Loading...

Installation & Integration

//Installation & Integration
Installation & Integration2019-03-22T08:41:40+01:00

Installation & Integration

Every project, large or small, should be fully assessed so a correct installation method can be agreed and therefore full integration achieved. All projects have differing and specific demands so it is important for designers to make a full risk assessment. The position of the kerbs/drainage units, the surrounding structure/landscape, functions, road alignment, levels, specific local design criteria and the type/volume of traffic will determine a best method of installation. (Ref DMRB – MCHW Series 1100 – Series 500 – HA83/99 – EN1433 – (Ian117/08 Rev 2) – EN1340 – BBA/HAPAS Certification 08/H133.

It is important for designers to understand that as manufacturers our products meet the required tests stipulated within the covering standard/certification however the actual load performance and longevity of a product/system is not limited to the strength of the individual unit. Correct design and installation will enhance performance and ensure best integration across a project providing longevity for product, system and function.

In kerbed areas that are particularly exposed or you expect likely over-runs then it is good practice to ensure the brace is high and strong so it supports impact from the front and rear of the unit. If the local design criteria is not restrictive, a full batter/45 degree splay kerb will perform much better in these instances.

With kerbing generally, impacts are more frequent in low-speed parking/stopping areas, roundabouts and over-runs so to reduce risk, it is best to check and assess each section of kerbing and its function across a project and chose a suitable method of installation.

The solid ductile iron access points and gully outlets ensure a full robust extent to all sections of CKD.

Recent Posts

Installation: Plan, Manage & Monitor

To help you comply with the Construction (Design & Management) Regulations 2015, our products offer a choice for a lighter, safer and easier method of installation. All processes, from design through to future maintenance, require assessment so all involved can plan, manage and monitor.

Our installation and product data provides all the information required so Principle Designers and Contractors can meet their obligations by reducing risk and the demands on their workforce.

1 – All our standard units are manufactured in an automated process that guarantees the consistency and precise weight of each item produced. (Please see technical brochure for product details).

2 – All standard units are well below the threshold for manual handling (4-7kg).

3 – Iron Gully Units, Access Points and ancillary fittings will require a specific assessment. The weights, dimensions, COSHH data are stipulated on the website and within our technical literature and accurate as of November 2018. When necessary we will revise information and list on our website if the changes present an increase in risk. If in doubt please contact us.

4 – To mitigate risk, we pack and supply Iron Gully Units, in three parts, and supply fixings loose for  a lighter assembly on site.

5 – The lightweight & single-phase install allows all partners to meet their CDM obligations by choosing a  reduced risk method of installation. Lightweight standard units mean transporting to and across site, setting out and installing is a simple, lightweight and speedy process.

6 – Standard units can be cut using hand tools reducing the risk from RCS (Respirable Crystalline Silica), and risk of injury or accidents resulting from the use of power tools.

7 – The main principles of the CDM regulations are embedded within the installation processes in reducing the risks of musculoskeletal disorders and occupational lung disease.

DuraKerb Installation Advice

DuraKerb is installed in the traditional manner & no additional training is required.

Durakerb’s single function kerb units are installed in the traditional manor and no additional training is necessary. Installation advice is available in text, in video format, and is also available within the scope of our BBA/HAPAS certification.

Detailed here is typical Wet/Dry Bed Method of installation for a road/footpath construction.

Dry and Wet Bed Laying Method

A dry mixed concrete, or ready mixed concrete, the latter having a slump of 25mm to 35mm (ST1 / BS 8500), is required. The string line is to be set up on pins and set to correct level. The concrete is to be placed along the intended line behind the string. The concrete should then be spread and struck level with a shovel, leaving no high or low points. Check that the minimum specified thickness of concrete at least is under the struck concrete surface.

The DuraKerb is then to be taken from the pallet or truck and placed on the concrete bed, laying from the left offering it to the string line. This is done from the verge/footway side, holding the DuraKerb with both hands. It is then to be adjusted into position using a small rubber hand maul. With a hand on the top, the surface is then to be tapped into position until flush with the string line.

The second unit is then introduced by offering it to the string line at the end of the first DuraKerb. Ensure that the male alignment spigot on the end face of laid kerb is located snugly in the female slot of the kerb being laid. The DuraKerb has a 2.5mm lug integrated into the side face to reduce contact between kerbs, which in turn facilitates the reduction of spalled kerbs during installation.

