INNOVATION IN COMPOSITES

Transcription

1 INNOVATION IN COMPOSITES Infrastructure Call us on +44 (0) or visit

2 MCL have developed a range of composites solutions for the civil engineering industry for use in a variety of applications. Composite GRP offers many benefits over iron or steel:. Strong. Lightweight. Corrosion resistant. Maintenance free. Cost-effective. No theft value. Non-conductive. Non-sparking. Suitable for telemetry Who we are MCL are one of Europe s leading manufacturers and suppliers of engineered composite products for the utility, construction and infrastructure markets. Working daily in partnership with utility companies, design consultants, building contractors and civil engineers in many sectors throughout the UK and Europe, MCL are at the forefront of innovative progress. MCL are committed to the design, manufacture and evolution of products which support global infrastructure developments. We provide a unique range of composite civil engineering products which are extensively installed within the water, waste water, power, telecommunications, rail and highways market sectors. MCL supplies its range of well known and trusted products both in the UK and abroad. Market Sectors Highways Traffic Signals/Street Lighting Water and Wastewater Power & Energy Rail Renewable Energy Construction Security 1 Innovation & Reliability in Engineered Composites

3 Content RapidSTACK Access Chamber System Pages 3-5 MCC RapidSTACK Chamber and Kiosk Page 6 RapidSTACK+ Access Chamber System Pages 7-8 Composite Pole Retention Sockets Manhole Covers and Frames Pages 9-10 Pages Composite Footway Boards and Ramps Page 14 Composite Road Plates Page Corporate Overview Pages Call us on +44 (0) or visit 2

4 RapidSTACK MCL s RapidSTACK chambers are a superior alternative to traditional class B engineering brickwork, blockwork or reinforced cast concrete and plastic chambers on the market. RapidSTACK is extremely quick to install as there is no need for a concrete surround or internal bracing, is available in a wide range of sizes and is highly cost effective with significantly lower labour, plant and road closure costs. RapidSTACK is lightweight - the sections and smaller rings conforms to HSE manual handling regulations for one man lift weighing less than 16kgs. The chambers are tested to EN124: B125, D400 and E600 loadings. RapidSTACK s unique design of interchangeable sections provides a flexibility of clear opening chamber sizes, simply bolt four sections together to create a stackable ring. Each ring is 150mm deep, stack the rings together in the pre-prepared excavation to create a chamber of the required depth. Visit mcl-infrastructure.co.uk for full installation guidelines. RapidSTACK Range and sizes B125 - White D400 - Grey E600 - Black Fire Retardant - Cream Interchangeable Sections Standard lengths available Ex Stock 450mm 750mm 1000mm 1500mm Example bespoke lengths made to order Lead-times apply 2400mm 2800mm 600mm 850mm 1220mm 1800mm 2500mm 3300mm 675mm 900mm 1300mm 2000mm 2600mm 4000mm Delivery Options Available flat-packed: Up to 120No. RapidSTACK sections per pallet Reduced storage space on site Use/build only when required Fully interchangeable Fixings supplied Available fully assembled: Rapid installation Pipe entry cutting available Fitting of chamber furniture available 3 Innovation & Reliability in Engineered Composites

5 The Complete Access Chamber Solution Unique design of interchangeable sections Wide range of sizes available Depth in multiples of 150mm, stackable system Fully assembled or flat-packed for transport cost savings Full range of cover & frames available to suit application Full range of chamber furniture and cable management kits available kg Technical support available from design through to installation B125, D400 & E600 loadings Tested to perform to the vertical load requirements specified in pr-en 124 and BS EN124: 1994 Pre-drilled duct entries available to customer specification Extremely quick to install No internal bracing required during initial installation Design Ribbed structure design maximises chamber performance Resistant to both vertical and lateral loads/forces 76mm wide bedding area - cover and frame fits directly on top Four modular panels bolted together within each corner Moulded integrated up-stand ensures that the chamber rings fit tightly together Cavities within each chamber section ensure that specified backfill fills each void increasing chamber stability (ideal in areas of high water tables) Typical Installations Rail chamber Thermal heating Highways Chamber Multiple duct entries High pressure water main Security chamber Bespoke chamber Water pressure pipe Large gas valve chamber Multiple duct entries Call us on +44 (0) or visit 4

