New Brochure

Integrated Railway Design Solutions
Permanent-Way Drainage Systems 1
GRP Products and Bespoke Items 3
Signalling and Power Installation Systems 2
Geotextiles and Geocomposites 4
Innovation, safety and support right down the line

Version 3.1
Design solutions
This catalogue is designed as a help and a guide to engineers, designers and
specifiers involved in the construction and maintenance of railways.
The products detailed are drawn from over thirty years of experience in
getting the right engineering solution to meet the far ranging requirements
of a working railway.
The products are designed from engineering criteria and are technically
and laboratory proven to perform as you would expect. Network Rail and
its engineers have been fully consulted and involved in the selection of the
products offered, which meet product acceptance standards. What is of
significant consideration is that the products are the most cost effective
and time saving solutions available on todays market and can help you play a
major part in achieving the value engineering Network Rail expect.
BR/PADS 2000
APPROVEDSUPPLIER
Working with the Railways

Since Network Rails conception they have worked
consistently on improving and standardising the
quality of products accepted for use in Britains
railways. Aqua have welcomed this move to
introduce standards in railway drainage and have
worked closely with Network Rail in ensuring
that all its products have the full support, approval
and confidence of that body. This inter company
consultancy has enabled us to achieve full Pads 2000
recognition for all our products.
Quality Assurance
Railtrack Approval
Link-up Approval
Product tested and approved in Europes

leading railway test houses
Hochschule Fur Tecknick und
Wirschaft - Dresden
02
Installation
This catalogue represents the joining together of the Aqua S & TS and
the Aqua Geocomposites catalogues into one. With these sections
below please note that when you specify your product requirements you
should also specify the company it belongs to.
Catalogue Index
1
Aqua S & TS
Permanent-Way
Drainage Systems
pages 4 - 16
Aqua S & TS
Signalling and Power

Installation Systems
pages 17 - 30
Aqua S & TS
GRP Products and

Bespoke Items
pages 31 - 35
Aqua Geocomposites
Geotextiles and
Geocomposites
To assist in the design of railways, Aqua have

introduced a new section on its website
www.aquafab.co.uk, which is intended to
provide a range of solutions in putting
together a working railway drawing.
PDF drawings are fully available and in our
RailCAD section, DWG details are available
in AutoCad 2007 and 2012 for you to copy
and paste as required.
In addition to the above we also offer a free
bespoke CAD drawing service as an aid
when required.
pages 36 - 44
Quality Assurance
Aqua manufacture all its products
to ISO 9001:2008 Quality
Management System,
This assures that all the products
that you receive are made to
the highest standard and are
rigorously quality checked.
Partnership
Aqua have supplied its product range into railways
for over 30 years. Its products are fully approved for
use in the UKs rail system, either by Grandfathers
Rights or by Network Rail Product Acceptance
system. This allows you to use or specify Aquas
products in the complete confidence that they are
fully fit for purpose.
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RailCAD
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03
1
Permanent-Way Drainage Systems
Aqua S & TS

Drainage Pipes
Aqua presents four options of drainage pipe, each designed to perform
a specific engineering solution. All these pipes have been in use with
the railways for over thirty years, with 100% reliability in all manner of
installations. Network Rail Approved for use in the CESS or the 6 foot.
Product selections
TDX Extreme Duty Large Bore Pipe
TDK Reinforced Wall Pipe
This is the workhorse for permanent-way drainage. It can be installed in

the CESS or 6 foot and is fully Network Rail endorsed, who confirm that
The product is also supported by no reported locations where twin-wall
pipe had in some way failed prematurely in the past, sic.
TDE Heavy Duty Pipe
This is selected where a more robust product is preferred, where pipes

may come into physical contact with construction equipment, extremely
shallow CESS or 6-foot applications or under track crossing. Independent
scientific evaluation and on site experience have proved that the product is
an ideal solution.
For any application in the rail environment this pipe can be expected
to perform. Generally it is expected for selection as a drainage pipe in
diameters in excess of 400mm dia.
TDS Helical Wound Steel Pipe
For use in undertrack crossing, but not to be used on 3rd and 4th rail
electrified line.
Note: Some suppliers have been promoting very thick walled pipes
for their applications. Their products are grossly over engineered and
unnecessarily expensive. Network Rail demand value-for-moneyengineering. Aquas products have been value engineered to deliver
this demand. Up to 73% less material is used in Aqua products giving
great coast savings with no loss of performance.
Ballast
Sleeper
Invert level
to be min
0.85 below
rail level
Separating Terratex
Geotextile overlapping
0.5m
300
Min 0.85m top of

rail to invert
150mm min
Trenchliner Geotextile
trimmed into formation
TDK 225mm dia perforated
permanent-way drainage pipe
bedded on a min of 25mm pea
gravel surround to pipe
150mm min
500mm
min
Trench to be back filled with

pea gravel or other approved
free draining material suitably
compacted
Typical Cross Section
CESS Drainage Applications

