Our extensive in-house design and manufacturing facilities are home to well established research and development unit and comprehensive testing facility. Our commercial offices incorporate our design team who utilise the latest computer aided design technology and work alongside our dedicated planning section who oversee everything from surveying, scheduling and contract reviews, to the management of framework agreements.
Technocover have been designing and manufacturing innovative steel products since 1993. In that time, through organic growth, planned expansion and acquisition, we have gained a reputation as the UK’s leading supplier of Physical Steel Security Access Products. We have a range of aperture security solutions for virtually every application, establishments in the UK and overseas have sought our expertise in providing security products for asset protection.
We operate a Total Service Philosophy and can handle complete projects from site survey to final installation, whether for new or refurbishing projects, the adaptability of our galvanised steel access products means the most complex design criteria can be met. Our range of high quality access products offer custom built operational and security solutions to prevent unauthorised persons gaining access, securing key assets against all levels of trespass, malicious vandalism, theft, extortion, contamination or terrorism.
Many of our access system products have been tested and approved by the Loss Prevention Certification Board (LPCB) to LPS 1175 issue 5 or above, Security Rating Levels 2, 3, 4 or 5.
Technocover hold both exclusive and shared framework agreements with most of the major UK water companies. Framework Security items include:
- LPCB Level 2 Universal Gas Cylinder Clamps
- LPCB Level 3 Mesh Cage Systems
- LPCB Level 3 Flush Access Covers
- LPCB Level 4 Upstand Access Covers
- LPCB Level 4 Padlockable Access Doors
- LPCB Level 4 Key Entry Doors
- LPCB Level 4 Enclosures/Kiosks/Cabinets
- LPCB Level 4 Walk-In Modular Buildings
- LPCB Level 4 Window Bar Sets
- LPCB Level 5 Louvres
Please e-mail: [email protected] to request a copy of Technocover’s 226 page A5 guide to Physical Security Access Solutions for Water Asset Protection.
Press Releases & Case Studies
High Security Enclosures for Water Assets (2020)
Access Hatch Solutions - Cardiff Bay Barrage (2019)
Physical Protection of Assets (2018)
Physical Security for Infrastructure (2016)
Brook Street (Dawlish) CSO (2023)
Barkers Haugh STW (2021)
Ludham Licence Reinvestment (2021)
Service Reservoir Isolation Programme (2021)
Birmingham Resilience Project - Treated Water Project (2020)
High Security Enclosures for Water Assets (2020)
Invercannie WTW (2020)
Lough Fea Clear Water Basin South (2020)
Birmingham Resilience Project - Treated Water Project (2019)
Davyhulme WwTW Modernisation Project (2019)
High Security Enclosures for Water Assets (2020)
The security of the UK water network is integral to investment plans and operational management for water companies in the face of an ever-growing hierarchy of threats. These risks range from trespass, vandalism, malicious damage and opportunistic theft, to organised crime, infiltration and sabotage by activists, and terrorist attack invariably intent on causing major disruption and harm to life. Any breach of a restricted area or critical process will have an impact on site operations, incurring time and cost of incident management, of equipment repair or replacement, and from service interruption. More catastrophic still, there may be ramifications for regional if not national water supply and public health.
Other emerging threats have highlighted the critical role of water supply resilience. Weather extremes and flooding caused by climate change pose the risk of network disruption and costly remediation, as well as unplanned maintenance due to the premature ageing or failure of infrastructure. Most recently we have seen that the response during a pandemic like COVID-19 relies on a secure water supply to maintain life-saving medical services and a population in lockdown.
In combatting these omnipresent threats, water companies continue to review and enhance the physical security of the water network alongside technology for surveillance, personnel ID and access control.
A mesh UltraSecure enclosure, measuring 3300mm x 7000mm on plan, being installed in two halves to harden asset protection at a pumping station site
As the UK water industry reaches an advanced level of maturity in physical protection, the high security enclosure has seen significant demand and diversification through AMP6. This is set to continue in AMP7 as manufacturers like Technocover push the boundaries in the design and versatility of modular buildings, kiosks and cabinets meeting the rigorous performance standard of LCPB security certification.
Working in close partnership with water companies and contractors, Technocover has designed, built and installed a diverse range of secure, steel enclosures with certified, measurable levels of protection for many applications - from boreholes, pumping stations and reservoirs, to treatment processes, power generators and switchgear, and the storage of hazardous chemicals and materials.
Technocover organised special transport and lifting plant for the delivery and installation of several pre-assembled enclosures measuring 6000mm long by 5460mm wide by 3000mm high to reduce site time
The core function of these enclosures is to protect the asset against forced entry by hostile actors, giving time for first responders to arrive. However, the design and planning of these critical pieces of engineering can also address other important project considerations in maximising whole life benefits and saving cost for the client.