6 RapidSTACK Highways MCL s RapidSTACK Highway Communication Chambers are fully compliant with the current specification for highway works, 1500 series, and are the preferred solution for highways jointing chambers. All chamber sizes are suitable for specified chamber sizes and are manufactured to the latest MCX0815 specification. Each RapidSTACK chamber ring has a unique 76mm bedding area for the specified cover to sit on, ensuring that the full B125 or D400 loading is accurately distributed. As a result of the high strength of MCL s Highway communication chamber, no internal bracing is required during the installation process. MCL Highways Communications chambers for England and Wales Chamber Sump Chamber Cover & Frame Loadings Badged (L) (W) (D) Type Base Furniture Type specified by HA Hinged?Locking? (W/Way) RapidSTACK+ Type T Chamber 300mm 300mm 600mm No No Composite B125 Composite No Yes No RapidSTACK Type Loop Chamber RapidSTACK Type C Chamber 450mm 450mm 600mm No No Composite B125 - Composite No Yes No D400 - Ductile Iron B125 - Composite 600mm 450mm 600mm No No Composite/Ductile Iron No Yes No D400 - Ductile Iron RapidSTACK Type B Chamber B125 & D mm 675mm 1050mm No No Ductile Iron Yes Yes Yes Ductile Iron RapidSTACK B125 & D mm 850mm 1050mm Yes Yes Ductile Iron Type A Chamber Ductile Iron Yes Yes Yes Please refer to current Highway Specification for clarification on preffered access chamber size and installation details MCL Highways Communications chambers for Scotland Chamber Type (L) (W) (D) Sump Base Chamber Furniture Cover & Frame Type Loadings Badged specified by HA Hinged?Locking? (W/Way) RapidSTACK Type Loop Chamber RapidSTACK Type B Chamber B125 - Composite 450mm 450mm 600mm No No Composite/Ductile Iron No Yes No D400 - Ductile Iron 600mm 600mm 600mm Yes No Ductile Iron B125 & D400 Yes Yes Yes RapidSTACK Type C Chamber 1300mm 1000mm 600mm No No Ductile Iron B125 & D400 No Yes Yes RapidSTACK Type A Chamber 1300mm 850mm 1050mm Yes Yes Ductile Iron B125 & D400 Yes Yes Yes Please refer to current Highway Specification for clarification on preffered access chamber size and installation details 5 Innovation & Reliability in Engineered Composites

7 MCC Kiosk with Chamber Following consultations with water companies about the challenges of AMP6, MCL considered how the group s existing range of composite products could be combined to deliver value to our customers. MCL Utility, supplying the water sector with GRP kiosks and enclosures, identified an opportunity for MCC kiosks. Traditionally, the power to a motor control centre is fed through the top left-hand side of its kiosk or from underneath through a concrete chamber. Most often the underground entry method is used due to the problems associated with overhead cabling. The MCL solution resolves the issue of civil construction of a bottom entry concrete base by combining the kiosk with a RapidSTACK chamber. The combination offers a unique opportunity for innovation and standardisation. With a standard width and depth, the length of the chamber suits the MCC, in increments of 1m up to 11m long. With both elements of the package being built off-site, up to two weeks are saved on site which reduces costs and lowers the risk of accidents. Step 1: RapidSTACK chamber assembled off-site complete with cable bearers, step irons and pre-drilled duct entries. Step 3: Control panels delivered and placed onto pre-installed bearers. Step 2: Chamber positioned onto prepared concrete base then surrounded by concrete/backfill/ MOT type1 to surface level. Step 4: GRP kiosk delivered full-assembled and fixed down Reduced project design time Standard manufacturing processes Shortening lead-times Efficiency in construction with off-site build and standard assembly methods Ensuring high-grade, low maintenance, long-life installations Significantly reduced material and installation costs Less disruption on site Ideal for wastewater and clean water sites as well as other industries Fixed Height Chambers MCL Joint Boxes were originally designed for the cable TV industry in which their many benefits are widely recognised. Utility and other market sectors have also adopted Joint Boxes for their underground cable duct chamber requirements. Product Reference JB23 JB26 Width Depth Height Call us on +44 (0) or visit 6

