Supply Chain - Sewerage - Products
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Case Studies
- Arklow Long Sea Outfall (2023)
- Potters Way Sewer Rehabilitation (2023)
- Exmouth Offshore Project (2024)
- Ballygowan WwTW (2023)
- WINEP Durham Transfers (2024)
- Ards North Long Sea Outfall (2023)
- Esholt STW (2024)
- Sherston S101a - First Time Sewerage Scheme (2023)
- Chilton Foliat STW Flow Compliance (2023)
Outfall pipe arrival from Norway by sea to the dock in Arklow for preparation and assembly - Courtesy of Van Oord Ireland[/caption]
The proposed outfall pipeline was required to discharge the treated effluent from the wastewater treatment plant to receiving waters. Both marine and river outfall options were initially considered for the proposed development.
However, hydrodynamic and water quality modelling demonstrated that the wastewater discharge standards required for a river outfall would be much more onerous than that of a marine outfall. For that reason, the river outfall was not considered further.
Outfall pipe floated along the quay wall in Arklow prior to preparation and assembly works - Courtesy of Pipelife Norge AS[/caption]
The marine outfall was also designed to be stable in the ‘worst case’ design loads for current and wave loading conditions provided. It was therefore necessary to weight the pipeline with concrete collars and subsequently concrete kennels after installation (float and flood method), to provide a specific gravity of not less than 1.35 that could be achieved without any reliance on backfill material.
This installation weight was provided with 1015kg (290kg/m) (in air) fixed weight concrete collars at 3.5m centres and to satisfy the permanent on bottom stability, 2292kg (654.86kg/m) (in air) concrete kennels were provided at 3.5m centres in between the fixed weight concrete collars. The collars and kennels were provided by Tracey Concrete.
Welding of risers for diffuser section of outfall pipe - Courtesy of Van Oord Ireland[/caption]
Excavation of trench at the onshore connection point using the backhoe dredger ‘Razende Bol’ - Courtesy of Van Oord Ireland[/caption]
(left) Outfall pipe during sinking operation and (right) outfall pipe aligned prior to sinking operation - Courtesy of Van Oord Ireland[/caption]
Outfall pipe concrete collars being fitted in water with special lifting equipment - Courtesy of Van Oord Ireland[/caption]
Once the outfall pipeline had been sunk to the sea bottom and pressure tested, concrete kennels, each weighing 1 tonne were placed in between the concrete collars at 3.5m centre to centre spacings to provide additional permanent weighting. Additionally, six diffusers were installed from the backhoe dredger platform by divers. Each diffuser comprised of a flanged PE pipe, fittings and a riser with a four-port crosshead, each with a flange allowing for Tideflex S35 valves to be fitted directly. Included as part of the diffuser installation, was a removable access flange at the top of the riser to enable access inside the riser.
After completing the diffuser and kennel installation, the pipe was backfilled over its full length to provide 1.5m cover. Rock armour protection was further provided extending approximately 7m around the diffuser section from its centre to protect the area around the diffuser from scour. Also provided was a steel protection frame for the diffuser, fitted with sacrificial anodes to allow a 50yr design life for protection from dropped objects, anchors, trawlers and fishing nets. Finally, on the offshore end a marker buoy and on the onshore end a Saint Andrews Cross were installed to mark the pipeline location.
Due to the turbulent weather at the site location, including hold points in the working method, so that each installation step could be paused at planned intervals, allowed Van Oord to work around the weather. Additionally, working with local contractors who helped to adjust and adapt work methods and techniques within the limited amount of space, allowed the team to prepare and install the outfall system using specialised equipment and marine vessels, with minimal disruption to the environment and public. In particular, a bespoke rigging system was designed and fabricated using a local yard to assist with the efficient installation of the collars whilst working from the water.
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Outfall pipe during sinking operation - Courtesy of Van Oord Ireland[/caption]
Installation of the overhead diversion - Courtesy of @one Alliance[/caption]
(left) Live flow conditions and (right) inserting a new section of Amiblu Norway AS GRP pipe - Courtesy of @one Alliance[/caption]
Operating in live flow removed the necessity to install an additional over pumping solution that would have dealt with 95% of Peterborough’s sewage as it combined into one flow towards Flag Fen WRC.
In order to commence the GRP lining, the crown of the pipe was removed on a bend and concrete platforms were constructed on either side ensuring a safe working area. A pipe pusher attachment was then used to insert segments upstream and downstream from the bend location. Finally, a prefabricated GRP bend section was installed and connected to straight sections.
