Box Culverts Structural Precast Concrete Solutions and System Overview 4 Products for Civil Engineering, Commercial Benefits 5 and Domestic Applications

Hanson Building Products

Structural Precast Products FORTHECIVILENGINEERINGSECTOR Structural Precast Products FORTHE CIVILENGINEERING SECTOR

Hanson Building Products provides Box Culverts structural precast concrete solutions and System overview 4 products for civil engineering, commercial Benefits 5 and domestic applications. Design and specification 6-7 Technical data 8-9 In addition to our dedicated Installation guide 10-11 flooring products the Omnia Bridge Deck company designs, System overview 12 manufactures and supplies Benefits 13 non-standard structural Product details 14 precast components to Manufacture 15 clients’ specifications. Delivery, offloading 16-17 and erection

Hanson Quickbuild™ Quickbuild™ walls Wall System

Systems overview 18 Escape shafts Benefits 19

Bespoke Products

Expertise and 20-21 capabilities Retaining walls and flood defence Nationwide service 22

2 Specialist structure precast concrete components can be incorporated into a wide range of applications.

Specialist stair flights

Digester tanks and other large bespoke structures

Omnia Bridgedeck

By taking an active involvement in the design work to offer value engineered solutions, Hanson Building Products is able to offer a competent and economic service, to provide quality assured units to a wide range of bespoke precast concrete structures.

These include :

Box culverts and channel sections

Omnia Bridgedeck Bridge parapets Beams

Columns Columns and beams Wall and floor panels

Sandwich panels Box culverts and Bespoke units to a maximum channel sections handling capacity of 24 tonnes.

3 Box Culverts PRODUCTOVERVIEW Easy to install, suitable for very shallow or deep fill, ideal for use in a wide variety of civil engineering applications

Hanson Building Products is the Whilst offering increased flexibility conditions and are efficiently produced largest producer of box culverts in Hanson Box Culverts retain all their in standard sizes. the UK, and are members of the original advantages. As these advantages have become Box Culvert Association. They are easy to install and can be widely recognised their range of Since its introduction over 45 years made to suit very shallow or deep fill. applications has increased making them ago the range of box culverts we offer They also offer economy by being ideal in a wide variety of civil has continued to expand. uniquely designed for particular loading engineering applications.

4 Box Culverts benefits Flexibility of range to accommodate Civil engineering almost any size requirement applications

Availability of multi-cell sections Culverting Watercourses Use with shaped invert for dry weather flow situations Attenuation Tanks eg. sloping vee and half round Road Crossings Ease of installation Multi-cell Construction Can be laid as singles or in multiple runs Pipe Replacement Pedestrian and Accommodation of high Vehicle Subways storage volumes Sea Outfalls Escape Tunnels Box culvert design specific Shafts to client requirement Service Tunnels Qualified technical department with CAD facilities, Pumping Stations available to assist at all stages with design specification Channels and contract development Portals Quality Service Guaranteed Basements Solutions Available nationwide on a supply only basis CSO Chambers Complies with all relevant standards and manufactured in accordance with ISO 9001 and 14001

Hanson Box Culverts are available in Unlike pipes and corrugated steel a range of 144 standard sizes from assemblies, box culverts can be 1000mm x 600mm to 6000mm to designed to carry vertical load without 3600mm. Non-standard sizes and the relieving effect of side pressure. internal profiles can also be readily provided including shaped inverts, Therefore, when culverts are used in dwf channels, and units with cross multiple sections, they can be laid side over channels. by side with only a nominal gap between them. Reference to our table of standard sizes will give the size necessary to By comparison with arched or circular meet any conditions which may be sections no flow area is lost through required in terms of storage volume, either excessive spacing apart or flow capacity etc. For larger culvert curved profiles. widths, twin or multiple sections may also be considered.

5 Box Culverts DESIGN & SPECIFICATION

Hydraulic design

Discharge rates for box culverts in the Thus, for a 2400 x 1200 section laid Hanson standard range are calculated at a gradient of 1 in 500 and with an for a gradient of 1 in 1000 in assumed roughness coefficient of accordance with the Colebrook-White 0.6mm, the discharge rate is given by equation assuming the culvert running 4.29 x 1.4 x 0.93 = 5.59m3/s. full under uniform flow conditions. Comparable discharge rates for The flow capacity of a culvert is circular pipes are given in the Table 2 determined by a number of different (overleaf). factors. In addition to the gradient and roughness coefficient, the geometry For any gradient between 1 in 1000 of the inlet and outlet and the and 1 in 250, the gradient multiplier tailwater level can affect the mode of (Table 3 overleaf) should be applied. flow and may prevent the culvert from running full or under uniform flow A value of 0.3mm has been assumed conditions. for roughness coefficient, ks, which depends upon the accuracy of laying In such cases the flow capacity will be and jointing in addition to the quality lower than the full discharge rate. of the culvert surface. Where a different value is required, the discharge rate at the appropriate gradient should be adjusted by the use of the roughness multiplier (Table 4 overleaf).

