø 90°end termination


3000 6000

6000 40001500

Sump

InletInlet


1200mm Ø 90°end termination

1200mm Ø90° end termination

Assumed FGL

Assumed FGL



IL

20006000

PLAN

ELEVATION



Dim ‘Y’

1050mm ØRidgistorm-XL unitInspection point






1500mm Ø fabricated manhole

1050/1050mm Ø equal T-junction



3000 6000

6000 40001500

Sump

InletInlet


3.4.3 General Arrangement Example 1


Figure 3.4.3 Generalarrangement1

Figure 3.4.4 General arrangement 2

30

Unit Type ‘F2’(incl 1200mm Ø access point)




6000 6000

6000 40006000

4000

90° bend(incl 1200mm Ø access point)


Inlet/outletspigot

Inlet/outletspigot

CL

FGL

Dim ‘Y’

Dim ‘Y’

ILIL

CL

Unit Type ‘F2’(incl 600mm Ø inspection point)


Inspection point Access point



General Arrangements



31

3section

Unit Type ‘F2’(incl 1200mm Ø access point)










Inlet/ouletspigot

ILIL

CL CL

6000

6000 6000 6479

6000 4000




32

Bespoke Fabrications

3.5 Bespoke Fabrications

PolypipeWMShasadedicated,in-houseFabricationsTeam.CertifiedandfullytrainedbyTheWelders

Institute,thedepartmentmanufacturesandfabricatesbespokeattachments,bends,fittingsandchambers

toaccompanytherangeofwatermanagementsolutionsfromPolypipeWMS.

FabricatedsolutionsfromPolypipeWMSaredesignedtointegrateintoavarietyofotherapplications,

includingconcretechambersandsteelcarriagepipes.Reducersandbespokebendsalsofacilitatethe

integrationofRidgistorm-XLintoexistingdrainagenetworks.

WeofferavalueengineeredapproachtobespokefabricationswhichissupportedbyourTechnical

Departmentwhoprovidesoundadviceanddesignexperience.

3.5.1 Fittings

FabricatedCunit-Plan FabricatedCunit-Elevation

FabricatedTunit-Plan FabricatedTunit-Elevation

FabricatedBunit-Plan FabricatedBunit-Elevation


Figure 3.5.1 FabricatedCunit

Figure 3.5.2 FabricatedTunit

Figure 3.5.3 FabricatedBunit

33

3section

FabricatedFunit-Plan FabricatedFunit-Elevation

Ridgistorm-XL Storage Capacities

Unit Ø (mm)

Min spacing Dim Y(mm)

Unit Dimensions (mm) Volumes of Fabricated Items

W1 W2 W3 W4 W5 Z

750 500 1385 2265 2765 1885 1385 1385 1.000 1.594 1.374 0.834

900 500 1540 2580 3050 2040 1540 1540 1.445 2.345 1.994 1.298

1050 500 1715 2930 3430 2215 1715 1715 2.255 3.711 3.278 1.918

1200 500 1820 3140 3640 2320 1820 1820 3.257 5.315 4.681 2.624

1500 750 2395 4040 4540 2645 2145 2145 5.693 9.255 7.892 4.680

1800 750 2705 4660 5160 2955 2455 2455 8.991 15.877 12.932 8.286

2100 750 3050 5355 5855 3300 2800 2800 14.376 23.559 21.827 11.423

NOTE:Basedonapiperingstiffnessclassificationof2.0kN/m2

Table 3.5-1 Ridgistorm-XL storage capacities


Figure 3.5.4 FabricatedFunit

34

Manholes

3.5.2 Large Diameter Manholes Ridgistorm-XLpipecanbeusedintheconstructionofbespokelargediametermanholesforuseinboth

surfacewaterandfoulsewerapplications.TheRidgistorm-XLrangecanalsobemanufacturedwithintegral

manholeaccesstoofferacompletepipelinesolutionwithmaintenanceaccess.

Bespoke and Off-set Manholes/Catchpits TheflexibilityandadaptabilityoftheRidgistorm-XLsystem,alongsidetheexperienceandcapabilityofour

in-houseFabricationsTeamenablesustodesignandmanufacturebespokemanholestomeetsite

requirements.

Off-setmanholescanbeintegratedintoaRidgistorm-XLpipelineorattenuationsystemtoprovideeasier

maintenanceaccesstothesystem.Thisutilisesauniquestepfeaturewithintheconstructionofthemanhole

toreducetheneedfordirectaccessintothepipewithimprovedhealthandsafetybenefits,particularlyin

foulsewers.

TYPICAL INSTALLATION DETAIL

Manhole cover & Frame

Manhole Chamber

225mm Ø RidgidrainD/S Coupling

225mm Ø Ridgidrain pipe

Pre-cast Concrete Cover Slab

Min 150mm Concrete Bed & Surround

Manhole Benching

Polymer benching sheet

Manholechamber

225mm ØRidgidrainU/S coupling

Polypropylenedouble step-irons(optional)

225mm ØRidgidrainD/S coupling

225mm ØRidgidrain pipe

Benching sheetwelded to top ofhalf channel

225mm ØRidgidrainU/S coupling

Manholechamber

225mm ØRidgidrain pipe

225mm ØRidgidrainD/S coupling

Figure 3.5.5 Typical manhole installation detail

Figure 3.5.6 Typical manhole installation plan

35

3section

Ridgistorm-XLwall

Ridgistorm-XLwall

Min 150mm concrete bedand surround

Typical offset manhole installation


Double step irons

Double step ironsDouble

step irons

A

A

JointSocket

Joint 2Spigot

Chamberbase

Manhole Chamber

Chamberbase

Chamberbase

Pre-cast ConcreteCover Slab

Load RatedCover & Frame

Seating ringsFGL

Ridgistorm-XLwall

Ridgistorm-XLwall




Double step irons


step irons

A

A

JointSocket

Joint 2Spigot

Chamberbase

Manhole Chamber

Chamberbase

Chamberbase



Seating ringsFGL

Ridgistorm-XLwall

Ridgistorm-XLwall




Double step irons


step irons

A

A

JointSocket

Joint 2Spigot

Chamberbase

Manhole Chamber

Chamberbase

Chamberbase



Seating ringsFGL


Figure 3.5.7 Typical off-set manhole installation detail

Figure 3.5.8 Typical off-set manhole plan

Figure 3.5.9Typicaloff-setmanholesectionA-A

36

3.5.3 End Termination Inadditiontotraditionalmanolechambers,Polypipeareabletoofferalternativemethodsofterminatinga

Ridgistorm-XLpiperun;thefollowinggivesanumberofexamples.

3.5.4 Pipe with Lateral Connection Lateralpipeconnectionsmaybeincorporatedintostandardpipelength.

Inlet/Outlet

Min500

Joint 1

Access chamber

Min500

Joint 1

Inlet/Outlet

Inlet/Outlet

Joint 1

Access chamber

Joint 1

Joint 2

Dim L

Joint 1

Joint 2

Joint 3Joint 3

Joint 1

Joint 2

Dim L

Joint 1

Joint 2

Joint 3Joint 3

Pipe with Lateral Connection

Nominal unit diameter (mm) Lateral pipe diameter available

Allunitdiameters 150,225,300,400,500,600

NOTE:Spigotorsocketconnectionmaybeoffered,dependingonspecificationanddiameterofconnectingpipe.ContactthePolypipeWMSTechnicalteamforfurtherdetailson 01509 615100.

Figure 3.5.10 End Termination

Figure 3.5.11 Pipewithlateralconnection

Table 3.5-2

37

3section

3.5.5 Access/Inspection Points WheremanaccessisnotrequiredorundesirablePolypipeareabletoofferarangeofsmalldiameter

inspectionpointsincorporatedintotheRidgistorm-XLpiperun.

Inspection point

Joint 1

Dim L

Joint 2

Min 500

Joint 2

Joint 1

Fabricatedto suit

Inspection turret

Joint 1

Dim L

Joint 2

Min 500

Joint 2

Joint 1

Fabricatedto suit

Inspection turret

Inspection Points

Nominal unit diameter (mm) Inspection point diameter450 mm

Inspection point diameter600 mm

750 3 7

900 3 3

1050 3 3

1200 3 3

1500 3 3

1800 3 3

2100 3 3

NOTE:Additionalinspectionpointdiametersareavailableonrequest.


Figure 3.5.12 Inspection point

Table 3.5-3 Inspection points

38

Man Access

Joint 1

Dim L

Joint 2

Min 500

Joint 2Joint 1

Fabricatedto suit

Access turret

Joint 1

Dim L

Joint 2

Min 500

Joint 2Joint 1

Fabricatedto suit

Access turret

Man Access

Nominal unit diameter (mm) Man access diameteravailable (mm)

750 N/A

900 N/A

1050 N/A

1200 1200

1500 1200,1500

1800 1200,1500,1800

2100 1200,1500,1800,2100

NOTE:TheaccesspointdiametersindicatedinthetableareforthoseincorporatedintotheRidgistorm-XLdrainagerun.Alternativeaccessarrangementsareavailable.

Figure 3.5.13 Manaccess

Table 3.5-4 Manaccess

39

3section

Step Iron/Ladder Polypipeareabletoofferchambersincorporatingeithersrepironsoraccessladders.

