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Bespoke Fabrication

Systems

SEPTEMBER 2008FB-V1


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Polypipe Civilsunique solutions in abrication

The UK Market Leader

Polypipe Civils is the UKs leading

manuacturer o cable protection, drainage,

sewerage and water management systems,

serving the utilities, construction and civil

engineering markets.

Polypipe is one o Europes largest and astest

growing manuacturers o piping and sanitary

systems or the residential, commercial and

inrastructure sectors. Supported by this

established oundation, Polypipe Civils is able

to make signicant investment in its

manuacturing processes and now operates

over three sites in Loughborough, Horncastle

and Glasgow, employing over 300 people.

Unique In-house

Fabrications Department

Polypipe Civils is the only plastic pipe

manuacturer in the UK with its own in-house

abrications department. This unique service

enables Polypipe Civils to overcome the most

dicult site constraints to create truly bespoke

solutions to meet the needs o customers.

Our in-house abrications department, which

includes a 30,000 square oot acility, allows

us to work in partnership with our clients to

provide bespoke, pre-abricated solutions

designed to reduce time and installation

costs on-site.

With the abrications department located

within the Polypipe Civils business it

provides direct access to the raw materials

or the abricated items. This not only

results in reduced lead times, but also gives

the abrications department access to the

extensive knowledge, experience and

resource o the wider Polypipe Civils team.


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Tailor made solutionsrom Polypipe Civils highly skilled

in-house abrications team

Tailor Made Solutions

As part o the unique abrications service

oered by Polypipe Civils, ully qualied

design engineers work in partnership with

our customers to create a bespoke solution

to match individual specications and site

requirements. Our abrications team does not

only include a team o highly experienced

welders, but also calls upon the resource and

capabilities o the wider Polypipe Civils team,

including Civils Specialists, Design Engineers

and technical support to ensure our

customers receive the very best service.

O-site Construction

Polypipe Civils is unique in its position o being

able to oer pre-abricated, bespoke solutions

constructed o-site. This approach to modern

methods o construction reduces time and

installation costs on-site as well as minimising

health and saety risks in handling, storage

and installation. The strong, yet lightweight

properties o plastic pipes also enables urther

reduction in the use o heavy plant on-site.

Seamless Integration

Fabricated solutions rom Polypipe Civils are

designed to integrate into an overall drainage

application, with the abricated element

designed specically to meet the requirements

o the scheme. Polypipe Civils oers a value-

engineered approach to bespoke abrications

and is supported by a technical department

that provides sound advice and design

experience. Our products can be designed

and manuactured to suit any project timeline,

without the need or lengthy lead times that

oten limit more traditional materials.

1200

400 400

2180

45

90

400 400


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The Rangeabricated products rom standard applications

to one-o bespoke solutions

The range

Years o experience has enabled Polypipe

Civils to produce a core range o products

that although bespoke to each site, orm part

o a standard stable o abricated products.

Manholes

Fittings

Catchpits

TanksFilters

Flow Controls

Accessories

45

90

400 400


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Catchpits

our structured wall catchpits are manuactured

to exact customer requirements

Our range o catchpits are designed to be

used in conjunction with our attenuation

and soakaway products. They provide easily

accessible maintenance points beore the

attenuation or soakaway structure.

Benefts

Lightweight chamber design

Tough and durable product

Pre-abricated o-site and delivered

ready to install

Choice o chamber sizes rom

1050mm, 1200mm, 1500mm, 1800mm

and 2100mm

Inlets and outlets supplied with integral

sockets as standard

Provides easy access maintenance

points or silt collection prior to the

attenuation structure

Catchpits are also available perorated or

use as a lightweight soakaway chamber

Specifcation Requirementswhat we need to know:

Internal diameter o chamber (mm)

Base required

Step irons/ladder access required

Number o inlets

Orientation o inlets

Depth to invert level o inlets


Internal diameter o chamber

Base required

Step irons/ladder access required

Number o inlets

Orientation o inlets

Depth to invert level o inlets

Full Range o Options

Manholes

surace water and sewer manholes

manuactured to adoptable standards

Associated Products

Ridgidrain is the rst structured wall surace

water drainage system to achieve the HAPAS

specication issued by the BBA. Ridgisewer is

the largest range o integrally socketed pipes

or use in gravity sewers.

