Surface water drainage scheme at Thornton Waste Technology Park

Sunday, 6 December 2009

Located on the western bank of the River Wyre, the Thornton Waste Technology Park developed by Global Renewables will be one of the UK’s first operational UR-3R (Urban Resource - Reduction, Recovery and Recycling) process facilities that integrates waste sorting systems and proven anaerobic waste digestion technologies.

This innovative development in waste recycling is scheduled to be operational in 2010. It is expected the facility will recover valuable resources, such as glass, metal, paper, plastic, land nutrients and energy in the form of usable gasses from up to 225,000 tonnes of waste generated every year by households in Blackpool, Fylde, Wyre and the surrounding areas.

The riverside location has meant particular attention was paid to rainwater run-off and pipe depth issues in general. Influenced by the tidal river, the water table can be only 0.7 metres below the surface. Ground-works contractor, Churngold were keen to specify an integrated scheme that would offer effective drainage of the whole facility. Additionally, any drainage installed had to withstand the compression and twisting forces exerted by the numerous fully laden waste collection trucks accessing the site.

In order to optimise the environmental benefits of the whole project, all aspects of its construction and operation had to taking into account the strict ecological requirements demanded for the facility. For this reason drainage components made from recycled materials were considered.

Two surface water drainage systems were chosen, both supplied by Hauraton Limited. RECYFIX HICAP high capacity slot drainage channels were specified for access and service areas, whilst the ENVIROKERB system was selected for road-side drainage.

Each RECYFIX HICAP and ENVIROKERB unit delivered to the site weighed less than 25 kg so complied with current one-man-lift legislation. This not only reduced the need for heavy lifting hoists, but, compared with the concrete equivalent units, reduced the number of delivery lorries by approximately half. In addition, the recycled components are very impact resistant making them almost unbreakable and much less vulnerable to the usual on-site damage. Using modern reclamation techniques, components are also recyclable as their strength allows them to release relatively easily from their concrete foundations.

The 775 metres of RECYFIX HICAP channels specified for the project is made from 100% recycled Polyethylene-Polypropylene (PE-PP) derived from post consumer and post industrial sources. HICAP allows hydraulic engineers and contractors’ wide flexibility during the design and installation stages by reducing the number of channel runs normally required. This reduction means less foundation materials being used with fewer underground excavations, all resulting in a more environmentally friendly installation. Not only is no prime polymer used in the manufacture of RECYFIX channels but it is the shredded recycled material, not reformed pellets, that is fed directly into the injection moulding machines providing even more savings.

Landscaped roads into the new Park incorporated over 825 metres of Hauraton ENVIROKERB road-side drainage. Each half metre unit supplied weighed 24kg, this compares to 89 kg if a similar sized concrete unit had been specified. Having the appearance of a standard concrete kerb, ENVIROKERB units are in fact moulded from 100% reclaimed polyethylene PET, HDPE and LDPE plastic bottles and packaging materials. These materials if not reclaimed in plants like that at Thornton, would be destined for landfill, and would take 750 -1000 years to degrade.

James Baylis, Churngold Group, Project Environmental Manager for the project was pleased with the technical support from Steve Wiseman, Hauraton’s Project Manager and how easy the drainage systems were to install, “Being made from recycled materials the systems were in keeping with the thinking behind the Waste Technology Park and it was good to know we helped “close the loop” by using components made from recycled materials in the construction of the new plant”.

Tim Connolly, Hauraton’s Director of Sales and Marketing explains his company’s approach to environmental issues that affect the company’s products: “Encouraged by European Community legislation on waste and recycling, the management at Hauraton decided some years ago they must further reduce the company’s carbon footprint. It seemed at first all we had to do was moderate the amount of energy used in their manufacturing processes to achieve our aim. However, after an initial assessment it became abundantly clear this action alone would not achieve the efficiencies currently demanded. Nothing short of a full energy audit and re-evaluation of the company’s manufacturing and distribution facilities, products, processes and installation techniques would be required if worthwhile, economically viable energy reductions were to be attained”.

To help attain their new sustainable goal the company established four guiding principles:
1. Conserve energy - Whenever possible conserve energy, save energy or reduce its expenditure during the administration, manufacture, transport and installation of products.
2. Reduce pollution – Where practical, source recycled materials which would otherwise go to waste or pollute the environment. Including recycling water and generated heat.
3. Eliminate unnecessary use of energy and materials – Even where a source of recycled material is not available, reduce the volume of any raw materials and the associated energy needed to achieve the engineering requirement.
4. Benign energy - Whenever possible self generate and optimise “Green” energy solutions and use on-site water resources for manufacturing processes.

“Our products of course improve the effective control of rainwater and provide tangible environmental benefits, but they have to meet stringent international performance criteria, so components need to be made from materials like concrete, ductile iron, steel and plastic – all energy intensive materials. Achieving a carbon neutral status is probably not realistic for companies that manufacturer highly engineered products in the construction sector. However, our energy reducing stratagem eventually resulted in the company building a new energy efficient production and distribution facility. We are now able to manufacture in a more sustainable way and even improve our bottom line!”