The laying process is then repeated, checking that the first DuraKerb has not been disturbed, adjusting as necessary with the rubber maul. Successive DuraKerb units can then be added to the line.

On completion of the kerb line, backing concrete is to be run out from the shute behind the DuraKerb, covering the lateral flange, keying the DuraKerb to the haunching and race. The kerb layer then faces off the front of the kerb race, trimming flush to the front flange of the DuraKerb. The rest of the haunching should then be trowelled into shape and then the line of DuraKerb should be checked again for accuracy.

Single Installation and Cutting Method

The male fitting can easily be removed if required for single installation, by cutting. If lengths shorter than standard kerbs are required then measure the required length and cut accordingly.

DuraKerb advocate the use of hand tools when cutting to eliminate respiratory concerns. When cutting a (P1) dust mask must be worn and all necessary PPE workwear.

Durakerb allows installers to produce a precise finish using hand tools. When cutting for length or change in direction then it is best to fill the ends with haunch/bedding material for a robust and clean joint.

Loading...
Loading...
Loading...

Duradrain Installation Advice

Duradrain Combined Kerb & Drainage Systems must be installed as per our instructions. Both kerb and hydraulic function should be considered for each and every section to outlet/outlets. Duradrain can be installed at a transition/border between variable surfacing and landscape with variable function across a project. Given details we can advise on a best method or methods of installation.

When choosing a best installation you should consider;

1 – Resistance to impact and load is not limited by the strength of the unit. The choice of bed and brace are fundamental to a system’s load performance on site.

2 – It is possible to improve a system’s load performance by increasing the height/width of the brace and/or the strength of the material used in the installation.

3 – It is possible to improve a system’s load performance by ensuring a best integration between unit, bed and brace so all is tied-in and robust.

4 – For large projects, where areas may be at differing stages of completion, yet open to traffic, it is important to ensure the installation is sound. If the road surfaces are not made-up to full height then you should protect the front face of the units, and/or you can consider installing a tapered front haunch of 150mm.

Duradrain is available in Half Batter and Full Batter/Splay Profile. Inlet windows are set to the following range of kerb/weir heights.

Half Batter – 75-125mm

Full Batter/Splay – 75-100mm

Where there are changes in function affecting kerb-heights, transitions should be gradual and the invert depth within the channel body maintained. The choice of profile and kerb-show are generally consistent with standard BS-EN1340 kerbs (1100) series, see DMRB – HA83/99

Duradrain Installation Advice

We recommend each section of CKD should start with an access point at the head of the run to allow jetting/cleanout. We also recommend access points are placed at intervals of 40-50mtrs subject to site conditions and any ongoing maintenance strategy. Sealed end caps should be fitted at the head/start of any section of ckd.

Once the line and levels are determined, installation can commence. Setting out is carried out generally as with a standard BS kerb however a deeper excavation is generally required to accommodate the channel body and a 150mm minimum bed of concrete.

In all instances the excavated foundation must be well compacted and sound before the bed is laid

All units within a run should be laid out in position. End Caps, outlets or spigot connections should be fitted and sealed before you begin installation. You can install Duradrain sections from the head of the run or from the outlet back.

In all instances the excavated foundation must be well compacted and sound before the bed is laid. Site conditions, position and restrictions can determine different methods of pouring the bed and brace, here we recommend a best method however other methods can be considered as long as they are equal in strength and deliver an equal integration.

For best compaction and reduced waste, formers are recommended and the bed can be poured separately or as one with the unit, brace/backing. Please see our installation example for details on the minimum strength and type of concrete. If the base is laid first, the units can then be installed on a mortar bed.

For adoptable highways all joints must be sealed (IAN117/08 Rev 2). The sealant is applied to each unit before it is presented. Using a rubber maul, the units can be hammered together in line and level and any excess sealant can be smoothed-off. For functionality, the sealant is only required around the channel body up to the road surface/inlet level. Please see following examples in varied applications within varied landscapes.

Integration is key to longevity so it is important that the bed and rear brace are keyed together. The Duradrain retention element provides improved integration, you may also consider inserting dowels and using a wider haunch in areas subject to frequent and heavy impacts.

Please see following examples in varied applications within varied landscapes and specific installation notes/data.

The rear brace/haunch must be of the correct width and height suitable for the position and application. In pavements the rear brace can be tapered and the pavement surface should then be fully rolled tight up to the back of the Duradrain units.