Platform units

6 Design and Surface loading detailing and fill depth

Box culverts are generally designed Loading applied at the ground surface and detailed in accordance with the and weight of fill material produce a Box Culvert Association Standard combination of vertical and horizontal Specification which covers materials, forces on the box culvert. manufacturing tolerances, external loading design and detailing standards. Surface loading may be specified as a standard loading type, equivalent Box culverts carrying highway loading uniform loading or individual wheel or railway loading are designed to loads. The critical load on a culvert can

current standards and specification as occur at minimum or maximum fill. Cast on end walls stipulated by the client. Each enquiry for a culvert should state The lowest grade of concrete used is the minimum and maximum fill depth C45/55 with a 20mm maximum size and the amount or type of surface of aggregate. The nominal cover to loading. reinforcement complying with the exposure requirements of BS8500. It is recommended that the minimum fill depth should be not less than An experienced team of engineers and 200mm or one fifteenth of the internal technicians backed by CAD facilities width of the culvert if this is greater. provide a flexible and comprehensive design and detailing service enabling the clients design and specification criteria to be satisfied. Access units

D.W.F channels Animal crossing ledges Twin cell construction (solid or cantilever)

7 Box Culverts TECHNICAL DATA Please size by span x height. All dimensions are internal

Table No.1 Dimensions, flow area and discharge rate Internal 1000 1200 1500 1800 2100 2400 2700 3000 3300 height

600 0.53 0.65 0.83 1.01 1.19 ✘✘✘✘ ✘ ✘ ✘ ✘✘✘ ✘✘✘ mm 0.50 0.64 0.86 1.07 1.29

800 0.73 0.89 1.13 1.37 1.61 1.85 2.09 2.33 ✘ mm 0.77 0.99 1.33 1.67 2.01 2.36 2.71 3.06

1000 0.93 1.13 1.43 1.73 2.03 2.33 2.63 2.93 3.23 mm 1.07 1.37 1.84 2.32 2.80 3.29 3.79 4.29 4.79

1200 ✘ 1.37 1.73 2.09 2.45 2.81 3.17 3.53 3.89 mm 1.76 2.37 3.00 3.64 4.29 4.95 5.61 6.28

1500 ✘✘2.18 2.63 3.08 3.53 3.98 4.43 4.88 mm 3.21 4.08 4.98 5.89 6.81 7.74 8.68

1800 ✘✘ ✘3.17 3.71 4.25 4.79 5.33 5.87 mm 5.21 6.38 7.57 8.78 10.00 11.24

2100 ✘✘ ✘ ✘4.34 4.97 5.60 6.23 6.86 mm 7.83 9.31 10.82 12.36 13.92

2400 ✘✘ ✘ ✘✘5.69 6.41 7.13 7.85 mm 11.11 12.94 14.81 16.70

2700 ✘✘ ✘ ✘✘ ✘7.22 8.03 8.84 mm 15.11 17.32 19.56

3000 ✘✘ ✘ ✘✘ ✘ ✘8.93 9.83 mm 19.88 22.49

3300 ✘✘ ✘ ✘✘ ✘ ✘ ✘10.82 mm 25.48

3600 ✘✘ ✘ ✘✘ ✘ ✘ ✘ ✘1 mm

Notes 1. The standard range of box culverts generally have flat inverts and 190mm corner splays up to 4800mm span and 225mm splays from 5100mm to 6000mm span and a maximum length of 2m. 2. Sizes other than those stated can be manufactured to suit customer requirements. 3. Special internal profiles, shaped inverts and dry weather flow channels can be produced and are available on request.

8 Table No.2 Table No.3 Table No.4 Circular pipe discharge rates for Gradient multiplier Roughness multiplier comparison with standard culverts Diameter Flow area Discharge Roughness DN m2 rate m3/s Gradient Multiplier coefficient ks Multiplier 0.06 1.11 900 0.64 0.67 1 in 1000 1.0 0.15 1.05 1050 0.87 1.00 1 in 800 1.1 0.30 1.00 1 in 700 1.2 0.60 0.93 1200 1.13 1.42 1 in 600 1.3 1.50 0.85 1 in 500 1.4 1350 1.43 1.93 1 in 400 1.6 1500 1.77 2.54 1 in 300 1.8 1650 2.14 3.25 1 in 250 2.0 1800 2.54 4.08

Width mm (internal span) Flow area m2 Discharge rate m3/s 3600 3900 4200 4500 4800 5100 5400 5700 6000

✘✘✘✘✘✘✘✘✘ m

3.53 3.83 4.13 4.43 4.73 ✘✘✘✘ m 5.29 5.80 6.30 6.81 7.32

4.25 4.61 4.97 5.33 5.69 6.02 6.38 6.74 7.09 6.95 7.62 8.29 8.97 9.64 10.28 10.96 11.64 12.32