B

A A

B

4035(13 x step irons)

Typical300

2500

250

1750

Max1750 Standard 4000 reinforced

220

GRP ladder Wall bracketWall bracket

Wall bracket

PLAN

PLAN

ELEVATION B-B

ELEVATION B-BELEVATION A-A

Stepironplan

Stepladderplan

StepladderelevationA-A

StepironelevationB-B

StepladderelevationB-B

Figure 3.5.14 Stepiron/ladder

40

Hydraulic Design

3.6 Hydraulic DesignVelocitiesandflowratesforthermoplasticstructuredwallpipescanbecalculatedusingeithertheManningor

Colebrook-Whiteequations.TheColebrook-Whiteequationformsthebasisofthisguideasithasbeenshown

toprovideaccurateresultsforawiderangeofflowconditionsandisthemethodcommonlyusedintheUK.

Analternativeapproachisrequiredwhenutilising

theColebrook-Whiteequationtodetermineeither

thepipediameterorhydraulicgradientvariables.

Hydraulic gradient (Sƒ)

Hydraulicgradientisgovernedbythepipeslope.

Pipe roughness (kS)

Ameanmeasurementoftheheightthatsurface

roughnessprojectsfromthepipewall.Measuredin

termsofanequivalentsandroughness.

Sewertypeandagewillinfluencethechoiceofpiperoughness.Exceptforcalculatinginitialflowconditions,

considerationshouldalsobegiventoenvironmentalfactors,suchassedimentandbiologicalslimedeposits.

Typicalvaluesofroughness(kS),foruseintheColebrook-Whiteequation,aregivenintable3.6-1.

Selected Roughness Coefficient Values (ks)

Suitable ks value (mm)

Material Good Normal Poor

Clean and new pipes

Twinwallpipeswithcouplingjoints 0.003 0.006 -

Standardpipeswithspigotsandsocketjoints,andO-ringsealsat6to9mintervals

- 0.06 -

Slimed sewers

Flowinghalffull,velocityapproximately0.7ms-1 - 0.6 1.5

Flowinghalffull,velocityapproximately1.2ms-1 - 0.15 0.3

ν = -2 (2gSfD)log10 x kS+2.51v 3.7DD√(2gSfD) Where ν=Meanwatervelocity

g=Gravity

Sf=Hydraulicgradient(hf/L)

D = Internal pipe diameter

ks=Piperoughness

v=Kinematicviscosity

However,certaincodesofpractice,suchasSewersforAdoption6thEdition(SFA),stipulatesaminimum

piperoughness,irrespectiveofthesewertype.

Where: Foulgravitysewerdesign kS=1.5mm(Clause2.12SFA)

Surfacewatersewerdesign kS=0.6mm(Clause2.13SFA)

Ascanbeseenfromtable3.6-1thesevaluesareveryconservative.Theverylowsurfaceenergyinherent

withthermoplasticpipes,makessignificantbiologicalgrowthoradhesionofothermaterialsunlikelyto

occur.Avalueof0.009isrecommendedfortheroughnesscoefficientwhenManningsequationisused.

AllchartsinthissectionarebasedontheColebrook-Whiteequation.

Q=νA

Where:Q=Flowrate(m3/s)

ν =Watervelocity

A=Cross-sectional

areaofpipebore

Kinematic viscosity (v)

Kinematicviscosityisaratiooffluidsviscosityanddensity.

Viscosity

Viscosity is independent of pressure and depends on

temperatureonly,therefore,valuesvaryaccordingtothetype

offluidanditsambienttemperature.

Fordesignpurposes1.141x10–6m2/smaybeused(Waterat15°C).Thevolumeofflowmaythenbe

calculatedusingthecontinuityequation.

Table 3.6-1Selectedroughnesscoefficientvalues(kS)

41

0section

41

3section

Hydraulic Design

Determiningthecorrectpipesize,gradientordischargecapacityusingtheColebrook-Whiteequationis

aniterativeprocess.Bothgraphicalandtabularmethodshavebeenpublishedtoassistinthe

determinationofapipeshydrauliccapacity.Typicallyachartortable,validforaparticularpiperoughness,

detailsfourdependantvariables(D,Sf,v&Q).Thereforeifanytwovariablesareknown,itispossibleto

determinetheremainingtwovariables.

ExtensiveworkhasbeencarriedoutinthisfieldbyH.R.Wallingford,whohavepublisheddatainatabular

format.(H.R.WallingfordandD.I.H.Barr;“Tablesforthehydraulicdesignofpipes,sewersandchannels”;

7thEdition,Volume1).

Table3.6-1,figures3.7.1and3.8.1aregraphicalexamples,basedontypicalroughnessco-efficientsused

instructuredthermoplasticpipedesign.

3.7 Hydraulic PerformancesRidigstorm-XLpipesbenefitfromasmoothinnerwall,providingsuperiorhydraulicperformancewhen

comparedwithrigidmaterialssuchasclayorconcrete.Seefig.3.7-1belowfordetails.

3.8 Abrasion ResistancePipesmanufacturedfromPolyethyleneorPolypropyleneofferfargreaterabrasionresistancethanalternative

materials.Thefollowinggraphshowstheabrasioncurveofvariouspipematerialsaccordingtotheresultsof

theDarmstadtprocedure.ThisgraphdemonstratesthesuperiorperformanceofPEandPPpipes.

Wall roughness kS

Inches

PE Clay Steel Ductile Concrete

3

2

1

0

Fig. 3.7.1 Hydraulic performances graph

Fig. 3.8.1 Abrasionresistancegraph

2.0

Abrasionin mm

Concrete pipeConcrete pipecoated GFK pipe

Clay pipe

PVC pipe

PP or PE pipe

Cycles

1.5

1.0

0.5

0 50 100 150 200 250 300 350 400 450

0.25

Abrasion resistance

Handling and Installation

42

43

4section

Ridgistorm-XL offers a robust, durable

and adaptable solution in comparison to

rigid materials such as concrete and steel.

Due to its longer lengths and lighter

weight, Ridgistorm-XL can be 70%

cheaper to transport than equivalent size

concrete pipes and can be handled and

stored much more safely on-site.

44


4. Handling and Installation Thissectioncoversthetransportation,handlingandinstallationoftheRidgistorm-XLsystem.

Ridgistorm-XLpipesandfittingsshouldbetransported,handledandinstalledinaccordancewiththerequirements

ofBS5995:Part6:1980and,forapplicablecontracts,theHighwaysAgencyManualofContractDocumentsfor

HighwayWorksandSewersforAdoption.

4.1 Health and Safety

UndertheConstruction(DesignandManagement)Regulations2007,unlesstheyareadomesticclient,

allpartiesinvolvedinconstructionorbuildingworkhavelegalduties.

These include:

Clients

• Checkcompetenceandresourcesofallappointees.

• Ensuretherearesuitablemanagementarrangementsfortheprojectwelfarefacilities.

• Allowsufficienttimeandresourcesforallstages.

• Providepre-constructioninformationtodesignersandcontractors.

Designers

• Eliminatehazardsandreducerisksduringdesign.

• Provideinformationaboutremainingrisks.

Contractors

• Plan,manageandmonitorownworkandthatofworkers.

• Checkcompetenceofalltheirappointeesandworkers.

• Trainownemployees.

• Provideinformationtotheirworkers.

• ComplywiththespecificrequirementsinPart4oftheRegulations.

• Ensurethereareadequatewelfarefacilitiesforworkers.

Itshouldbenotedthatadditionallegaldutiesareimposedwhereconstructionworkisnotifiable.

AllinstallationactivitiesshouldbecarriedoutobservingtherequirementsofTheHealthandSafety

atWorkEtc.Act1974;andTheManagementofHealthandSafetyatWorkRegulations1999.

Ridgistorm-XL Benefits for CDM Compliance

ApplicationsusingRidgistorm-XLWaterManagementSystemsareactuallybeneficialtoCDMcompliance.

Thisisbecausethesystemavoidsorreducesseveralrisksassociatedwiththeuseoflargediameterpipes.

SpecificadvantagesofRidgistorm-XLinthisrespectare:

• InstallationofRidgistorm-XLisquick–soopenexcavationtimeisminimisedandhigh

numbersofmanpowerandmachineryisreduced.

• Lightweightincomparisontorigidmaterialssuchasconcreteandsteel,makingRidgistorm-XL

easierandsafertohandleon-site.

4.1.1 Risk Assessment Contractorsarerequiredtosubmitamethodstatementwhichincludesamethodology

forinstallationandriskassessmentfortheworktobecarriedout.

Riskassessmentexamplesareavailabletoviewonwww.polypipewms.co.uk.

45

4section

4.2.2 Moffat Off-load Service

PolypipeWMSareabletodeliverRidgistorm-XLpipesusingaflatbedtrailerwhichwouldbechockedwith

woodtoenableacraneorforkliftoff-load.Alternatively,PolypipeWMSareabletodeliverusingaMoffat

off-loadingservice.WhereaMoffatoff-loadingserviceisutilised,thedriverwillprovideafulloff-load

serviceusingaMoffatforkliftandwilltransfertheRidgistorm-XLpipestothenearesthardstandingground.

Hardstandinggroundisrequiredforboththeoff-loadingandstorageofRidgistorm-XLpipes.Pleasestate

yourinterestinthisserviceatthetimeoforderplacement.

4.2.3 Method for Self Off-load and Safe Storage On-siteItisthecontractor’sresponsibilitytoensureHealthandSafetymeasuresareinplaceandriskassessments

arecarriedoutpriortoselfoff-loadandstorageon-site.Seeexampleriskassessmentsat

www.polypipewms.co.uk.

