SEPTEMBER Bespoke Fabrication Systems

Transcription

1 FB-V1 SEPTEMBER 2008 Bespoke Fabrication Systems

2 Polypipe Civils unique solutions in fabrication The UK Market Leader Polypipe Civils is the UK s leading manufacturer of cable protection, drainage, sewerage and water management systems, serving the utilities, construction and civil engineering markets. Unique In-house Fabrications Department Polypipe Civils is the only plastic pipe manufacturer in the UK with its own in-house fabrications department. This unique service enables Polypipe Civils to overcome the most difficult site constraints to create truly bespoke Polypipe is one of Europe s largest and fastest growing manufacturers of piping and sanitary systems for the residential, commercial and infrastructure sectors. Supported by this established foundation, Polypipe Civils is able to make significant investment in its manufacturing processes and now operates solutions to meet the needs of customers. Our in-house fabrications department, which includes a 30,000 square foot facility, allows us to work in partnership with our clients to provide bespoke, pre-fabricated solutions designed to reduce time and installation costs on-site. over three sites in Loughborough, Horncastle and Glasgow, employing over 300 people. With the fabrications department located within the Polypipe Civils business it provides direct access to the raw materials for the fabricated items. This not only results in reduced lead times, but also gives the fabrications department access to the extensive knowledge, experience and resource of the wider Polypipe Civils team. 2 3

3 Tailor made solutions from Polypipe Civils highly skilled in-house fabrications team Tailor Made Solutions As part of the unique fabrications service offered by Polypipe Civils, fully qualified design engineers work in partnership with our customers to create a bespoke solution to match individual specifications and site requirements. Our fabrications team does not only include a team of highly experienced welders, but also calls upon the resource and capabilities of the wider Polypipe Civils team, including Civils Specialists, Design Engineers and technical support to ensure our customers receive the very best service. Seamless Integration Fabricated solutions from Polypipe Civils are designed to integrate into an overall drainage application, with the fabricated element designed specifically to meet the requirements of the scheme. Polypipe Civils offers a valueengineered approach to bespoke fabrications and is supported by a technical department that provides sound advice and design experience. Our products can be designed and manufactured to suit any project timeline, without the need for lengthy lead times that often limit more traditional materials. Off-site Construction Polypipe Civils is unique in its position of being 1200 able to offer pre-fabricated, bespoke solutions constructed off-site. This approach to modern methods of construction reduces time and installation costs on-site as well as minimising 2180 health and safety risks in handling, storage and installation. The strong, yet lightweight properties of plastic pipes also enables further reduction in the use of heavy plant on-site

4 The Range fabricated products from standard applications to one-off bespoke solutions Catchpits Manholes Flow Controls Filters Tanks Fittings The range Years of experience has enabled Polypipe Civils to produce a core range of products that although bespoke to each site, form part of a standard stable of fabricated products. Accessories 6 7

5 G Catchpits our structured wall catchpits are manufactured to exact customer requirements Manholes surface water and sewer manholes manufactured to adoptable standards Our range of catchpits are designed to be Full Range of Options Associated Products Foul or Surface Water Manholes used in conjunction with our attenuation Ridgidrain is the first structured wall surface and soakaway products. They provide easily water drainage system to achieve the HAPAS accessible maintenance points before the specification issued by the BBA. Ridgisewer is attenuation or soakaway structure. the largest range of integrally socketed pipes for use in gravity sewers. Benefits Lightweight chamber design Tough and durable product Pre-fabricated off-site and delivered ready to install Choice of chamber sizes from 1050mm, 1200mm, 1500mm, 1800mm and 2100mm Inlets and outlets supplied with integral sockets as standard Provides easy access maintenance points for silt collection prior to the attenuation structure Catchpits are also available perforated for use as a lightweight soakaway chamber Benefits Designed to integrate with the extensive range of systems from Polypipe Civils Choice of chamber sizes from 1050mm, 1200mm, 1500mm, 1800mm and 2100mm One piece shaft Fully welded water tight solution Depth of manhole bespoke to customer requirements Fully bespoke option of inlets and outlets Double step irons to BS 1247 as standard, with orientation set to customer requirements Stormwater manhole Foul manhole Specification Requirements what we need to know: Specification Requirements what we need to know: Internal diameter of chamber (mm) Internal diameter of chamber Base required Base required Step irons/ladder access required Step irons/ladder access required Number of inlets Number of inlets Orientation of inlets Orientation of inlets Depth to invert level of inlets Depth to invert level of inlets 8 9