8 RapidSTACK+ MCL have designed and developed a ground breaking, fast build, ducted chamber system for the Utility and TSSL markets. RapidSTACK+ overcomes the problems associated with conventional access chambers which require concrete surround, making the system extremely cost effective during the installation process. Achieving B125 loading with an integral composite cover, the patented, interchangeable RapidSTACK+ design is available in sizes ranging from 290mm x 275mm to 1200mm x 600mm. RapidSTACK+ is extremely quick to install - simply bolt four sections together to create a stackable ring. Each ring is 150mm deep, stack the rings together in the pre-prepared excavation to create a chamber of the required depth. Raising pieces and height and tilt pieces are available to create a perfectly flush top ring which incorporates the composite cover. Visit mcl-infrastructure.co.uk for full installation guidelines. RapidSTACK+ V conventional methods All too often, projects using visually pleasing hard landscaping products are blighted by service duct chambers that are surrounded by an infil of concrete which destroys the overall effect. The concrete can crack and disintegrate and, over time, this area traps litter and becomes an unsightly potential trip hazard. Features No need for galvanised or ductile frame support No need for concrete surround, eliminating time and cost during installation Rebated design enables B125 composite cover to fit flush with chamber Problem Solution Knock-out duct entries - no drilling required Decorative concrete, tarmac, block paviours, slabs etc. can be laid directly alongside the chamber creating a level surface Complete system manufactured from a mixture of thermoset moulding compounds Central removable beam (CRB) supporting twin covers on larger chambers Benefits Typical Installations Complies with health & safety requirements one man lift Performs against diverse temperature changes from -40 C to O +140 C (will not soften by heat or brittle by frost) O Can be supplied fully assembled or flat-packed for transport cost savings Composite covers have approved anti-slip design, optional locking Telemetry reading can be made directly through the composite cover Much stronger than typical thermoplastic alternatives Resistant against aggressive soil conditions 7 Innovation & Reliability in Engineered Composites

9 Sizes available Clear Opening mm 290 x 275 x x 450 x x 450 x x 450 x x 450 x x 600 x x 600 x x 900 x x 450 x x 600 x 150 Knock-out duct entries Now available with additional duct entries 275mm section 290mm section 300mm section 450mm section 450mm - 3 knock-outs per section 600mm section 900mm section 1200mm section 600mm - 4 knock-outs per section Delivery Options Available flat-packed: Up to 480No. RapidSTACK sections per pallet (240 for larger sizes) Reduced storage space on site Use/build only when required Available fully assembled: Rapid installation Assembled standard rings with assembled top rings (integral, locking cover fitted) or assembled complete chambers Call us on +44 (0) or visit 8

10 Pole Retention Sockets Following the successful launch of the composite 115mm pole retention socket, MCL have developed a range for illuminated and non-illuminated poles and columns up to 168mm diameter. The Pole Retention Socket range allows a damaged or destroyed traffic signal pole or lighting column to be replaced in minutes. Once installed, the anti-rotational cam locking mechanism holds the pole in place, loosening the mechanism with a socket or ratchet enables fast removal and replacement of a damaged pole. Combined with the widely used RapidSTACK+ access chamber, the MCL system offers many advantages over traditional ductile iron or steel sockets. The MCL guard rail socket and loop box compliments our comprehensive range of products for the Street Furniture, Traffic Signals, Street Lighting and Communication markets. MCL retention sockets have been tested in conjunction with passively safe support structures that meet the requirements of EN The retention sockets show no signs of mechanical failure and work effectively after several impacts. MCL retention sockets do not adversely affect the passive safety perfomance of the support structure. Replace a damaged pole or column in minutes The Complete Composite Solution Highly cost-effective Quick and easy installation For steel and aluminium poles Lightweight 100% non-rusting materials Anti-rotational locking mechanism Twin cam-lock design resulting in no damage to columns (115mm, 140mm, 145mm, 165mm & 168mm) Manufactured in the UK, national distribution Rotating collet within the guard rail socket for ease of orientation Illuminated and non-illluminated systems Range 50x50mm Guard rail socket 50x60mm Guard rail socket 76mm Ø pole/ column socket 115mm Ø pole/ column socket 140mm Ø pole/ column socket 145mm Ø pole/ column socket 165mm Ø pole/ column socket 168mm Ø pole/ column socket 9 Innovation & Reliability in Engineered Composites

11 Typical Installation Top surface (example shown block paving) Surface ground level Traffic signal pole/ lighting column Top section (incorporating anti-rotational pole clamping mechanism) Locator plate Connecting tube (cut to desired height) Duct pipe fully inserted into duckfoot bend Connecting tube fully located into both locator plate and top section FOR ILLUMINATED POLES FOR ILLUMINATED POLES Existing ducting (smoothbore or twinwall) Duckfoot bend (bottom section) Lay duckfoot bend level onto hardcore, gravel or concrete base Typical Installations MCL Loop Box The MCL composite loop box is quick to install in the carriageway against the kerb or away from the kerb and achieves C250 loading. Designed for use with general purpose duct bends and general purpose connections for deeper installations, the MCL loop box is resistant to water ingress. Choice of four knock-out entry points for loop tails in the side walls o o o o 80mm Ø cable exit Call us on +44 (0) or visit 10

12 Manhole Covers & Frames MCL offer a comprehensive range of covers and frames suitable for all applicaitons. Manufactured from galvanised steel, ductile iron or GRP composite, depending on the loading of the chamber, MCL offer a suitable cover for the chamber size required. Composite Ductile Iron Steel Concrete Infill Loading B125 B125 / C250 / D400 Anti Slip Surface Design? Secondary Security Cover Available? Locking Options? Recessed? Hinged Available? Badging Options? FACTA A, B, C, D (slow moving wheel load) FACTA A, B, C (slow moving wheel load) Spring Assisted? Loadings Gross laden vehicle weight (slow moving) FACTA Class EN124 Class Pedestrian duty A A15 5 Tonne AA N/A Internal & external areas which can only be used by pedestrians or cycles ie. toilets, changing rooms, footways and cycle lanes Very light Industrial areas where small trolleys and private cars / vans can manoeuvre ie. domestic driveways, trolley parks etc. 10 Tonne AAA N/A Delivery / service areas, shopping malls and light industrial areas Up to 44 Tonne Special conditions only Up to 44 Tonne Special conditions only B B125 Pedestrian precincts, forecourts, commercial / delivery parking areas C C250 Factories, Industrial plants, special axle loads and kerbside drainage Up to 44 Tonne Special conditions only D D400 Heavy duty plant areas, carriageways and industrial service roads where fast moving HGVs reach speeds of 20mph max. Special application vehicles E E600 Dockside and container storage areas where heavy transporters operate. Special application vehicles F F900 Civil and military airfield aprons, where particularly heavy wheel loads are imposed by aircraft and towing vehicles. Commercial & Bespoke MCL offer a comprehensive range of fabricated chequer plate and block infill covers. Our range includes a standard range of both single and twin units, bespoke and specialist covers which are available within a set lead-time. Technical and site support is available on request, ensuring our clients needs are fully supported. A full range of options are available including double seal, locking, hinges, hasp and staple box and torsion spring assisted lift. 11 Innovation & Reliability in Engineered Composites

13 Ductile Iron Often utilised with RapidSTACK commercial B125 & D400 chambers, MCL offer a full range of manhole covers & gully grating which are manufactured in accordance to BS EN124 : 994. The majority of access covers hold BSI Kitemark certification and, where applicable, meet Highway Agency specification HA104/02. The standard range of ductile iron covers is available in B125 or D400 loadings. Ductile Iron Range Size - Clear opening mm 450 x x x x x x x x 600 (Badged Motorways Communications optional) 750 x 675 (Badged Motorways Communications optional) 1300 x 850 (Badged Motorways Communications optional) MOD Specified Sizes B125 (grass) MOD Specified Sizes D400 (carriageway) Typical Installations Concrete Infill Covers Concrete Infill Size Range - Clear opening mm 380 x x x x x x 445 Call us on +44 (0) or visit 12