For example, the mode of assembly should minimise, if not eliminate down-time, and overcome access and space constraints on site. Equipment design should provide scope to add functionality and contingencies to enhance operational safety and efficiency, while allowing for system extension or reconfiguration according to future needs. And, in line with TOTEX (total expenditure) accounting, the engineering should provide long-term, predictable performance and minimum maintenance in delivering best value over the product lifecycle.
In meeting these complex criteria, each enclosure is different. However, based on many years’ experience of solving challenges large and small, from urban to remote highland sites, Technocover has evolved three main approaches to the secure housing of water assets, suitable for refurbishment or new build.
Off-site assembly, delivery and installation of an LPCB SR3 enclosure
Long-established sites, especially those in urban areas, often have limited space for construction activities, and access to refurbish an existing asset can be very challenging. In this scenario, offsite assembly is playing a grow role in the upgrading of security enclosures to existing assets.
With a need for speed of completion and minimum disruption to water processes and service continuity, Technocover has devised the ‘drop-on’ security enclosure – a factory assembled unit which is shipped to site, often as one piece, and simply lifted over the existing enclosure and asset, to create a new, upgraded protective skin.
Drawing on Technocover’s full technical services in surveying, design, manufacture, logistics and installation, these solutions:
- Simplify assembly and eliminate the need to reinstall plant and fittings, reducing site time and minimising, if not avoiding, asset downtime.
- Are precision designed and fabricated to fit snugly around the existing structure with minimum encroachment on floorspace and aligning with vents, doors and apertures in the existing enclosure.
- Enable the unit to be distance lifted according to the capacity and reach of the permitted vehicle hoist or crane and its working location, whether on a public road or within the site.
Drop-on UltraSecure kiosk provides upgraded protection around existing GRP enclosure at water booster station
The photo above shows a ‘drop-on’ type UltraSecure kiosk being installed around an existing GRP enclosure at a water booster station site. The new kiosk features LPCB approved accessories including protective mountings for the security light, alarm and telemetry sensors. Guided by a detailed site survey and CAD design, it incorporates slightly wider doors with shallow thresholds to permit the inner GRP doors to open and close, as well as vents aligning with the existing unit. To prepare for the upgrade, Technocover extended the concrete base to allow bolting of the new unit.
The same ‘drop-on’ principle can be applied to the new generation of performance tested, heavy duty modular mesh systems. In addition to permitting natural ventilation of the asset, the see-through mesh allows instant visual inspection. This benefits site security and productivity by reducing the need for personnel to enter the enclosure involving the repetition of access protocols.
Technocover’s deep expertise in resolving the parameters of design, lifting logistics and LPCB criteria ensures that the most complex of assemblies are achieved right first time to minimise downtime.
Drop-on UltraSecure modular buildings can save several days of site time, allowing the existing brick structure and fittings to be retained and processes to remain live while hardening the asset to an enhanced standard.
With the opportunity to design from the ground up, the new build project offers the greatest scope to maximise the lifecycle benefits and return on investment from a secure enclosure. Through early involvement and close collaboration with the client and project team, designs can address and benefit many more aspects of the construction programme and life-time operations than is often anticipated.
Working together, all parties can consider the product at each stage of its life cycle, ensuring that the design responds to logistical, construction, health and safety, and operational needs, right through to its ease of dismantling at end-of-life. This enables potential problems to be designed out and features to be designed in that facilitate installation, site productivity and low maintenance, with a focus on time and cost savings and preserving service continuity.
Measuring 8700mm long by 5300mm wide by 3000mm high, this UltraSecure modular building was 3D modelled and precision manufactured to fit snugly around existing infrastructure with minimal extension of footprint
Depending on site logistics and co-running construction, kiosks can be planned and delivered as pre-built units with the option of pre-fitting with M&E services, for rapid connection to mains electricity. Alternatively, they can be supplied in ‘flat pack’ where crane lifting of a pre-assembled unit is undesirable and working space is less constrained.
Systems can be adapted to specific operational needs from a range of accessories and module options. These include single or double doors (with or without vision panels), venting louvres, roof escape hatches, and internal lining (timber or recycled plastic). This is supported by compatible LPCB approved padlocks and locking/user ID systems, entry and exit hardware, and full integration with site alarms and the latest access control management.
With the potential for creating significant buildings with large footprints, internal space can be compartmentalised to create separate control rooms, storage, welfare areas in addition to the main process or plant zone.
Enclosures can be supplied fully fitted with M&E services, tool racking, hygienic wall finishes and restroom facilities, to create ready-to-use accommodation that is security tested
UltraSecure modules offer a sophisticated range of contingencies within the scope of their LPCB approval, including turned-out frames, special anchoring systems and support beam assemblies. These features allow them to be installed against concrete upstands and walls, or as part of a larger, integrated security assembly such as a multiple leaf access system over underground water treatment processes or UV equipment.
