Manchester Metrolink Trafford Park Line Manchester Metrolink Design Phase

In 2015 Aecom’s Manchester team contacted access chambers throughout the route to Trafford Park Line Cubis representatives for discussions in the ensure the best solution that was suitable for design of the communications and drainage the contractor. Such benefit was the heavy-duty networks for the new Metrolink Trafford park GRP STAKKAbox™ ULTIMA chamber system that line. Having previously worked with Cubis placed directly adjacent to the track without the on a number of other stages of the Metrolink need for any structural or concrete backfill. The development of Greater Manchester’s Light covering 60 miles, new and ongoing explorations infrastructure project, Cubis was more than Rail Network (Metrolink) began in April 1992; are underway to expand the Metrolink further and happy to help the team at Aecom. With much of the line being located in a busy city primarily to address the absence of a North–South to develop new rapid transit schemes as part of centre Cubis took this opportunity to introduce link across the city. Continued progression, over the Greater Manchester Transport Strategy 2040. This was an extensive and technically difficult the MULTIduct™ cable protection system. In nearly three decades, has provided the city with project to design with all the different factors to heavily trafficked areas traditional ducting must one of the largest light rail networks within the consider. Cubis was able to provide the team be buried deep typically with a large concrete UK, and has played an essential part in keeping with a vast range of detailed product drawings encasement, but due to its high structural the city moving and the economy growing. and models all within suitable CAD formats to strength, the MULTIduct™ system not only vastly Currently running seven lines, with 93 stops and meet the needs of Aecom design team. This reduced the trench depth but also reduced was also backed up with structural calculations the width by keeping all the cables closely and test reports on all their products throughout grouped in a neat narrow unit. The MULTIduct™ the design giving an extra level of quality eliminated the need for any concrete within the assurance. duct route reducing the time required to install and backfill the units and considerably reduced With Cubis’ extensive access chamber and the carbon footprint of the entire project. 93 cable protection range the specification team Train was able to refine the design of hundreds of Stations 60 Miles of Track

7 Rail Lines

Greater Manchester Transport Strategy 2040 Map Engagement New Product Developments

In 2016 Laing O’Rourke began gearing up for to the technical team who then created bespoke Throughout the project Cubis kept regular The ground team then requested if this the huge civils undertaking of the Manchester drawings as requested. Laing O’Rourke then contact with the ground teams on the feature could be adopted for the power & Metrolink Trafford Park Line. Cubis’ early reviewed these drawings and approved them installation process. What became apparent communication chambers with the use of engagement with the Laing O’Rourke team prior to orders being placed by procurement. on an early site visit was the adjustability of MULTIduct™ instead of the twin wall duct. The consisted of several meetings around how best the “FLEXI Pit” trackside drainage system was Cubis R&D team quickly turned around this to manage the design and procurement process. These early processes put in place led to a huge extremely well received. request, ensuing the ground teams could keep It was decided that Cubis were to create a increase in efficiency and established an orderly the project moving forward. standard product document for the projects communication line throughout the project. This The FLEXI Pit system has been designed procurement team to make it easier to call off was of paramount importance due to the sheer and developed to offer easily adjustable duct The new adjustable MULTIduct™ system the necessary products as required. scale of the project. positions for varying pipe invert levels during comprised of varying duct invert level, to suit installation on-site. the full range of Cubis’ MULTIduct™ units (4, 6, 9 All non-standard products were co-ordinated and 4XL) if required.

between the Laing O’Rourke Section Engineers B125 BLOKadjust Frame with Hex Locking Composite Covers and Steel Grate and the Cubis technical department. This was 1327 1200

B125 BLOKadjust Frame with 1327 Hex Locking Composite 1200 managed by Laing’s outlining their requirements Covers and Steel Grate 1327 1200

600 LDPE Base 727 600 727 B125 BLOKadjust Frame with 4 x M16 Lifting Eyes fitted Hex Locking Composite to bottom riser section