To safely cut the existing mains the team needed to excavate an area of 6m x 4.5m with a depth of 3.5m. While having to excavate in an urban area is an option the team would have liked to have avoided, the next best solution to the live flow repair would have included installing a temporary pumping station that would have taken up all of Potters Way’s parking and grass area requiring 10 pumps and a 10m x 7m x 7m temporary wet well to complete the required repair. This would have been a major inconvenience for residents and would have seen an increase in the overall cost of the project of 200%.
(left) H2S attack on a manhole and (right) inside a relined section of pipe - Courtesy of @one Alliance[/caption]
(left) Pipe string along coastal path and (right) Pushing pipe lower car park and compound - Courtesy of South West Water[/caption]
(top left) 500t drill rig compound and entry point and (bottom) pipe pushing operation at sunrise - Courtesy of South West Water[/caption]
500 T drilling rig - Courtesy of Galliford Try[/caption]
(left) Drill pipe and pilot drill bit and (right) outfall pipe, roller and guide - Courtesy of Galliford Try[/caption]
900mm diameter pipe welder - Courtesy of Galliford Try[/caption]
(left) Existing Ballygowan WwTW - Courtesy of NI Water and (right) demolition in progress: (top) the existing storm tank and (bottom) the existing CAS basin tank - Courtesy of GEDA Construction[/caption]
CAS basins - Courtesy of NI Water[/caption]
New storm tank being utilised during construction - Courtesy of GEDA Construction[/caption]
Ballygowan WwTW under construction (December 2021) - Courtesy of NI Water[/caption]
Interface between new and old works during construction
The majority of the new WwTW works was to be built on a greenfield site which allowed GEDA Construction to build most of the new structures without having to work around existing infrastructure.
However, in order to construct pipelines which would eventually take the flow into the new works, and to construct the new WwTW access road, it was necessary to demolish the existing storm tank in the old works prior to the new works becoming live. GEDA Construction carried these works out by utilising the newly-constructed storm tank and incorporating a carefully developed phasing plan.
A temporary 300mm gravity fed sewer was laid from the existing inlet works to the new storm tank, which in turn rendered the existing storm tank surplus to requirements, as all storm flows had been diverted away from it. GEDA Construction also had to lay a temporary 200mm pumped sewer from the new storm tank complete with temporary pumps to send the storm flows back to the existing pumping station in order for the influent to then go through the treatment process. This in turn allowed us to demolish the existing storm tank and construct the new permanent inlet sewers to the new works ahead of turning flows. This process had to be carefully managed both hydraulically and biologically to ensure the treatment process was optimised and effluent compliance was maintained at all times.
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New permanent high-level sewer under construction - Courtesy of GEDA Construction[/caption]
Turn of flows
Influent flows were successfully diverted into the new works in early May 2022. In order to bring the new biological treatment process online, several tanker loads of seeded sludge were brought to site from another treatment facility and were introduced into the new CAS basin tanks to promote bacteria growth. With flows diverted, and effective treatment established through a rigorous sampling regime, approval was received from NI Water to proceed with the demolition of the remainder of the existing treatment works. Once the existing works were decommissioned and demolished, the entire new WwTW site was able to be finished and access roads completed.
Demolition
Post turn of flows in early May 2022, the existing treatment works was decommissioned and then demolished. Reusable mechanical and electrical assets from the old treatment process were removed for future use by NI Water, while the effluent left in the old CAS basin and pumping station was removed from the site to allow demolition to commence. Effluent was filtered through the new treatment process to minimise unnecessary removal and disposal from site.
CAS basins in operation - Courtesy of NI Water[/caption]
Solmatix Renewables Ltd solar farm - Courtesy of NI Water[/caption]
Ballygowan WwTW nearing completion - Courtesy of NI Water[/caption]
Piling operations by Francis & Lewis International Ltd, for the construction of the pipe bridge substructure - Courtesy of Esh-Stantec[/caption]
Active Tunnelling constructing the new wet well shaft at Pity Me STW
Construction of new valve chamber and associated pipework at Pity Me STW - Courtesy of Esh-Stantec[/caption]
Aerial view of working area at Brasside STW - Courtesy of Esh-Stantec[/caption]
Construction of pipe bridge structure by Francis & Lewis International Ltd - Courtesy of Esh-Stantec[/caption]
Tow and sink operation - Courtesy of NI Water[/caption]
Aligning pipeline over pre-dredged trench - Courtesy of NI Water[/caption]
A range of pipeline diameters and materials were considered to achieve optimum velocities, a balance between pipe diameter and TWL in the proposed header tank. PE pipes were selected for the outfall with varying SR ratings used to offer material cost savings using only higher rated pipes for the marine sections to take account of installation (towing and sinking) stresses on the system.