5.33 5.78 6.23 6.68 7.13 7.55 8.00 8.45 8.90 9.62 10.57 11.52 12.48 13.44 14.37 15.33 16.30 17.27

6.41 6.95 7.49 8.03 8.57 9.08 9.62 10.16 10.70 12.48 13.74 15.00 16.26 17.54 18.79 20.07 21.35 22.64

7.49 8.12 8.75 9.38 10.01 10.61 11.24 11.87 12.50 15.49 17.07 18.67 20.27 21.88 23.48 25.11 26.74 28.37

8.57 9.29 10.01 10.73 11.45 12.14 12.86 13.58 14.30 18.61 20.55 22.50 24.46 26.43 28.40 30.40 32.40 34.41

9.65 10.46 11.27 12.08 12.89 13.67 14.48 15.29 16.10 21.84 24.14 26.46 28.80 31.15 33.52 35.90 38.29 40.70

10.73 11.63 12.53 13.43 14.33 15.20 16.10 17.00 17.90 25.14 27.82 30.53 33.27 36.02 38.80 41.59 44.40 47.22

11.81 12.80 13.79 14.78 15.77 16.73 17.72 18.71 19.70 28.52 31.59 34.71 37.85 41.02 44.22 47.44 50.68 53.93

12.89 13.97 15.05 16.13 17.21 18.26 19.34 20.42 21.50 31.95 35.43 38.96 42.53 46.13 49.77 53.43 57.11 60.81

4. Tapered units for bends, units with 6. Joints are a standard rebate within the For more technical manhole openings and pipe access holes wall of the unit and the box culverts can can be produced and are available on be jointed using sealant strip to provide information please contact request. a seal and flexible joint if required. Hanson Building Products 5. All box culverts are manufactured to order 7. Special insert pins are cast in to each box Tel: 0870 609 7094 and to the specific required design criteria, culvert to enable them to be lifted. the external loading conditions will govern 8. Channel units can also be produced the wall, roof and floor thickness, unit if required. length and reinforcement content.

9 Box Culverts INSTALLATION GUIDE

Delivery and offloading

It is the contractors responsibility to For reasons of safety and economy The offloaded box culverts should be offload the box culverts on delivery. certain box culverts are delivered to levelled carefully on a firm level base A hard level access area should be site on end rather than as laid, and will away from the edge of the trench, and provided which can be used safely by require a safe method of turning during if any further movement is required it standard articulated delivery vehicles. offloading. A data sheet giving should be by lifting; the culvert should The contractor should provide a guidance of lifting and turning is never be dragged or dropped. suitable crane of adequate capacity available and is issued to clients prior for lifting the culvert. to the first delivery.

Bedding, laying and backfilling

Excavation can be kept to a minimum As an alternative to granular bedding a The trench should be backfilled as soon with only nominal working space concrete blinding layer is sometimes as possible after the culvert has been required on each side of the box preferred to protect the formation or to laid and it should be filled evenly on culvert. When working in trenches the allow a faster rate of laying the culverts. each side of the trench. Backfilling normal requirements for health and should continue in 200mm compacted safety must always be observed. A layer of unreinforced concrete layers to reach the required depth of approximately 75mm thick on a trench cover. The base of the trench should be bottom which has been well prepared uniformly prepared before laying a to provide a uniform support is Where loads from construction plant 200mm bedding of compacted granular generally sufficient. may exceed the design load of the material over the full width of the box culvert protective measures will trench. A surface blinding of the fine A culvert line is usually laid directly on be required. This is particularly material will assist levelling. Local the bedding starting from the relevant at shallow fill depths. packings are subject to settlement and downstream end with the sockets facing should not be used. upstream, to receive the next culvert.

10 Jointing

The culvert sections generally have rebated joints and can be laid open, or sealed using pre formed strips and/or pointing materials. Reference should be made to the jointing material manufacturer’s specification and recommendation for use of the product.

A system using preformed strip within the joint is most commonly used. When the strip is bitumen based the joint faces should be cleaned, primed and allowed to dry.

The strip is then applied to the internal corner of the socket just before the culvert is laid in the trench. Heat may be required to soften the Joints are closed to a nominal gap by strip when working at low temperature. pulling against previously laid culverts When the box culvert is of sufficient with an applied load of approximately size for access, it can be pointed one tonne per metre of strip plus about internally with an elastomeric or half of the weight of the culvert unit to bitumen based material using a suitable overcome base friction, less if the unit primer. Not all methods of jointing, is suspended from the crane whilst however, should be expected to be jointing. completely watertight.