The tailoring of roof systems can add significant value to operational efficiency and ease of maintenance. Substantial pipe sections and large components are far easier through removable sections of roof which offer much larger apertures and manoeuvrability than available LPCB door systems.
Modular building with a roof assembly that can be removed in sections or completely for flexible plant access. Inset photo shows roof support beams and fall protection grids positioned below the roof access hatches
Precision manufactured by Technocover, the photo above shows a very large UltraSecure kiosk, measuring 11,000mm long by 8600mm wide by 3150mm high, with a roof assembly designed for multiple options for access to plant below, including complete roof removal. Note the proliferation of lifting eyes on roof panels and the series of upstand escape hatches, which are also assist safe assembly and dismantling. The inset photo shows the roof support beams and fall protection grids positioned below the roof access hatches.
The row of escape hatches are covered with a black, non-slip finish for the safety of personnel using them, while the roof structure is also domed to shed water.
The larger of these two special mesh enclosures has an irregular footprint and roof system to fit securely to an existing wall structure (see roof detail in righthand image)
Sometimes, enhanced in situ security is required for ancillary plant, generators, cylinder or material storage located within recesses and close to walls. These can be resolved with tailored mesh assemblies, with or without roof sections, drawing on Technocover’s expertise and product capability to stay within the scope of LPCB certification.
The example above shows a pair of special mesh enclosures to enhance the protection of a main discharge water pipe. The larger unit has an irregular footprint and roof system to fit securely to an existing wall structure. Similarly, solid enclosures provide scope for unusual shapes to fit site conditions, for example, to around kerbs, concrete plinths, retaining walls, and other structures (see examples below).
(left) UltraSecure kiosk, 3800mm x 3000mm on plan, with an angled side to leave clearance for the opening/closing of a nearby access cover, while fitting snugly between concrete wall elements, and (right) specially shaped kiosk with protective bumper strip to suit kerb location.
Whatever the size or complexity of enclosure, system integrity and longevity are assured by a high quality specification of structural steel and post-galvanised protection. This provides a demonstrable life expectancy of at least 20 years to minimise maintenance interventions, underpinning long service and cost certainty during the product life cycle.
This article was prepared by Technocover, a company with over 25 years’ experience in the turnkey delivery of LPCB certificated, high security enclosures, doors, access covers and associated protection for water and other critical national infrastructure. Under the HS Security brand, a division of Hill & Smith Holdings plc, Technocover partners other innovative group specialists to provide advanced, integrated physical security solutions.
Access Hatch Solutions – Cardiff Bay Barrage (2019)
Completed in 1999, the Cardiff Bay Barrage was designed to regenerate the city waterfront as a vibrant and attractive destination while creating an efficient, two-way control interface between the tidal waters of Cardiff basin and the river estuaries beyond. The challenge of achieving this balance of functionality both sides of the barrage is reflected to a degree in a more recent engineering feat - though on a very much smaller scale. Two-way access management, water resistance along with discrete appearance are embodied in the design of access hatches installed to enhance the safety and resilience of the barrage plant gallery. When asked to engineer these special access solutions, Technocover’s surveyors and technical team soon realised that more than standard galvanised steel access covers would be required.
The £220m civil engineering project saw the creation of a focal 200 ha freshwater lake or bay, the catalyst for a £2 billion regeneration of the old dockland areas of Cardiff and Penarth. The bay replaced the unattractive sight of mud flats exposed within an urban estuary with a tidal range of 14m, the second highest in the world.
The barrage features several bascule bridges, locks, sluice gates and a fish pass, as well as a landscaped embankment area providing public space to promenade and picnic.
At the centre of operations is the barrage control room, the main point of contact for boats navigating to and from Cardiff Bay. This is staffed 24 hours a day, 365 days a year by a team of operators, lock managers and engineers.
View of the three locks and bascule bridges where Technocover’s special emergency hatches provide 2-way access to the below plant gallery
Three locks, each measuring 40m long, allow boats to navigate between the Severn Estuary and Cardiff Bay. They can accommodate up to 10 average sized vessels at any one time, with passage through the locks taking between 5 and 20 minutes, depending on the tide. Each lock has a bascule bridge weighing approximately 88 tonnes. The lock gates are up to 16m high to enable boats to pass through at all stages of the expansive 14m tidal range. When the locks are closed, they allow passage over the barrage structure for pedestrians, cyclists and vehicles.
