In a formidable upgrade endeavor at Warwick Hospital, mechanical and electrical engineering firm FP Hurley & Sons successfully tackled the challenge of replacing extensive heating pipelines without causing disruption to patient services. The company transitioned from traditional welding to the innovative Victaulic grooved mechanical pipe joining system, a decision integral to navigating logistical complexities and ensuring swift and efficient project completion.
The ambitious undertaking began in September 2023 and is projected to span 18 months. According to Euan Jones, FP Hurley & Sons' contracts manager, executing the infrastructure uplift in an active hospital demanded strategies that minimized disturbances while maintaining operational flow. Key elements of the decarbonization project included the integration of water source heat pumps, solar PV panels, window replacements, and enhanced thermal insulation to revamp the hospital's heating framework.
Historically, pipework installations leaned heavily on welding, necessitating specialized labor and stringent safety measures such as permits and fire watches. In contrast, the grooved mechanical pipe joining process simplifies these requirements by utilizing grooved pipe ends coupled with a gasket and secured with bolts—facilitating a quick visual inspection to ensure a robust connection. This technique allowed FP Hurley & Sons to eliminate fire risks, reduce fumes, cut installation time by up to 80%, and lower the project’s carbon footprint.
The adoption of Victaulic’s grooved mechanical system offered a cleaner worksite and adaptability for routing changes, essential in the tightly spaced hospital environment. Modifications to the pipework were achieved without the need for trenching, an approach particularly vital in the Emergency department where traditional methods would have impeded ambulance services.
The switch to the grooved mechanical pipe joining method also enabled the use of lightweight stainless-steel pipes, which provided significant logistical benefits including easier handling and reduced manual handling risks within the hospital. The StrengThin 100 system, a first in industry-standard grooved mechanical pipe joining on thin wall stainless steel pipes, powered the project, allowing for high-performance connections without welding challenges such as pickling or overheating risks.
According to Jeff Morris, a Victaulic sales engineer, the lightweight StrengThin 100 system was instrumental, providing labor and installation efficiency. Morris worked closely with FP Hurley & Sons to optimize the piping system designed for the hospital's structural upgrade. "The weight of traditional iron pipes would have been an issue, especially navigating them to various parts of a live hospital," noted Jones.
FP Hurley & Sons also praised the invaluable support from Victaulic throughout the project at Warwick Hospital. Jones highlighted the rapid response from Victaulic whenever issues arose, such as the quick replacement of a grooving machine, emphasizing the company's steadfast commitment and partnership.
This project demonstrates the advantages of Victaulic solutions in complex healthcare infrastructures. The project reduced the hospital's carbon footprint significantly by replacing gas-fired boilers and installing nearly two kilometers of heating pipes. With products made from 98% recycled materials, Victaulic supports sustainability by offering assemblies that can later be reused or resmelted.
Euan Jones concluded with optimism about the project's trajectory, crediting Victaulic solutions with helping deliver a secure, efficient, and sustainable piping system, and expressing eagerness for employing similar solutions in future projects.
Imagine trying to replace miles of heating pipes in a busy hospital without disrupting patient care. That was the task facing mechanical and electrical engineering contractor FP Hurley & Sons at Warwick Hospital.
The solution? A shift away from traditional welding in favor of the Victaulic grooved mechanical pipe joining system – a move that proved instrumental in overcoming logistical hurdles and ensuring quick and seamless project delivery.
Major infrastructure upgrade
The project, which commenced in September 2023, has been an 18-month endeavor
“Executing a major infrastructure upgrade in a live hospital environment comes with considerable challenges,” explains Euan Jones, contracts manager at FP Hurley & Sons.
“Minimizing disruption to patients and staff while maintaining an efficient workflow required innovative approaches, particularly in our piping solutions.”
The project, which commenced in September 2023, has been an 18-month endeavor. The decarbonization initiative has included the installation of water source heat pumps, solar PV panels, window replacements, and enhanced thermal insulation, all working in unison to modernize the hospital’s heating infrastructure.