Benefts

Designed to integrate with the extensive

range o systems rom Polypipe Civils

Choice o chamber sizes rom 1050mm,

1200mm, 1500mm, 1800mm and 2100mm

One piece shat

Fully welded water tight solution

Depth o manhole bespoke to customer

requirements

Fully bespoke option o inlets and outlets

Double step irons to BS 1247 as standard,

with orientation set to customer

requirements

Foul or Surace Water Manholes

G

Stormwater manhole Foul manhole


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Flow Control Chambers


Number o inlets

Pipe diameter o inlets (mm)

Design head o water (m)

Available fow rate (litres/sec)


Roo area (m)

Pipe diameter o inlets and outlets (mm)

Depth to invert o tank inlet (m)

Stormcheck Chambers

The Stormcheck Vortex Flow Control

Chamber comprises o a pre-abricated

plastic chamber in a range o diameters.

Supplied pre-installed with an integral Vortex

Flow Control device which allows precise

control o site discharge rates rom an

attenuation storage system. Vortex Flow

Control devices are widely recognised as the

most hydraulically ecient means o fow

regulation. The unique design utilises no

moving parts, meaning they are virtually

maintenance ree.

Benefts

Vortex Flow Control housed within sealed

chamber or plug and play installation

Integral sump or silt catchment with

optional drain down system to ease

maintenance and silt removal

Choice o depth up to maximum invert

level o six metres

Factory-tted pre-installed Vortex Control

device saves time and expense on-site

Available as manual, bypass and

non-bypass system

Eco-Vat Tanks

Eco-Vat tanks are designed or both

residential and commercial projects to

collect rainwater rom roo areas or

re-use in non-potable applications, such

as toilet fushing, washing machine use

and wash down areas. Constructed rom

either structured-wall pipe or shallower

burial depth or GRP or larger capacity

requirements, the Eco-Vat rainwater

harvesting solution can typically reduce

mains water demand by as much as 50%.

Polypipe Civils can also supply tanks or use

in oul water or surace water applications.

Benefts

Designed specically or the UK market

Robust as well as quick and easy

to install

Can sustain high water tables without

the need or concrete surround

Comes pre-assembled, ready or

installation

Based on a proven and tested product

Associated Products

Polypipe oers a range o modular attenuation

and soakaway solutions. Polystorm Xtra has a

load bearing o 80 tonnes, with Polystorm and

Polystorm Lite oering 40 and 20 tonne load

bearing capability respectively. Each variety o

Polystorm unit is light enough to carry and

installations can be built up to orm a load

bearing tank structure. Polypipe also oers

a large diameter pipeline and attenuation

system, Ridgistorm-XL.Various tank sizes

can be oered to suit specic sites.

Tanks

Associated Products

To accompany our structured-wall or GRP tanks

in rainwater harvesting applications, Polypipe

Civils supplies a range o lea lters which

prevent the ingress o leaves, silt and other

debris rom entering and contaminating any

run-o water in the tank.

S to rm ch ec k Vor te x F lo w Co nt ro ls S tor mc he ck Vo rt ex F low C on tr ols

Rainwater Harvesting Tanks

Surace Water & Foul Water Tanks


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Storm X4

Utilising the latest our stage upward ltration

technology, Storm X4 reduces surace water

run-o contamination rom road and roo

areas to enable clean water to enter the

watercourse or soakaway structure.

Storm X4 is delivered to site within a

pre-abricated chamber, reducing installation

time dramatically and providing an innovative

solution to the issue o surace water quality.

Benefts

Treated surace water run-o can be

discharged directly to watercourse

Delivered to site within a chamber or

quicker, easier and saer installation

Low maintenance - lter lasts or 2 years

on average

Designed specically or projectrequirements

Compliant with Water Framework Directive

Filters within Chambers

quicker, easier and saer installation

with o-site construction


Roo area (m)/Trac fow



Filters within Chambers

Polypipe Civils provides sediment and lea lters

pre-abricated 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 o rainwater

harvesting products with the capability to oer

such a service. Utilising no moving parts, theyare virtually maintenance ree.

Low Invert Drop Lea Filters

In situations where the existing drain run

dictates the invert level, low invert drop lters

may need to be considered. Polypipe Civils is

unique in its ability to oer bespoke low invert

drop lters within a pre-abricated chamber.

Designed to exact customer specications the

low invert drop lters and chambers allow a

minimum head loss o only 66mm, enabling

connection to an existing drain run.

Benefts

All lters are abricated within a sealed

chamber, built to exacting standards

and customer specications

Low maintenance-lter

Lightweight chamber design

Tough and durable product

Designed specically to meet project

requirements

Range o lters available or roo sizes

up to 9,000 square metres


Roo area (m2)




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The Fabrications Teamskill and commitment throughout

the design and abrication process

Technical Expertise

Our qualied Civils Specialists provide

exceptional standards o customer service

and operate as the link between the site

and the technical oce. By working with

a dedicated representative, our customers

can take advantage o our detailed

knowledge to ensure the solution meets

their exact requirements.