Five sluice gates control the level of water in the bay. These permit flows from the rivers Taff and Ely to exit into the Bristol Channel, or create a barrier to stop the high tide from entering the bay. Over a quarter of a million litres of water per second can flow through each gate, which measure 7.5m high and 9m wide.
Technocover was contracted to redesign the existing covers and manufacture four new flush-fitting emergency escape hatch access covers over shafts to the barrage operations gallery in areas close to the bascule bridges.
The four units were required to provide safe exit routes for personnel carrying out inspection and maintenance within the barrage’s internal gallery shafts, even if closed and locked from above.
Technocover’s knowledgeable designers set about the challenge of creating these special emergency escape hatches to meet the specific operational needs of the Cardiff Bay Barrage application.
By incorporating an external locking system compatible with internal emergency escape hardware, access from above is controlled and facilitated via a turn-catch hasp and staple padlocking entry system. From below, this can be overridden by a single lever handle, providing efficient exit from inside the shafts, especially in an emergency situation.
Each cover also has a shrouded and hinged anti-trip padlock housing, designed to accept a LPCB approved security padlock. This is operable from above (once the padlock has been removed), and also from below by using a release handle on the slam-shut locking facility. An additional grab handle on the underside of the cover lid further assists exit from the chamber.
Management of surface water - to prevent ingress into the shaft - was another important aspect of the design.
The frame design was adapted to incorporate a moated drainage channel with twin drainage pipes and hose connection points. This allows any water build-up from inside the frame to drain through a top connection pipe and drain tube into a sump at the bottom of the shaft.
In addition, sealing was provided to help prevent the ingress of water. This was fitted to the underside of each cover lid as standard, to safeguard it from damage when the cover is in the open position.
The 18m descent from the emergency escape cover at bascule bridge level to the internal barrage gallery
Three of the covers are located within block paved pedestrian areas, requiring appropriate underbracing to meet a C250 load requirement for occasional trafficking by utility plant. The fourth needed no additional strengthening, being sited within a tarmac area enclosed by protection rails.
In addition to these special adaptations, Technocover’s hinged, flush fit access cover offered the following standard features and benefits:
- Concealed holding down anchor points to maintain secure anchoring of frame within paved area.
- Single, sealed lifting keyhole (BSI conformant) in left-hand side of cover.
- Recessed padlock with hinged and anti-trip locked-down cover plate, complete with loading identification, to safeguard against tampering and ensure stable surface underfoot.
- Stainless steel, torsion-sprung lid providing operation by a single person in compliance with the Health and Safety Executive directive for manual handling.
- Concealed hinges to protect against damage from vehicle overrun and ingress of grit and other potentially damaging debris.
- Cover lid opens to 95 degrees to give convenient, safe and unobstructed access to chamber shaft.
- Hand operated, automatic safety stay that firmly holds hatch lid in open position during entry/exit.
- Wide sealing strip to underside of cover lid, preventing damage to seal when cover is open.
- Structural underbracing to underside of hatch cover, designed to withstand the required C250 loads.
- All mild steel hot dip galvanised after manufacture to BS EN ISO 1461 for long life weather-resistance and durability.
(left) Access cover within tarmac zone with protection rails around it. Note the custom locking key required by the client and the concealed padlock housing, as well as the shrouded hinges at far edge maintaining flush anti-trip finish and (right) Interior showing copper pipe from frame drainage connection points and the central single black hose that carries water 18+ metres down to the sump in gallery base
Careful design attention was needed to ensure that the hidden hinges and concealed padlock were achieved while maintaining a flush, hazard-free finish and discrete look to minimise visual disruption of the surrounding block paved aesthetics.
Simple routine maintenance is carried out to ensure the covers continue to function efficiently. This involves opening the covers periodically to vent the chambers, and to check that the internal drainage connections and hoses are kept clear of any obstructions. If water is present, it can be drained away from the side frames and down the 18 plus metres shaft to the barrage gallery sumps.
Twenty years on from completion of the barrage, Technocover’s access solutions continue to reflect the development’s ethos to achieve excellence and innovation in the field of urban regeneration and meet the highest standards of design and quality. Their structural integrity, water-resistant design and long life post-galvanised zinc finish will also ensure system weather-proofing and durability for the next twenty years and beyond.
For water supply and process sites - such as reservoirs, water treatment installations, boreholes and pumping stations - upstand versions of these emergency escape hatch covers are also available.
This article was prepared by Terry Batten, Marketing Manger with Technocover Ltd.
