Ridgistorm-XL - the latest innovative

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1 Ridgistorm-XL - the latest innovative solution to SUDS and stormwater management Combined with the technical expertise, knowledge and support of Polypipe, Ridgistorm-XL is designed as a bespoke application for each project and offers the most advanced large diameter plastic pipe solution available in the UK. Building regulations and legislative guidance now require Architects, Consulting Engineers, Contractors and Developers to seek out alternative ways to manage and control surface water run-off from a developed site. Ridgistorm-XL offers an effective and adaptable solution to this issue, without impacting on development footprint. 22

2 Products and Solutions 2A Products and Solutions Ridgistorm-XL Contents Page Pipe Profiles and Key Benefits 2A Unique Pipe Stiffness 2A Bespoke Design, Fittings, Manholes and Applications 2A Unique Electro-Fusion Jointing System 2A Frequently Asked Questions 2A Case Histories 2A

3 Ridgistorm-XL - the most advanced large diameter plastic pipe solution 750mm 900mm 1050mm 1200mm 1500mm Ridgistorm-XL an innovative pipe solution Ridgistorm-XL is the latest innovative solution to SUDS and stormwater management applications. With a range of large diameter pipes from 750mm up to 2100mm plus the design and product technology features, it offers an effective and adaptable solution, without impacting on the development footprint. Bespoke pipe profile providing individual stiffness class Ridgistorm-XL can be engineered to suit any application. By analysing the site conditions and installation parameters, our design engineers can create a solution with the appropriate profile strength and stiffness that is neither over nor under engineered. Our production flexibility allows pipe strength to be produced at varying stiffness classes to meet the design requirements of a project, without the need to step-up pipe specification. The Ridgistorm-XL Technical Manual is available to download at 24

4 Products and Solutions 2A 1800mm 2100mm Key benefits Ideal for use as large-scale attenuation system Fabricated tanks to any size Light weight for ease of handling and installation combined with high stiffness and durability 100% recyclable Strong yet flexible design Able to withstand ground movement without leakage WRc Approved Exceptional leak tightness Ridgistorm-XL is designed as a flexible structure to minimise the effects of ground movement and deformation and prevent leakage from the pipeline or attenuation structure. Exceptional pipeline integrity is achieved with Ridgistorm-XL due to the reduced number of joints, therefore minimising the number of potential leakage points and removing the risk of groundwater pollution. Ridgistorm-XL versus rigid materials Ridgistorm-XL offers a robust, durable and adaptable solution in comparison to rigid materials such as concrete and steel. Due to its longer lengths and lighter weight, Ridgistorm-XL can be 70% cheaper to transport than equivalent size concrete pipes and can be handled and stored much more safely on-site. WRc Approval Ridgistorm-XL and all pipe profile options, stiffness classes SN2 to SN8 and diameters from 750 to 2100mm are approved by WRc. The approval also extends to all work carried out by Polypipe s in-house fabrications department, the design software used to engineer the product (for SN1 - SN8) and Ridgistorm-XL s unique and patented Electro-fusion jointing method, which covers the tensile strength of each joint, the jointing method and Polypipe s installation manual and guidance. BBA Approved* Superior hydraulic PT/193/1102 performance achieved through smooth bore Up to 2100mm diameter Durable materials Excellent resistance to sulphate and chemical attack Longer pipe lengths for improved pipeline integrity and fewer joints Unique patented Electro-fusion jointing system Excellent load bearing capability Water company approved *750mm and 900mm as a sealed system BBA BRITISH BOARD OF AGRÉMENT CERTIFICATE No. 10/H159 25

