The manhole system the drainage
industry has been waiting for
 The UK concrete pipeline systems industry has introduced a new precast manhole system packed with many benefits that will satisfy designers, contractors and operators alike.
- Reduced construction time
- Decreased installation costs
- Improved safety on site
- Superior quality, reduced maintenance
- Watertight –reduced running costs at treatment works and pumping stations
- Reduced carbon footprint
Traditionally, manhole construction has required the base to be formed in-situ where building of the channel, connections and benching occurs in the trench, often in wet and unpleasant conditions. The process can take around 40 hours per manhole and is not always successful, particularly in terms of leakage where egress of waste water can lead to contaminated groundwater and ingress can contribute to the common problem of overloaded sewer networks plus increased energy usage and running costs at treatment works and pumping stations.
The new manhole system comprises a precast concrete base unit, complete with channel and benching with predetermined combinations of inlet(s) and outlet and new chamber rings with watertight flexible joints and no lifting holes, thereby removing points of possible leakage.
Both base units and chamber rings are made with thicker, stronger walls. The robust design means that the requirement for a concrete surround is eliminated, unless specifically required. The excavation is backfilled sooner and there is less need for men to work in confined spaces. This reduces time spent in the excavation, further improving site safety and reducing installation costs.
Installation of the whole system is speedy and efficient. Once in position, wet trades are eliminated, formation of benching on site and sealing of lifting holes is avoided and follow-up operations can start immediately. Field trials indicate that time savings of over 30% can easily be achieved, particularly when installed without a concrete surround. The system also yields environmental advantages as less concrete is used, there is less waste and less excavated material is disposed to landfill. An annual saving of over 15,000 tonnes of CO2 is estimated in the UK if all manholes manufactured by members of CPSA changed to the new precast base system. The quality of material and finish is well above that normally achieved on site and the full system is manufactured under factory conditions by third party certified companies to ISO 9001 quality management system. Products are Kitemarked to BS EN 1917:2002 and BS 5911-3:2002 Concrete Manholes and Inspection Chambers and tested under laboratory conditions.
UK Water Companies have embraced the new precast manhole system and given their acceptance to use the design for new projects in lieu of traditional in-situ concrete construction. Full acceptance is anticipated throughout the UK in the near future.
For further details about precast manhole bases and product availability, please contact CPSA on 0116 253 6161 mail@concretepipes.co.uk |
Life made easier with launch of new website
Engineers, contractors and operators within the wastewater sector can benefit from the new web site launched by CPSA in late 2010. The revamped site offers easier navigation, useful new material and improvements to the popular on-line Calculators for Structural Design and Material Cost comparisons. The site provides vital information relating to installation and operating costs of pipeline systems; transport, handling & installation; design & technical guidance; maintenance, integrity & durability; sustainability; innovation and details of CPSA’s CPD accredited training programme. The site contains a wealth of information on all aspects of pipeline system design, installation and operation with a full library of freely available downloads.
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New CPSA offloading guide ensures safe deliveries
The CPSA has published a new guideline document to help customers ensure the safe off-loading of concrete pipeline product deliveries.
Falls from vehicles and delivery accidents make up a large proportion of workplace injuries and the Guide offers advice on the risks associated with delivery and transport operations. The scope of responsibilities before, during and after products have been delivered are demonstrated and the Guide complements other industry reference documents including HSE Information Sheet WPT06 ‘Delivering safely: Co-operating to prevent workplace vehicle accidents’ and the Freight Transport Association Guide ‘Preventing Falls from Vehicles’. A PDF copy can be found here.
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Twelve environmental advantages of concrete drainage systems
CPSA, in collaboration with the Box Culvert Association (BoxCA), have published "Concrete Drainage and Sewerage Systems: Your Sustainable Option".
The brochure identifies 12 sustainability advantages of concrete drainage systems and offers information about the manufacture of products and why the environmental impacts associated with these systems are typically low. It also illustrates how concrete drainage products can be used to improve sustainability and reduce environmental impacts. The publication is available at CPSA and BoxCA websites as a PDF download and is also available as a hard copy
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20 Reasons why concrete pipes are the best option: Now and for the future
A booklet detailing the advantages and applications of concrete pipeline systems is now available at CPSA's website dedicated training page.
This CPD certificated booklet offers a detailed explanation why concrete pipeline systems meet the needs of the sewerage and drainage industries and why they are the most suitable choice in the short and long term. Free copies will be made available as part of the Choosing the right pipeline system CPD programme or you can download your copy from here
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German BRU GmbH Ultimate “Test”
German Concrete Pipeline Systems Manufacturers BRU GmbH & Co carried out their own pipe strength testing trial using a 44.2 tonne Komatsu excavator! In a demonstration almost identical to the one made in 2006 by Norwegian BASAL.