Phone: 01938 555511 Web: www.technocover.co.uk
Physical Protection of Assets (2018)
The security landscape within the UK’s water industry has evolved beyond recognition since the advent of dedicated legislation twenty years ago. From the upgrade of service reservoir protection that rolled out from the late 1990s, to the mature and sophisticated levels of security that ramify through today’s network, UK water sets a world-class standard in its approach to water asset hardening. It has seen nothing less than a revolution in the water security product market dominated by LPCB certificated equipment, from upstand covers and security louvres, to large security kiosks - built off-site and craned into place. Today, security hardware is being seamlessly integrated with today’s digital technology including electronic access control, wireless alarm networks and CCTV. As the industry gears up for AMP7 with talk of asset optimisation, operational efficiency and a hefty focus on ‘value’ rather than ‘cost’, security company Technocover believes its founding principle of ‘Total Service’ is more relevant than ever before.
With the introduction of reservoir security legislation in 1997, Technocover was one of the first to market with a double-skin upstand access cover tested and approved to the Loss Prevention Certification Board’s (LPCB) exacting LPS 1175 standard for security performance.
While LPCB has been critical to Technocover’s success, the company has maintained its lead by also focusing on project and customer support through ‘Total Service’. This includes site surveys, risk assessment advice, design with value management input, specialised logistics and delivery, installation, maintenance, even removal and recycling at end of service.
‘Total Service’ takes a holistic view of the product’s ‘journey’, from concept to decommission, to ensure it provides the best value, whole life solution focused on customer needs and cost efficiency.
While maximising customer satisfaction, it tailors UltraSecure solutions to the long-term outcomes, operational efficiency and ‘optimised asset intervention’ which have become the imperative of AMP6 and AMP7.
The emphasis is on close cooperation, listening to needs, and dovetailing products and site services to make life as easy as possible for clients and their delivery team, as well as avoiding under- or over-specification.
The current asset management plan (AMP) focus on transformative innovation and operational and cost efficiency is relying heavily on improving supply chain interaction, including closer collaboration between water company delivery parties.
Early involvement is a crucial part of this approach. Through close partnership and early engagement with the water company and their chosen tier 1 or tier 2 contractor, Technocover as a technology supplier is better able to support the delivery of high quality, timely and cost-effective solutions compliant with security needs.
Close collaboration with the client and project team at early planning stage allows the screening of every aspect of the product solution - its design, installation and operation - to identify opportunities for efficiency gains and cost savings, and achieve on-time, on-budget construction.
With this level of technical and service input, operational issues can typically be identified and resolved in the design that might otherwise lead to delays or difficulties in completing routine inspection and maintenance tasks, or even emergency procedures.
The importance of early consultation with suppliers is highlighted by a recent upgrade project. The client placed an order for a twin-leaf LPCB SR 4 upstand access cover to harden the security of a borehole chamber.
As shown in Figure 1 (below), the cover was fitted on a high plinth which was accessed from the road via steps. To unlock the cover, the operative would need to climb a further 950mm using a ladder to gain access to the borehole. Due to the chamber height from the ground, it was not possible for an operative to open the cover leaves standing at ground level. More hazardous still, it meant using a ladder at the side of the chamber introducing the added danger of a fall from height.
Figure 1: Early consultation with the supplier could have identified the need for a more appropriate access solution to secure the borehole and protect operatives
Under normal circumstances, the cover would have been entirely fit-for-purpose if installed on a conventional upstand at typical ground level. However, in this case the client did not stipulate when ordering that the cover needed to be raised almost a metre above ground height.
To overcome this initial oversight, Technocover proposed a new physical security access solution (Figure 2 below).
Figure 2: Technocover devised a half-height kiosk to fully secure the borehole while providing personnel with safe access to the chamber via a full height door
The twin hinged cover was removed and replaced by a 1335mm high, half height UltraSecure modular kiosk. Measuring 2300mm x 2300mm on plan, it features a single piece, removable roof sited in place of the upstand cover unit. The refit was done by one of Technocover’s installation teams within a morning. This included the cutting of a new 940mm x 900mm opening through the existing 200mm thick wall for integration of the SR 4 security door where the ladder had previously been.
The new assembly was hot dip galvanised after manufacture to BS EN ISO 1461 and then painted with a forest green finish.
This enclosure also has high and low louvre vents with internal insect mesh, the SR 4 door has rim lock with external ‘T’ handle entry and shrouded hasp and staple locking to suit LPCB approved padlock.
Clearly, early engagement could have avoided the additional costs of remediation.
Fully resourced project support, like Technocover’s Total Service, will become increasingly important to an industry tasked with working in more efficient and collaborative ways in AMP 7 and future spending programmes.
Early planning and supplier involvement can have a significant impact, in both the short and long-term, on the cost and other important outcomes of security procurement. It allows delivery partners to work proactively and be innovative, combining their individual expertise to anticipate issues and problem-solve, from design to installation to in-service operation.
As well as avoiding specification errors, early collaboration helps to ‘design out’ risks associated with health and safety and asset failure. There is also scope to ‘build in’ maximum functionality and necessary contingencies so that reactive maintenance, unplanned interventions and service disruption are minimised.