6 Flow Control Chambers Tanks Stormcheck Chambers Eco-Vat Tanks The Stormcheck Vortex Flow Control Eco-Vat tanks are designed for both Chamber comprises of a pre-fabricated residential and commercial projects to plastic chamber in a range of diameters. collect rainwater from roof areas for Supplied pre-installed with an integral Vortex re-use in non-potable applications, such Rainwater Harvesting Tanks Flow Control device which allows precise as toilet flushing, washing machine use control of site discharge rates from an and wash down areas. Constructed from attenuation storage system. Vortex Flow either structured-wall pipe for shallower Control devices are widely recognised as the most hydraulically efficient means of flow Stormcheck Vortex Flow Controls Stormcheck Vortex Flow Controls burial depth or GRP for larger capacity requirements, the Eco-Vat rainwater regulation. The unique design utilises no moving parts, meaning they are virtually Associated Products harvesting solution can typically reduce mains water demand by as much as 50%. Surface Water & Foul Water Tanks maintenance free. Polypipe offers a range of modular attenuation installations can be built up to form a load Polypipe Civils can also supply tanks for use Benefits Vortex Flow Control housed within sealed chamber for plug and play installation and soakaway solutions. Polystorm Xtra has a load bearing of 80 tonnes, with Polystorm and Polystorm Lite offering 40 and 20 tonne load bearing capability respectively. Each variety of bearing tank structure. Polypipe also offers a large diameter pipeline and attenuation system, Ridgistorm-XL. Various tank sizes can be offered to suit specific sites. in foul water or surface water applications. Benefits Designed specifically for the UK market Associated Products To accompany our structured-wall or GRP tanks in rainwater harvesting applications, Polypipe prevent the ingress of leaves, silt and other debris from entering and contaminating any Integral sump for silt catchment with optional drain down system to ease maintenance and silt removal Choice of depth up to maximum invert level of six metres Factory-fitted pre-installed Vortex Control device saves time and expense on-site Available as manual, bypass and Polystorm unit is light enough to carry and Robust as well as quick and easy to install Can sustain high water tables without the need for concrete surround Comes pre-assembled, ready for installation Based on a proven and tested product Civils supplies a range of leaf filters which run-off water in the tank. non-bypass system Specification Requirements what we need to know: Specification Requirements what we need to know: Number of inlets Roof area (m²) Pipe diameter of inlets (mm) Pipe diameter of inlets and outlets (mm) Design head of water (m) Depth to invert of tank inlet (m) Available flow rate (litres/sec) 10 11

7 Filters within Chambers quicker, easier and safer installation with off-site construction Storm X4 Utilising the latest four stage upward filtration technology, Storm X4 reduces surface water run-off contamination from road and roof areas to enable clean water to enter the watercourse or soakaway structure. Storm X4 is delivered to site within a pre-fabricated chamber, reducing installation time dramatically and providing an innovative solution to the issue of surface water quality. Benefits Treated surface water run-off can be discharged directly to watercourse Delivered to site within a chamber for quicker, easier and safer installation Low maintenance - filter lasts for 2 years on average Designed specifically for project requirements Compliant with Water Framework Directive Filters within Chambers Polypipe Civils provides sediment and leaf filters pre-fabricated within chambers and delivered to site ready to install. Used in conjunction with the Eco-Vat Rainwater Harvesting system to eliminate siltation within the system, Polypipe Civils is the only supplier of rainwater harvesting products with the capability to offer such a service. Utilising no moving parts, they are virtually maintenance free. Low Invert Drop Leaf Filters In situations where the existing drain run dictates the invert level, low invert drop filters may need to be considered. Polypipe Civils is unique in its ability to offer bespoke low invert drop filters within a pre-fabricated chamber. Designed to exact customer specifications the low invert drop filters and chambers allow a minimum head loss of only 66mm, enabling connection to an existing drain run. Benefits All filters are fabricated within a sealed chamber, built to exacting standards and customer specifications Low maintenance-filter Lightweight chamber design Tough and durable product Designed specifically to meet project requirements Range of filters available for roof sizes up to 9,000 square metres Specification Requirements what we need to know: Roof area (m²)/traffic flow Pipe diameter of inlets and outlets (mm) Depth to invert of tank inlet (m) Specification Requirements what we need to know: Roof area (m 2 ) Pipe diameter of inlets and outlets (mm) Depth to invert of tank inlet (m) 12 13