Jointing diagram Self adhesive cover strip nominal 10mm joint

s Foam filler e i r a v

Area to be primed

l prior to laying units l a w

0 /

1 r o o l f

5 f 2 o Compressed strip o r

with joint closed –

s s

e 15 n Position of sealing strip k c

i before closing joint

h Foam filler/bond T breaker 75 s e i r a v

Inside face 0

3 Rebate for internal Internal pointing pointing is used

11 Omnia Bridge Deck PRODUCTOVERVIEW Provides a solid base for deck slabs on Civil Engineering structures

Omnia Bridge Deck Omnia Bridge Decking is a practical Omnia Bridge Decking can be Hanson Building Products has supplied and economical means of providing considered as participating formwork, Omnia Bridge Deck for numerous permanent formwork to deck slabs of and the concrete and reinforcement in projects to most civil engineering bridges, especially where these span the pre-cast plank taken as part of the contractors. over live roads, rail tracks and rivers. deck with corresponding cost savings compared to traditional methods of construction.

12 Omnia Bridge Deck Benefits Practical and economical Can be designed to cope with splayed and curved structures Each panel is designed to suit its specific location Fully participating Omnia Bridge Decking can be considered as participating formwork, if required Easy to handle, simple to lay Panels are lifted into place without the need for slings Minimises road/rail closures Saves time and money on site Concrete and reinforcement in the precast Omnia unit may be taken as part of the deck with corresponding savings Quality service Factory-manufactured to consistent quality standards Complies with all relevant standards Omnia Bridge Deck is manufactured to all relevant British Standards and the ‘Specification for Highway Works’

13 Bridge Deck PRODUCT DETAILS Design details and cross section

The planks are primarily designed to Wherever possible. the correct size cope with temporary condition loads of lattice girder will be selected to only, however it is very often the case provide a chair for the top mat of that Bridge Designers use the reinforcement and they are aligned reinforcement provided as part of the during manufacture to ensure ease of permanent works design, and fixing longitudinal reinforcement over furthermore often ask us to increase the Omnia planks. the amount of reinforcement in the plank thereby saving reinforcement in There will normally be 3 or 4 the in-situ portion. reinforcing bars cast within each plank, minimum 10mm diameter, maximum Hanson Building Products design the 16mm diameter. planks to carry construction loading but also limit deflections to span/400 The Interim Advice Note and crack widths to 0.1mm in the (IAN 74/06) allows 35mm cover to temporary case. the reinforcement at the soffit.

Threaded anchors can also be cast Tolerance on given into the planks for supporting lighting, + dimensions shall be – 5mm drainage etc. unless shown otherwise

85 130 85

m 5m 2 60mm depth of plank does not Design 60mm cover include for the exposed aggregate Approx 35 35 Depth finish which could add up to 10mm 35mm of plank 47-50mm 12mm Cover to the overall depth

290mm

+0 300mm - 3 Prime Dimension + Tolerance on length – 10mm

A typical cross section of a Bridge Deck plank shows the arrangement of the lattice girder and the reinforcement within the precast concrete.

14 Bridge Deck MANUFACTURE Factory controlled production ensures accuracy in plank size, reinforcement position and cover to the soffit

‘Specification for Highway Works’ Manufacture to expose the aggregate. Omnia Bridge Deck is manufactured to all relevant British Standards and This surface accommodates the the ‘Specification for Highway Works’, horizontal shear stresses at the using C40/50 concrete in planks precast/in-situ interface. The 300mm wide x 60mm deep, although manufacturing tolerances and soffit special widths can be manufactured up finish (Type F2), are also as specified to 600mm wide for use as infill panels and the production process is at transverse beams or abutments. controlled by the procedures set out in our model specification. Each 300mm wide Omnia Bridge Deck plank has an Omnia lattice girder The Omnia lattice girder is at the heart centrally placed and the plank is of all of the Omnia product range and portion, and as lifting points during reinforced with either 3 or 4 steel bars is responsible for ensuring that the erection. We will also endeavour 10-16mm dia. panels will span the required distance wherever possible to provide a lattice in the temporary condition. The lattice girder that is set at the correct height The upper surface of the Omnia planks also acts as a physical link between for placing of the top mat of has a Class 2 finish as required by the the precast panel and the in-situ reinforcement.

The graph below shows the maximum Planks can be manufactured with Dimensions clear span for a range of span depths. skewed ends to suit the shape of the Please contact the office for spans and structure if necessary, however as the Omnia Bridge Decking can be depths outside of this range. maximum plank length can be no manufactured in lengths up to 3.80m greater than 3.80m, the clear span will and depending on the overall slab The long edges are formed with a be reduced. depth can be used for clear spans of chamfer to the underside, so that when 3.69m with a preferred bearing of placed adjacent to each other, the 55mm at each end. effect of a birds-mouth joint at 300mm centres can be seen on the soffit. Hanson Omnia Bridge Deck Soffit Max Clear Span for Slabs of Overall Depth Treatment

4.00 We can now offer Pavix CCC100 surface protection treatment applied 3.80

) at works, which meets the m (

n 3.60 a

p requirements of BD43/03. S r a e l 3.40 C Please contact us for a quotation. m u m i 3.20 x a M 3.00

2.80 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 8 9 0 0 1 2 3 4 5 7 3 4 5 6 7 8 9 3 3 3 3 3 3 3 3 3 4 2 2 2 2 2 2 2 3 Overall depth (mm)

