Siphonic Pipe Repairs to Global Cosmetics Giant’s Warehouse
Table of Contents
Background of Case Study
RPMG were appointed by a specialist structured facilities management company to repair a leaking drainpipe at a cosmetics warehouse in Bury. The project consisted of the removal and replacement of a 160mm sleeve that was causing high levels of water leakage that was causing stock damage and potential risks such as mould.
The primary objective was to fix the drain pipe with minimal disruptions to operations. Following the identification of water ingress issues within the facility in Bury, RPMG were determined to coordinate specialist repairs to the site’s siphonic rainwater drainage system. The works were undertaken to address the leaking HDPE pipe sleeve connection and a defective siphonic roof outlet that had been causing persistent leakage within the warehouse environment. The project required specialist access solutions and careful planning due to the operational nature of the facility and the high-level location of the drainage system.
Scope of Works
The project involved the investigation and repair of a leaking 160mm siphonic rainwater pipe serving the facility. Following a detailed inspection, the defective section of pipework was carefully removed and replaced using new electrofusion couplers, creating a permanent watertight connection. This repair method not only resolved the immediate leak but also improved the long-term durability and performance of the drainage system, reducing the likelihood of similar failures occurring in the future.
A leaking siphonic roof outlet was also identified for replacement as part of the planned works. To safely access the high-level drainage infrastructure within the operational warehouse, specialist MEWP access equipment was utilised by trained operatives. Upon completion of the repairs, all works were inspected and tested to verify system integrity and ensure the continued efficient operation of the siphonic rainwater drainage network.
Challenges Faced and Overcome
The project presented several operational and environmental challenges:
Working at Height in a Live Occupied Environment
The drainage repairs were located at high level within an operational warehouse, requiring specialist MEWP access and strict working-at-height procedures to ensure the works could be carried out safely while minimising disruption to daily operations.
Water Ingress
Water leaking in created a risk of damage to stored stock, operational disruption, and potential loss of revenue. If left unresolved, the ongoing leak could also have led to environmental issues such as damp conditions, mould growth, and vegetation build-up. These repairs were therefore essential to protect both the facility and its day-to-day operations
Access Issues
Access to one of the defective siphonic outlets was obstructed by stored stock on the upper racking level. Careful planning was required to make sure stock could be moved temporarily to allow access.
Scheduling Restraints
The required pallet could not be removed on the day of works due to the unavailability of a forklift operator on site. The team assessed alternative solutions and offered a temporary measure to prevent continued water ingress, demonstrating a proactive approach to minimising disruption.
Completed Works & Summary
The specialist drainage team successfully removed the leaking section of the 160mm HDPE pipework and installed two new electrofusion collars, restoring the integrity of the siphonic drainage system and eliminating the pipe leak. The repair was completed safely and in accordance with the project’s method statement and risk assessment requirements .Through careful planning, specialist access equipment, and experienced operatives, the leaking pipework was repaired efficiently and safely, helping protect the facility from further water ingress, water damage and mould while extending the lifespan of the existing drainage system.
Outcomes & Benefits
Communication Throughout
Close communication was maintained with site management throughout the works to ensure safe working practices and manage project constraints effectively.
Job Completed to High Standard
Water ingress caused by the defective pipe connection was successfully eliminated and the repaired siphonic drainage system was returned to full operational condition.
Enhanced Asset Protection
The works extended the service life of the existing drainage infrastructure without the need for extensive replacement works.
Great Planning
The project highlighted the importance of collaborative planning within live warehouse environments to maximise access and minimise operational disruption.
Safety and Compliance
Safe delivery was achieved through specialist access methods and robust health and safety controls.
Future Thinking
Recommendations were provided regarding the outstanding outlet replacement to enable future completion once access restrictions are removed.