14 GRP Composite A wide range of sizes are available from 275mm x 290mm for the smallest inspection chamber, to 600mm square. Manufactured in the UK at MCL, GRP composite covers are tested and certified in accordance with BS EN124:1994. All composite covers weigh less than 25kg, conforming to current manual handling guidelines, and are chemically resistant to engine oil, diesel and petrol. Size (clear opening) mm For use with RapidSTACK+ Supplied with Galvanised frame Single Twin 290 x x x x x x x x x x x x x 600 Composite cover sits within the recessed RapidSTACK+ chamber ring Fitted into a galvanised frame to suit the RapidSTACK B125 chambers Anti-slip design / optional locking / telemetry reading possible / badging available (additional cost applies) Tested in accordance with BS EN124:1994 Loading Galvanised Steel MCL offer an extensive range of UK manufactured, domestic, commercial and bespoke galvanised steel covers and frames including pressed steel, recessed and block paviour covers for driveways etc. Our range of covers include single, twin and multiple specialist covers and are tested and certified to BS EN124:1994 or FACTA class loadings. Spring assisted Hidden hinged lid Recessed for concrete infill Chequer plate Recessed block paviour cover Twin folding MCL supply an extensive range of steel covers for domestic use including pressed steel manholes, recessed internal covers and block paviour driveway access covers. All covers are available within short lead-times in a wide range of clear opening and weight loadings and are galvanised to BS EN IS Innovation & Reliability in Engineered Composites

15 Trench Covers & Ramps Trench Covers The MCL trench cover enables utility companies and their contractors to quickly deploy a safe, secured cover across a trench in a footpath, maintaining pedestrian and light vehicle access along footpaths. Judged Best Practice by National Grid For maximum vehicle weight of 2000kg, evenly distributed, with a single load per wheel maximum of 500kg Dimensions of 1200mm x 800mm Encapsulated steel reinforcement, slip resistant surface Lightweight 18kgs per trench cover Approved to National Grid Gas standard T/SP/E/42 HAUC approved Compliant with DETR Safety at Streetworks and Roadworks Code of Practice Anchor points at each corner Available with the Radlock Series 12 locking mechanism The problem: The solution: Ramps The MCL footpath ramp completes the range of footpath access systems maintaining a clear footpath for pedestrians and wheelchair users when diverted from the path to the carriageway during road works. Wheel retainers to prevent slipping over the edge Suits up to 15cm kerb height Stackable for transport and storage Maximum load 250kgs Weight 7.5kgs Slip resistant surface Call us on +44 (0) or visit 14

16 Composite Road Plate System MCL s Composite Road Plate System is ideal for the utility and infrastructure market sectors. The MCL carriageway system enables utility companies and their contractors to quickly deploy a safe road crossing over a trench thereby maintaining traffic flow and avoiding congestion. The product is very simple: an interlocking composite plate system with a patented locking mechanism to fasten it into place in minutes. The many advantages of this system over the traditional steel roadplates include being lighter and quicker to install, increasing site operator safety due to being a two-man lift and increasing road safety due to its high visibility and non-slip surface. A standard road crossing is deployed in minutes without drilling the road surface, therefore reducing congestion like never before. For linear trenches, road crossings and core-vac works National Grid Best Practice Tested and recommended for use by the Transport Research Laboratory (TRL) Testing sponsored by Transport for London (TfL) and the Department of Transport No need for specialist lifting equipment to deploy Lifted into place with standard manhole lifting keys Quickly locked down and secured in place with the Radlock Series 15 locking mechanism and a torque wrench Interlocking boards with an anti-slip surface design Spans trench up to 700mm in width, any length of run TRL Recommendation The newly developed Carriageway Road Plate System board was internally load tested in June 2012, and exceeded the required loading of 5.75 tonnes by a significant margin. In August 2012 the Transport Research Laboratory (TRL) in Wokingham commenced testing of the whole system. This testing is sponsored by Transport for London (TfL) and the Department of Transport as part of their undertaking to find quick wins in reducing congestion on London s road network. The test included an accelerated test on a specially designed rig, which passed a loaded rotating lorry wheel 65,000 times at loads of between 4 and 5.75 tonnes over the system at speeds of up to 20mph. The Transport Research Laboratory completed the testing of our system on the 5th November 2012 and recommended for use. 15 Innovation & Reliability in Engineered Composites