The huge excavator was driven over 4 BRU concrete pipes and the pipes passed the test successfully, sufficiently proving why concrete pipeline systems are the safe option. To date, no information is available on similar tests carried for plastic pipes!
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CPSA improves Online design and pipeline cost comparison tools
CPSA has updated its popular Online Structural Design and Material Cost Calculators.
The new Online Calculators now include bedding Classes N and F, in addition to Classes B and S.
The addition of these two bedding Classes can help drive further reductions in installation costs and carbon footprint as the requirement for virgin aggregates is reduced considerably. It should be noted that while flexible pipes (such as plastic) mainly use Class B bedding with full surround, rigid pipes (concrete, clay, etc) can be installed using other bedding applications.
The two calculator tools are a hit with consultants, developers and contractors, helping them to optimize decisions on the type of pipe bedding and choice of pipe. |
Eco project adopts sustainable Easi-Base
for manholes
Cawrey Homes have been building houses in Ratby, Leicestershire since 1968, completing over a 1,000 new build and refurbished properties all to an exacting high standard and using the most energy efficient and cost effective materials available. The most recent development of 36 homes have all been designed to meet the Code for Sustainable Homes – Level 4, a sustainability standard that will be mandatory from 2013.
In recognition that the total build extends below ground to include storm and waste water drainage, the house builder in conjunction with its civils ground worker, M&J Beddard Construction, was quick to see the benefits FP McCann’s Easi-Base manhole system could bring by fitting into the sustainability criteria for materials.
The DN 1200 Easi-Base addresses a long-standing problem associated with traditional methods of manhole construction. Labour intensive, in-situ practices typically taking up to 36 hours are eliminated by the fully integrated unit which can be installed and connected in a matter of minutes. There are also considerable savings associated with reductions in embodied energy and embodied greenhouse gas emissions due to reduction in materials use and installation efforts.
The precast concrete base complete with channels and benching formed into a polypropylene liner is placed on a formation comprising compacted granular material. Pipe connection is made simple as connection bells are cast into the base for the specific pipe in use, thus allowing the ground worker to simply push the pipe into the base via the sealed connector. A watertight seal is instantly achieved. Water flows through the unit via a 1% preformed fall in the channel exiting at the outlet point. Conventional methods of constructing the manhole above the base are then followed, with precast concrete chamber rings placed directly on top.
In total, 12 DN 1200 Easi-Base units were supplied to the Ratby scheme, mainly for the site foul and storm system, however the ground worker was so impressed with Easi-Base, that Severn Trent Water was persuaded to use the product in adopted sewers. Each unit was installed and connected within 30 minutes.
John Cawrey, MD of Cawrey Homes commented, “The Easi-Bases have helped to speed up drain-laying and have reduced time spent benching manholes. The base being pre-formed, can be set and left ready for inspection once the cover is on.
The system saves on labour and materials; there should be less time spent ‘snagging’ chambers prior to formal adoption by the water company.” |
Stanton Bonna launches Perfect Manhole video on You Tube
 Now that the majority of water companies have approved Stanton Bonna’s new watertight manhole and pre-formed base, known as The Perfect Manhole System, the company has launched a video to demonstrate the ease of achieving a safe, rapid and consistently high quality installation.
Stanton Bonna’s short video, available on its web site and on You Tube, shows a typical installation to help contractors, specifiers and merchants to appreciate the benefits of the system, as outlined at the top of this Newsletter. The six minute film shows a straightforward step-by-step installation of:
- a DN1200 factory made watertight base unit, pre-benched with a 167º channel bend, DN300 inlet and outlet holes with seals
- DN300 concrete spigot and socket butt pipes
- 1 no. 1000mm and 1 no. 500mm thick-walled watertight chamber rings
It was the first time that Yorkshire based contractor Peter Duffy Limited had installed the Perfect System and despite being unfamiliar with it, the total installation time was only 1¼ hours including all pipework and partial backfilling. As a concrete surround is not required with the Perfect System, contractors can continue pipe laying immediately, gaining substantial and valuable time over the traditional method of manhole construction. Stanton Bonna has also ensured that its sustainable Perfect Manhole System benefits from a low carbon footprint and a design life of 120 years. Click here to view the video on You Tube or here to find it at Stanton Bonna’s web site. |