Preferred pipe
Normally pipe selection would be a TDK pipe with a minimum
cover of 300mm above the crown, however, where the pipe is
installed in a shallow position a TDE pipe may be preferred.
Trench to be back filled with

pea gravel or other approved
free draining material suitably
compacted
Sleeper
300
Aqua-Tex trench liner

Geotextile
Perforated TDK
225mm min pipe to be
surrounded in pea gravel
Typical Cross Section
6-0 Drainage Applications

Preferred pipe
Historically in normal applications TDK pipes are used, however,
in shallow applications or very tight 6 foots TDE pipes may be
preferred.
Note: Suggested details of 6-0 installations and cross drains
are available in CAD format from Aquas website.
Note: Suggested details of CESS installations are available in

CAD format from Aquas website.
Both TDK & TDE have been examined physically by the University of Birmingham test facility in the Railway Section of the Civil Engineering
Department and scientifically by GGP, Hull Consult Hall for use in the 6-0 in deep and shallow applications.
04
AQUA TDK is a corrugated outside wall with a reinforced smooth

wall inside, achieving a strong twin-wall pipe. This combination
gives a very strong product with good performance and yet is still
lightweight and easy to handle (available plain or slotted).
In 6 metre length or less to suit
TDK Reinforced-Wall x 6 Mtr

Structural Design
It is universally accepted that flexible walled pipes resist imposing
loads by deflection, the control of this deformation is based on
several basic parameters; the bedding factor, pipe material and profile
stiffness and the interaction of pipe and surrounding fill material.
TDK Reinforced-Wall Pipe
Size Range
Dia I/D O/D
BR/Pads 2000 Code
4TDK
6TDK
8TDK
9TDK
12TDK
16TDK
18TDK
24TDK
004/103119
004/103122
004/103125
004/103127
004/103129
004/103131
004/131093
004/131094
100mm 118mm
150mm 178mm
200mm 230mm
225mm 266mm
300mm 354mm
375mm 426mm
450mm
600mm
Larger sizes available on request.

Pipes available in 6 metre, 3 metre or 2 metre lengths on request.
Pipe can be either full or half perforated.
High Stress Performance

Technical examination by an independent consultancy has
proven TDK as suitable for installation in the 6-0 and
this has been accepted by Network Rail. Copies of these
independent reports are available on request.
Advantages
TDK achieves significant cost savings against over engineered
thick walled HDPE pipes with no loss of performance.
TDK can:
be installed as a UTX, with 900mm cover to crown
(High Load applications)
be installed in the 6 foot with 300mm of cover
manufactured from HDPE which has a 60 year design life
perforated to BSI standards
be installed in insitu using local fill
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Installation suggestions, porosity details and hydraulic

performance are described on pages 11 and 12 of this catalogue.
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Performance
PP R O
Network Rail approval for use

in the Cess or the 6-foot.
TDK pipe is environmentally friendly,

manufactured from recycled plastics.
TDE Heavy Duty Track Crossing Pipe
Dia I/D O/D
BR/Pads 2000 Code
AQUA TDE is manufactured from de-stressed high density

polyethylene which gives the pipe great strength and rigidity yet
remains lightweight and manoeuvrable. (Available plain or slotted).
4TDE
6TDE
8TDE
9TDE
10TDE
12TDE
16TDE
057/100749
057/100750
057/100997
057/100751
057/100752
057/100753
103mm 110mm
150mm 160mm
188mm 200mm
211mm 225mm
235mm 250mm
296mm 315mm
376mm 400mm
Larger sizes available on request. Pipes available either fully or half perforated.
High impact performance

Will not fracture under crushing loads
Can be installed in shallow position with cover just to crown
Will withstand contact with construction equipment
High Stress Performance