Covers and Steel Grate 727 600 600

LDPE Base

385

4 x M16 Lifting Eyes fitted 385 to bottom riser section

385 LDPE Base

385 385 385 385 385

4 x M16 Lifting Eyes fitted

to bottom riser section 385 385 385

300 385 385 375mm ID

Twinwall Pipe 300 385 385 375mm ID Twinwall Pipe Copyright of Cubis. No part of this document may be communicated, copied or used 150mm ID without prior permission of Cubis. Date 525 13/03/18 Third Angle Twinwall Pipe Projection 525 www.Cubis-Systems.com Drawn LRobinson Material 150mm ID 300 300 MS Twinwall Pipe Appr. 375mm ID 375mm ID TITLE 525 150mm ID . Weight Finish 1200x600x1050mm Ultima Flexi Pit 150mm ID Twinwall Pipe Galv to EN 1461 Twinwall Pipe

. kg TwinwallDIMS Pipe 525 Twinwall Pipe 150mm ID Tolerance unless 525 Otherwise Stated SIZE . --/--/-- Twinwall Pipe +1,-1 DWG NO mm . --/--/-- A3 SYMFF1-MPT00379-SC07KBE8CSHEET 1 OF 1 . . --/--/-- 150mmREV ID . . . --/--/-- . Twinwall. Pipe --/--/-- . . . . .

Copyright of Cubis. No part of this TITLE 1200x600x1050mm Ultima 525 Flexi Pit . Date 13/03/18 Third Angle Material MS Rev Date . document may be 300 --/--/-- ...... communicated, copied or used Projection 375mm ID . Revision History: Description . --/--/-- . . without prior permission of Cubis. Drawn LRobinson Finish Galv to EN 1461 DIMS ...... Twinwall Pipe SIZE DWG NO SHEET 1 OF 1 REV . . --/--/-- . .Drwn. . . Weight . kg Tolerance unless --/--/-- . Appr

www.Cubis-Systems.com 300 Appr. 375mm. ID Otherwise Stated +1,-1 mm SYMFF1-MPT00379-SC07KBE8C . . . A3 Rev Date Revision History:. Description Drwn. Appr . --/--/-- Appr Twinwall Pipe . Drwn . --/--/-- 1200x600x1050mm Ultima Flexi Pit --/--/-- TITLE REV . Revision History: Description SHEET 1 OF 1 MS . Rev Date Material DIMS SIZE DWG NO Third Angle Galv to EN 1461 SYMFF1-MPT00379-SC07KBE8C 13/03/18 Finish Date Projection mm A3 Tolerance unless +1,-1 Copyright of Cubis. No part of this LRobinson . kg Otherwise Stated document may be Drawn Weight communicated, copied or used . without prior permission of Cubis. Appr.

www.Cubis-Systems.com

250+ FLEXI Pits Installed

Cubis also developed a new and bespoke FLEXI Pit inspection chamber cover. The cover consisted of 2 x B125 composite covers and 1 x part steel grate. These catchpits were to be in areas subjected to occasional vehicle loads and thus a more robust inspection grate was required. Giving that Cubis employs a specialised steel fabrication team they were able to create this alternative grate. Specified Systems

STAKKAbox™ ULTIMA The Cubis STAKKAbox™ Chamber System provided an adaptable network access solution that was used throughout the project within a range of communication, power and drainage applications. The STAKKAbox™ ULTIMA chamber made from GRP material provided no compromise on strength alongside any highways or railway tracks. The ULTIMA chamber system was developed to provide an adjustable UTX system and trackside drainage inspection chamber where adjustability in the invert levels were required when working within the challenging conditions of the project. 11km MULTIduct™ Installed

500+ Chambers CABLEprotect MULTIductTM Installed

The chamber and ducting systems used on the TPL had been in use since 2011 when first used on the Manchester Metrolink Airport Line. They were then specified by the designer for the Trafford Park Line with some new ideas for product development that would suit the different applications require. Over the years of using the Cubis products, I feel as though we have developed the best product solution for the applications required on the Metrolink Line with the client being extremely pleased with the final network system and installation. MULTIduct™ Cubis’ MULTIduct™ Cable Protection system methods. These can often move, crush or twist The MULTIduct™ product integrated with the STAKKAbox™ ULTIMA chambers well and worked provided a lightweight, structural ducting system during backfill making it difficult to locate cables perfectly for our ducting systems on the project. The MULTIduct™ provided a quality product with that was easy to install offering a modern at either end of duct runs. ease of installation and a right first-time installation every time. My operatives on-site provided alternative to traditional cable ducting systems. excellent feedback on the product and the M&E guys also commented on how easy it was to pull Its structural strength allowed for a shallower The system also greatly reduced the removal of the cables through. Previous issues with traditional “stick” ducting that was installed poorly made burial depth requirement, this was due to it’s spoil from site along with decreased dig, excavator the decision to use MULTIduct™ easier and I would recommend the use of the Cubis MULTIduct™ much greater crush resistance than conventional movements and fewer lorry loads to and from site. cable protection system to anyone looking to install a new ducting network. - Senior Project Manager Laing O’Rourke Installation Guidance

