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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.
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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
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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
Specifcation Requirementswhat we need to know:
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
Specifcation Requirementswhat we need to know:
Number o inlets
Pipe diameter o inlets (mm)
Design head o water (m)
Available fow rate (litres/sec)
Specifcation Requirementswhat we need to know:
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
Specifcation Requirementswhat we need to know:
Roo area (m)/Trac fow
Pipe diameter o inlets and outlets (mm)
Depth to invert o tank inlet (m)
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
Specifcation Requirementswhat we need to know:
Roo area (m2)
Pipe diameter o inlets and outlets (mm)
Depth to invert o tank inlet (m)
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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
Polypipe Civils Service: 19 years
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
Polypipe Civils Service: 15 years
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