17 For Road Crossings For Core & Vac For Linear Trenches Road Plate Packs and features: Road Crossing Pack 10 no. 1516mm x 590mm inner plates Maximum Trench Width 700mm. 2 no. 1516mm x 790mm outer plates Each inner composite road plate weighs 44kg and can be lifted using manhole keys by two operatives. 12 no. Radlock Series 15 Locking Mechanism Each Radlock Series 15 locking mechanism weighs 5.2kg. Center Crossing Pack (Inner plates only) 12 no. 1516mm x 590mm inner plates Each end composite road plate weighs 48kg and can be lifted using manhole keys by two operatives. Maximum vehicle weight 44000kg kg Single Wheel Load. 12 no. Radlock Series 15 Locking Mechanism Maximum vehicle speed over the system is 30mph (recommended safe max 10mph). Call us on +44 (0) or visit 16

18 Who We Are We are one of: MCL are one of Europe s leading manufacturers and suppliers of engineered composite products for the utility, construction and infrastructure markets. Production capabilities and expertise of four group companies take products from innovative new concept designs and prototypes to high volume manufacturing of precision components, and assembled products, for highly demanding environments. Securbilt LPCB security rated kiosks RapidSTACK B125 & D400 chamber systems Railway carriage Interior components Through our innovative processes, bespoke design and development gateway, we can deliver collaborative design projects on time, every time. Due to the groups unique vertical value stream, we can develop new materials and produce cost effective samples prior to fully manufactured tool commissioning utilising: Design for Manufacture - DFM, FEA, DFMEA processes including 2D/3D CAD modelling services Structural calculations Design verification Validation techniques Corbilt kiosks RapidSTACK+ B125 chamber system GRP door skins This ensures that we always meet customer exacting requirements and achieve the best added value for all partners. MCL evolve an idea from Concept design to prototype To production tooling Gas Care Services GC gas meter housings Composite roadplate Enclosures for industrial lighting To a product in its moulded state To a fully finished, assembled, complete item MCL have included QCD considerations within our quality management system and our scope of certification including design and development processes. These processes satisfy the requirements of ISO9001 and, combined with third party certification and our internal audit processes, ensure we maintain a focus on continual improvement, maintaining compliance and the needs of our customer. Mitras meter boxes Composite trench cover Enclosures for industrial telephones 17 Innovation & Reliability in Engineered Composites

19 MCL Composites, based in Biddulph Moor, Staffordshire, who developed the first Mitras box in 1975, have been at the forefront of composite design, manufacture and supply solutions since the 1960 s. During this time we have supplied products to a wide range of customers and industries and have developed expertise and capabilities in various moulding and finishing techniques: Compression moulding Resin-transfer moulding Injection moulding Vacuum fusion moulding CNC operation Final assembly tier 1/2/3 Wet spray painting A division of MCL Composites, MCL Infrastructure are specialists in underground access chambers offering solutions that are cutting edge and highly cost effective. Working daily in partnership with design consultants, building contractors and civil engineers in many sectors throughout the UK and Europe, MCL are at the forefront of innovative progress supplying: Comprehensive range of underground access chambers Composite manhole covers Ductile iron manhole covers Galvanised steel manhole covers Composite pole retention sockets Composite road plates, footway boards and ramps MCL Industrial Enclosures produce larger kiosks in our sizeable facilities in Fenton, Stoke-on- Trent, utilising a number of different low to medium volume manufacturing techniques. The Gas Care Services GC kiosks range from a small GC2 kiosk (for larger houses) to a large walk-in kiosk suitable for public, civic and industrial premises. Including LPCB 1175 Security Rating 3 and 4 full GRP housings, MCL manufacture bespoke kiosks up to 25m by 10m primarily for the electricity, gas and water sectors with optional Brick/stone/textured or glossy finish Non-metallic colour of choice Gas tight rooms, partitioning walls Structural bases, hinged transoms Range of fittings and accessories, electrical installation Removable roofs, sliding hatches One piece or flat-pack delivery Design, manufacture & installation CSCS certified installation team MCL Compounds have the capacity to manufacture over 6,000 tonnes of polyester dough moulding compound for its sister company MCL Composites, for use in over 40% of the MCL group s range of products. Capacity 6000 tonnes per annum Approved fire performance grades Semi-automated process ISO9001:2008, Achilles approved Batch control and lot traceability Comprehensive material development and trial process Call us on +44 (0) or visit 18

20 MCL INFRASTRUCTURE Units 3 & 4 Monarch Works New Street Biddulph Moor Staffordshire ST8 7NL MCL Group Industries Ltd Tel: Fax: sales@mcl-infrastructure.co.uk Innovation & Reliability in Composites