5 Ridgistorm-XL - unique pipe stiffness providing flexible and variable loading specifications VW profile PR profile Profile type VW enables the production of a solid pipe with a smooth inner and outer surface. These pipes can be produced with a wall thickness of 5mm to 80mm. Pipes produced with a PR profile achieve high stiffness with relatively low weight. This is a common pipe profile for use in sewer and surface water drainage applications. LIGHT LOADING Individual pipe profiles Following many years of development, structured wall pipe technology has been designed and engineered to maximise the strength of the pipeline. Utilising the latest manufacturing technology and unique, state of the art software enables Polypipe to create unique profile designs to match customers site requirements. Pipe profile designs can be adapted to maximise strength and minimise use of material within the pipeline, which improves pipeline performance and provides a value engineered solution. Our bespoke range of profiles are integral to the strength and performance of the pipeline. Optimised wall thickness and pipe profile design ensures that the pipeline can cope with both external and internal pressures and any subsequent deformation. Ridgistorm-XL is designed as a flexible structure to withstand point loading and ground movement once installed. 26

6 Products and Solutions 2A Polypipe is unique in its ability to produce large diameter pipe and attenuation solutions to match your exact requirements and site conditions. The flexibility of our manufacturing process enables you to specify exact stiffness requirements and utilise a value engineered solution that is neither under nor over specified. Olympia profile SQ profile SQ2 profile In addition to the PR profile, the Olympia profile option can achieve greater pipeline stiffness with a comparatively low weight. This profile option has a smooth inner and outer surface, including internal profile to one layer. High stiffness is achieved through the SQ profile, making it ideal for extremely high loads or larger diameters. SQ2 offers the same benefits as the single-layer SQ profile, yet it can be produced with additional profile layers for added ring stiffness. HEAVY LOADING 27

7 Ridgistorm-XL - applications Bespoke project design Ridgistorm-XL is designed as a bespoke solution to suit each individual project. Our team of Design Engineers and Drainage Specialists utilise the latest design and manufacturing techniques to engineer a drainage scheme to specific requirements. This flexibility enables us to design-in required elements such as inspection chambers at determined intervals and manhole access. Ridgistorm-XL Ridgistorm-XL fittings Utilising the skills of our in-house Fabrications Team we can offer customers a complete range of bespoke fittings, reducers, bends and attachments to the standard Ridgistorm-XL pipe. Our bespoke fittings also enable the Ridgistorm-XL system to be connected to a variety of other applications, including concrete chambers and steel carriage pipes. Reducers and bespoke bends also facilitate the integration of Ridgistorm-XL into existing drainage networks. Bespoke fabrication Large diameter manholes Ridgistorm-XL pipe can be used in the construction of bespoke large diameter manholes for use in both surface water and foul sewer applications. The Ridgistorm-XL range can also be manufactured with integral manhole access to offer a complete pipeline solution with maintenance access. Bespoke and off-set manholes Pre-cast manhole The flexibility and adaptability of the Ridgistorm-XL system, alongside the experience and capability of our in-house fabrications team enables us to design and manufacture bespoke manholes to meet site requirements. Off-set manholes can be integrated into a Ridgistorm-XL pipeline or attenuation system to provide easier maintenance access to the system. This utilises a unique step feature within the construction of the manhole to reduce the need for direct access into the pipe with improved Health and Safety benefits, particularly in foul sewers. 28

8 Products and Solutions 2A Applications With a range of diameters from 750mm to 2100mm, Ridgistorm-XL offers a durable and engineered solution to large-scale attenuation and pipeline requirements for use in: Surface water drainage Large-scale attenuation structures Specialist pipeline applications Foul sewers River diversions and culverts Sea outfalls Rainwater Harvesting Air ventilation Renewable energy Bespoke large diameter manholes & catchpits Filters in large diameter pipes Step irons or ladders 29

