Off-Site Solutions. CPM Headwalls. Concrete for Life

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1 Off-Site Solutions CPM Headwalls Concrete for Life

2 Welcome to CPM CPM is a market leading manufacturer of concrete products with production facilities across the UK. This combined with a network of specialist distributors, enables us to provide our customers with complete coverage. The CPM business is built on a solid reputation for delivering quality products and providing a first class service with diversification and innovation a key to our strength. We supply a vast range of sustainable precast concrete products to every sector of the construction industry, fully supported by our experienced technical and engineering teams. CPM Headwall Solution CPM has developed an offsite precast concrete solution headwall system designed to connect pipe work discharging into open water courses. The spillway headwall offers a cost effective alternative to in-situ structures for connecting discharge from pipework into open watercourses, such as culverts, collection ponds, balancing ponds, rivers and swales. Concrete pipeline systems have a proven life of over 100 years, demonstrating lower whole life costs and providing installed cost savings as well as minimising erosion at the discharge point and immediate structure. CPM headwalls are the ultimate recycling product as they can be removed and refitted elsewhere should the need arise. CPM Headwalls are compliant with the Sewers for Adoption standard The precast concrete headwall is available in three standard sizes: S40 (small), S60 (medium) and S90 (large). These three sizes accommodate a range of connecting pipes from 150mm to 900mm outlets. Advantages of the CPM precast concrete headwalls include Proven design life of 100 years Lower whole life costs cost effective option Low maintenance Quick and efficient installation Offsite solution made under factory conditions No on-site shuttering or formwork required Increased health and safety on-site with off-site manufacturing Reduction in carbon footprint A full range of accessories available from stock The headwall and toe are manufactured as separate monolithic precast units. CPM operates a quality management system accredited to ISO 9001 with all constituent products subject to regular quality inspection. Both components are manufactured to exposure class XD3.

3 Components A spillway Headwall will typically comprise of two standard elements. Headwall headwall units can comprise of the following: A precast concrete unit, size dependant on connecting pipe (three sizes available). Fitted with closed coupled and cranked gratings. Pre fitted with hydro-brakes, penstocks, non-return flap valves. Toe Toe units can comprise of the following: A precast concrete unit, size dependant on ordered headwall and depth to adjacent water course (three heights available for each headwall size). Accessories A full range of accessories are available, including flap valves, penstocks, hydro-brakes, silt traps, safety gratings, hand rails etc. Concrete for Life

4 CPM Headwall Range Headwall Sizes Small - S40 Medium - S60 Large - S90 Pipe Diameters up to 375 up to 600 up to 900 Hole Sizes Designed Pipe Diameter Table Key: = stock item = made to order Minimum Hole Size Small S40 Medium S60 Large S90 Headwall Images

5 Offloading and Lifting CPM is able to offer advice and recommendations for offloading products on site and assist in the preparation of a safe delivery plan in accordance with the HSE document Delivering safety: co-operating to prevent workplace vehicle accidents. CPM recommends that ALL lifting operations should comply with the Lifting Operations and Lifting Equipment Regulations (LOLER) 1998, and the Provision and Use of Work Equipment Regulations 1998 (PUWER). The lift system is of a Utility Anchor system incorporating a cast-in loop, adequately rated lifting brothers can attach directly for lifting, where brothers are too large to safely be placed, D Shackles should be used. More information is available at Spillway Headwall Toe S60 Concrete for Life