Specialist hydraulic modelling was then completed by Hydraulic Analysis Limited (HAL) to provide confidence in the performance of the system against all combinations of design flows and tidal levels. The analysis confirmed the pipe diameter selection, siting of air and scour valves and provided specific specifications for pipeline gradients, bends and air valves installation to ensure stable free surface flow conditions were achieved within the mains gravity driven sections.
Barge mobilisation from Bangor Marina - Courtesy of Farrans[/caption]
The final solution was therefore to discharge treated effluent directly from the sample chamber to a gravity outfall which acts in part as a pressurised system. This amendment to the design approach was verified by HAL and removal of the pumping station and header tank was agreed by all prior to finalising the construction details including:
The outfall was installed off the coast at Ballyferris adjacent to a caravan park - Courtesy of NI Water[/caption]
(left) Onshore pipeline assembly - Courtesy of Farrans, and (right) installation of concrete kennels - Courtesy of NI Water[/caption]
Re-excavating the proven trench - Courtesy of Farrans[/caption]
At high tide, the pipe was floated, towed and positioned above the pre-dredged trench. Connection was made to the pre-installed land section of the outfall and the pipe was filled with water allowing a gradual sinking and pipe placement along the trench. Backfilling operations commenced once the pipe was surveyed and verified.
Professionally qualified divers installed the prefabricated diffuser head. Live underwater video surveys were conducted to monitor the installation of all equipment.
The execution of these activities adhered to stringent health and safety protocols, strict environmental considerations, and project timelines, ensuring the successful completion of the project on time and within budget.
NI Water and Farrans held a joint safety initiative for children in caravan parks - Courtesy of NI Water[/caption]
Primary ferric point of application cabinets - Courtesy of MMB[/caption]
Deep bed sand filter, post refurbishment - Courtesy of MMB[/caption]
Dirty backwash rising main - Courtesy of MMB[/caption]
Side view of primary ferric dosing compound - Courtesy of MMB[/caption]
Delivery of 3D printed draw-pits - Courtesy of Mott MacDonald Bentley[/caption]
(left) Schematic showing the route of the new gravity sewer and new rising main and location of the new SPS and (right), illustration from the Wessex Water leaflet to property owners showing responsibility split - Courtesy of Wessex Water[/caption]
Residents in Sherston applied for an FTS scheme due to this pollution, which led to an assessment by Wessex Water which concluded that a public FTS was viable and could be progressed to design and construction. Wessex Water carried this out using their in-house capabilities at a cost of £2m. Although only a few properties were causing environmental and public health issues, Wessex Water included as many properties as possible within the FTS scheme, taking into account the viability of doing so. As a result, 24 properties (estimated population equivalent of 60) currently on septic tanks will be able to connect to the new public sewerage system by July 2023. Wessex Water’s FTS policy is to construct the new public sewerage system up to the inside the property boundary, where it terminates within a demarcation chamber. This chamber denotes the boundary between the public and private drainage system.
Penstock ready to be installed over the outgoing pipe (on the left) within a manhole chamber upstream of the wet well - Courtesy of Wessex Water[/caption]
Several iterations of the design were undertaken to confirm the best route of the pumped rising main, location of the proposed new SPS and access road, as outlined below:
Connection to the existing sewerage network in Easton Town (B4040) - Option discounted
This solution provided the shortest route for the proposed new rising main and access track to service the new SPS. However, the rising main route would need to pass through a narrow driveway between existing houses.
Due to the depth of the excavation, an open cut construction method was discounted as it would be within the zone of influence of the building foundations and consequently had the risk of undermining and causing structural damage to these buildings. Trial holes indicated shallow rock which would have further exacerbated structural damage due to vibration when breaking out the rock.
Trenchless techniques were considered, however due to the rock, only micro-tunnelling would be suitable, and would require a reception pit within Easton Town road, which would cause significant disruption to the community. Micro tunnelling would have also resulted in the scheme becoming financially unviable.