15 Bridge Deck DELIVERY, OFFLOADING ANDERECTION

Omnia Bridge Deck Planks are Prevention of grout loss generally laid on Structural Steel We would recommend that flanges Delivery beams, and whilst the details and of steel that will be supporting Omnia Omnia Bridge Deck planks are recommendations below may Bridge Deck planks be treated to generally delivered on articulated apply to other structures, they are prevent grout loss when pouring the vehicles paletted in batches of 24 primarily written for Steelwork in-situ section of the slab. We would planks (6 deep x 4 wide) and will be structures. suggest a 12mm deep bituminised delivered to a previously agreed compressible strip available from sequence of planks and times/dates. a number of sources including Preparation Depending on the spans of the planks, Illbruk Alfas at Washington each delivery will have approx. 130m² Bearings (0191-419-0505). of planks. Except where agreed All bearings should be structurally previously, the first delivery of planks acceptable before any Omnia planks will come with a lifting frame which are placed. Any variation in levels of Safety should be used to lift a layer of planks. bearing will need to be addressed prior Notes to the planks being delivered. Notwithstanding the above, propping Temporary Supports may be necessary in the following Omnia Bridge Deck planks are always circumstances:- designed to be erected without any Where the top or diagonal bars temporary props during the of the Omnia lattice has been construction sequence. cut or damaged.

Minimum Bearing Dimension Where the bearings are not true Picture courtesy of Carillion All planks will be designed to have a and or level. minimum bearing of 55mm both ends, Where a bearing of less than Offloading therefore the minimum plank length 40mm is provided We would recommend that full pallets will be ‘clear span + 110mm’ to a Cantilever sections and of planks are offloaded adjacent to maximum of 3.80m. adjacent to the edges of their ultimate position on the large openings structure, and then each layer is lifted and placed in position at a later date.

All personnel who are required to be on the trailer bed whilst on site should be protected from Overall depth falling from height in accordance of slab with “The Work At Height Regulations”.

A lifting frame will normally be Agg +5mm provided to suit 4 planks and will weigh approx 500kg, however if 55mm nominal bearing required, a larger frame can be provided (weighing approx. 750kg) to Minimum bearing dimension lift 8 planks, in which case pallets need to be placed adjacent to each other.

16 Lifting Weights Slab Completion

Placing in position Each plank weighs 36kg/m and each pallet will normally have 24 planks. Panels lifted in sets of 4 will be approx The pallet weight will need to calculated prior to uplifting from the vehicle, 1200mm wide (8 planks will be 2.40m and the layer weight of 4 (or 8) planks will need to be calculated before wide) and will need to be butted lifting to the structure. together to close any gap between them, minimising the risk of grout loss. Pallet Weight It is recommended that a method of A pallet of 24 planks 3.60m will weigh:- 24 x 3.60m x 36kg/m = 3110kg setting adjacent ‘sets’ be adopted so that each set is placed at 1200mm Use the calculator below... dimensions. This will keep the layout of ………. Planks x …………. m x 36kg/m = ………kg the planks close to that on the Layer Weight drawing, the amount of gaps to a A layer of 4 planks 3.20m long plus frame will be:- minimum, and reduce the risk of any 4 x 3.20m x 36kg/m = 461kg plus 500kg frame = 960kg cutting or make-ups due to creep. 4 planks x ……… m x 36kg/m = ………… + 500kg = ……….

A layer of 8 planks 3.40m long plus frame will be:- 8 x 3.40m x 36kg/m = 979kg plus 750kg frame = 1729kg 8 planks x ………. m x 36kg/m = …………. + 750kg = ……….

Protection against falls Erection In line with the PFF Code of Practice, Handling the erection of Omnia units will be subject to the application of a hierarchy Units must be lifted and placed Joint Grouting of safety systems as recommended by without jerking to prevent cracking to Joints will need to be addressed to the HSE. There are a range of the panel or damage to the lattice. prevent grout loss during concreting. measures available from passive systems Various methods can be used, and we such as working platforms, staging, Always lift Omnia panels by the lattice would suggest a bead of sand/cement safety nets and air bags to active with the hooks positioned under the grout towelled along all joints. systems such as work restraint/fall diagonal. arrest using safety harnesses. Placing of Reinforcement Reinforcement will need to be placed in accordance with the Structural Engineers requirements and one layer may need to be threaded through the diagonals. Other layers are placed between and over the lattice.

Concreting The slab will then be concreted in accordance with the Structural Engineers specification.

17 Bespoke Products EXPERTISEANDCAPABILITIES

In addition to core product ranges Hanson facilities include three sites in Hanson provides a comprehensive the Midlands with the capability of design and manufacturing service, producing single component units up to supplying bespoke precast 24 tonnes. These are at Derby, concrete components to the civil Hoveringham and Cotes Park, Derbyshire. engineering sector, public utilities and local authorities. Mould manufacturing, reinforcement, cutting, bending and cage fabrication are all generally completed in-house.