6 Receipt and Handling of Headwalls on Site Time and place of off-loading should be agreed before units arrive at site. For safety, all units are delivered in the upright position as installed. During delivery and off-loading, the units should be placed on 300mm skids to ensure no damage to the toe end. Units must be stored individually and not stacked. Off-loading should take place at the nearest hard standing area to the point of installation. Off-loading must be carried out using appropriate lifting equipment. It is recommended that telescopic handlers, or equivalent, with forklift toes are used to off-load on-site, lifting from the back of the unit (or sides of the headwall only), to prevent operatives from climbing onto the trailer. Each headwall section is supplied with 3 lifting anchors cast into the reinforced floor for site handling. The units Centre of Gravity has been calculated so there is no need to shorten the chains, but we advise a test lift prior to installation so that the contractor is happy with the angle to help guide the opening over the pipeline. If needed, shorten the legs accordingly so that the back of the unit is lower than the front. Each Toe unit has 2 cast-in anchors with 2 equal chains used to transport on site and position. Carefully inspect units during off-loading to verify that products are undamaged and comply with the units ordered. Two types of check are required: Visual Inspect the headwall and/or extended toe for any sign of damage, including cracked or chipped concrete, or damage that could affect the performance. Design Check that the item received is the one ordered. Headwalls are a standard CPM product and are labelled with the following information: Headwall Size Pipe Diameter Production date All CPM products are stamped with the production date (this is part of a quality control procedure). Any Headwalls rejected should be labelled and stored separately with the discrepancies for each noted on the delivery docket and reported for further action.

7 Installation Guide Cut and install the last section of pipe that the headwall will cover. Ensure that the pipe is fully fitted, leaving either the first (or last) section of pipe free from backfill to allow the headwall to locate over it. Excavate to formation level, and dig a trench to suit the toe, place and compact a 300mm bed of 50mm clean drainage stone or similar free drainage aggregate (compacted in 100mm layers). Check that the correct headwall and toe has been brought to the installation point. Cross reference and check pipe connection diameter to that of the headwall. The movement of the toe and headwall on-site must be undertaken in a manner that is safe and will not cause any damage to the units in any way the use of the cast-in lifting anchors connected to equal length 2 legged chains is recommended for lifting the toe ensuring a minimum lifting angle of 60 degrees. Place the toe into the bedded trench and confirm levels and alignment, backfill the voids with 50mm clean drainage stone to approximately 200mm below the crown of the toe and level off the bed. Ensure the ends of the toe are not exposed and place approximately 200mm of lean mix concrete behind the toe filling up to the crown of the unit, ensuring a level surface for the headwall to rest on. Lift the headwall unit with 3 legged chains and manoeuvre it so the opening is over the pipeline and lower the toe register into the positioned toe until resting completely on the prepared bed. Placing a shim to the underside of the pipe to centre in position as required. Using the appropriate grout or an epoxy resin, fill in the void between the reinforced concrete headwall and the pipe. This will ensure a firm fit. Backfill the pipe section between the headwall and embankment. It is recommended that 300mm surround of 50mm or similar free drainage aggregate is used to surround the headwall to ensure good groundwater drainage. Disclaimer This document is produced by the CPM Group as a recommended guideline document to the industry. Its purpose is to aid contractors in the installation of the CPM precast concrete headwalls. It is the responsibility of the contractor to ensure that the precast concrete headwall is in accordance with the design specifications for the site. It is the responsibility of the contractor to install the precast concrete headwall safely in accordance with site conditions. Concrete for Life

8 Technical Spillway Diagrams Off-Site Solutions Spillway Headwall S40

9 Technical Spillway Diagrams Spillway Headwall S60 Spillway Headwall S90 Off-Site Solutions Spillway Headwall S60 Concrete for Life

10 Technical Spillway Diagrams Off-Site Solutions Spillway Headwall S90

11 Headwall Accessories Headwall Flap Headwall Grill Headwall Silt Trap Headwall Handrail Hydro-Brake Concrete for Life

12 Complete UK Coverage HEAD OFFICE / ENGLAND / WALES SALES AND SOUTHERN WORKS CPM Group Ltd, Mells Road, Mells, Nr Frome, Somerset, BA11 3PD Tel: Fax: NORTHERN WORKS CPM Group Ltd, Pollington, Goole, East Riding of Yorkshire, DN14 0DU Tel: Fax: SCOTLAND SALES CPM Group Ltd, 101 Main Street, Newmains, Wishaw, Lanarkshire, ML2 9BG Tel: Fax: PERFECT MANHOLE SALES CPM Group Ltd, 1st Floor Alexandra Mill, Queen Street, Leek, Staffordshire, ST13 6LP Tel: Fax: TECHNICAL OFFICES CPM Group Ltd, CPM House, Heath Mill Road, Wombourne, Staffordshire, WV5 8AP Tel: Fax: sales@cpm-group.com Designed by Pixel Creative