9 Ridgistorm-XL - advanced jointing system Insert support ring Total flexibility Polypipe has designed the Ridgistorm-XL system to offer customers a range of options. This flexible approach ensures that customers can take advantage of systems designed and manufactured to their exact requirements and to project specification. The range of jointing options available for Ridgistorm-XL offers customers the greatest flexibility over other comparable systems. Unique, patented Electro-fusion jointing Polypipe offers the only large diameter plastic pipe solution with integral Electro-fusion jointing Electro-fusion jointing. Electro-fusion wire is connected to the socket end of the pipe during manufacture and supplied with a unique barcode containing the settings and installation parameters for the pipe. Exceptional joint performance Once the two connecting pipes have been brought together, internal and external support rings are fitted to apply pressure to the seal during the jointing process. The Electro-fusion wire is then connected to an electrical supply which joins the pipes together. Using the Electro-fusion jointing method, 100% seal tightness can be achieved to guarantee exceptional joint and pipe performance. Barcode scan for jointing parameters Speedier jointing In comparison with other large diameter systems, Ridgistorm-XL can be handled, jointed and installed much quicker, resulting in time and cost savings on-site. 30

10 Products and Solutions 2A Multiple jointing options Ridgistorm-XL can be designed and manufactured to suit any jointing requirement on-site. EPDM, internal-welds and flange connections can all be achieved with the Ridgistorm-XL system, depending on the installation and application requirements of the project. Less joints, less leakage Ridgistorm-XL is available in standard lengths of 6 metres. With less joints, Ridgistorm-XL significantly reduces the potential for leakage. Ridgistorm-XL offers flexibility in specifying a joint that is appropriate for the project. Release external compression chain Health & Safety benefits Electro-fusion jointing offers improved Health and Safety benefits over traditional jointing methods by reducing the need to work within confined spaces. On-site, Ridgistorm-XL can also be jointed at the side of the trench before being craned into position, reducing Health and Safety risks during installation. Installation Ridgistorm-XL units are installed in the same tried and tested way as twin-wall flexible pipe systems. Ridgistorm-XL units are suitable for installations under car park areas or roads. Separators are required only in high risk areas with sustainable drainage systems. Consult Polypipe s water management solutions technical team for further advice. Placing next pipe in position Maintenance Properly designed Ridgistorm-XL attenuation systems, incorporating suitable catchpits, require no maintenance other than the removal of silt and leaves from the catchpit, which may be done easily by on-site maintenance staff. 31

11 Ridgistorm-XL - frequently asked questions 1. Can Ridgistorm-XL be recycled? Ridgistorm-XL is manufactured from polyethylene and is 100% recyclable at the end of its useful life. 2. What quality standards does Ridgistorm-XL meet? Ridgistorm-XL is approved by WRc (see page 25 for details) and is designed to meet the performance requirements of the European sewer pipe standard BS EN Ridgistorm-XL also meets the requirements of DIN BBA approved for sizes 750mm and 900mm as a sealed system. Approved by most water companies for capital works and section 104 schemes. 3. Do Ridgistorm-XL pipes deform under loading? Ridgistorm-XL pipes are designed to deform. The deflection of flexible pipes is controlled by the settlement of the soil. After settlement, traffic and other loads do not affect pipe deflection. With rigid materials such as concrete, traffic and other loads must be resisted by the pipe itself, making the pipe prone to cracking. However with flexible pipes such as Ridgistorm-XL the surrounding soil absorbs the stresses ensuring that the pipeline remains intact. Pipe deformation 4. What happens to the Ridgistorm-XL joints when deformation occurs? The joints within the Ridgistorm-XL pipe system are tested for leakage under deformation. This stringent test ensures that the joint remains water tight even when pipes are deformed by 5% and the socket by 10%, deformation far in excess of that encountered by the pipes in application. inches Does Ridgistorm-XL have a proven track record? The technology used to produce Ridgistorm-XL pipes and fittings is tried and trusted and has been in operation for 20 years. In fact, over 40 production lines are in operation worldwide including Germany, Italy and Australia. 0 PE Clay Steel Ductile Concrete Wall roughness 6. What is the co-efficient of friction for the Ridgistorm-XL pipes? Ridgistorm-XL pipes benefit from a smooth inner wall, providing superior hydraulic performance when compared with rigid materials such as clay or concrete. See bar chart (left) for details. 32