Connection to the existing sewerage network in Sandpits Lane (access via Sandpits Lane) - Option discounted
This solution provided the next shortest route for the access track to service the new SPS, and although the rising main route was extended, it allowed for an additional gravity sewer to be laid within the same trench to connect four additional properties at minimal cost, which increased the cost viability of the scheme.
Prior to submitting a planning application for this option, Wessex Water consulted with the community. Significant public objections were raised due to the visual impact of the proposed new access track and SPS, particularly from those who were already on mains drainage and would not benefit from the FTS scheme. In addition, land purchase negotiations for the access track could not be resolved.
Connection to the existing sewerage network in Sandpits Lane (access via Tetbury Road) – Selected Option
The sewerage network for this option was similar to Option 2, however the access track route and SPS location changed to take into account the points raised from those objecting on the grounds of visual impact and land purchase issues.
This option was confirmed to be both technically and financially viable and no public objections were raised, which was valuable in securing planning permissions.
(left) Excavation of shallow rock for rising main and (right) internal view of the wet well before sump benching - Courtesy of Wessex Water[/caption]
(left) Shuttering around the wet well in preparation for pouring the final layer of concrete surround and installing dowels into the valve chamber and (right) construction of wet well - Courtesy of Wessex Water[/caption]
All pipework within the valve chamber was constructed in ductile iron DN80 and the rising main was constructed in MDPE pipe, SDR17, OD 110. The gravity pipework was constructed in PVCu Funke Gruppe pipe (100 mm and 150 mm internal diameter), which was selected to provide due to its light weight and construction durability compared to conventional vitrified clay pipework.
Penstocks were required so that incoming sewerage flows can be controlled, to allow isolation of the wet well for cleaning and maintenance. The penstock was designed to be located within the wet well, however concerns were raised by the site team that the proposed opening for the penstock spindle would be difficult to cast in the correct location during the off-site fabrication of the cover slab. To resolve this, the cover slab design was amended to remove the penstock spindle opening, and it was moved to an upstream manhole, where the penstock could be positioned within the clear opening of the manhole cover.
An overpumping connection allows for the temporary pumps to be installed and connected to the rising main via a Bauer coupling on the pipework from within the valve chamber. The valve chamber cover was designed to allow for the safe operation of the Bauer coupling by having a split walk-on grid over the coupling.
This allowed the operator to place the foot on one of the closed flaps, whilst the other flap is lifted, thereby allowing them to position themselves directly over the Bauer coupling. This avoids the operator having to lean over an opening or handling the tankering hose with one hand.
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Valve chamber cover, with split walk-on grid over the Bauer connection - Courtesy of Wessex Water[/caption]
(left) Q-bic system construction and (right) concrete slabs being cast over the crates to form the turning area - Courtesy of Wessex Water[/caption]
Public drop-in session and (inset) 3D model of the new sewage pumping station - Courtesy of Wessex Water[/caption]
All temporarily affected habitats were seeded with a species-rich grassland and wildflower mix, managed to avoid cutting during the late spring and summer to benefit invertebrates and other wildlife. Off-site biodiversity enhancement measures were also undertaken in Sherston Primary School, including planting of additional trees, wildflower meadow, and providing bird nesting pockets to students.
Close interaction with residents is a key feature of FTS schemes due to the work within private gardens. All residents were contacted prior to construction via face-to-face meetings and community drop-in session to give them the opportunity to ask any queries direct to the Wessex Water Project Team. A 3D model of the proposed sewage pumping station was created and used during the drop-in session to provide more clarity for the public on the proposed solution.
Aerial view of setup - Courtesy of A. Thomas Plant Hire Ltd (ATP)[/caption]
Assessment of the existing pump arrangement at Mill House SPS confirmed that they would be suitable to transfer flows along the new rising main pipe alignment which had a reduced head to that of the previous arrangement. However, the existing pumps were determined to be nearing the end of their asset life and their replacement was also included.
The gravity sewer section was designed to maintain self-cleansing for the expected pass forward flow of up 8 l/s with the fall gradient varying between 1 in 90 and 1 in 60.