8 Fittings & Accessories to accompany our range of bespoke and fabricated products Installation quicker, safer and robust installations for pedestrian, light load and traffic applications Fittings Accessories Quick and easy installation Manhole cover & frame Loading Polypipe Civils chambers and manholes can be installed in a fraction of the time of traditional concrete or brick construction with Riser Pieces Gully Riser Pieces reduced health and safety risks. These time and cost savings are passed directly to the Concrete cover slabs contractor on-site. Step Irons or ladders Gravel surrounds are suitable for pedestrian Tank/Turret Riser Pieces Covers and Frames or light field loading. Concrete surrounds should be used in carriageways or locations We offer a range of covers and frames in a variety of materials: subject to heavy loads or frequent trafficking, or where a high water table is present. Steel Step irons or ladder Bespoke Gullies Non-standard Ts and Bends for Sewer Plastic Ductile Iron Composite Bespoke fabricated to suit site Drain and Duct Split Duct Chamber Benching Channel 14 15

9 The Fabrications Team skill and commitment throughout the design and fabrication process Technical Expertise Our qualified Civils Specialists provide exceptional standards of customer service and operate as the link between the site and the technical office. By working with a dedicated representative, our customers can take advantage of our detailed knowledge to ensure the solution meets their exact requirements. Technical Department The calibre of people and technical expertise within Polypipe Civils provides an enviable standard of technical service and customer support. The technical services team includes fully qualified Design engineers who provide detailed specification right through to installation and guidance. Our technical department are able to take existing drawings and employ the principles of value-engineering to design a more cost effective solution. We also work closely with our customers to design a specific element of an overall project plan as part of our design take-off service. Profile: Andy Cullum age 30 Position: Commercial Manager for Polypipe WMS Qualifications: BEng Civil Engineering from Nottingham University Polypipe Civils Service: 8 years Achievements: Being a Civil Engineer allows me to understand both the needs of the project and the technical data requirements for our technical team. As the link between the technical department and site this knowledge is invaluable. Profile: Satnam Johal age 40 Position: Fabrications Manager at Polypipe Civils Qualifications: City & Guilds (Brickwork) and IOSH Managing Safely Polypipe Civils Service: 19 years Achievements: As the only UK plastic pipe manufacturer to offer a dedicated fabrications service, we are very proud of the work carried out by the team. There is often a lot of work that goes into the jobs we undertake and we operate strict controls to ensure that we supply products that are the highest quality to our customers. Profile: Pal Johal Qualifications: TWI certification Polypipe Civils Service: 15 years Achievements: The fabrications department is a rewarding place to work as I get to work on some of the most high profile projects within the business. We ve recently completed work on over 40 bespoke manholes for the CJL project which I m very proud to have been involved with

10 Fabrications process in-house fabrication for every site specific application Justifiably Proud Our team of highly experienced welders have all successfully completed The Welding Institutes Certification Scheme for Welding and Inspection Personnel, a tailored training course which is carried out in accordance with the British and European Standard. Working together with technical support, our Fabrications Team ensure that we can respond efficiently to customers needs to design and provide solutions to pipeline problems. As part of our continuous improvement plan, our fabrications operatives undergo continued training and development to ensure the service we offer our customers is the very best available. The Fabrications Process As part of our unique fabrications service, we undertake full problem analysis to identify the initial issue on-site and the most appropriate fabrication solution. In situations where standard products are not the preferred option, Polypipe Civils can fabricate a complete and bespoke solution to meet specific site requirements. Once a bespoke solution has been designed, our Technical Department work closely with the Fabrications Team to produce the desired product, which is then quality checked and tested to ensure a fit for purpose solution is delivered to site