After 25 years, Technocover offers leading capability in harnessing value engineering and operational efficiency in the increasingly innovative security solutions demanded by the industry while maintaining LPCB compliance.
With the opportunity to add value and optimise performance, early planning of physical security work enables greater transparency and control/forecast of cost throughout the asset life-cycle. Its role should not be underestimated as the water industry strives for better outcomes within the supply chain and customer service.
This article was prepared by Technocover Ltd
(T) 01938 555511 (W) www.technocover.co.uk
Physical Protection of Water Assets (2017)
During two decades of working to legislated levels of security for physical access, the UK water industry has ushered a revolution in certified physical protection. While meeting this critical and immovable benchmark of resilience, solutions in AMP6 are pushing the envelope in design and functionality as never before. Security performance, of course, remains king, but criminal attack, extortion, infiltration, and terrorism in its many and increasingly unexpected forms are all a constant threat to lifestyle and the national infrastructure that underpins it. But applications are becoming more specialised as the drive for greater cost efficiency is being seen in upgrades and refurbishment of older assets to extend service life.
With the introduction of reservoir security legislation in 1997, water companies were initially immersed in the widescale upgrading of service reservoirs with a new staple - the double-skin upstand access cover approved to LPCB (Loss Prevention Certification Board) criteria.
In successive AMPs, security programmes have been rolled out to all areas of the industry, prompting the development of a raft of high security access systems, doors, cabinets, and other physical protection. Alongside a tranche of equipment evolved to CPNI criteria, a vast range of needs have been met by significant growth in LPCB certified products. These have taken the form of largely standardised designs with little differentiation, giving rise to a crowded market for these water security staples over the last decade.
AMP 6, however, has heralded different, more complex challenges which can be met less and less by off-the-shelf commodities.
Predominantly, projects are focused on the hardening of existing infrastructure and its adaptation for new process technologies. These retrofit challenges run the full gamut of the UK’s water heritage, from Victorian waterworks and towers to the post-war development of the 1950s and 60s.
The procurement of high security access covers, buildings and enclosures to both protect and support the operational efficiency of the complex refurbishment project is rarely met by standard product solutions. While new build assets offer scope to accommodate standard products, each refurbishment site poses unique challenges - spatial, logistical, operational, and health and safety.
Invariably, needs will not be met by a hotchpotch of standalone products. With the ‘whole life’ cost efficiencies of TOTEX in mind, the best value solutions being delivered by Technocover are typically in the form of fully integrated access and housing systems.
LPCB certificated SR4 UltraSecure mesh cage system being installed by Technocover
Many are built off-site and devised with exhaustive functionality which clients are often unaware they should or can demand, though is crucial to providing lowest whole life cost. This functionality embraces a range of considerations, some obvious and others more subtle, which can have significant impacts on site safety and operational efficiency.
For example, do covers within a multi-cover assembly meet manual handling criteria where required? Does the frame provide sufficient shielded space for the installation of alarm equipment? Will you need to purchase and retrofit additional items to heighten a cover frame to allow access to the padlock?
The refurbishment project calls for unusual shapes, such as hexagonal access systems, in hard-to-reach places - the top of reservoir towers or hemmed in between existing structures. With the emphasis on keeping assets live, clients and contractors want ‘plug and play’ solutions; built and kitted off-site with full M&E, then craned in and hooked up to services the same day, if possible.
The challenge is delivering these more complex and increasingly super-size solutions within the scope of LPCB performance parameters. Water UK’s vision for AMP6 has pointed to the role of innovation in realising cost-efficiencies.
However, innovation in the physical protection of water is not always possible through thinking ‘outside the box’. More often than not, it relies on the manufacturer’s ingenuity to problem-solve within the constraints of certification. The move from off-the-shelf products to complex, tailored systems that meet certification is like charting new territory, where design credentials and track record truly come to the fore.
LPCB certificated SR3 UltraSecure Sentinel twin security doors
Now more than ever, the industry is turning to the engineering know-how of time-served LPCB specialists like Technocover to execute intelligent and complex solutions that fully exploit, but do not breach, the envelope of their security certification. As a trail-blazer in LPCB solutions for water, we are ahead of the game. Our designers and installers are already well versed in the discipline and finer detail of configuring successful bespoke systems within the performance scope of LPCB.
It is no coincidence that Technocover’s Total Service approach has been evolved for over 20 years around the whole life cost-efficiencies embodied in TOTEX. Based on the premise of providing the lowest cost solution, it addresses every possible aspect of the product’s life cycle to ensure the best return on investment.
This goes from maximising the buildability and operational advantages of the design, to ensuring a high quality system finish for long, low maintenance service.