(top left) winch/anchor unit, (bottom left) bedding conveyor and (right) test pit on installed pipe - Courtesy of MMB[/caption]
The pipe plough - Courtesy of MMB[/caption]
(left) Pipe plough in progress and (right) reducer installed - Courtesy of A. Thomas Plant Hire Ltd (ATP)[/caption]
Mini CS & Company News
- Raigersfeld Culvert Re-lining
Raigersfeld Culvert Re-liningKent County Council‘s programme of planned highways maintenance works to be carried out during 2019 – 2021 included strengthening works to structures such as the Raigersfeld Culvert situated beneath the A20 Ashford Road, Maidstone, Kent. Following on from previous culvert rehabilitation works for Kent County Council, Steadline Ltd. were once again commissioned to make the required improvements to an existing historical brick and steel beamed culvert which was showing signs of deterioration resulting the restriction of flow capacity. With the same project team comprising Steadline Ltd., BdR (Civil & Structural Engineering) Ltd. and Amiblu, a bespoke, non-circular GRP liner was designed with specific challenges to overcome, including:- Steel cross sections to the soffit of the culvert
- Inconsistent shape
- Traffic loads
- Restricted access
- Environmental considerations
Existing Raigersfield culvert - Courtesy of Steadline Ltd[/caption]
The result, 16m x 1m length sections, 1244mm x 754mm Eliptical shaped NC Line with a 27mm wall weighing just 175kg per metre with a push fit bell & spigot socket, was designed to maintain the required cross section and flow capacity.
Steadline Ltd and BdR (Civil & Structural Engineering) Ltd worked in conjunction with Kent County Council, to ensure all works were carried out safely and efficiently whilst meeting the requirements set out by the client in respect of strength, durability and finished aesthetics.
Forward planning of this scheme was critical as the culvert runs beneath the main A20 which is a major arterial route through Maidstone and a road closure was never an option, so the team at Steadline worked closely with park rangers within Mote Park to secure the downstream access and with residents of a gated housing estate for the upstream access.
The stream was damned and over-pumped with precautions in place to ensure that no unwanted debris found its way into the natural water course. The 1m long NC Line sections were then craned onto the upstream landing area before being installed using a purpose built roller system to accommodate for the inconsistent internal condition of the existing culvert.
Once all 16m of NC Line had been installed, grouting was carried out in stages as per Amiblu’s recommendations and the headwalls were finished in keeping with the original culvert construction.
Amiblu relining pipes are particularly suitable for pipe and culvert rehabilitation, as they are light in weight, corrosion resistant, quality assured, easy to install and engineered to give 150 years’ service life, they are manufactured in a wide range of sizes in both circular and non-circular options and with varying strengths to cater for all locations and performance criteria.
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NC Line example shape options[/caption]
Amiblu NC Line pipes are produced to ISO16611. The non-circular cross-sections are ideal for relining and strengthening aging sewer networks, culverts and channels. Non-circular pipes are also used for open trench applications where capacity is required, but allowable depth to invert is limited. They can be customised according to project requirements and easily be adapted to different types of shapes and geometries.
Project parameters
- Country: UK
- City: Maidstone
- Year of construction: 2021
- Application: Storm sewer
- Installation: Trenchless
- Technology: Amiblu NC Line
- Total length of pipe: 16m
- Nominal diameter DN: 1244mm x 754mm
- Nominal pressure PN (bar): PN1
- NC Line shape: Elliptical (1m lengths)
Supply chain
- Client: Kent County Council
- Contractor: Steadline Ltd
- Engineer: BdR (Civil & Structural Engineering) Ltd
- NC Line relining pipe: Amiblu
(left & right) Finished Ragstone headwalls courtesy of Steadline Ltd and (middle) Amiblu NC Line Raigersfield design drawing - Courtesy of Amiblu[/caption]
What was said
Aaron Harber, Contracts Manager, Steadline Ltd.” All in all the scheme was very successful and certainly improved the flow of the stream/small river and with the new rag stone head walls looked very pleasing to the eye.”
