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SEPTEMBER 2008

Bespoke Fabrication Systems

Polypipe Civils
unique solutions in fabrication

The UK Market Leader

Polypipe Civils is the UKs 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 Europes 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 over three sites in Loughborough, Horncastle and Glasgow, employing over 300 people.

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.

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.

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 90 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 45 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.
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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

Catchpits
our structured wall catchpits are manufactured to exact customer requirements
Our range of catchpits are designed to be used in conjunction with our attenuation and soakaway products. They provide easily accessible maintenance points before the attenuation or soakaway structure.

Manholes
surface water and sewer manholes manufactured to adoptable standards
Associated Products
Ridgidrain is the first structured wall surface water drainage system to achieve the HAPAS specification issued by the BBA. Ridgisewer is the largest range of integrally socketed pipes for use in gravity sewers.

Full Range of Options

Foul or Surface Water Manholes

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Benefits
Lightweight chamber design Tough and durable product Pre-fabricated off-site and delivered ready to install 1050mm, 1200mm, 1500mm, 1800mm and 2100mm sockets as standard points for silt collection prior to the attenuation structure  Catchpits are also available perforated for use as a lightweight soakaway chamber Choice of chamber sizes from

Benefits
 Designed to integrate with the extensive range of systems from Polypipe Civils Choice of chamber sizes from 1050mm, 1200mm, 1500mm, 1800mm and 2100mm
Stormwater manhole Foul manhole

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

Inlets and outlets supplied with integral  Provides easy access maintenance

Specification Requirements
what we need to know: Internal diameter of chamber (mm) Base required Step irons/ladder access required Number of inlets Orientation of inlets Depth to invert level of inlets

Specification Requirements
what we need to know: Internal diameter of chamber Base required Step irons/ladder access required Number of inlets Orientation of inlets Depth to invert level of inlets

Flow Control Chambers

Stormcheck Chambers
The Stormcheck Vortex Flow Control Chamber comprises of a pre-fabricated plastic chamber in a range of diameters. Supplied pre-installed with an integral Vortex Flow Control device which allows precise control of site discharge rates from an attenuation storage system. Vortex Flow Control devices are widely recognised as the most hydraulically efficient means of flow regulation. The unique design utilises no moving parts, meaning they are virtually maintenance free.
Stormcheck Vortex Flow Controls Stormcheck Vortex Flow Controls

Tanks
Eco-Vat Tanks
Eco-Vat tanks are designed for both residential and commercial projects to collect rainwater from roof areas for re-use in non-potable applications, such as toilet flushing, washing machine use and wash down areas. Constructed from either structured-wall pipe for shallower burial depth or GRP for larger capacity requirements, the Eco-Vat rainwater harvesting solution can typically reduce
Surface Water & Foul Water Tanks Rainwater Harvesting Tanks

Associated Products
Polypipe offers a range of modular attenuation and soakaway solutions. Polystorm Xtra has a installations can be built up to form a load 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.

mains water demand by as much as 50%. Polypipe Civils can also supply tanks for use in foul water or surface water applications.

Benefits
Vortex Flow Control housed within sealed chamber for plug and play installation

load bearing of 80 tonnes, with Polystorm and Polystorm Lite offering 40 and 20 tonne load bearing capability respectively. Each variety of Polystorm unit is light enough to carry and

Associated Products Benefits

Designed specifically for the UK market Robust as well as quick and easy to install To accompany our structured-wall or GRP tanks in rainwater harvesting applications, Polypipe Civils supplies a range of leaf filters which prevent the ingress of leaves, silt and other debris from entering and contaminating any run-off water in the tank.

Integral sump for silt catchment with optional drain down system to ease maintenance and silt removal

Can sustain high water tables without the need for concrete surround

 Choice of depth up to maximum invert level of six metres Factory-fitted pre-installed Vortex Control device saves time and expense on-site

Comes pre-assembled, ready for installation

Based on a proven and tested product

 Available as manual, bypass and non-bypass system

Specification Requirements
what we need to know: Number of inlets Pipe diameter of inlets (mm) Design head of water (m) Available flow rate (litres/sec)

Specification Requirements
what we need to know: Roof area (m) Pipe diameter of inlets and outlets (mm) Depth to invert of tank inlet (m)

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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.

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
Treated surface water run-off can be discharged directly to watercourse

Benefits
All filters are fabricated within a sealed chamber, built to exacting standards and customer specifications

Delivered to site within a chamber for quicker, easier and safer installation

Low maintenance - filter lasts for 2 years on average

Low maintenance-filter Lightweight chamber design Tough and durable product Designed specifically to meet project requirements up to 9,000 square metres  Range of filters available for roof sizes

Designed specifically for project requirements

Compliant with Water Framework Directive

Specification Requirements
what we need to know: Roof area (m)/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 (m2) Pipe diameter of inlets and outlets (mm) Depth to invert of tank inlet (m)

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Fittings & Accessories

to accompany our range of bespoke and fabricated products
Fittings Accessories

Installation
quicker, safer and robust installations for pedestrian, light load and traffic applications
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 reduced health and safety risks. These time

Riser Pieces

Gully Riser Pieces

and cost savings are passed directly to the contractor on-site.

Concrete cover slabs Step Irons or ladders

Gravel surrounds are suitable for pedestrian or light field loading. Concrete surrounds

Tank/Turret Riser Pieces

Covers and Frames

We offer a range of covers and frames in a variety of materials: Steel
Step irons or ladder

should be used in carriageways or locations subject to heavy loads or frequent trafficking, or where a high water table is present.

Bespoke Gullies

Non-standard Ts and Bends for Sewer

Plastic Ductile Iron Composite Bespoke fabricated to suit site

Benching

Drain and Duct

Split Duct

Chamber

Channel

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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. Weve recently completed work on over 40 bespoke manholes for the CJL project which Im very proud to have been involved with.

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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.

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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.

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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 2008. 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.

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Bespoke Fabrications Systems

Polypipe Civils Head Office Charnwood Business Park North Road Loughborough Leicestershire LE11 1LE

Tel: 01509 615100 Fax: 01509 610215 Email: enquiries@polypipecivils.co.uk www.polypipecivils.co.uk