Technocover’s TOTEX/Total Service response comes down to the rigorous application of value engineering principles through early consultation and close collaboration.
Will the system be easy to install, operate and maintain? How can it be constructed to overcome access constraints on site, or reduce construction time? Is the design configured in every aspect for site compatibility and functions such as water-shedding, installation of site alarms and client locking suites? Can components be hoisted to give access for inspection and replacement equipment where it is needed? Can bespoke interfaces between security enclosures and impinging cover frames be resolved within the certification parameters, or does the assembly need modifying?
LPCB certificated SR4 UltraSecure walk-in modular security kiosk
The industry must be wary of pursuing short-term savings through low product price. Specifiers and procurers must get to grips with the whole life implications of equipment choices. While LPCB certificated products conform to a defined series of security ratings, there can be wide differences in their operational sophistication and system finish. Meeting a security rating alone is not enough.
Product designs, especially the bespoke systems highlighted in this article, will result in significant outcomes in terms of cost-efficiency across service life.
A study of the operational costs, health and safety risks, and labour input of running and maintaining a complex access system would be revealing. If poorly designed, you would undoubtedly see cost impacts accrue from retrofit work, unexpected maintenance and longer cycle times for personnel using the systems. These could dramatically affect the bottom line for site operations over the life of the product, especially if it required premature replacement.
When it comes to equipment designed to safeguard lives and critical resources, the longevity and integrity of materials is paramount. Specifiers must ask: What’s protecting the protection?
LPCB certificated SR4 UltraSecure multiple leaf flush covers
A defensive and potentially life-critical piece of engineering warrants a high quality finish, which means a galvanised zinc coating to properly corrosion-proof steel. Clients must also scrutinise this aspect of a product as it may not meet service life expectations, or could possibly be compromised to lower price. The outcome can be a product that may meet the security specification but needs replacing after, say, as little as three or five years.
Despite technical advancements in the performance of modern paint systems, few if any will give much more than 10 years complete protection. Technocover uses high quality steel, galvanising and paint processes to provide 25 years minimum service life of products. While we also offer the option of a paint finish for aesthetic purposes, galvanised steel is the crucial element to assuring long service life.
When adding functionality, every component and accessory should be included within the LPCB certification for the product to be security compliant. Photo shows a Technocover LPCB certified twinleaf door, with a primary door leaf, entry and exit ironmongery, and an arched head blanking plate.
Originators of the LPCB approved service reservoir cover certified to LPS : 1175 Issue 7, Security Rating 4
With its early adoption of LPCB certificated equipment, the water industry has led the way in operational resilience and set a bar for other utilities to follow. As the originator of the LPCB approved service reservoir cover and numerous innovations since, Technocover remains committed to leading the way in meeting the industry’s security and operational needs.
Our success in delivering solutions that achieve the full continuum of functional needs within the LPCB performance envelope provides the only truly robust foundation for total cost accountability in this TOTEX era. We firmly believe it can help water companies and their design/construction partners to better control ‘whole life’ cost in the pursuit of lower prices for customers.
This article was prepared by Technocover Ltd. For more information on Technocover’s range of physical security solutions:
(Tel) 01938 555511 (Web) www.technocover.co.uk
Physical Security for Infrastructure (2016)
The physical security of assets on infrastructure sites is reaching new levels of sophistication and technical challenge. Utilities and other critical industries are systemically ‘hardening’ their operations, above and below ground, against identified risks of attack or infiltration by the criminal, saboteur or terrorist. Not only are the challenges growing in scale, clients are also demanding even greater functionality, adaptability and speed of installation from security enclosures, access covers and associated products for protecting vital process, storage and distribution assets.
Above or below ground, new build or retrofit, small or large: Technocover has unmatched design, production and installation capabilities to deliver right-first-time, lowest cost solutions answering every physical protection challenge.
How our ‘Total Service’ works to deliver the lowest cost solution:
- Early involvement and close collaboration with the project team ensures every opportunity to value-engineer and rigorously plan solutions. This ensures efficient, problem-free installation incurring minimum site impact and asset downtime.
- System design and manufacture is refined to address the full range of project considerations: identifying and resolving site access and installation constraints addressing health & safety and operational needs.
- 3D modelling allows design verification of standard and complex assemblies and coordination with the client design teams if required.
- Flexible build and installation options ensure most efficient solution to suit site logistics – from full factory build complete with M&E services, to part-built systems finished on site for ‘dropping’ over existing assets, or flat pack delivery for traditional installation.
- With advanced steel fabrication facilities and delivery fleet, we can take on complex and large off-site builds under quality management factory-controlled conditions. This reduces client/subcontractor costs while alleviating site safety and project management risks.