Thefollowingoff-loadingmethodisrecommended.Mechanicalliftingequipmentthatliftstoaheightof

5.2mmustbeusedtounloadpipes.Sitesmustconsiderworkingatheightregulationswhenaccessinga

trailertoplaceliftingslings.

1. PleasecarryoutanappropriateHealthandSafetyRiskAssessmentforyoursite.

2. Beforepreparingtounloadcheckthattheloadhasnotmovedduringtransitandthatallwedgesand

bandingaresecurelyinplace.

3. Loadstrappingmustremaininplaceuntiltheliftinggearisinplace.

4. Loadsshouldbeliftedwiththeuseofappropriatenylonslingsandcarriedoutbyproperly

certifiedpersonnel.

5. Inspectunloadedpipesanddeemthemtobeacceptableandthatnodamagehasoccurred.

Anypipesthatareconsideredunsatisfactoryforinstallationshouldbeseparatedfromthedelivery

andaPolypipeWMSagentcontacted.

6. WhenstoringRidgistorm-XLpipesandfittingsitisnecessarytoensurethattheyarestoredonflat

ground,freeofstonesandothersharpobjectstoavoidanypointloading.

7. Ifstackinginmultiplelayers,ensurepipesinhigherlayersarerotatedto180°tothosebelowsothat

thesocketsoftheupperlayerarenotlyingdirectlyoverthesocketsoverthelowerlayer.

8. DonotstackRidgistorm-XLpipesmorethan2.4mhigh.Usewoodbearingsupportsbetweeneach

pipetoensureevenloaddistributionandchockstopreventpipesfromrolling.

Lengths Delivered per Load

Diameter (mm) No. of 6m pipe lengths

750 18

900 8

1050 8

1200 8

1500 4

1800 2

2100 2

Table 4.2-1Numberofpipesdeliveredpervehicle

4.2 Handling

4.2.1 Transportation and Delivery of Ridgistorm-XL Pipes

WhenRidgistorm-XLpipesaredeliveredtosite,thedrivermustreporttothesiteofficeandawait

instructionsfromthedesignatedindividualon-sitebeforeanyunloadingactivitiescanbeundertaken.

• Thedriverwillabidebysiterulesatalltimes.

• Thecontractormustbeinattendanceduringoff-loadingactivitiesandberesponsibleforselfoff-load.

46

4.2.4 Method for Safe Handling On-site

Ridgistorm-XLpipesarerobust,lightweightandeasytohandleon-site.Howeverpleasetakecaretopreventdamage,

i.e.pipesshouldnotbethrown,draggedordropped.Ifpipesareremovedbyrolling,pleaseensuretheyare

adequatelysupportedalongtheirlength.

Whenlifting,pipesshouldbesupportedattwoplacesalongthelength.Ideally,protectedslingsshouldbeused,

however,ifmetalhooksorchainsaretobeusedthenpaddingshouldbeplacedbetweenthemandthepipes.

Movementofpipeson-siteshouldbeinamannernotdetrimentaltothepipes,inanyway.

4.3 Installation

4.3.1 PipeInstallationDetail

Unlessasitespecificinstallationdetailhasbeenassessedattheinitialdesignstage(Refertosection3.0),Polypipe

recommendthattheRidgistorm-XLsystembeinstalledinaccordancewiththefollowinginformation.Adverseground

conditionsmayrequireadditionalmeasurestomaintainpipesupport(i.e.reinforcementofthetrenchbasethrough

soilimprovementtechniquesortheuseofgeosyntheticreinforcement).

Pleasenotethatadoptingorapprovingauthoritiesmayhavespecificinstallationrequirements;theinstallershould

thereforeverifythatthefollowinginstallationmethodwouldbeacceptablebeforeconstructionactivitiescommence.

4.3.2 TrenchPreparation

Trenchesshouldnotbeexcavatedtoofarinadvanceofpipeinstallationandshouldhaveadequatesupporttocomply

withhealthandsafetyrequirements.Trenchesshouldbeasnarrowaspracticable,whilestillmaintainingsufficient

spacefortheoperationofappropriatecompactionequipment,oraccessforsitepersonal(i.e.ifrequiredduring

electro-fusionjointing).Thetrenchwidthwilltypicallycorrespondtothepipeouterdiameter,plusanadditional150

–750mmeithersideofthepipe;theexactdimensiondictatedbypipediameterandassumedinstallationconditions.

Wheremultiplepipesareinstalledinatrench,sufficientspaceshouldbeallowedbetweenadjacentpipestoensure

thatmaterialcanbeplacedandcompacted.

Thetrenchbaseshouldbeassessedtoensureithassufficientbearingcapacityandmeetstherequiredlevel/gradient.

Anysoftspotsshouldbeexcavatedandfilledwithasuitablecompactedgranularmaterial.

Watershouldnotbeallowedtoaccumulateinthetrench.

Adequateprovisionshouldbemadefortheremovalofgroundwater,toaconsenteddisposalpoint,beforeand

duringinstallation.

4.3.3 PipeBedding

Thebeddingmaterialislaidbelowthepipetoprovideuniformsupportandtopermitsmalladjustmentsofthepipe’s

lineandlevel.Incaseswherethe‘asdug’materialissuitableaspipesurround,importedbeddingisnotrequiredand

thetrenchbottomshouldbeloosened.Otherwiseaminimum150mmbeddingdepthofgranularmaterialshouldbe

placedandcompactedinthetrenchbottom.Ifrequired,depressionsshouldbeformedwithinthebeddingmaterial

toaccommodatepipesocketsorcouplers.

Bricks,stones,blocksofwoodorothersimilarobjectsshouldnotbeplacedbelowthepipe,tofacilitateadjustment

oflineandlevel;asthismaycausehighlocalstressconcentrationsandpipedeformations(i.e.objectstemporarily

placedbeneathapipewhilebeddingisaddedorrearranged,willrapidlybecomecovered,difficulttolocateand

easilyforgotten).

PipesshouldbejointedinaccordancewithPolypipeWMSrecommendations,(Refertosection4.5).

Airtestingisrecommendedpriortoplacementofthesidefillandbackfillingtoensurecorrectworkmanship,

(Refertosection4.6).


47

4section

4.3.4 SidefillPlacement

OnceapipesectionhasbeenlaidandsuccessfullytestedinaccordancewithBSEN1610,anydepressions

formedinthebeddingmaterialtoaccommodatesocketsorcouplersshouldbereinstated,ensuringthatno

voidsareleftaroundthejoint.Pipesurroundmaterialshouldbeevenlyplacedacrossthewidthofthetrench

in150-300mmlayers**,inaccordancewiththedesignandspecification.A95%degreeofcompaction

shouldbeachievedunlessotherwisespecifiedwithinthestructuralassessment.Materialshouldbeplacedin

suchamanorasnottodislodge,distortordamagethepipe.Careshouldbetakentoensurethatfill

materialisplacedandcompactedbeneaththehaunchofthepipebeforeplacementandcompactionofthe

remainingsurroundmaterial.Compactionplantshouldnotbepermittedtocontactthepipe.Trench

supportsshouldbeprogressivelyremovedduringplacementofthesidefillmaterial,therebyallowingsidefill

tobecompactedagainstthenativesoil.Wherethisisimpractical,itshouldbenotedattheinitialdesign

stage.

**Requiredcompactionlevelsmaybeachievedthroughanappropriatemethodofwork,relatedto:

• Fillmaterialspecification.

• Thicknessofplacedlayer.

• Compactionplantbeingusedalternatively,ifrequired,compactionmaybeverifiedbyin-situtests.

4.3.5 Backfill Placement

Materialshouldbeplacedandcompactedaminimum150mmabovethepipecrown;compactionplant

shouldnotbeuseddirectlyabovethepipeuntilsufficientlayersofbackfillmaterialhasbeenplaced.

Backfillingofthetrenchshouldbeundertakenafterthesuccessfulcompletionofthepreviousoperations.

Unlessotherwisedescribedinthespecification;Class1,2or3fillmaterialinaccordancewithSHWSeries

600maybeplacedandcompactedinlayersnotgreaterthan300mmthick.Nostoneorsoilparticle

exceeding40mmindiametershouldbeusedwithin300mmofthepipecrown(i.e.Class8fillmaterialin

accordancewithSHWseries600).

4.4 Typical Installation Details

4.4.1 Minimum Cover Depths

PolypipeWMSrecommendsthefollowingminimumdepthsofcover:

• 1.2mfromthecrownofthepipetothesurfaceunderroadssubjecttoHighwaysAgencyrequirements.

• 0.9mfromthecrownofthepipetothesurfaceunderroadsnotsubjecttoHighwaysAgencyrequirements.

• 0.6munderfieldloadingconditions.

Reducedcoversdepthsmaybeallowable,subjecttospecificdesign.Itshouldbenotedhowever,thatthe

relevantadoptingAuthoritymayhavespecificinstallationrequirements.ForExampleSewersforAdoption

6thEditionstipulatesthatsewerslaidwithinahighwaymaintainaminimumdepthofcoverof1.2manda

depthof0.9minallotherareas.

48

4.4.2 Maximum Burial Depths

TheflexibilityoftheRidgistorm-XLsystemissuchthatpipesaredesignedtomatchtheexactsiteconditions.