12 Products and Solutions 2A 7. Are Ridgistorm-XL pipes abrasion resistant? Pipes manufactured from polyethylene (PE) or polypropylene (PP) offer far greater abrasion resistance than alternative materials. The graph (right) shows the abrasion curve of various pipe materials according to the results of the Darmstadt procedure. This graph demonstrates the superior performance of PE and PP pipes. 8. Are Ridgistorm-XL pipes UV resistant? abrasion in mm 2.0 concrete pipe 1.5 concrete pipe coated GFK pipe Clay pipe PVC pipe 0.25 PP or PE pipe cycles Abrasion resistance Yes, Ridgistorm-XL pipes are resistant to UV attack and can be safely stored on-site without any damage or ageing effects. Ridgistorm-XL pipes may also be suitable for some above ground applications. 9. What is the standard bedding detail for Ridgistorm-XL pipes? Type S bedding detail is standard for the installation of the Ridgistorm-XL system. However, by using the unique Easypipe software, we are able to engineer alternative trench bed and surround details to ensure optimum construction methods to suit each individual project. 10. Are Ridgistorm-XL pipes easy to handle and store on-site? Yes, Ridgistorm-XL pipes can be handled by forklift without the need for any additional equipment on-site. Ridgistorm-XL pipes can be unloaded and transported to the trench by excavator which will already be present on-site. 11. How should Ridgistorm-XL pipes be stored? When storing Ridgistorm-XL pipes and fittings it is necessary to ensure that they are stored on flat ground, free of stones or other sharp objects to avoid any point loading on the pipes. It is also important to rotate each pipe layer by 180 degrees so that the sockets of the upper layer are not lying directly over the sockets of the lower layer. See diagram below. Do not stack Ridgistorm-XL pipes more than four metres high. It is also important to use wood bearing supports between the pipes to ensure even load distribution and wooden chocks to prevent pipes from rolling. Please carry out an appropriate Health and Safety Risk Assessment for your site. 33

13 Ridgistorm-XL case histories River diversion project using Ridgistorm-XL Polypipe completed a challenging river diversion project at the Ffos-y-Fran Land Reclamation Scheme in Merthyr Tydfil, Wales using its Ridgistorm-XL large diameter pipe system. Working alongside the main contractor, Dawnus Construction and project engineers Peter Brett Associates, Polypipe has supplied and installed 72 metres of 1200mm diameter Ridgistorm-XL pipe along two separate runs. Ridgistorm-XL s patented Electro-fusion jointing process achieved quicker and safer installation in comparison with other large diameter pipe solutions and guarantees 100% seal tightness for each joint. Ridgistorm-XL was specified for a section of this diversion due to its inherent strength and cost effectiveness when compared to traditional rigid materials. The system was installed in an enclosed concrete structure and then covered with wet-cast concrete. This then enabled the construction of a temporary road for heavy plant and vehicles to travel across the watercourse, whilst allowing the re-routed water to flow through the pipeline. 34

14 Products and Solutions 2A Bespoke - Large diameter attenuation and rainwater harvesting solution for new livestock market A detailed cost analysis carried out by the main contractor, on the cost-effectiveness of plastic and concrete materials resulted in Polypipe re-engineering a bespoke SUDS solution for a new livestock market. Having proved that Ridgistorm-XL large diameter pipe system could achieve significant savings on the whole-cost of the project, Polypipe s water management solutions team worked closely with the contractor to design a 400 metre balanced attenuation tank with a storage capacity of one million litres, using Ridgistorm-XL large diameter pipe in 1800mm diameter to manage surface water run-off from all hard standing areas. In addition to the attenuation tank, Polypipe also designed and fabricated a bespoke 300,000 litre rainwater harvesting solution using Ridgistorm-XL pipe in 2100mm diameter, to re-use rainwater from the 6,000 square metre roof area on-site. Alongside its full design and technical support service, Polypipe supplied a wide variety of bespoke fabrications for the non-standard elements of the project, including bespoke 150mm stubs at intervals along the attenuation structure to connect gullies from each cattle grid. The rainwater harvesting tank also included a fabricated T section that features an in-line leaf filter to prevent debris from entering the tank. 35