20 Benefits of using precast concrete solutions Cost savings on site programme Factory controlled processes; engineered products to recognised 3rd party quality assured standards Efficiency of thermal mass Inherent fire protection Low whole-life cost benefits Typical bespoke structures Bridge structures Deck slabs Edge beams Parapets etc Marine & Sea Defence Works Flood retaining walls etc Stadia Terraces Staircases Domitory walls Raker beams etc Railway Schemes Platform units Specialist culverts for jacking etc Frame Structures Beams Columns Edge beams Spandrels etc Bespoke specialist items Digester tanks Towers etc

21 Nationwide SERVICE

The Floors and Precast Division of Hanson Building Products now operates from a total of three dedicated plants located in the Midlands.

All three sites – Hoveringham Other precast concrete (near Nottingham), Derby, products and Cotes Park in Derbyshire Jetfloor – are directly involved in the manufacture and supply of Box Beam and Block Culverts, Omnia Bridge Deck Staircases and Bespoke Products. Hollowcore Omnia products These central locations enable us to provide a fast and efficient For structural precast concrete Hoveringham service of structural precast solutions please contact us at: products to sites throughout the Hanson Building Products country. Birchwood Way Cotes Park Industrial Estate Standards Alfreton, Derbys UK Tel: 0870 609 7094 All products are manufactured in accordance with relevant British/ Derby European/Trade Association Standards. All Hanson Building Products sites are quality assured to BS EN ISO9001:2000 Hanson Building Products Floors and We operate environmental precast locations management systems at all our production sites in accordance with the methodology set out in the Omnia Bridge Deck production BS EN ISO14001:2004. Bespoke Structures and Box Culverts

Somercotes

Why Hanson?

Hanson Building Products has for many years been acknowledged as the UK market leader in the design & manufacture of precast concrete box culverts, providing a high quality service, sound technical expertise and contract administration. We are committed to partnering concept through experience gained in operating long-term framework type contracts with national contractors and water companies etc.

This expertise and manufacturing capability has been built up over the last 45 years since the use of box culverts became recognized as a practical solution for drainage solutions. The merger and amalgamation of the businesses of FC Precast Concrete Ltd and Birchwood Concrete, along with the later acquisition of Marshalls Flooring in 2002 formed Hanson Building Products Floors and Precast division. Hanson was in turn acquired by Heidelberg Cement Group in 2007.

The current team of Estimators, Project Engineers and Contract Managers each have no less than 10 years precast experience with Hanson Building Products. Continued investment in the business has seen manufacturing move from our original base in Derby to the larger facility in Somercotes, close to Junction 28 of the M1, allowing greater capacity, increased efficiency and improved transport links.

The company prides itself on its levels of service from scheme conception and design input through to the manufacture and delivery of units to site. Great emphasis is placed on using our experience and design capabilities backed up by AutoCAD to add value to schemes to the benefit of all parties. This can take the form of individual inputs by ourselves or working closely in harmony with a client’s design team. Our aim is to offer the most cost effective engineered solution for individual requirements with as much of the solution being engineered and manufactured offsite as is practical. This helps shorten the site works and minimise site disruption.

We are regularly involved in design/build & PFI contracts as well as the more conventional supply only approach. Our flexibility and constant strive to offer added value to our customers has led to the development of a standard range of 144 culvert sizes ranging between 1000mm & 6000mm spans, offering the market’s widest choice to suit specific hydraulic requirements. Standard units can also be supplied with special features such as access openings, solid end walls, dry weather flow channels and tapered units for radial deployment.

Hanson Building Products has supplied a large amount of precast culverts and bespoke precast to the Water Industry, working on schemes that have involved most of the local Water Authorities. Projects are currently being undertaken for Yorkshire Water, Wessex Water, Thames Water and Severn Trent Water.

Hanson Building Products has also supplied significant amounts of precast culverts and bespoke precast for the Highways Agency and the Local Authorities on infrastructure schemes plus high profile projects such as a multi-million pound contract for the Olympic Games site at Stratford.

Meet the Team

Despite our market-leading position and the scale of the manufacturing facility the offices continue to house a small but experienced core of staff. Every member of the team has a minimum of ten years experience at Hanson within precast concrete.