In heavy trafficked areas restricted by narrow alignment at roundabouts/tight junctions and on external curves/exposed angles you must consider a robust detail and ensure a full risk assessment is carried out as other factors such as the presence of a safety barrier or railings can impact on the system performance.

If you have any questions or need project specific advice on any aspect of installation and design, please get in touch. Typical Details in both PDF and AutoCAD are available for download.

Durachannel Installation Advice

Durachannel is a linear surface drainage system and must be installed as per our instructions. Durachannel can be installed at a transition/border between variable surfacing, structure and landscape with variable function across a project. Given details we can advise on a best method or methods of installation.

A successful system will quickly collect and dispose of run-off from and within the structure/landscape. Durachannel provides a seamless integration for the most toughest of applications.

It is possible to increase the load performance of a system by installing within a robust detail. It is important to ensure the strength of the bed and haunch and its integration into the hard-landscape is at least equal to the strength of the slab, structure or pavement. When choosing a best installation you should consider;

1 – Resistance to impact and load is not limited by the strength of the unit. The choice of bed and haunch are fundamental to a system’s load performance on site.

2 – It is possible to improve a system’s load performance by increasing the depth and width of the haunch and/or the strength of the material used in the installation.

3 – It is possible to improve a system’s load performance by ensuring a best integration between the side haunches, bed and surrounding surfacing. It is therefore important to choose a best method of installation so the units, bed and haunches are fully integrated within the surrounding landscape/structure.

4 – Expansion and Contraction of structure and surround should be considered specific to the position of each channel and the structure composition. For exposed concrete structures, it can be good practice to include a U-Cage and re-bar within the haunch and bed to prevent contraction. Please see typical robust detail.

The most severe types of load experienced when installed are generally dynamic, from vehicles turning and at speed therefore a balance of flexural and compressive strength in each unit is key to the system’s longevity. The one-piece monolithic design and the ductile material properties ensure a robust and solid construction able to withstand loads from all types of road going vehicles.

Once the line and levels are determined, installation can commence. A trench is excavated to accommodate the channel and a 150mm minimum bed of concrete. The following installation details show examples in varied applications within varied landscapes.

In all instances the excavated foundation must be well compacted and sound before the bed is laid

All units within a run should be laid out in position. End Caps, outlets or spigot connections should be fitted and sealed before you begin installation. You can install Durachannel sections from the head of the run or from the outlet back.

Site conditions, position and restrictions can determine different methods of pouring the bed and brace, other methods can be considered as long as they are equal in strength and deliver an equal integration.

For best compaction and reduced waste, formers are recommended and the bed can be poured separately or as one with the unit and haunches. Please see our installation example for details on the minimum strength and type of concrete. If a bed is laid first, the units can then be installed on a mortar bed.

For adoptable highways all joints must be sealed (IAN117/08 Rev 2). The sealant is applied to each unit before it is presented. Using a rubber maul, the units can be hammered together in line and level and any excess sealant can be smoothed-off. For functionality, the sealant is only required around the channel body up to the road surface/inlet level.

Integration is key to longevity so it is important that the bed and haunches are keyed together. The Duradrain retention element provides improved integration, you may also consider inserting dowels, re-bar/reinforcement and/or using a wider haunch in areas subject to frequent and heavy traffic.

The units can be cored and sealed on site or at the works to produce angles and junctions. Access units have the option for 160mm connection and can be used for access at corners or junction for cleanout purposes.

In most instances the design requirements for a linear channel will be set out in MHCW – Series 500 appendix 5/5.

We recommend each section of linear channel should start with an access point at the head of the run to allow jetting/cleanout. We also recommend access points are placed at intervals of 40-50mtrs subject to site conditions and any ongoing maintenance strategy.

Sealed end caps should be fitted at the head/start of any section of ckd.

Standard units can then be used to channel the flows directly to outlet.

Durachannel Universal Gullies are a robust unit manufactured from ductile iron with a 160mm standard connection-out. The flows-out of the gully unit will always exceed the potential maximum dual flows-in from the channel units. They allow for flows to drop-out into the box with large access to remove silt and debris when required.

If you have any questions or need project specific advice on any aspect of installation and design, please get in touch. Typical Details in both PDF and AutoCAD are available for download.

Contact Us Today For Your Sample