Large UltraSecure drop-on multiple upstand cover
The client’s initial layout for this multiple-leaf access cover was overly complicated, with 14 inspection points and 8 personnel access points. Through early consultation with us, we were able to CAD model a much leaner solution, reconfiguring and value engineering the design to provide all required personnel, inspection and plant access without conflicts. This saw a reduction from 32 to 15 covers, resulting in a cost saving to the client in excess of 20%.
Our UltraSecure LPCB approved new generation of modular covers allow unprecedented scope in the size, number of leaves, and provision of inset lids for inspection, personnel entry, spindle valves – all as a standard solution.
For this utilities project, four kiosks were pre-built and pre-fitted with electrical and Heating & Ventilation services, tested and certificated under factory-controlled conditions. Through early consultation and careful planning of equipment delivery, lifting and installation was completed in just three days, saving up to five days programme time.
The kiosk build was completed under ISO9000 quality management at our Mid-Wales factory, including service fit-out. With a 27m2+ footprint & weighing 4.6 tonnes, the largest was engineered and constructed in two halves for simple bolt down and connection to site power.
Our factory-assembled, ‘plug and go’ security kiosks are fully fitted-out prior to delivery with all required M&E. On site, they simply need bolting to their foundations and connection to mains power, saving labour and programme time.
UltraSecure drop-over modular building installation
These UltraSecure enclosures reduced off-line time on security upgrades at this utilities site from around four weeks to just one day. The larger kiosk was designed to fit with minimal tolerance over the existing asset and with minimal extension of footprint, being assembled on site and craned over.
Reducing installation time and operational downtime provides significant programme benefits – it removes the associated cost, health and safety, and security impacts when extended time is spent on the asset upgrade.
Our large LPCB enclosures have removable roofs, while all enclosures have the option of our new louvre system, which provides excellent yet secure free airflow.
UltraSecure modular building in position over existing structure
Technocover’s LPCB approved mesh cages provide naturally vented security of plant and visibility of the asset at all times. With extensive size and accessory options, including operational compliant sliding doors, they are a cost and time-efficient way to harden existing assets without dismantling structures and disrupting site operations.
The photograph (below) shows a full five-sided (with security gates and roof) UltraSecure LPCB mesh enclosure hardening the security of chemical storage, with a sliding door to accommodate delivery vehicle access due to site constraints.
UltraSecure mesh cage system with sliding gate
Our UltraSecure LPCB mesh enclosures provide unlimited sizes within their certification scope: from a simple two-sided structure against an existing building, to a full, stand-alone, multi-sided structure with roof providing secure encapsulation of existing buildings or processes, inside and out.
The photograph shows UltraSecure LPCB vertical partitions with single leaf hinged mesh panel padlocking outward opening doors providing protection of transformer installation.
UltraSecure LPCB certificated vertical mesh partitioning with entry gates
Technocover is scaling up to the growing security challenges of today’s infrastructure site; and so is the scope of the company’s LPCB certification to the latest LPS1175 test update (Issue 7).
Technocover’s leading range of UltraSecure doors, modular enclosures, cabinets, kiosks, cages systems and access covers offer versatile sizing and configuration options, plus wide choice of locking, operational, and health & safety features for customisation to client needs – all within the scope of their LPCB certification.
Exclusive to Technocover, the new, wider single span design of our multiple leaf drop-on covers features simplified support structures, meaning less material and installation time. This significant development enhances our lowest cost proposition on large access covers all within the scope of their LPCB certification to issue 7. We also offer greater scoping in the sizes of valve spindle covers and hatches available for multiple cover assemblies.
The photograph (below) shows a large UltraSecure upstand cover assembly, single span multiple ‘drop-on’ access covers with in-line hinged twin leaf personnel inspection access hatch lids.
UltraSecure LPCB certificated SR4 upstand assembly with hinged access covers
LPCB issue 7 certified single and twin leaf doorsets with optional accessories including head blanking plates and louvre vents – now offering bigger sizing scope. Certified entry and exit locking control systems as well as louvre vents and vision panels.
Improved functionality is offered by our UltraSecure cabinets under the scope of their LPCB certification to issue 7. These include sloped cabinet roofs, shedding water away from the access doors to the rear, for the comfort of personnel carrying out maintenance and inspection. There are new louvres, lockable cat flaps, cable entry cowls plus padlocking and key entry options.
(left) UltraSecure plug and go walk-in modular security kiosk and (right) UltraSecure drop-over twin door cabinet/enclosures
For over 25 years, Technocover Ltd have refined a total service experience bar none, closely partnering the client’s project team from site survey, early planning and design, through to delivery, installation and in-service maintenance.
This paper was prepared by Terry Batten, Marketing Manager with Technocover Ltd. All photographs are courtesy of Technocover Ltd.