UV Lining, Robotic Cutting & Trenchless Technology

“Gateway Construction Services Limited” have expanded their drainage division last year with a major investment in both industry leading equipment and personnel. Headed up by the newly appointed drainage manager Stamatis Ketsetzis, Gateway is now able to offer numerous options regarding drainage rehabilitation, inspection, cleaning and repairs including UV-lining, hydro-cutting, high pressure water jetting and CCTV surveys. Since July 2018, Gateway placed themselves at the forefront of the drainage industry area and developed practical, long term solutions to meet their clients varying requirements. Gateway has already signed a drainage framework with LUL (Track Partnership) for the next financial year (2019-2020) and quoted for various other LUL tenders.

No Dig UV Pipeline Repair Technology

This process involves the rehabilitation of drainage systems without the need for costly and disruptive digging of trenches. A structural liner is pulled through the existing host pipe, inflated with air and then cured in place with UV light, all this with the only access required being from two manholes along the length of the pipe. Lengths of up to 400m with diameters ranging from 150mm to above 1500mm can be installed using this method in a fraction of the time taken by traditional open cut methods. Any connections into the newly renovated pipe are then re-opened with the use of advanced milling machines which are driven into the pipe and controlled remotely from the vehicle on the surface.

Using this method means that assets can March 2019 be back in use within the same day, as a fully cured pipe within a pipe, perfect for situations where road closures or disruption to the railway would cause untold inconvenience and interruption to services. Varying pipe cross sections can be repaired using this energy efficient, low environmental impact method and many different shapes have been completed from the basic circular through to the more unusual.

 

Pipeline Inspection & Mapping

Gateway now use Mainline Tractor Cameras and Rigid Push Rod Cameras as part of their specialised drain clearing and pipe relining services. The CCTV drain cameras travel down into the pipes to conduct drain inspections and can show exactly what’s going on several meters under the ground. The drain camera technology is exceptional, with clear colour images that allow to identify issues within the pipe easily and confidently that could develop into damage later. The crystal-clear images can also show to expert staff exactly what is causing a blockage/problem in order that further damage can be prevented.

All cameras have built in Sondes which are locator devices used in underground surveying, which mean that the exact location and depth of the camera can be pinpointed in the drainage system. The huge advantage of this is that the blockage or damaged section in a pipeline or culvert can be found where exactly are or can even just surveyed so they can be mapped onto a site plan. The camera’s footage is recorded straight onto either memory stick’s or DVDs, so the customers can see exactly, and immediately, where the drainage problems are. Possible solutions can be then detailed to ensure that the problems can be rectified in the most cost and time efficient manner.

Point Repair Lining

1 A sectional point repair can be installed to repair any individual defect that may come across during the investigations/surveys. These are a costeffective solution when the whole line does not require rehabilitation. Defects can include root ingress, holes, cracks and defective joints in the ageing pipework and sections can be repaired up to 1200mm in length, in a single application and installed within a couple of hours on site.

After the defect has been identified, the line is cleaned, and the point repair prepared by wrapping a resin impregnated matting around an inflatable packer. This is then inserted into the pipe to the point of the defect (1.) and then inflated to a recommended pressure (2.). The repair is allowed to remain in position, under pressure, for a specified length of time before the packer is deflated, leaving the matting fixed in place covering and sealing the original defect (3.).

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High Pressure Water Jetting & Root Removal

Gateway High-Pressure Water Jetting Units are designed as a high velocity water jetting system for the purposes of root removal, scouring and back flushing of sewers and drains. The high velocity water is propelled through nozzles via a pressure hose. Specialised nozzles are designed with positioned jets that allow it to self-propel and efficiently clean pipelines. The rate of travel is controlled by a hydraulic reel fixed to the rear of the vehicle. A large selection of specialist nozzles is stocked to enable the staff to cover a large variety of tasks including:

  • Clearing of blockages
  • Root removal
  • Debris removal
  • Encrustation removal
  • De-greasing

Ultra High Pressure Water Cutting (hydro-cutting)

Ultra High-pressure water Jetting (hydro-cutting) is a solution for cutting hard concrete and any other hard obstacle (e.g. steel) with needle jet precision and control. With pressures of up to 40,000PSI, Gateway makes light work of even the toughest materials in the most difficult to reach locations.

Roofing – Brentwood Station

Year: 2018
Client: Crossrail
Overall Cost: Circa £40K

Constructed in the 1840’s Brentwood station serves the Great Eastern Main Line into Liverpool St London. On platform 4, the roof of the toilet and waiting room which was still used by MTR staff and passengers, had failed in many places and fallen into a severe state of disrepair, allowing water to ingress the building, resulting in the ceiling collapse to the facilities below.

During traffic hours and NWR possessions a fixed scaffold was erected, and the entire roof stripped back to the rafters and re-instated and localised repairs made to the chimney stacks and the plaster board ceilings of the toilets and waiting rooms before re-decoration.

Working closely with Crossrail, no disruption to train or pedestrian traffic was caused throughout the duration of these works.

Resurfacing and line painting – Slough Power Station

Year: 2018
Client: Amco-Giffen
Cost: Circa £62,000

Gateway were awarded the works to extend the existing car park and associated works at Slough Power Station by approx. 80m2.

A new 85m Triple Point Palisade fence, Armco Barrier Turnstile Pedestrian Entry and security gate was installed, while the existing remained in place to maintain security.

Once the new fence line was established, floor and hand-held petrol saws were used to cut the existing surface to enable a 5T excavator fitted with a breaker to break out and remove the concrete.

The new fence comprising of 3m high, 2.75m panels was then installed and the existing security gates removed and re-used to form the new entrance to the power station.

The existing carpark was also extended approximately 80m2 and laid with HRS to match existing.

New white lines were applied, demarcating parking bays and official pedestrian walkways.

All works were completed within the estimated time with no disruption to power station staff or visitors.

Platform Nosing Stones – Newbury Park

Year: 2018
Client: Skanska
Cost: Circa £183K

Gateway Construction Services Limited were employed to carry out the structural supporting of nosings on platforms 1& 2 Newbury Park and platform 2 Grange Hill Station on the central line, LUL network.

On all platforms, there were a number of nosings that exceeded the permissible overhang. In order to rectify this, In line with the approved design a series of galvanised unequal angles were fixed to the back face of the concrete cantilevered wall, directly below the nosings. M12 resin anchors were inserted at 240mm centres through the steel into the concrete and chemically secured, then pointed with a non-shrink mortar. Where the cantilever support was formed of brickwork, the nosings and tactiles were lifted the existing mortar bed removed back to clean dust free brickwork. 900 x 600 x 12mm thick galvanised steel plates were fixed using Cintec Anchors directly through the brickwork into the concrete foundations of the platform, these were pull tested to 20kn before the plates were installed and tightened to the specified torque settings. The nosings and tactiles were then re-bedded, pointed and lines re-painted.

The station had to remain operational throughout the remedial works thus works were carried out in  engineering hours shifts, and as such the platforms were left safe for pedestrian and train traffic nightly ensuring no disruption to the service.

Groundworks & Civil Engineering – Upminster Depot

Year: 2018
Client: Amco-Giffen
Cost: £174,573

As part of the development works at London Undergrounds Upminster Depot, Gateway Construction Services Limited were commissioned by Amco-Giffen’s to construct the new concrete roads & walkways around the ancillary buildings, including new drainage and kerb lines at the eastern end of the Depot.

The existing damaged concrete slabs were broken out by mechanically and removed, the ground was then prepared for a new kerb line and manholes covers raised where needed to suit the new install, before mesh could be laid.

Expansion joints installed, and tied in with re-bar dowels where necessary, the new C40 concrete was the poured and floated off, before the final brush finish could be applied.

Constant monitoring of weather conditions proved invaluable when planning the delivery and pouring of the concrete to avoid unproductive shifts, and ensure the works ran to schedule.

Fencing & Access Gates – Feltham Station

Year: 2018
Client: Amaro
Cost: Circa £5,000

Following the installation of a signals LOC cabinet and hardstand, a secure palisade perimeter fence with access gate was constructed, enclosing the asset.

To eliminate the risk of arc/flash electrocution whilst being maintained, a touch potential barrier was constructed between the cabinet and the metal perimeter fence

With access being from the platform, necessary site security arrangements were implemented and maintained throughout the course of the works.

Drainage – Northfields Depot

Year: 2017
Client: Lanes
Overall Cost: Circa £20k

The existing combined system at Northfields Depot was originally constructed to convey all surface

water drainage from hard surfaces of the car park, access road and storage areas as well as the facilities including sanitary and grey water within the depot buildings.

The aim of this project was to connect an additional grey water connection from a

new proposed sink and a foul water connection from the future portable cabins that were be installed along the access road in the parking bays, to mitigate the lack of female facilities within the Depot main building

The pre-works comprised of Topographic, CCTV and PGI surveys of the existing site drainage with focus on investigating the depth of MH1 and condition and size of the main pipe.

A new manhole (MH1B) was constructed and connected to MH1A via a pipe and spurred off to allow for the future connection of the portable toilets.

2 new manholes and approximately 30m of new pipe were installed to take the waste from the sink and proposed new toilet facilities to the existing drainage system.

CRMS, Troughing & Concrete Works – Thales

Year: 2018
Client: Thales
Cost to Date: Circa £760.000

Thales have been charged with delivering the worlds largest signalling upgrade of its kind, across what are considered to be London Undergrounds most important lines, Hammersmith & City, District, Circle & Metropolitan for the 4LM(Four Lines Modernisation) project.

To enable the CBTC(Communication Base Train Control) system, a series of antenna’s, wayside radio units and a variety of other electrical signalling installations have to be installed the full length of each line, 90% of which require foundation bases.

Gateway, having many years’ experience with civil works of this nature were invited to tender and subsequently, a main frame contract was awarded.

Teams of skilled Gateway operatives, working from survey and drainage sheets produced by Thales,  have been able to keep ahead of the mechanical installation teams with the foundation bases thus ensuring a smooth delivery of the project.

Cable Pulling – Earls Court

Year: 2017
Client: Track Partnership
Cost: Circa £85K

Earls Court to Triangle Sidings was a 2-phase cable pull totalling 1100m of 50mm 3-core cable being pulled and secured on new and existing high and low level CRMS for points 8AB.

The high level cable posed its own set of challenges with the majority being over 4m from track level and OTX’s spanning all 4 roads.

Additional installations for these works included core hole drilling, Cable troughing, 2 new hardstands to house the Isolation Transformers, Points Control Kiosk, support frames for Monitoring Equipment and Schneider Boxes.