15 Ridgistorm-XL - Electro-fusion joint delivers stormwater diversion for Gatwick Airport Polypipe supplied a bespoke large diameter pipeline solution using Ridgistorm-XL for the construction of a new airside building at Gatwick Airport s North Terminal. Ridgistorm-XL was specified by the main contractor for its Electro-fusion jointing system. The existing storm drain needed to be relocated and the Ridgistorm-XL pipeline installed prior to the piling work being carried out for the new building. Concerns over the pipeline integrity as a result of the piling work were negated by using Ridgistorm-XL. The patented Electro-fusion jointing method guarantees 100% seal tightness within the pipeline and is the only large diameter plastic pipe system in the UK to incorporate such technology. Ridgistorm-XL Large Diameter Pipe System Provides the Solution for Landfill Project Using its patented and WRc approved pipe design software and a soil report provided by the main contractor, Polypipe s water management solutions team determined a bespoke stiffness class for the Ridgistorm-XL discharge and collection pipe that was value-engineered to meet the project specifications. Polypipe are the only manufacturer of large diameter plastic drainage pipes with the capacity to engineer the solution for the project based on soil conditions, burial depths and installation parameters. Polypipe supplied over 600 metres of its Ridgistorm-XL system in 1050mm diameter. This was installed around the perimeter of the site to manage surface water run-off from the capped areas of the landfill. Sections of the Ridgistorm-XL pipe were also perforated to collect excess stormwater for carriage through the discharge pipe. In addition to its Ridgistorm-XL large diameter pipe, Polypipe also supplied over 700 metres of 300, 450 and 600mm diameter Ridgisewer and Polysewer sewerage pipe. 36

16 Bespoke - Ridgistorm-XL Large Diameter Pipe system Products and Solutions 2A Polypipe re-engineers original specification for Northumbrian Water flood alleviation scheme based on Ridgistorm-XL s proven performance and Electro-fusion jointing. Early involvement in a capital projects scheme in Penshaw, County Durham for Northumbrian Water enabled Polypipe s water management solutions team to work closely with consultant engineers Mott MacDonald and supply its Ridgistorm-XL large diameter pipe system. An alternative system was originally specified but this was re-engineered after Polypipe s water management solutions team demonstrated the performance capabilities and Electro-fusion jointing technology of the Ridgistorm-XL system. 114 metres of Ridgistorm-XL pipe in 1050mm diameter were supplied to the scheme, along with 1050mm elbow joints and two large diameter 1800mm manholes fabricated at Polypipe s dedicated facility in Loughborough - the largest fabrications department for plastic drainage products in the UK. Ridgistorm-XL s Electro-fusion jointing method was a significant factor for Northumbrian Water, Mott MacDonald and contractors Seymour Civil Engineering as this eliminated the need for internal welding within the pipework. Once on-site, the improved handling and quicker installation of the Ridgistorm-XL system compared to traditional rigid materials enabled Seymour to reduce the overall construction programme by two weeks. In addition to the design and technical support provided by Polypipe s water management solutions team during the initial stages of the project, Seymour s on-site team were also trained on the Electro-fusion welding of the Ridgistorm-XL system to aid in the rapid installation of the products. This offered further Health and Safety benefits as the need for working in confined spaces was reduced. This project marks the first capital works scheme to use the Ridgistorm-XL large diameter pipe system, with all parties working closely together to trial the new technology. As a modern alternative to traditional rigid materials that provides unique factors such as Electro-fusion jointing and bespoke, site-specific design, Ridgistorm-XL can deliver tangible benefits in terms of reduced Health and Safety risks, improved pipeline performance through joint integrity and an overall reduction in the construction programme. 37