TheperformanceofRidgistorm-XLpipeisinfluencedby:

• Nativegroundproperties(i.e.stiffnessofthesoilinwhichthetrenchiscut).

• Imposeddeadload(i.e.depthanddensityoftheoverburden).

• Imposedliveload(i.e.loadsduetovehicletrafficking).

• Hydrostaticloads.

• Pipebeddingdetail.

• Specifiedallowablemaximumlimitofdeflection.

4.4.3 Typical Installation Detail (applicable for drainage and attenuation)


Figure 4.4.2StandardRidgistorm-XLinstallation-detail2

Class 8 material in accordance with Series 600 SHW


Either Class 1, 2 or 3 material in accordance with SHW 600, (unless otherwise detailed in the specification)

Well compacted single sizecoarse aggregate in accordance with BS EN 13242; Clause 4.3.2. Grading 4/10 6/14 or 10/20


Granular bed and surround material to be placed and compacted to achieve a minimum proctor density of 95% (unless otherwise stated in the specification)



Reinforced concrete slab (by others)

Granular pip bed and surround material (to S.H.W. Clause 503.3)

Concrete bed and surround (by others)

Ridgistorm-XL unit

Ridgistorm-XL unit

150Min 150

Min 150

Min 150

Min 150

Min 150 Min 100

Min 150

Min 150Min 150

883

883

Unit I.D.

Unit I.D.

Dim ‘Y’

Finished G.L.

Finished G.L.

Min 150 if pipe 900Min 425 if pipe 1200Min 500 if pipe 1200





Min 150

ELEVATION B-B












Ridgistorm-XL unit

Ridgistorm-XL unit

150Min 150

Min 150

Min 150

Min 150

Min 150 Min 100

Min 150

Min 150Min 150

883

883

Unit I.D.

Unit I.D.

Dim ‘Y’

Finished G.L.

Finished G.L.






Min 150

ELEVATION B-B

Figure 4.4.1StandardRidgistorm-XLtrenchwithsinglepipeinstallation-detail1

49

4section

Figure 4.4.3Ridgistorm-XLinstallation-detail3

Figure 4.4.4Ridgistorm-XLinstallation-detail4

Wheninstalledwithagranularbedandsurround,Ridgistorm-XLpipesrequireaminimumdepthofcover

tobemaintainedabovethepipecrown,section4.4.1.Wherethesecoverlevelscannotbeachieved,

protectivemeasuressuchasdetail3(reinforcedconcreteslab)and4(concretebedandsurround)should

beused.TheConsultingEngineerandapprovingauthorityshouldbeconsultedwhendeterminingthe

mostappropriatemethod.












Ridgistorm-XL unit

Ridgistorm-XL unit

150Min 150

Min 150

Min 150

Min 150

Min 150 Min 100

Min 150

Min 150Min 150

883

883

Unit I.D.

Unit I.D.

Dim ‘Y’

Finished G.L.

Finished G.L.






Min 150

ELEVATION B-B












Ridgistorm-XL unit

Ridgistorm-XL unit

150Min 150

Min 150

Min 150

Min 150

Min 150 Min 100

Min 150

Min 150Min 150

883

883

Unit I.D.

Unit I.D.

Dim ‘Y’

Finished G.L.

Finished G.L.






Min 150

ELEVATION B-B

50

Electro-fusion Jointing

4.5 Unique, Patented Electro-fusion Joint PolypipeWMSofferstheonlylargediameterplasticpipesolutionwithintegralelectro-fusionjointing.

Electro-fusionwireisconnectedtothesocketendofthepipeduringmanufactureandsuppliedwitha

uniquebarcodecontainingthesettingsandinstallationparametersforthepipe.

Oncethetwoconnectingpipeshavebeenbroughttogether,internalandexternalsupportringsareapplied

toapplypressuretothesealduringthejointingprocess.

Theelectro-fusionwireisthenconnectedtoanelectricalsupplywhichjoinsthepipestogether.Usingthe

electro-fusionjointingmethod,100%sealtightnesscanbeachievedtoguaranteeexceptionaljoint

andpipeperformance.

Incomparisonwithotherlargediametersystems,Ridgistorm-XLcanbehandled,jointedandinstalledmuch

quicker,resultingintimeandcostsavingson-site.

Health & Safety Benefits

Electro-fusionjointingoffersimprovedhealthandsafetybenefitsovertraditionaljointingmethodsreducing

theneedtoworkwithinconfinedspaces.On-site,Ridgistorm-XLcanalsobejointedatthesideofthe

trenchbeforebeingcranedintoposition,reducinghealthandsafetyrisksduringinstallationandspeeding

upinstallation.

51

4section

4.5.1 Equipment Requirements (depending on site conditions)

• 415v3Phasegeneratorwith(preferably15kva)outputormainspower*.

• PolypipeElectro-FusionControlUnit*

(pleasenotethatthesystemdoesnotworkwithastandardUKECU).

• Polypipetransformer*.

• Alcoholcleaningfluid(99.9%alcohol).

• Dry,lintfreecleaningcloths.

• Aninternalsupportring(forsizes900mmandabove).

• Anappropriatelysizedoutertensionclamp.

• 5mmAllenkey.

• Wreckingbar/steelbarfortighteninginternalsupportingring.

• OuterTensionClamptighteningdevice.

• Weldingadapter*.

• Suitablelifting/manoeuvringplant/straps.

• Waterproofmarkingpen.

• Hammer.

• Meansofcommunicationbetweenalloperatives.

• Dewateringequipment(ifgroundwaterpresent).

Note:*Twowillberequiredfor1500mmandabovepipesizesifjointingsimultaneously.

4.5.2 Preferable

• Clean,drybaseboardsorgroundsheets.

• Weldingshelter.

• Torch.

4.5.3 Pre-joint Checks

• Allequipmenttobeclean,ingoodcondition,regularlymaintainedandwithincalibrationorservicedates.

• Checkthattheinnerandoutertensionclampsareingoodcondition.

• Ensurethatthegeneratorhassufficientfuelforthedurationoftheelectro-fusionprocess.

• Donotstarttheprocessunlessitcanbecompletedinonego.

The following four pages outline and explain the electro-fusion jointing process in easy to follow steps

52

Electro-fusion Jointing

4.5.4 Do

• Understandtheelectro-fusionprocess.

• Ensurethattheoperativesarefamiliarwiththeequipmenttobeused.

• Alwaysusetheoutertensionclampingband.

• Usetheinternalsupportingringforsizes900mmandabove.

• Observecorrectfusionandcoolingtimes.

• Allowallofthealcoholcleaningfluidtoevaporatebeforeassemblingthejoint.

• Providingthatthecorrectliftingequipmentisavailable,considerfusingthejointsoutofthetrench

andlowerthepipeintoplacelater.

• Protecttheweldingareaagainstdirt,humidityanddirectsunlight.Itisgoodpracticetouse

aweldingshelteratalltimes.Itisessentialtouseashelterindamporwetconditions.

• Useabaseboardorgroundsheettoprotectagainstdirtanddamp.

• Ifambienttemperaturefallsbelow10degreesuseoneormorepre-heatcycles(seetable4.5-1below).

• Riskassessmentsandworkinginconfinedspaceregulationsshouldbeadheredto(seeexamplerisk

assessment at www.polypipewms.co.uk).

• Oncethefirstpipeisinposition,supportofthepipecanbeachievedbycompletingthepipe

bedsurround.Thiscanbedoneforallupstreampipesoncethejointingprocessforeachpipe

iscomplete.

• Checklineandlevelsoftheinstallationatregularintervals.

• Protectthepipefromdamagewhenusingforcetopushthepipestogether.

• Ifthepipesdonotgotogethereasily,placeabandaroundthespigot,heattheareaandtighten.

• Ifairtestfailsrepeatelectro-fusionprocess.(Ifairtestfailsaftercompletingelectro-fusionprocess

twice,contactaPolypipeWMSagent).

4.5.5 Do Not

• Donotstartanyelectro-fusionjointifitcannotbecompletedwithoutinterruption.

• DonotpositiontheECUinthetrenchoruseitinpotentiallygaseousatmospheres.

• Donotusedirtyorcontaminatedfittings.

• Donottouchpreparedsurfaces.

• Donotpreparefittingsuntilimmediatelybeforetheyaretobeused.

• Donotallowthejointingareatobecomewetordamp(considerationshouldbemadeforgroundwater).

• Donotbackfillthejointuntilitisdeterminedsatisfactory.

• Donotcarryoutelectro-fusionjointingifambienttemperatureisbelow5°C.

Welding Preheat Intervals

DN (mm) Welding Voltage Preheat Interval Sec.

750 28 400

900 39 400

1050 40 400

1200 43 450

1500 32 500

1800 40 500

2100 40 600

Table 4.5-1 Electro-fusion welding parameters for preheating

53

4section

4.5.6 Jointing

• Withthepipestillsuspendedjustabovethetrenchbed,locatetheoutertensionclampintothegroovearoundthe

socketendofthepipetobeweldedandtightenoneoftheAllenboltsontheclampbracket,justenoughtoholditin

place.Makesurethattheclampbracketisapproximately250mmfromtheelementwireswiththefreeendfacingaway.