Peter Humphrey Commercial Manager

At Hanson since 1998

Tel: 01773 600208 (office) 07843 595077 (mobile) [email protected]

Craig Laws Ian Prince Senior Estimator Senior Estimator

Contact for: Contact for: Precast Culvert enquiries Precast Culvert enquiries

At Hanson since 2000 At Hanson since 1996

Tel: 01773 600238 (office) Tel: 01773 600243 (office) [email protected] [email protected]

David Chamberlain Liam Mulholland Project Engineer Project Engineer

Contact for: Contact for: Project technical enquiries: Project technical enquiries:

At Hanson since 2000 At Hanson since 2001

Tel: 01773 600247 (office) Tel: 01773 600218 (office) 07967 187374 (mobile) [email protected] [email protected]

Graham Jamieson Simon Wain Contracts/Planning Manager Contracts Manager

Contact for: Contact for: Project delivery enquiries: Project delivery enquiries:

At Hanson since 1974 At Hanson since 2002

Tel: 01773 600228 (office) Tel: 01773 600229 (office) [email protected] [email protected]

Product Range

Hanson has a standard mould range of 144no different possible combinations. Some sizes are more common than others and therefore more moulds are available in those sizes. Unit sizes range from 1000mm to 6000mm in width and 600mm to 4000mm in height. Units as standard have a flat invert however special inverts and channels are available upon request. Please note that special inverts are built up off of smaller moulds therefore the shallowest Dry Weather Flow channel available would be 750mm, and the shallowest Shallow V invert would be 675mm. The internal height of a special unit is always measured from the base of the invert.

Units can be supplied tapered to enable bends in culvert runs, typically no more than 10° per unit. Manhole openings and pipe access holes can be produced on request, and runs can be capped with an integral endwall to form a tank. Channel units are also available.

Product Range All box culverts are manufactured to order and to the specific required design criteria. The external loading conditions will Width (mm) Height (mm) govern the wall, roof and floor thickness, unit length and reinforcement content. 1000 600

1200 675 With some exceptions the stated widths and heights can be 1300 750 combined to create the internal size of your choice. All 1400 800 measurements are internal sizes. External measurements will be 1500 900 dependant upon design conditions. Please contact us to discuss 1750 1000 your specific requirements. 1800 1200

2000 1300 2100 1400 2250 1500 2400 1600 2500 1800 2700 1800 2750 1900 3000 2000 3300 2100 3500 2250 3600 2300 3750 2400 3800 2500 3900 2700 4000 2750 4200 2850 4500 3000 4800 3300 5000 3500 5100 3600 5400 3900 5800 4000 6000

Pricing Guidance

Hanson accepts emailed, faxed or posted enquiries which we aim to price within 7-10 days of receipt. Depending on current workloads this timescale can often be significantly reduced if requested. Please be aware that because of the bespoke nature of culvert pricing each enquiry will take at least a few hours to prepare once started and possibly several days for more complex schemes.

We ask that when sending your enquiries to us your full company contact details should be shown, either on letter headed paper or email signature, to ensure our customer databases are maintained and quotations reach their correct destination. In the first instance quotations will be returned by email if an address is supplied followed by a hard copy in the post.

To assist us ensuring that our quotations are as accurate as possible we request that your enquiry is accompanied by as much information relating to the culverts as is available. We can provide budget quotations with minimal information such as size, length of run and location, but firm prices will require additional detail.

Location of project Culvert size (internal dimensions) The length of culvert run Minimum/Maximum fill depths above the culvert – Invert and Ground Levels preferably Loading conditions (Field loading, HA, HB, Eurocode etc) If the culvert is to be used as a storage tank, and if any special inverts are required Design class (XD1, XD2, XD3 etc)

Frequently Asked Questions

How quickly can I expect a quotation returned? We aim to turn quotes around within 7-10 days of receipt of your enquiry. If requested however it may be possible to quote by return.

Is there a minimum/maximum order value? Our factory facility has the capacity to support even the largest schemes. Likewise, we are happy to supply smaller projects where only minimal numbers of units are required. Note that there are fixed costs in the design and manufacture of culverts that make larger schemes more economical than smaller ones.

You give the internal sizes of the culverts but what are the external dimensions? We give the internal profile sizes of the culverts within our literature as these are the important dimensions when specifying the correct unit for your requirements. The external dimensions are determined by several design conditions such as fill depths, loadings and exposure class which make each project unique. As such we don’t indicate external sizes until a design has been run. Contact the team for further guidance.

Do you supply your own designs? Hanson Building Products will supply full design calculations and drawings once appointed as a supplier. Normally this is a full order to design and manufacture the culverts however if workload allows we can occasionally take on design-only orders at a cost of £500.00 per set of calculations (contact the team for costs for Eurocode specified projects). If the project ultimately leads to a full supply order this charge of £500.00 will not be payable.

Can you supply culverts with special inverts? If requested our culvert units can be manufactured with special precast inverts such as Dry Weather Flow channels and Shallow V profiles for increased flow rates. These are normally located centrally however we can offset channels if desired. Please note that the smallest unit that can contain a Dry Weather Flow channel is 750mm while the smallest Shallow V unit is a 675mm. Contact the team for details on benching and flow rates.

How quickly can you deliver the culverts to site? Several factors determine how quickly units can be delivered to site. Typically designs can be issued within two weeks of an order being placed and only once the approval of these designs is received will manufacture commence. From there the number of units required and availability of our moulds will dictate delivery times. Current order levels will affect both design and manufacturing processes so deliveries vary. Please contact the team to discuss your delivery requirements, and remember that delivery dates are valid on day of offer and may need to be renegotiated as necessary. In all cases Hanson supplies bespoke precast culverts that are specific to your requirements therefore we do not carry stock in any size.

Will Hanson supply an Approval in Principle (AIP) document? Our expertise in the design and manufacture of box culvert units enables us to offer information within Section 5 of the AIP to enable the purchaser to complete the document. We are not able to offer interpretive recommendations from the ground surveys soils reports in respect of ground bearing pressure, settlement or ground water effects, etc. It should be noted that the box culvert units have a unique design for each project and that this design, and the associated detail drawings, will only become available after an order has been placed. A design certificate for the box culvert units can be issued in accordance with the signed Approval in Principle.

Are your culverts designed to Eurocode standards? By default our precast culverts are not designed to Eurocode standards as presently the overwhelming majority of projects are not requiring this, however if requested we are more than happy to provide full designs to enable units to be manufactured to this standard. Additional costs and extended lead-in times are likely so please contact the team to discuss your requirements.

What information do you need to be able to give me a quotation? We are able to offer a budget price against the minimal information of culvert sizes, length of run and location of project. For an accurate formal quotation we request design information including the minimum/maximum fill depths, loading conditions, design class, profile shape, use of units (storage tank, crossing etc) and details of any specific requirement such as changes of direction, openings or coatings. Drawings and specifications are the best way to ensure a compliant bid. We also ask that in all cases you provide full contact details to ensure we can contact you if we have further queries and that the quotation arrives safely.

Do you offer an installation service? Unfortunately we do not install precast culvert units, we are simply the manufacturer. This is usually carried out by a ground worker/contractor and we will deliver the units to site in accordance with their programme. We can supply you with a copy of the Box Culvert Association’s Guide to Site Practice which offers information relating to the installing of the culvert units.

How do I lift the units? By their nature precast culverts are heavy items, ranging from around 3 tonnes up to close to 30 tonnes depending on size and design requirements. Hanson uses a Halfen lifting system, and the size of the unit will dictate the type and number of lifting points required. Up to 15 tonnes we generally use the Halfen-Deha (product code 6102-10) lifting system. Over 15 tonnes, or if culverts are of a size that requires units to be delivered face down and need turning on site, we will use the Frimeda (product code TPA-R1) lifting system. Both types are available from Halfen on 08705 316300 or www.halfen.co.uk.

What should be the minimum fill above the culverts? Although possible to go below we do recommend a minimum of 200mm of fill above the culvert units.

Do you have any restrictions on delivery locations? We deliver to all mainland UK destinations in England, Scotland and Wales. For projects that are off of the mainland we can either deliver units to a designated port or they can be collected from our factory in Derbyshire. Some unit sizes may require wide/escorted loads which naturally may restrict certain delivery locations if access conditions are not suitable.

Can I see my culverts being manufactured? If you wish to view the manufacture of the precast culverts we would be more than happy to arrange to guide you around our factory. We are centrally based with excellent transport links, located just a few minutes from Junction 28 of the M1 motorway.

Our address is:

Hanson Building Products Birchwood Way Cotes Park Industrial Estate Somercotes Derbyshire DE55 4NH Tel: 01773 602432 Fax: 01773 603134

If there is anything further that you wish to know about Precast Culverts or any of the other products that Hanson Building Products can offer then please contact one of the team.

Hanson Building Products Floors and Precast Division Hanson House 14 Castle Hill Maidenhead 0870 6097094 SL6 4JJ

Website: www.hanson.com/uk

Hanson - A global business

Hanson is one of the world's largest suppliers of heavy building materials to the construction industry. We produce aggregates (crushed rock, sand and gravel), ready-mixed and precast concrete, asphalt and cement-related materials and a range of building products including concrete pipes, concrete pavers, tiles and clay bricks

We are part of the HeidelbergCement Group, which employs 70,000 people across five continents, has leading positions in concrete and heavy building products and is the global leader in aggregates.

Hanson Building Products is the UK’s largest brick and aircrete block producer. We also produce aggregate blocks, bagged aggregate and cement products, renders, pavers, pre cast floors and stairs, SUD systems and prefabricated building systems. The division incorporates London Brick, Thermalite, Red Bank, Cradley, Formpave and Structherm.

Hanson Building Products - A sustainable business

Hanson Building Products is committed to being a sustainable business and contributing to sustainable development. We achieve this by continuous improvement of our manufacturing and extraction processes and by providing products which contribute to sustainable construction.

Made at factories certified to ISO 14001, our clay and concrete products have many features which assist our customers in constructing attractive, sustainable buildings which enrich the built environment and are ideal for zero carbon developments. These include: thermal mass, insulation, longevity, durability, low maintenance, flexibility, flood resistance and the ability to be recycled. We can advise on how best to use our products in sustainable buildings and how they contribute to high ratings under the Code for Sustainable Homes and BREEAM.

Email: [email protected] SP 01 | July 2010 Web: www.hanson.com/uk/sustainability