Technical Department

The calibre o people and technical expertise

within Polypipe Civils provides an enviable

standard o technical service and customer

support. The technical services team includes

ully qualied Design engineers who provide

detailed specication right through to

installation and guidance.

Our technical department are able to take

existing drawings and employ the principles

o value-engineering to design a more cost

eective solution. We also work closely with

our customers to design a specic element o

an overall project plan as part o our design

take-o service.

Profle: Andy Cullum age 30

Position: Commercial Manager

or Polypipe WMS

Qualifcations: BEng Civil Engineering

rom Nottingham University

Polypipe Civils Service: 8 years

Achievements: Being a Civil Engineer

allows me to understand both the

needs o the project and the technical

data requirements or our technical

team. As the link between the

technical department and site this

knowledge is invaluable.

Profle: Satnam Johal age 40

Position: Fabrications Manager

at Polypipe Civils

Qualifcations : City & Guilds

(Brickwork) and IOSH Managing Saely


Achievements : As the only UK plastic

pipe manuacturer to oer a dedicated

abrications service, we are very proud

o the work carried out by the team.

There is oten a lot o 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.

Profle: Pal Johal

Qualifcations: TWI certication


Achievements : The abrications

department is a rewarding place to work

as I get to work on some o the most

high prole projects within the business.

Weve recently completed work on over

40 bespoke manholes or the CJL project

which Im very proud to have been

involved with.


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Fabrications processin-house abrication or every

site specic application

Justifably Proud

Our team o highly experienced welders

have all successully completed The Welding

Institutes Certication Scheme or 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 eciently to customers needs to

design and provide solutions to pipeline

problems. As part o our continuous

improvement plan, our abrications operatives

undergo continued training and development

to ensure the service we oer our customers

is the very best available. The Fabrications Process

As part o our unique abrications service,

we undertake ull problem analysis to

identiy the initial issue on-site and the most

appropriate abrication solution. In situations

where standard products are not the

preerred option, Polypipe Civils can

abricate a complete and bespoke solution

to meet specic 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 t or purpose solution is

delivered to site.


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Case studies

our proven track record o providing

tailored solutions or specic projects

Knowles Transport

Polypipe Civils worked closely with

groundworker DJE Construction to supply

17 pre-abricated and bespoke catchpits

at the redevelopment o a transport depot

in Wisbech, Cambridgeshire. A concrete

drainage solution was originally specied

on the project. This was re-engineered to

incorporate plastic chambers which oered

quicker and more ecient installation, as

well as improved health and saety benets

on-site. The bespoke solution designed by

Polypipe Civils included catchpits in 1500mm

and 1800mm diameters alongside more

than 100 metres o Ridgidrain structured

wall pipe in varying sizes. Polypipe Civils

Fabrication Department played a key role in

determining the specic catchpit design to

meet the objectives o DJE on-site.

CJL

Sub-contractor CJL Construction required

over 70 manholes or a oul water scheme

on a new housing development in

Weston-Super-Mare. The project suered

rom 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-ormed

and pre-benched manhole with a complete

shat, which signicantly reduced the number

o leakage points within the structure.

Each manhole was also installed with a

concrete bed and surround to resist fotation

caused by the high water table.

Geo Post

Polypipe Civils were approached by Barneld

Construction to supply technical advice or

the most appropriate drainage system during

the construction o a new 30,000 sq eet

depot and car park or Geo Post; an

international delivery company based in

Warrington. To collect excess rainwater and

surace water run-o rom the large roo

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 o pipe was installed in total.

To enable the surace water run-o to be

discharged saely to the local drainage

network, Polypipe Civils installed its

Stormcheck fow control products, which

were constructed o-site in preabricated

chambers, enabling quicker and easier

installation on-site.

All descriptions and illustrations in this publication are intended or guidance only and shall not constitute a sale by description. All dimensions given are nominal and Polypipe Civils Limited may modiy and change the

inormation, products and specifcations rom time to time or a variety o reasons, without prior notice. The inormation in this brochure is provided as is on 1st September 2008. Updates will not be issued automatically.

This inormation is not intended to have any legal eect, whether by way o advice, representation or warranty (express or implied). We accept no liability whatsoever (to the extent permitted by law) i you place any reliance on

this brochure and you must do so at your own risk.


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Polypipe CivilsHead Ofce

Charnwood Business Park

North Road

Loughborough

Leicestershire LE11 1LE

Tel: 01509 615100

Fax: 01509 610215

Email: [email protected]

www.polypipecivils.co.uk