For more information: Amiblu UK | +44 (0)7786 013574 | www.amiblu.com
- Gipsy Patch Lane (Bristol) Sewer Rehabilitation
Gipsy Patch Lane (Bristol) Sewer Reh...Gipsy Patch Lane, Bristol is a main road forming part of a new Cribbs Patchway Metrobus route in South Gloucestershire. As part of an asset assesment programme a few years ago, a CCTV survey showed many defects throughout the length of the surface water culvert at Gipsy Patch Lane. The defective sections ran under the busy carriageway so, as an interim maintenance measure the local authority excavated a section of the road and installed a concrete slab over the pipe to protect it from further deterioration or collapse. During heavy rainfall over the summer of 2020, the same pipe was found to have suffered structural defects and root ingress through open joints and connecting laterals resulting in localised blockages of up to 90%. A new man-entry survey showed the pipe beneath the concrete slab to be deformed. Major works were already under way in the area to replace a railway bridge on Gipsy Patch Lane, so South Gloucestershire Council took the opportunity to make improvements to the sewer in conjunction with the Network Rail works to minimise disruption, which was further aided by lighter traffic due to the regulations set in place for Covid-19 pandemic. Under the Council’s Climate Resilient Scheme, the task was to find and deliver a suitable solution before opening the road up to traffic and risking a pipe collapse; two options were considered; open-cut to replace the section of pipe or trenchless technology to reline the affected pipe with little disruption to the area. [caption id="" align="alignnone" width="1200"]
First post-Brexit delivery of Amiblu pipes (January 2021)[/caption]
Doug MacKay, Project manager, South Gloucestershire Council consulted with Julian Britton, Critical Sewers Manager, Wessex Water and Matt Durbin Associates; specialist confined space and GRP structural relining installer to determine the most efficient and economic technique. As with many suburban roads, Gipsy Patch Lane is laden with many services within the carriageway, so rehabiliatation of the existing pipeline through trenchless installation of 210m x DN800 structural GRP jacking pipe supplied by Amiblu was decided upon. As the contract was classed as emergency works, subject to time constraints and speed of execution the use of Amiblu’s GRP pipes meant that MDA were able to remove the need for costly over-pumping and install the pipes in live flows, whilst minimising their work area to a single lane closure for uninterupted access to local businesses.
During the installation of the initial contracted 210m, a further 70m section of the pipe downstream required attention, so MDA undertook the additional works saving additional costs and disruption at a later date.
Amiblu jacking pipes are often utilised in pipe rehabilitation projects such as this as they offer a high compressive strength and, compared with conventional materials, an improved hydraulic coefficient. The hydraulic analysis carried out for Gipsy Patch Lane showed no reduction in hydraulic performance and as the pipes are designed to offer a service life in excess of 150 years with minimal maintenance, the life expectancy of this asset is greatly improved.
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(left) GRP pipe installation and (right) the completed relining - Courtesy of MDA Ltd[/caption]
Doug MacKay, Project Manager with South Gloucestershire Council, commented:
"For this project, the Council had concerns about the risk of potential pipe collapse under traffic loading. The fact that road was already under a full closure due to an adjacent project to replace an old railway bridge meant that timing was critical for this project. It was essential that the work had to be completed before the proposed re-opening of the carriageway. Additionally, there was a limit to the funds available through the Climate Resilience budget to complete the scheme. We worked very closely with MDA and our designers to review the site constraints, risks to programme delivery and budget constraints to determine the most appropriate remedial solution. I was grateful for the time, input and patience spent by MDA during this period to explain the construction process and provide answers to all our questions and concerns in advance of making the final decision on the preferred option.
Once the decision was made to proceed with the pipe-jacking option the process was relatively straight-forward and stress-free from the Council side of things. In the main this was down to the excellent communication, planning and execution of the works by MDA. Both projects were completed on-time, within budget and with minimal disruption to the public and businesses that rely on using Gipsy Patch Lane.”
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Amiblu pipes require minimal site storage - Courtesy of MDA Ltd[/caption]
Project details
- Country / city: UK, Bristol
- Year of construction: 2021
- Installation time: 4 weeks
- Application: Sewer rehabilitation
- Installation: Trenchless technology
- Technology: Hobas
- Total length of pipe: 280m
- Nominal diameter DN (mm): DN800
- Nominal pressure PN (bar): PN1
- Nominal stiffness SN (N/mm²): 32,000
Supply chain
- Client: South Gloucester Council
- Contractor: Matt Durbin Associates Ltd
- Consulting engineer: South Gloucester Council
- Structural GRP jacking pipe: Amiblu
Amiblu Structural Relining Pipes
Amiblu pipes have a smooth, resin rich internal surface with high abrasion resistance which consistently prevents fouling and build up, leading to low maintenance costs and high flow rates even at low gradients. Both Jacking and relining pipes are supplied with in-line flush joints which prevent the intrusion of roots and further ensure the integrity of the asset. Available in diameters from DN300 to DN3600, in varying strengths and lengths. Amiblu’s systems are cost effect, durable alternatives to traditional pipe systems.