To ensure the safest installation and best practice for the project, Cubis worked closely with team at Laing O’Rourke’s to create a series of installation Product Overview Introduction The STAKKAbox™ ULTIMA and ULTIMA Connect are modular scalable solutions which can be prebuilt in a Cubis factory or built on-site with easily connectable components. It is understood there are alternativeULTIMA ways that Connect might consists be of corner components (known as Significantly reducing costs of in-situ construction through ‘hockey sticks’) and sidewall lengths. These components videos showing best practice in on-site conditions. ≤ 3500mm required and/or recommended based on site or> 2500mm project to This guide addresses the method and time detail savings, for the the light weight chamber systems feature are connected using a jointing peg to form a variety of

conditions. Cubis Systems4 reserves the right to alter these installation of the STAKKAbox™ ULTIMAtwin and wall ULTIMA sectional designs that are made up of GRP. The clear opening sizes. With sidewall lengths beingMinimum used in concrete 200 mm dry surround guidelines and encourages contact with the business or lean mix C40 Connect access chamber system. The purpose is to conjunction with corner components additional chamber its representatives to review any possible modificationto to serve as a guideline, and is not intended for any specific sizes specified by the contractor can be made. hard shoulders. these notes prior to commencing installation.> 1310mm This resulted in a number of sample products being ≤ 2500mm construction project.

Minimum

concrete 150 mm dry surround

lean mix C40

reinforced with A393 mesh For use in areas where cars and lorries have frequent access, including carriageways and

150mm of dry lean mix concrete C40 ≤ 1310mm

Manchester www.cubis-systems.com supplied for hands-on training with guidance and [1]

Minimum

concrete 100 mm dry surround Metrolink lean mix C40

≤ 3500mm instruction from Cubis. The training videos were Contents > 2500mm to 3 Minimum

Installation concrete 09 150 mm dry surround lean mix C40

Chamber Assembly to STAKKAboxTM concrete C20 02 ULTIMA Guide> 1310mm 09 100mm of dry lean mix Introduction ≤ 2500mm Duct Entries then used by the wider groundwork teams when Strength 03 STAKKAboxTM ULTIMA Connect 10 Minimum of similar) 200mm well compacted

Product Overview as car parks (excluding carriageways) (i.e. MOT1 or Overbuilding Existing Services granular stone Vertically load rated to04-05 F900, and offers excellent sidewall Smooth Outer Walls with Lip to ‘Key In’ strength. Areas with controlled, slow moving traffic, such 10 Table 1 - Installation Guidelines ≤ 1310mm

similar) Wall Furniture & Cable ManagementSTAKKAbox™ chamberscompacted have smooth outer walls and an 100mm of well 06 (i.e. MOT1 or granular stone 11 installing out on-site. Minimum of outer lip which keys into the backfill. similar) 150mm well compacted EN124 Diagram ULTIMA & ULTIMA Connect (i.e. MOT1 or Lightweight Backfill Bracing granular stone 06 11 Frame & Cover Options Due to the sectional twinwall design and the GRP material ≤ 3500mm Chamber Backfill Fast and> 2500mm Easy to to Install both ULTIMA and ULTIMA07 Connect have 150mm deep ring 2 11 Health & Safety Minimum of similar) sections and ULTIMA Connect components are under 10kg ULTIMA Connect chambers are significantly200mm well compacted faster to install Depth Adjustment (i.e. MOT1 or in weight. 07 granular stone thanCross bracing should be the fulltraditional depth of the chamber to alternatives, with complete installations concrete C20 12 Equipment and Additional Materials typically> 1310mm taking up to one hour. This results in reduced costs