Minimal disruption
Traditionally, pipework installers have relied on welding, a process that demands skilled labor and extensive safety measures, including permits and fire watches.
In contrast, grooved mechanical pipe joining is a straightforward process, where the pipe ends are grooved, a coupling with a gasket is fitted over the joint, and two bolts secure the connection. A simple visual check ensures proper installation, making it both efficient and reliable.
By eliminating welding, FP Hurley & Sons removed fire hazards and fumes, reduced the project’s carbon footprint, and significantly cut installation time – by up to 80%.
Grooved mechanical system
Victaulic’s grooved mechanical system also provided a cleaner workspace and allowed for easy route modifications
Victaulic’s grooved mechanical system also provided a cleaner workspace and allowed for easy route modifications; crucial in an environment where existing infrastructure posed significant spatial challenges.
The pipe simply needs to be cut to the new length required and then joined with a coupling as usual.
A prime example of this adaptability was in the hospital’s Emergency department, where initial plans to trench underground were reconsidered due to the disruption it would cause to ambulance services. Instead, an innovative above-ground solution was devised, rerouting the pipework to ensure uninterrupted emergency operations, and which Victaulic solutions were easily modified to.
Grooved mechanical pipe joining method
Furthermore, the grooved mechanical pipe joining method also facilitated the use of lightweight stainless-steel pipe, providing significant logistical advantages for the large diameter pipework.
This enabled easier handling and transportation within the hospital, reducing manual handling risks and improving site safety.
The specific pipe joining solution employed was Victaulic’s StrengThin 100 system, the industry’s first grooved mechanical pipe joining system to perform up to 16 bar on thin wall stainless steel pipe. This eliminated the challenges associated with welding thin wall stainless steel, including the need for pickling or passivating the joints or the risk of overheating the pipe.
Lightweight StrengThin 100 system
“Given the extensive external large-diameter pipework in the existing building, our lightweight StrengThin 100 system provided both ease of installation and significant labor savings, making it a win-win for everyone involved,” says Jeff Morris, Victaulic sales engineer, who has been working closely with FP Hurley & Sons since early 2023 in designing and implementing the optimal piping system for the hospital’s retrofit.
Euan adds: “With a traditional iron pipe system, the sheer weight of the pipe would have been a real issue in carrying it through a live hospital, up staircases and above operating theatres. It would have been really problematic.”
Exceptional support
Euan also highlights the exceptional support provided by Victaulic throughout the Warwick Hospital initiative
Euan also highlights the exceptional support provided by Victaulic throughout the Warwick Hospital initiative. “Whenever we encountered challenges, the Victaulic team was on hand to assist,” he explains.
“When our grooving machine required a replacement, we had a new one on site within 24 hours. Their responsiveness and commitment have been invaluable.”
Jeff also emphasizes the strong partnership with FP Hurley & Sons and the extensive support Victaulic has provided. “We don’t just supply a product and walk away,” he says. “We offer full design assistance, on-site training, and installation inspections to ensure success.”
Future-proofing piping systems
The project ultimately underscores the advantages of using Victaulic solutions in complex healthcare infrastructure projects.
With nearly two kilometers of heating mains installed, feeding eleven plant rooms and removing multiple gas-fired boilers, the project has made significant strides in reducing Warwick Hospital’s carbon footprint.
The integration of Victaulic’s solutions not only delivered efficient and emission-free installation but has also contributed to the long-term sustainability and operational resilience of the hospital’s heating system. They allow for easy maintenance access and infinitely reconfigurable piping systems as building needs change over time.
Made from recycled materials
Victaulic’s products, made from 98% recycled materials, support a circular economy, as, at the end of their lifecycle, they can be disassembled, repurposed, or melted down for reuse, ensuring they contribute to both immediate and long-term sustainability goals.
“We’re incredibly pleased with how this project has progressed,” adds Euan. “Victaulic solutions have played a crucial role in ensuring we delivered an efficient, safe, and future-proofed system. Given the success of this installation at Warwick Hospital, we look forward to implementing similar solutions on future projects.”