For more information: Amiblu UK | +44 (0)7786 013574 | www.amiblu.com
- East Budleigh Culvert Re-lining
East Budleigh Culvert Re-liningEast Budleigh is a small village in East Devon, UK located about 2 miles (3.2km) north of Budleigh Salterton. The village features a bypass culvert, constructed in the 1970s. The culvert is approximately 280 metres in length, of Armco construction, oval shaped and constructed from corrugated metal sheeting (with a concrete floor laid over it during the last 10 years). The existing culvert was in a poor condition, with joints failing and large voids appearing in the material outside the culvert structure. These failures led to a small localised collapse in the road above during flooding in 2012 and there were concerns that in the future that a larger collapse could occur, causing a failure in the highway surface. It was decided that this culvert required structural strengthening due to minimal cover to the busy road above, and to maintain flows through the culvert in storm conditions. [caption id="" align="alignnone" width="1200"]
(left) Host pipe inspection and (right) site preparation - Courtesy of MDA Ltd[/caption]
Project scope
The Environment Agency employed Atkins to design the culvert rehabilitation, with Kier appointed as main contractor who in turn appointed specialist contractor Matt Durbin Associates to consult on rehabilitation options and carry out the work. Given that the location was a highly trafficked residential area with minimum cover to the road, it was decided that lining with a structural GRP segment lining system offered the best solution and Amiblu‘s NC Line, non-circular GRP Structural Relining system was selected for the project. In total some 300 metres of Amiblu NC Line Arch Shape liner, 2360mm wide x 1350mm high was manufactured to the required WRC Type II standard and ISO 16611. Amiblu’s application engineers worked in partnership with Matt Durbin Associates to understand specific performance criteria required in order to create the optimal shaped pipe to fit the needs of the project and production started in January 2022 at Amiblu’s Gdansk factory in readiness to commence February deliveries. The culvert meandered with the local water course, and on inspection for the design of the linings was found to include long radius bends which were designed for pre-manufacture so that they would install without issue on site. Despite the apparent loss of cross-section in the culvert the design and smooth internal finish of the linings ensured that the flow capacity requirements for the culvert would be met. Given the small village size and the traffic management requirements for the installation works, coordination with local residents and parish councils regarding the large deliveries to site was essential and worked extremely well. [caption id="" align="alignnone" width="1200"]
Amiblu NC Line 2360 x1350mm ready for installation[/caption]
Work commenced on site on 14 February with site preparation works. Installation into the culvert commenced in March. In total, all installation and annulus grouting operations were completed in just 8 weeks.
Amiblu’s NC Line provides structural rehabilitation to existing non- circular culverts and host pipes that have reached a point in their service life where the asset owner must decide to renovate or replace.
GRP pipe systems made by Amiblu maintain excellent long-term stiffness, corrosion and abrasion resistance and are engineered for 150 years‘ service life.
Project parameters
- Country: UK
- City: East Budleigh
- Year: 2022
- Application: Culvert reline
- Installation: Trenchless
- Technology: Amiblu NC Line
- Total length of pipe: 300m
- Nominal Diameter DN (mm): 2360 x 1350mm
- Nominal Pressure PN (bar): PN1
- Nominal Stiffness SN (N/mm2): As per design criteria
Supply chain
- Client: Environment Agency
- Contractor: Matt Durbin Associates Ltd
- Consulting engineer: Atkins
- Structural GRP pipe liner: Amiblu
Completed installation - Courtesy of MDA Ltd[/caption]
What they said
Daniel Gay, Project Manager for the Environment Agency:“From a client perspective, the GRP liner solution has provided a cost and time-effective approach to prolonging the asset life. We were hopeful to avoid any requirement for open cut solutions to minimise the impact to the local community and meet delivery deadlines. We also needed to ensure that the flood risk standard of protection was not altered to upstream or downstream receptors. The structural GRP liner allowed for a bespoke unit to be installed which optimised the culvert capacity to retain the flow performance and extended the life. The outcome of improvements to the culvert have reduced flood risk to 27 residential properties, significantly reduced future maintenance costs and health and safety risks to the public.”
Adrian Parker, Senior Project Manager, Kier:“This project is a great example of how accelerated delivery can be achieved under the Environment Agency’s Collaborative Delivery Framework. From identification of the scheme for fast tracking in June 2021, the scheme was on the ground in February 22 and complete by June 22. MDA have done a great job and thanks also to Amiblu.”
For more information: Amiblu UK | +44 (0)7786 013574 | www.amiblu.com