100mm of dry lean mix Frame & Cover ≤ 2500mm 08 for the installer. NOTE: Guidelines apply to ULTIMA / ULTIMA Connect chamber depths ≤ 2400mm occasional vehicular access 12 Footprint Chamber sidewall > 1000mm but ≤ 2000mm requires single central bracing Cubis’ expertise extend across both the design Ground Level Reinstatement How it’s Built 08

Chamber sidewall > 2000mm requires bracing for every 1000mm interval as a minimum

Excavation For use in pedestrian areas where there is only

≤ 1310mm

similar) ULTIMA Connect corner components are manufactured in compacted MOT1 or similar) 100mm of well (i.e. MOT1 or granular stone Foundation left and right ‘handed’ designs, which offer the ability to Minimum of 150mm well and construction process, these abilities to meet offset joints between ring sections in order to provide a compacted granular stone (i.e. brickworked design.

≤ 3500mm > 2500mm to

1

Minimum of similar) 150mm well compacted

(i.e. MOT1 or the customers needs across all stages of the granular stone to

concrete C20

> 1310mm

100mm of dry lean mix ≤ 2500mm

Pedestrian access only (Footway) project were greatly appreciated by groundwork, or similar) [4]

≤ 1310mm

similar) compacted NOTE 2: The backfill requirements for each EN124 Group relates to where the chamber will be installed, rather than the load rating on the cover. MOT1 100mm of well (i.e. MOT1 or granular stone Level Minimum400 of 100mm well Detail Scan here to download technical resources, BIM level 2 Level 200 Detail NOTE 3: Minimum Excavation Footprint, 150mm to 200mm (depending on specified backfill) or width of compacting equipment, whichever is greater.

compacted granular stone (i.e.

Product models, videos and product(fig.1) information BIM Level 2 models Cubis’ network an aggregate containing a range of particle sizes in compliance with the Department of Transport Specification for Highway Works, clause 803 (SHW 803).

Length Therefore, if a chamber is specified with a D400 rated cover but will be installed in the footway, the backfill requirements for a chamber installed in a footway apply. Sidewall access and cableJointed protection pegs are inserted design and contractor teams, to ensure a safe Base [3] EN124 Group systems available Material (depth) NOTE 4: MOT1, also known as DOT Type 1, can be made from Granite, Limestone or clean Crushed Concrete. The product is crushed to 40mm down to dust creating for downloadat each intersection to Table 1 - Installation Guidelines NOTE 1: For chamber sizes that are > 3500mm in side wall length and > 2400mm in depth please contact the Cubis Systems Technical department, [email protected].

Type / Material Group Description Backfill Bracing securelyWidth of connect Backfill

Page 4 [2] www.cubis-systems.com each component

and efficient product installation and where Backfill

Page 3 Page 1 www.cubis-systems.com Page 4 seen right across the project with new product www.cubis-systems.com development, installation guidance and on-site Page 2 www.cubis-systems.com support throughout the 3+ year project. Driven by Innovation

Innovation is the engine that has driven Cubis Systems to its position as global leader in the design and manufacture of access chambers and cable ducting systems.

Inspired by innovation, we have developed quality products that replace traditional construction materials like bricks and concrete. Our lightweight plastics, incorporating intelligent design features, are used in the construction of infrastructure networks for the rail, telecoms, water, construction and power markets worldwide. Cubis products can be installed much faster than traditional methods and therefore save our customers both time and money. Contact us: therefore save our customers both time and money. Cubis manufactures the preformed STAKKAbox™ network access Head Office: chamber systems, the AX-S™ access covers range, a MULTIduct™ 4 Silverwood Industrial Estate, multiple duct system and the PROtrough cable troughing system at Lurgan, Co. Armagh, sites throughout the UK and Ireland. These innovative products are BT66 6LN, exported to more than 25 countries throughout the world. Northern Ireland At Cubis we are committed to ongoing innovation and dedicated Telephone: +44 (0)28 38 313 100 to delivering absolute product quality, detailed technical customer Email: [email protected]@cubis-systems.com support and the highest levels of customer satisfaction. www.Cubis-systems.comwww.cubis-systems.com