• Orientthepipeinthetrenchsothattheendsofthefusionelementareinaconvenientplacetoweld.Forpipes

upto1200mmthereisonecontinuouselementanditislikelythatthebestorientationwillbewiththeelement

endsinthe‘12o’clock’position.Forpipesof1500mmandabove,therearetwoelementswiththeends

diametricallyopposed.Thelikelybestorientationforthesepipeswillbeatthe‘3o’clock/9o’clock’position.

Onceorientationhasbeendecideduponensurethatallsubsequentpipesinthestringareallorientedthesame

way.Thiswillhelptoreduceanyissuesassociatedwithpipeovality.

• Usingasuitablebaseboardorgroundsheet,movethepipeendswithinafewfeetofeachother.Considerputting

aboardorgroundsheetundertheoppositeendofthepipetoo,tosimplifythenextjoint.

• Forsizes900mmandabove(notrequiredfor750mmpipe)positiontheinnertensionringinsidethe

mouthofthespigot,about20mmfromtheendofthepipeandtightenbyhanduntilitjust‘nips’

intoplace.Donottightenyet.Removetheprotectivewrappingandinspectthepipeendsfordamage.

• Usingseparatecleanandlintfreecloths,cleanthesocketandspigotofthetwopipestobejointed(see pic 1).

Measuretheinsertdepthofthesocketandmarkthisatintervalsaroundthespigotwithawaterproofpen.

Ensurethatallofthealcoholevaporatesfromthepipeends.Donottouchthepreparedsurfacesorallowthem

tobecomedirtyorwet.

• Ensurethatthefusionelementendsdonottoucheachotherandbendthemovertheoutsideofthespigot,

facingawayfromthejoint.Thisensuresthattheydonotbecomesnaggedwhilstassemblingthejoint.

• Pushthespigotendintothesocket(see pic 2),ensuringthatthewireendsarenotdisplaced.Ifusingmechanical

assistanceensurethatthepipeendbeingpushedissuitablyprotected.Pushthejoint‘home’untilthepreviouslymade

penmarks‘meet’thesocket.Ensurethatbothpipesarestraightandtrue,withnobending.Itmayhelpto‘rock’the

pipeswhilstmechanicalpressureisapplied.Ifrollingofthepipeispossibleusechockstopreventitdoingso.

• Enterthepipefromtheopenendandmovetothejointingarea.Ensurethatthepreviouslyinsertedinnersupport

ringisapproximately20mmfromthejointandfullytightenusingawreckingbarorsteelbar(see pic 3).

• ‘Backoff’tighteningtool.SlackentheAllenboltontheexternaltighteningbandandfitthetighteningtool

(see pic 4).Thisisdonebyslippingthefreeendofthebandintothe‘nose’ofthetoolandalsointothecentre

jawsection.Slidethetoolalongthefreebandingenduntilthenosepushesagainsttheclampbracket.Pushthe

toolagainstthepipesothattheshortclampingleverispressedagainstthepipewhichcausesitto‘nip’the

tighteningband.Alternatively,holdtheclampingleverwithonehandandtightenwiththeother.Tightenthetool

(see pic 5).Onceithasgrippedtheband,theclampinglevercanbereleasedandthetoolcanbeangledaway

fromthepipeslightlytofacilitatetightening.

Pic. 1 Pic. 3Pic. 2

54

Electro-fusion Jointing Process

• Finally,tightentheAllenkeystoavoidslipping.Ifafittingorshortlengthofpipeisbeingwelded

restrainitsothatthereisnopossibilityofmovingduringtheweldingprocess.Onpipes1500mmand

above,thetwoweldscanbedoneconsecutivelyorsimultaneouslyiftwoElectro-FusionControlUnits

(ECU’s)areavailable.

• Trimthewireelementendstoapprox80mm/3”andconnecttheadaptorblock.Connecttheterminalsof

the(ECU)totheadaptor(see pic 6).Theterminalscanbefittedeitherway.Ensurethattheweightofthe

leadsdoesnottwistorbendthewireelementendstowardseachother,causingashort-circuit.Positionthe

ECUoutofthetrenchandawayfromgaseousatmosphere.

• PlugtheECUintothetransformerandthetransformerintothegeneratororother415vthreephase

supply.Startthegenerator,allowtostabiliseandturnontheECU.Thegeneratorshouldbepositionedso

thatexhaustfumesdonotenterthetrench.

• Entertheweldingorpreheating**parametersintotheECUbyscanningthelabelonthejointwiththe

barcodewand(see pic 7).Passthewandoverthebarcodeonthestickeronthepipeendquitebriskly.

Themachinewillbeep,pleasenotethattonesmayvary.Ifareadingcannotbemadeusethe

appropriatebarcodeonthesuppliedsheetorenterthedetailsmanually(seeseparateinstructions).

Ensurethatthereaderwandisreplacedinitssheathforprotection.

Note:**Continuewiththeweldimmediatelyafterpreheating.

• Checkthatthescreenshowsthecorrectweldingparametersandifso,pressthegreenbuttontoaccept

(see pic 8).

• TheECUasksifthepipehasbeenscraped.Pressthegreenbuttonfor‘yes’(Scrapingisnotnecessaryas

contaminationisremovedduringthecleaningprocess).Weldingwillnowstart.Donotallowthepipes

orequipmenttomoveduringthefusionprocess.

• Atapointapproximately75%intotheweldingtime,retightentheoutertensionband.

• WhenthefusiontimehasfinishedtheECUwillbeep.Waitfor10minutesbeforetheterminalendsare

removedordisturbed.Allowthejointtocoolforanother30minutesbeforeremovingtheclamps.

DONOTassemblethenextjointwhilstthepreviousjointcools.ItMUSTremainundisturbed.Ifsite

conditionsallowandthereareenoughouterandinnerringsavailablethenitmaybepossibletosave

timebyassemblingseveraljointsinonestringandthenweldconsecutively.

Pic. 5

Pic. 7

Pic. 6

Pic. 8

Pic. 4

55

4section

Welding Parameter for Electro-fusion Socket

Diameter Voltage Time in secs. at one element Voltage Time in sec.

at two elements

DN750 28volt 1020secs - -

DN900 39volt 720secs - -

DN1050 40volt 1200secs - -

DN1200 43volt 1260secs - -

DN1500 - - 32volt 1020secs

DN1800 - - 40volt 900secs

DN2100 - - 40volt 1230secs

Pleasenote:Timesstatedaboveareapproximateonly.Visiblesignofweldingcompletionisthemeltingplasticprotrudingfromthesockettowardstheweldingwire(seeFig.4.5.4).

Fig. 4.5.2 Diagram showing the position of tools during electo-fusion process

Fig. 4.5.4Visiblesignofweldingcompletion

Table 4.5-3Weldingparametersforelectro-fusionsocket

Socket

Tension ring(larger as DN800)

Heating wire

Tightening strap(outside)

Welding adapter

Spigot

56

Testing

4.6 Recommendations on Pressure Testing

Ifrequired,structuredwalledthermoplasticpipesmaybetestedusingaconventionalairtestinaccordance

withBSEN1610.

4.6.1 Air Test Method

1. Blocktheendsofthepipe,includinganybranches,usingsealed,expandingstoppers/inflatablebungs.

2. FillaU-tubemanometerwithwatertothecorrectlevel,ensuringthattherearenotrappedair

bubblesinthewater.

3. Connectthemanometertotheappropriateportofoneofthestoppers.

4. Increasethepressureinthepipeuntilapressureof100mmofwater(0.01Bar)isreached.

5. Allowthepressuretostabiliseforseveralminutes,increasingthepressureto100mmheadofwaterifitdrops.

6. Recordanychangeinpressureovera5minuteperiod.Withoutfurtherpumpingitshouldnotdropbelow75mm

headofwater.Airtestproblemsaregenerallyduetofaultyequipmentortestproceduresandthefollowingadvice

maybeofassistance.

• AlwaysinstallpipesinaccordancewithPolypipeWMSrecommendationsandtheapplicablespecification.

• Checkthatthetestequipmentdoesnotleakandisinproperworkingorderbytestingashortlengthofpipe

submergedinawaterbath.

• Ensurethattheteststoppers,tubesandpumpareingoodconditionandthatallsealsarecorrectlyfitted.

• Ensurethatthepipeboresarefreefromdirtanddebristhatcouldaffectsealingofthetestbungs.

• Ensurethattheteststoppersareplacedtightly,squarelyandinthepipebarrel,notthefittings.

• Ensurethatallopeningsareproperlysealed,includingthosetobeburiedunderground,priortotestingand

backfilling(e.g.gulleyandlateralpipeconnections).

• Althoughconvenient,theairtestismoresensitivethanwatertestsandfailureisnotconclusive.Theairtest

isverysensitivetotemperaturechangesandmustnotbeperformedunlessthepipetemperatureisstable.

• Failuresduetotestingimmediatelyafterbackfillingapipethathaspreviouslybeenheatedinthesunare

common.A1ºCtemperaturechangeintheairinsidethepipewillresultinapressurechangesufficient

forthetesttofail.

57

4section

4.7 Maintenance

Structuredwalledthermoplasticpipesystemsdonotrequireroutinemaintenance.However,wherethe

designflowsthroughapipesystemisinsufficient,longtermdepositionofsiltand/orsolidsmayoccur.

Maintenanceisthereforenormallylimitedtode-silting/solidsremoval.

4.7.1 Access

Accesstothesystemshouldbeprovidedbyconventionalmeanssuchasmanholes,catchpits,inspection

chambersorroddingpoints.

4.7.2 Water Jetting

ItisrecommendedthatwaterjettingoperationsfollowstheprocedureslaidoutwithinSewerJetting

CodeofPractice,2ndEdition(WRc,2005).Observingallotherrelevantpiecesoflegislationand

recognisedcodesofpractice.

Therearetwoprincipletypesofjettingunit

• Lowpressure,highvolume.

Lowpressure,highvolumeunitsaretypicallylorrymounted,withalargewatercarryingcapacity

andafacilityforvacuumextractionofdebris.

• Highpressure,lowvolume.

Highpressure,lowvolumeunitsaretypicallysmalltrailermountedunitswithaminimalwatercarrying

capacityandgenerallydonothaveafacilityforremovingmaterialfromthesystembeingcleaned.

PolypipeCivilsalwaysrecommendstheuseoflowpressure,highvolumeunitswhenjettingplasticpipes.

Theappropriateunittypeislargelydependantonthepipediameterandwhetherjettingisbeingused

forblockageremovalorcleaning.Cleaninggenerallyrequireshigherflowratestoensurefinerdeposits

arere-entrainedintothesewageorsurfacewaterflowandtransporteddownstream.Largerandheavier

materialiskeptinmotionthroughthepowerofthejets,progressivelyrollingthedepositsdownthe

pipeline.Typically,forthesamepoweroutput,anincreaseinflowratecanbemoreeffectivethan

increasingthepressurewhenremovingdebris.

4.7.3 MaximumRecommendedPressures

Theabilityofadrainorsewertowithstandjettingwithoutdamagedependsonitsstructuralcondition.

Themaximumrecommendedpressureforplasticsewersanddrains,ingoodstructuralcondition,

is180bar(2600psi).

However,materialdoesnotreadilybondtopolymerpipesduetotheirsmoothnon-porousboreand

lowsurfaceenergy.Researchhasshownthatdebriscanbeeasilyremovedfromplasticpipesatpressures

below1500psi.

Itshouldbenotedthatwheredetailsofthesewermaterialorstructuralconditionisunavailableand

thereisnoevidencetosuggestthepipeisinagoodcondition,itisrecommendedthatamaximum

pumppressureof130bar(1900psi)isused[Exceptinareaswherebrickmasonryorpitchfibresewers

maybepresentamaximum100bar(1500psi)isrecommend].

Recommendedmaximumjettingpressuresmaybeaslowas80bar(1200psi)forpipesinextremely

poorstructuralcondition.

Maintenance

General Properties

58

5section

Ridgistorm-XL pipes are manufactured

from high density polyethylene and are

robust, durable and adaptable.

59

60

General Properties

5. General Properties

5.1 UV Light ResistanceRidgistorm-XLpipesareresistanttoUVattackandcanbesafelystoredon-sitewithoutanydamageor

agingeffectsforamaximumof6months.

5.2 Chemical ResistanceAllofthematerialsusedinPolypipe’sthermoplasticstructuredwallpipesystemshaveexcellentchemical

resistancecharacteristics,especiallywhencomparedwithtraditionalmaterialssuchasconcrete.For

example,sulphatesandsulphuricacid(nonfuming)havenomeasurableeffectonpolyethyleneand

polypropyleneyetareseverelydetrimentaltoordinaryconcrete.However,underrareconditions,thereare

substancesthatcanhaveaneffectonplasticandrubbermaterialsanddetailedchemicalresistance

informationisavailableinthefollowingstandards:

AnumberofstatementscanbemadeonthechemicalresistanceofPolypipe’sthermoplasticstructured

wallpipesystem.Undertypicalinstallationconditionsthesystemis:

• UnaffectedbypHintherangeof0.1–14.

• Unaffectedbyinorganicsaltsinanyconcentrations,includingheavymetals.

• Unaffectedbydiluteaqueoussolutionsoforganicchemicalssuchasdetergents.

• Unaffectedbylowconcentrationsofhydrocarbonsandoilsinnormaluse,suchasrun-offfromroads.

andcarparks.Wherehydrocarbonsarepresentinhigherquantities,forexampleagarageforecourt,

nitrilesealsshouldbespecifiedinplaceofthestandardEPDMsealsupstreamoftheseparator.

• Unaffectedbyanynaturallyoccurringcompoundinsoils,includinghumicandfulvicacidsfound

inpeatysoils.

• Unaffectedbysulphatesinanyconcentrationandsulphuricacid(non-fuming).

Chemical Resistance

CP312:Part1:1973 Codeofpracticeforplasticspipework(thermoplasticsmaterial) General principles and choice of material

BSISO4433-2:1997 Thermoplasticspipes-Resistancetoliquidchemicals ClassificationPart2:Polyolefinpipes

BSISO4433-3:1997 Thermoplasticspipes-Resistancetoliquidchemicals ClassificationPart3:PVCu

ISO/TR10358:1993 Plasticpipesandfittings-Combinedchemicalresistanceclassificationtable

ISO/TR7620:2005 Rubbermaterials-Chemicalresistance

Table 5.2-1Chemicalresistance

61

5section

• Affectedonlybyalimitednumberofindustrialchemicalsthatareonlyrarelyfoundinthe

environmentinsufficientconcentrationtobedetrimentaltoPolypipe’sthermoplasticstructuredwall

pipesystems.Thismayonlyoccurinheavilycontaminatedindustrialsiteswhereconcentrationsmay

behighenoughtowarrantfurtherinvestigation.Disposalofindustrialchemicalsintodrainsshould

notoccurduetoenvironmentalregulations.Spillagesshouldbecontainedandresultinshort-term

exposureanditshouldbenotedthatanyeffectsmaybereversibleandaredependenton

concentration,frequencyanddurationofexposure.Thecurrentworld-wideinventoryofindustrial

chemicalsextendstomanymillionsofcompoundsandnodefinitivelistdetailingtheireffecton

polymersexists.ForfurtherinformationordetailedadvicecontactourTechnicalTeamon

01509 615100.Thefollowinginformationisrequiredinordertoevaluatefullythesuitability

ofPolypipe’sthermoplasticstructuredwallpipeproductsforanygivenapplication:

• Thechemical(s).

• Theconcentrationofthechemical(s).

• Thefrequencyanddurationofexposure.

• Themaximumtemperatureofthechemical(s).

• Thedesignlifeofthepipesystem.

Wherepipesareplacedincontactwithcontaminatedground,specificassessmentshouldbe

undertaken,althoughitisrareforcontaminantstobepresentatconcentrationsthatwill

damagethepipes.

5.3 DurabilityWhenmakinganassessmentofthedurabilityoflargediameterpipesandfittingsitisimportanttotake

threefactorsintoaccount.Thefirstisstructuralintegrityi.e.isthepipestrongenoughtowithstandshort

terminstallationpractices.Thesecondislongtermdeformationorcreepandthefinalconsideration

shouldbetoanychemicaleffectsorageing.

Ridgistorm-XLismanufacturedfromhighlydurablePEorPPmaterialswhichhavebeenformulatedand

testedtoensurethatthematerialsusedhaveappropriateshortandlongtermmechanicalstrengthand

arechemicallyresistanttotheeffectsoflongtermagingoroxidation.Theshorttermstructuralintegrity

ofthepipesaredeterminedbydetailedstructuraldesignandanalysisandischeckedbycompression

testinginaccordancewithBSENISO9969ThermoplasticPipes;DeterminationofRingStiffnessand

BSEN1446PlasticsPiping;DeterminationofRingFlexibilityandDuctingSystems.Thelongterm

deformationresistanceofRidgistorm-XLischeckedbydeterminingthecreepratioofthepipeand

materialinaccordancewithBSENISO9967ThermoplasticPipes.

WhenallofthesefactorsaretakenintoaccountandprovidedRidgistorm-XLisinstalledinaccordance

withourinstallationinstructionsitissafetoassumethatthereshouldbenodeteriorationofthesystem

before100yearsoflife.

62

Project Solutions

63

6section

We have considerable project experience

in sustainable drainage projects,

providing tailor made solutions for our

customers’ requirements.

Case Studies

64

6.1 River Diversion Project using Ridgistorm-XL PolypipeWMScompletedachallengingriverdiversionprojectattheFfos-y-FranLandReclamation

SchemeinMerthyrTydfil,WalesusingitsRidgistorm-XLlargediameterpipesystem.Workingalongside

themaincontractor,DawnusConstructionandprojectengineersPeterBrettAssociates,PolypipeWMS

hassuppliedandinstalled72metresof1200mmdiameterRidgistorm-XLpipealongtwoseparateruns.

Ridgistorm-XL’spatentedelectro-fusionjointingprocessachievedquickerandsaferinstallationin

comparisonwithotherlargediameterpipesolutionsandguarantees100%sealtightnessforeachjoint.

Ridgistorm-XLwasspecifiedforasectionofthisdiversionduetoitsinherentstrengthandcost

effectivenesswhencomparedtotraditionalrigidmaterials.Thesystemwasinstalledinanenclosed

concretestructureandthencoveredwithwet-castconcrete.Thisthenenabledtheconstructionofa

temporaryroadforheavyplantandvehiclestotravelacrossthewatercourse,whilstallowingthe

re-routedwatertoflowthroughthepipeline.

6.2 Ridgistorm-XL Electro-Fusion Joint Delivers Stormwater Diversion for Gatwick Airport Scheme PolypipeWMSsuppliedabespokelargediameterpipelinesolutionusingitsRidgistorm-XLproductforthe

constructionofanewairsidebuildingatGatwickAirport’sNorthTerminal.

Ridgistorm-XLwasspecifiedbythemaincontractorforitselectro-fusionjointingsystem.Theexisting

stormdrainneededtoberelocatedandtheRidgistorm-XLpipelineinstalledpriortothepilingworkbeing

carriedoutforthenewbuilding.Concernsoverthepipelineintegrityasaresultofthepilingworkwere

negatedbyusingRidgistorm-XL.Thepatentedelectro-fusionjointingmethodguarantees100%seal

tightnesswithinthepipelineandistheonlylargediameterplasticpipesystemintheUKtoincorporate

suchtechnology.

65

6section

Case Studies

6.3 Bespoke Large Diameter Attenuation and Rainwater Harvesting Solution for New Livestock Market Adetailedcostanalysiscarriedoutbythemaincontractor,onthecost-effectivenessofplasticand

concretematerialsresultedinPolypipeWMSre-engineeringabespokeSUDSsolutionforanewlivestock

market.HavingprovedthatRidgistorm-XLlargediameterpipesystemcouldachievesignificantsavingson

thewhole-costoftheproject,PolypipeWMSworkedcloselywiththecontractortodesigna400metre

balancedattenuationtankwithastoragecapacityofonemillionlitres,usingRidgistorm-XLlarge

diameterpipein1.8metrediametertomanagesurfacewaterrun-offfromallhardstandingareas.

Inadditiontotheattenuationtank,PolypipeWMSalsodesignedandfabricatedabespoke300,000litre

rainwaterharvestingsolutionusingRidgistorm-XLpipein2.1metrediameter,tore-userainwaterfrom

the6,000squaremetreroofareaon-site.Alongsideitsfulldesignandtechnicalsupportservice,Polypipe

WMSsuppliedawidevarietyofbespokefabricationsforthenon-standardelementsoftheproject,

includingbespoke150mmstubsatintervalsalongtheattenuationstructuretoconnectgulliesfromeach

cattlegrid.Therainwaterharvestingtankalsoincludedafabricated‘T’sectionthatfeaturesanin-line

leaffiltertopreventdebrisfromenteringthetank.

6.4 Ridgistorm-XL Large Diameter Pipe System Provides the Solution for Landfill Project UsingitspatentedandWRcapprovedpipedesignsoftwareandasoilreportprovidedbythemain

contractor,PolypipeWMSdeterminedabespokestiffnessclassfortheRidgistorm-XLdischargeand

collectionpipethatwasvalue-engineeredtomeettheprojectspecifications.PolypipeWMSengineered

thesolutionbasedonthesoilconditions,burialdepthandinstallationparametersandaretheonly

manufactureroflargediameterplasticdrainagepipewiththiscapability.

ThisenabledPolypipeWMStooptimisetheamountofmaterialusedtomanufacturetheRidgistorm-XL

pipeline,whichinturnprovidedamoreeffectivesolutionfortheproject.

PolypipeWMSsuppliedover600metresofitsRidgistorm-XLsystemin1050mmdiameter.Thiswas

installed around the perimeter of the site to manage surface water run-off from the capped areas of the

landfill.SectionsoftheRidgistorm-XLpipewerealsoperforatedtocollectexcessstormwaterforcarriage

throughthedischargepipe.InadditiontoitsRidgistorm-XLlargediameterpipe,PolypipeWMSalso

suppliedover700metresof300,450and600mmdiameterRidgisewerandPolysewerseweragepipe.

Forrecentprojectstoriesgotowww.polypipewms.com/projects/.

SUDS overviewAmet euismod eu, te iusto in, dolore minim laoreet enim duis diam adipiscing facilisis delenit te laoreet at ut quis molestie lorem iusto aliquam quis.

Veniamtincidunt,nonummyetutteconsequaterataccumsan minimullamcorper,illumsit,quiwisidignissimadvelesse. Ameteuismodeu,teiustoin,doloreminimlaoreetenimduis diamadipiscingfacilisisfacilisisdelenittelaoreetatutquis.

66

0section

66

Associated ProductsA full range of complementary products

including stormwater treatment filters,

catchpits and flow controls, alongside

bespoke solutions from our dedicated

in-house Fabrications Team.

67

7section

7. Associated Products

7.1 Stormcheck ‘Vortex’ Flow Control Chamber

TheStormcheck‘Vortex’FlowControlChamber

comprisesofapre-fabricatedplasticchamber,

inarangeofdiameters,withintegralvortexflow

controldevice.OneaimofaSustainableDrainage

Systemistomimicgreenfieldrun-offratesfrom

developedsites.Onewayofachievingthisaimis

bystormwaterstorageandattenuation.Thenew

Stormcheckchamberallowsprecisecontrolof

sitedischargeratesandwhencombinedwithour

storagesystemsprovidesanindustryrecognised

flowattenuationsystem.

7.1.1 Key BenefitsAsealedchamberproducedinourdedicatedfabricationsdepartment,builttoexactingspecificationsand

deliveredtositereadytobeinstalled.Factoryfittedvortexflowcontroldevicesavestimeandexpense

on-site.Vortexflowcontroldevicesarewidelyrecognisedasbeingthemosthydraulicallyefficientmeans

offlowregulation.Theuniquedesignutilisingnomovingparts,meanstheyarevirtuallymaintenance

free.Stormcheckchambersaremanufacturedwithanintegralsumpforsiltcatchmentandanoptional

draindownsystemtoeasemaintenanceandsiltremoval.TheStormcheckchambercanbeintegrated

withanyPolypipeSUDSsolution.

Inlet

Head wall

Vortex flowcontroller

Controlledoutlet

Inlet

BypassFlap

Controlledoutlet

Bypasspipe

Vortex flow controller

Manual Bypass Design

Offersabypasstotheflowcontroldevicewhichis

manuallyoperatedfromthesurface.Theactivation

ofthebypasssystemopensadoorintheheadwall

allowingwaterinthechambertodraindownvia

thebypasspipe.

Auto Bypass Design

Stormcheckchamberswithautomaticbypass

systemsarealsoavailable,pleasecontact

thePolypipeWMSTechnicalTeam.

7.1.2 Chamber Types Non Bypass Chamber

Forsiteswheredischargeratesmustbeguaranteedandnotexceeded.

68

Associated Products

7.2 Storm-X4 Stormwater Treatment System for Roof and Surface Water Run-off Utilisingthelatestfour-stageupwardfiltrationtechnologytoimprovethequalityofsurfacewaterrun-off

fromroofs,carparksandthemostpollutedroads,eveninheavilytraffickedareas.

STORM-X4iscapableofcleaningsurfacewaterrun-offfromroofs,carparksandthemostpolluted

roads,eveninheavilytraffickedareas.STORM-X4hasbeendesignedtoremoveheavyparticles,silt

andnutrientsandheavymetalssuchascopper,zincandcadmiumfromthesurfacewatertoprovide

anenvironmentallysoundsolutionwhichbenefitsthenaturalwatercourseandincreasesbiodiversity.

7.2.1 Low MaintenanceTheadvancedfour-stagefiltrationsystemwithinSTORM-X4utilisesnomovingparts,providingalow

maintenancesolutionforallsurfacewaterrun-offapplications.Thefilterswithintheunitonlyneedto

bereplacedonaverageeverytwoyears,providinganeasilymaintainablesolutionon-site.

7.2.2 Easy to InstallPolypipeWMScansupplySTORM-X4asastandaloneunit,orhousedwithinabespokeplasticchamber.

Whenhousedwithinachamber,theunitsareconstructedoff-siteanddeliveredtositereadytoinstall,

makinginstallationquicker,saferandeasierwithamuchlowerdevelopmentfootprint.

69

6section

7.3 Polystorm ByusingPolystormLiteorPolystorm,youcan

easilyconstructattenuationtanksorsoakaways.

Thelightweight,load-bearingcellsfittogetherto

maketanksofanysizeorshape,providingthe

flexibilitytomeetawiderangeofsiterestraints.

Polystormcellsareusedunderloadedareas.

PolystormLitecellsareusedundernon-trafficked,

landscapedareas.

7.4 Bespoke Fabricated ProductsPolypipeCivilsistheonlyplasticpipe

manufacturerintheUKwithitsownin-house

fabricationsdepartment.Thisuniqueservice

enablesustoovercomethemostdifficultsite

constraintstocreatetrulybespokesolutions.

Our30,000squarefootfacilityallowsustowork

inpartnershipwithourclientstoprovidebespoke,

pre-fabricatedsolutionsdesignedtoreducetime

andinstallationcostson-site.

7.4.1 The RangeTherangeofproductsavailableisfromstandard

applicationstoone-offbespokesolutions

covering:

• Catchpits.

• Surfacewaterandsewermanholes

manufacturedtoadoptablestandards.

• Rainwaterharvestingtanksforboth

commercialandresidentialapplications.

• Sedimentandleaffilterspre-fabricated

withinchambers.

• Fullrangeoffittingsandaccessories.

7.5 Technical Information OnlineThePolypipeWMSwebsite,availableat

www.polypipewms.co.uk includes

comprehensivetechnicalinformation,installation

guidesandCADdrawings.Theeaseofnavigation

andclear,conciseinformationpresentedon

thesitehasbeendesignedtoofferusersmore

detailedandrelevantinformationwhenlooking

tospecifyRidgistorm-XLproducts.Alsoincluded

within the homepage is a product search facility

togiveeasyanddirectaccesstotheinformation

availableonthesite.

The Company

70

Title (text)

71 71

8section

The Company...

Ground breaking technology, innovative

products and total solutions.

ISO 9001

72

The Company

8. The Company

8.1 InnovationPolypipeCivilshasdedicatedresearchanddevelopmentfacilities,supportedbysixyearsofextensiveinvestmenttoset

thehigheststandardswithintheindustry.Ourlaboratoriesallowproductdevelopmentandcertificationtestingtobe

undertakenin-house,thereforeshorteningtimetomarketandmaximisingproductbenefitsforourcustomers.

ProducttestingatindependantfacilitiessuchastheUKASaccreditedBerryandHaywardlaboratoryensuresour

products,wherepossible,carrythird-partyaccreditationandcertification.

8.2 ManufacturingOperatingfromsitesinLoughborough,HorncastleandGlasgow,PolypipeCivilsemploysover300people,with

35productionlinesproducingover20differentproductrangesconsistinginexcessof1600individuallineitems.

Withinvestmentlevelsof£11min2006/07PolypipeCivilspridesitselfinhavingthemostextensivemanufacturing

capabilitiesinitssector.

PolypipeCivilsoperatesaQualityManagementSystemwhichcomplieswiththerequirementsofISO9001.

8.3 Environmental Commitments

8.3.1 Sustainability is not just a Pipe Dream Sustainabilityisnotjustaboutmakingproductsfromrecycledmaterial,orhelpingtoreduceenergyconsumption,there

aremanymoreelementstoconsider.PolypipeCivilsmakesaconsciousefforttoensureasmuchisbeingdonetohelp

theexternalenvironmentaspossible.ProductssuppliedtothemarketbyPolypipeCivilsaremanufacturedwith

sustainabilityinmind,makingsureweprovidesustainablesolutionsforgenerationstocome.Weconstantlyevaluateour

systemsandproceduressothatthewholeprocessofproductionisassustainableaspossiblefrommaterialusethrough

toproductapplication.

8.3.2 Recycled Product Usingrecycledproductisimperativeandforthepast15yearsithasbeenourpolicytouseasmuchrecycledmaterialas

possible,eitherfromotherindustriesorpostconsumerwaste.TothisendPolypipeCivilsusesover45%recycledmate-

rialintheproductionofourpipes,whichallowsustomaintaintheexactingstandardsofqualityanddurabilitythatwe

strivetoobtainandhelpprotecttheenvironment.

8.3.3 100% RecyclableAsourproductsaremanufacturedinplastic,theyare100%recyclableattheendoftheirusefullife,creatinga

sustainablepathbackintoreuse.

8.3.4 Lowering Energy ConsumptionInvestinginnewmachineryhasbeenkeytothewholePolypipeGroupandwehavestrivedtoensurethatourenergy

consumptionhasbeenaddressedtomakeournewmachinerymoreenergyefficient.Anexcellentexampleofthis

isthereplacementof17injectionmouldingmachinesatamanufacturingsitein2006.Thenewmachinessaved

between18-20%inenergyconsumptionovertheoutgoingmachinery.

8.3.5 Using Less TransportUtilisingourowntransportfleet,PolypipeCivilsensurethatthenumberofvehiclesdeliveringproducttositeiskept

toaminimum.Forexample,1kmof450mmplasticdrainagepipeswillonlyrequire3deliveries,comparedtoconcrete

pipeswhichwouldrequire12deliveries.Notonlywillthisbenefittheenvironmentbutitalsominimisestheriskof

on-sitetrafficrelatedaccidents,providingfurtherHealthandSafetybenefitson-site.

73

7section

8.3.6 Reducing our Fuel UsageOurtransportnetworkplaysasignificantroleinreducingourfuelconsumptionandaspartofthis,we

havemadesurethatourvehiclesrunonbio-diesel.PolypipeCivilshasalsoadoptedtheuseoflowrolling

resistancetyressaving5%onfuel.Wealsolimitourvehiclesto54mphasopposedtothestandard

56mphtosaveafurther5%onfuel.

8.3.7 Recovering Site WasteInthedistributionofsomeproducts,PolypipeCivilsusewoodenpallets.Inordertohelpreduceonsite

wasteandreduceconsumptionwehaveintroducedacollectionscheme,wherebywecollectanypallet

orstrappingusedonourproducts.Collectionofpalletsandstrappingiseasyandhassle-freeandcan

bearrangedbytelephone.

8.3.8 Helping our Communities PolypipeCivilsiscommittedtosupportingourcommunitiesasmuchaspossible.Whetheritbesupplying

alocalchildrenshospicewithdecorationsfortheirgardens,sponsoringyouthsportsteamsand

associationsorholdingoneofthelargestsailingregattasintheUKwhichbringsthewholeconstruction

industrytogethertoraisemoneyforchildreninMalawi.Sustainabilityisaboutthewholeenvironment

andPolypipeCivilstakesprideinhelpingtocreateasustainableenvironmentwhereverpossible.

8.4 Polypipe Health and Safety PolicyTheHealthandSafetyofemployeesisanintegralpartofPolypipe’sbusinessactivities.Healthand

Safetyisaresponsibilityandstatutorydutythateachandeveryemployeeandvisitortooursitesmust

share.Toenablethis,itisourintentthatresponsibilityforHealthandSafetybeacceptedandeffectively

carriedoutatalllevelswithinourorganisation.

AllPolypipeCompaniesshall,asfaraspossible,ensurethat:

• Weprovideasafeworkingenvironmentforouremployees,wherehazardandriskareeffectively

assessedandeliminatedoradequatelycontrolled.

• Weusesuitableandsufficientcontrolstoensurethatnon-employeeswhomaybeaffectedbyour

activitiesarenotexposedtoriskstotheirHealthandSafety.

• WemeetorexceedallcurrentlegislationandregulationrelatingtoHealthandSafety.

• WeclearlydefineandcommunicateorganisationalresponsibilitiesforthemanagementofHealth

andSafety.

• EmployeeinvolvementinmattersrelatingtoHealthandSafetyisactivelyencouraged.

• Adequateinformation,instructionandtrainingareprovidedtoallemployees.

• Weproperlyinvestigateaccidentsandcasesofwork-relatedillhealth.

• WemonitorandreviewHealthandSafetyperformanceusingappropriatemeasuresandmethods.

• Therearegoodworkingrelationshipswithregulatoryauthorities,neighbours,customers,suppliers

andstakeholdersonHealthandSafety.

The Company

74

8.5 Polypipe Environmental Policy PolypipeCivilsoperatesanEnvironmentalManagementSystemwhichcomplieswiththerequirements

ofISO14001

AtPolypipeweconsiderthepositivemanagementofthepotentialenvironmentalimpactofouractivities

asanintegralpartofourbusinessundertaking.Itisourintenttominimisethelastingimpactofour

operationsontheenvironmentandtotakeaccountofsustainabilityinourproductdesignandapplications.

ThemanufactureoftheseproductsconsumesbothrawmaterialsandenergyandPolypipethereforehas

introducedproactivesustainabilitypoliciestomanageboththeirusageandenvironmentalimpacts.

TheGroupshallensure,asfaraspossible,that:

• Wemeetorexceedallcurrentlegislationandregulationrelatingtotheenvironment.

• Weclearlydefineandcommunicateorganisationalresponsibilitiesforthemanagement

ofenvironmentalprotection.

• Employeeinvolvementinmattersrelatingtotheenvironmentisactivelyencouraged.

• Adequateinformation,instructionandtrainingareprovidedtoallemployees.

• Weproperlyinvestigateenvironmentalincidents.

• Wemonitorandreviewperformanceusingappropriatemeasuresandmethods.

• Weoptimisetheuseofwaterandutilities.

• Wetakestepstoreducewastegenerationanddisposalandincreaserecycling.

• Therearegoodworkingrelationshipswithregulatoryauthorities,neighbours,customers,suppliers

andstakeholdersonenvironmentalmatters.EnergyManagementandConservationPolicy.

PolypipeCivilsoperateanEnvironmentManagementSystemwhichcomplieswiththerequirements

ofISO14001.

All dimensions 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 may modify and change the information, products and specifications from time to time

for a variety of reasons, without prior notice. This information in this Technical Guide is provided ‘as is’ at March 2009. 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

Technical Guide you must do so at your own risk. All rights reserved. Copyright in this publication belongs to Polypipe and all such

copyright may not be used, sold, copied or reproduced in whole or part in any manner or in any media to any person without prior

consent. is a registered Trademark of Polypipe. All Polypipe products are protected by Design Right under CDPA 1988.

Copyright © 2008 Polypipe. All rights reserved.

8.6 Energy Management and Conservation PolicyAtPolypipewearecommittedtoapolicyofresponsibleuseofnaturalresources.Werecognisethe

needtooptimiseuseofandtoconserveasfaraspossiblethenaturalresourcesweconsume.

WethereforehaveimplementedanEnergyManagementandConservationPolicytoprovidea

frameworkforachievingthisobjective.

Title (text)

75

Ridgistorm-XL Technical Manual

Polypipe Civils

Charnwood Business Park

North Road

Loughborough

Leicestershire LE11 1LE

Tel: 01509 615100

Fax: 01509 615215

Email: [email protected]


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