11 Our commitment to the environment Our Future Commitments Sustainability is not just about manufacturing products from recycled material or helping to reduce energy consumption, there are many elements to consider. Polypipe Civils makes a conscious effort to ensure as much is being done to help the external environment as possible, whether it be through improved transport policies to reduce fuel consumption, machinery which uses less energy or recovering site waste. Our commitment to the environment is inherent throughout the business and we take pride in our position as a responsible manufacturer. Environmental Commitments Polypipe Civils has made significant investment in its commitment to the environment throughout the business. One key element of this commitment is our use of recycled product. For the past 15 years it has been our policy to use as much recycled material as possible, either from other industries or post consumer waste. In the overall production of our plastic pipe we use over 45% recycled plastic, enabling us to maintain the exacting standards of quality and durability to help protect the environment. Reducing Waste The use of pre-fabricated solutions manufactured off-site reduces the amount of traffic to and from site, whilst also dramatically reducing the amount of wastage. This offers contractors and developers a significant step in improving their green credentials. Any waste which occurs during manufacture is under our control and is fed back into our manufacturing process to be recycled. As many of our products arrive on-site ready to be installed, no excess work is required which reduces any waste occurring on-site

12 Case studies our proven track record of providing tailored solutions for specific projects Geo Post Polypipe Civils were approached by Barnfield Construction to supply technical advice for the most appropriate drainage system during the construction of a new 30,000 sq feet depot and car park for Geo Post; an international delivery company based in Warrington. To collect excess rainwater and surface water run-off from the large roof and hard standing car park areas, Polypipe Civils supplied its large diameter Ridgidrain pipe in 900 and 1050mm diameters to attenuate excess stormwater. Over 220 metres of pipe was installed in total. To enable the surface water run-off to be discharged safely to the local drainage network, Polypipe Civils installed its Stormcheck flow control products, which were constructed off-site in prefabricated chambers, enabling quicker and easier installation on-site. Knowles Transport Polypipe Civils worked closely with groundworker DJE Construction to supply 17 pre-fabricated and bespoke catchpits at the redevelopment of a transport depot in Wisbech, Cambridgeshire. A concrete drainage solution was originally specified on the project. This was re-engineered to incorporate plastic chambers which offered quicker and more efficient installation, as well as improved health and safety benefits on-site. The bespoke solution designed by Polypipe Civils included catchpits in 1500mm and 1800mm diameters alongside more than 100 metres of Ridgidrain structured wall pipe in varying sizes. Polypipe Civils Fabrication Department played a key role in determining the specific catchpit design to meet the objectives of DJE on-site. CJL Sub-contractor CJL Construction required over 70 manholes for a foul water scheme on a new housing development in Weston-Super-Mare. The project suffered from particularly challenging site constraints due to the high water table, which resulted in Polypipe Civils designing and supplying a bespoke sealed manhole solution. The unique design incorporates a pre-formed and pre-benched manhole with a complete shaft, which significantly reduced the number of leakage points within the structure. Each manhole was also installed with a concrete bed and surround to resist flotation caused by the high water table. All descriptions and illustrations in this publication are intended for guidance only and shall not constitute a sale by description. All dimensions given are nominal and Polypipe Civils Limited may modify and change the information, products and specifications from time to time for a variety of reasons, without prior notice. The information in this brochure is provided as is on 1st September Updates will not be issued automatically. This information is not intended to have any legal effect, whether by way of advice, representation or warranty (express or implied). We accept no liability whatsoever (to the extent permitted by law) if you place any reliance on this brochure and you must do so at your own risk

13 Bespoke Fabrications Systems Polypipe Civils Head Office Charnwood Business Park North Road Loughborough Leicestershire LE11 1LE Tel: Fax: