Concrete for Life

CPM Headwalls

Off-Site Solutions

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CPM is a market leading manufacturer of concrete products with production facilities across the UK. This combined with a network of specialist distributors, enables us to provide our customers with complete coverage.

The CPM business is built on a solid reputation for delivering quality products and providing a first class service with diversification and innovation a key to our strength. We supply a vast range of sustainable precast concrete products to every sector of the construction industry, fully supported by our experienced technical and engineering teams.

CPM – Headwall Solution

CPM has developed an offsite precast concrete solution headwall system designed to connect pipe work discharging into open water courses. The spillway headwall offers a cost effective alternative to in-situ structures for connecting discharge from pipework into open watercourses, such as culverts, collection ponds, balancing ponds, rivers and swales.

Concrete pipeline systems have a proven life of over 100 years, demonstrating lower whole life costs and providing installed cost savings as well as minimising erosion at the discharge point and immediate structure. CPM headwalls are the ultimate recycling product as they can be removed and refitted elsewhere should the need arise.

CPM Headwalls are compliant with the Sewers for Adoption standard

The precast concrete headwall is available in three standard sizes: S40 (small), S60 (medium) and S90 (large). These three sizes accommodate a range of connecting pipes from 150mm to 900mm outlets.

Advantages of the CPM precast concrete headwalls include

The headwall and toe are manufactured as separate monolithic precast units. CPM operates a quality management system accredited to ISO 9001 with all constituent products subject to regular quality inspection. Both components are manufactured to exposure class XD3.

Welcome to CPM

Proven design life of 100 yearsLower whole life costs – cost effective optionLow maintenanceQuick and efficient installationOffsite solution made under factory conditionsNo on-site shuttering or formwork requiredIncreased health and safety on-site with off-site manufacturingReduction in carbon footprintA full range of accessories available from stock

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Concrete for Life

Components

A spillway Headwall will typically comprise of two standard elements.

A precast concrete unit, size dependant on connecting pipe (three sizes available).Fitted with closed coupled and cranked gratings.Pre fitted with hydro-brakes®, penstocks, non-return flap valves.

A precast concrete unit, size dependant on ordered headwall and depth to adjacent water course (three heights available for each headwall size).

A full range of accessories are available, including flap valves, penstocks, hydro-brakes®, silt traps, safety gratings, hand rails etc.

Toe – Toe units can comprise of the following:

Headwall – headwall units can comprise of the following:

Accessories

Headwall Images

Small - S40

Medium - S60

Large - S90

150

225

300

375

450

525

600

675

750

825

900

198

320

460

540

635

720

825

870

950

1035

1130

up to 375

up to 600

up to 900

Headwall Sizes

Designed Pipe Diameter

Hole Sizes

Pipe Diameters

Small S40 Medium S60 Large S90Minimum Hole Size

CPM Headwall Range

Table Key: = stock item = made to order

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Offloading and Lifting

CPM is able to offer advice and recommendations for offloading products on

site and assist in the preparation of a safe delivery plan in accordance with the

HSE document ‘Delivering safety: co-operating to prevent workplace vehicle

accidents’.

CPM recommends that ALL lifting operations should comply with the Lifting

Operations and Lifting Equipment Regulations (LOLER) 1998, and the Provision

and Use of Work Equipment Regulations 1998 (PUWER).

The lift system is of a ‘Utility Anchor’ system incorporating a cast-in loop, adequately

rated lifting brothers can attach directly for lifting, where brothers are too large

to safely be placed, ‘D’ Shackles should be used.

Spillway Headwall S60

More information is available at www.cpm-group.com

Toe

Time and place of off-loading should be agreed before units arrive at site. For safety, all units are delivered in the upright position as installed.

During delivery and off-loading, the units should be placed on 300mm skids to ensure no damage to the “toe” end. Units must be stored individually and not stacked.

Off-loading should take place at the nearest hard standing area to the point of installation. Off-loading must be carried out using appropriate lifting equipment. It is recommended that telescopic handlers, or equivalent, with forklift toes are used to off-load on-site, lifting from the back of the unit (or sidesof the headwall only), to prevent operatives from climbing onto the trailer. Each headwall section is supplied with 3 lifting anchors cast into the reinforced floor for site handling. The units Centre of Gravity has been calculated so there is no need to shorten the chains, but we advise a test lift prior to installation so that the contractor is happy with the angle to help guide the opening over the pipeline. If needed, shorten the legs accordingly so that the back of the unit is lower than the front. Each Toe unit has 2 cast-in anchors with 2 equal chains used to transport on site and position.

Carefully inspect units during off-loading to verify that products are undamaged and comply with the units ordered. Two types of check are required:

Inspect the headwall and/or extended toe for any sign of damage, including cracked or chipped concrete, or damage that could affect the performance.

Check that the item received is the one ordered. Headwalls are a standard CPM product and are labelled with the following information:

All CPM products are stamped with the production date (this is part of a quality control procedure). Any Headwalls rejected should be labelled and stored separately with the discrepancies for each noted on the delivery docket and reported for further action.

Receipt and Handling of Headwalls on Site

Visual

Design

Headwall SizePipe DiameterProduction date

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Cut and install the last section of pipe that the headwall will cover.

Ensure that the pipe is fully fitted, leaving either the first (or last) section of pipe free from backfill to allow the headwall to locate over it.

Excavate to formation level, and dig a trench to suit the toe, place and compact a 300mm bed of 50mm clean drainage stone or similar free drainage aggregate (compacted in 100mm layers).

Check that the correct headwall and toe has been brought to the installation point. Cross reference and check pipe connection diameter to that of the headwall. The movement of the toe and headwall on-site must be undertaken in a manner that is safe and will not cause any damage to the units in any way – the use of the cast-in lifting anchors connected to equal length 2 legged chains is recommended for lifting the toe ensuring a minimum lifting angle of 60 degrees.

Place the toe into the bedded trench and confirm levels and alignment, backfill the voids with 50mm clean drainage stone to approximately 200mm below the crown of the toe and level off the bed.

Ensure the ends of the toe are not exposed and place approximately 200mm of lean mix concrete behind the toe filling up to the crown of the unit, ensuring a level surface for the headwall to rest on.

Lift the headwall unit with 3 legged chains and manoeuvre it so the opening is over the pipeline and lower the toe register into the positioned toe until resting completely on the prepared bed. Placing a shim to the underside of the pipe to centre in position as required.

Using the appropriate grout or an epoxy resin, fill in the void between the reinforced concrete headwall and the pipe. This will ensure a firm fit.

Backfill the pipe section between the headwall and embankment. It is recommended that 300mm surround of 50mm or similar free drainage aggregate is used to surround the headwall to ensure good groundwater drainage.

This document is produced by the CPM Group as a ‘recommended guideline document to the industry’.Its purpose is to aid contractors in the installation of the CPM precast concrete headwalls.

It is the responsibility of the contractor to ensure that the precast concrete headwall is in accordance with the design specifications for the site. It is the responsibility of the contractor to install the precast concrete headwall safely in accordance with site conditions.

Installation Guide

Disclaimer

Technical Spillway Diagrams

Off-Site Solutions

Spillway Headwall S40

Technical Spillway Diagrams

Concrete for Life

Off-Site Solutions

Spillway Headwall S60

Spillway Headwall S60 Spillway Headwall S90

Technical Spillway Diagrams

Off-Site Solutions

Spillway Headwall S90

Concrete for Life

Headwall Accessories

Headwall Flap Headwall Grill Headwall Silt Trap Headwall Handrail Hydro-Brake®

Complete UK Coverage

HEAD OFFICE / ENGLAND / WALES SALES AND SOUTHERN WORKSCPM Group Ltd, Mells Road, Mells,Nr Frome, Somerset, BA11 3PDTel: 01179 814500 Fax: 01179 814511

NORTHERN WORKSCPM Group Ltd, Pollington, Goole,East Riding of Yorkshire, DN14 0DUTel: 01405 860591 Fax: 01405 863606

SCOTLAND SALESCPM Group Ltd, 101 Main Street, Newmains,Wishaw, Lanarkshire, ML2 9BGTel: 01698 386922 Fax: 01698 387167

PERFECT MANHOLE SALESCPM Group Ltd, 1st Floor Alexandra Mill,Queen Street, Leek,Staffordshire, ST13 6LPTel: 01538 380500 Fax: 01538 380510

TECHNICAL OFFICESCPM Group Ltd, CPM House,Heath Mill Road, Wombourne,Staffordshire, WV5 8APTel: 01902 356220 Fax: 01902 356221

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sales@cpm-group.comwww.cpm-group.com