Technical examination by an independent consultancy has
proved TDE as ideal for installation in the CESS or 6-0
and this has been accepted by Network Rail. Copies of
these independent reports are available on request.
Hydraulic Design - Flow capacities of TDE will be as TDK.
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Technical and performance histories confirm the ability of TDE to

withstand both extreme pressures and impact. Actual installations
can be referred to, which confirm first hand experience of the
products ability to perform in railway applications.
GRAN
High Impact Performance
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TDE can be used in very severe applications and

will withstand great physical abuse.
PP R O
Network Rail approval for use

in the Cess or the 6-foot.
TDE pipe is environmentally friendly,

manufactured from recycled plastics.
05
1
Specialist Drainage Pipes (plain and perforated)

Drainage Pipes continued
TDS Helical Wound Steel Pipe
Diameter mm
AQUA TDS helical zinc-coated steel pipes have spiral corrugations

to give tremendous strength. Perforated with 8mm holes these
pipes prove ideal drainage pipes in extreme conditions.
0.8
1.0
1.5
300
400
500
6.6
8.8
11.0
8.1
10.8
13.5
11.9
15.8
19.8
Thickness mm
s=43
s=43
90
90
o
s=43
s=43
43
43
6000
6000
hoLes o 8
hoLes o 8
hoLes FoR
hoLes FoR
dRAiNAge
dRAiNAge
N.B. TDS can be supplied without holes.
TDX Extreme Duty Large Bore Pipe

For use in applications over 400mm dia
TDX is Aquas latest addition to its pipe range and is not
actually a pipe but a circular hollow section made up in
strong plastic cells welded together, spirally wound.
Box Section
TDX Large Bore Extreme Duty x 6 Mtr
Welding
Size Range
Dia I/D O/D
16TDX
18TDX
20TDX
24TDX
30TDX
400mm 454mm
450mm 506mm
500mm 560mm
600mm 675mm
750mm 838mm
Fittings = TDK
Dia I/D
Pads Code
4TDKC 100mm 004/130306

6TDKC 150mm 004/130307
8TDKC 200mm 004/130308
9TDKC 225mm 004/130309
12TDKC 300mm 004/130310
16TDKC 375mm 004/130311
Dia I/D
4TDKS
6TDKS
8TDKS
9TDKS
12TDKS
16TDKS
06
Pads Code
100mm 004/131211
150mm 004/131212
200mm 004/131213
225mm 004/131214
300mm 004/131215
375mm 004/131216
Network Rail Product

Accepted
Bends Junctions
A wide selection of bends
and junctions are available
for all types of pipes.
Rodding Points
Working with railway engineers Aqua has developed a

range of catch-pits designed to offer multiple solutions
to suit the performance required.
Derby GRP Catch-pit rings

S80/S100 circular Stafford HDPE
Catch-pit base units for use with large
Standard concrete Catch-Pit rings
diameter permanent-way drains
Stirling/Watford GRP base units
Nouva circular HDPE circular catch SE60 Circular HDPE Catch-pits
pit base and sections
Catch-pit application suggestions

Standard CESS drain employing GRP base unit/GRP rings
GRP Lid
Derby GRP rings
Stirling GRP
base units
6-0 drain incorporating an SE60 circular catch-pit

GRP Solid Lid or
Metal Lid
SE60 Catch-pit
CESS drain showing an S80 Stafford circular base

- with either Derby GRP rings or standard concrete rings with
large diameter permanent-way drains in a deep position
GRP Lid
Stafford Catch-pit
Large dia p-way
drainage pipe
Note: Suggested details
for catch-pit installations
are usually available in CAD
form in the RailCAD
section of our website
www.aquafab.co.uk
07
Catch-Pits and Lids
Watford, Stirling & Mini-Stirling GRP Base Units - Patent Approved

Time Spent Installing Permanent-Way Drainage
Systems is Critical
1290 x 760mm
1055 x 600mm max
The installation of permanent-way drainage pipes with a concrete ring

system is time consuming. To quicken installation Aqua have introduced
a range of GRP base units which can be used with both the new
Derby GRP rings and the conventional concrete rings. This will reduce
installation time and labour costs.
In particular where trenches exceed 1.2 metres in depth, E.E.C. legislation
demands that all excavations within which men are required to work,
must be supported or have correctly battened sides. This practice is
extremely expensive and can be eliminated by the use of the G.R.P.
bases which eliminates the need for men to work within that space and
the GRP pits can be simply dropped into position from the pipe trench.
Detail showing concrete rings
630
mm
650
mm
max
1000mm x 460mm
745mm x 360mm max
Standard Unit
Mini-Stirling Unit
Installation applications
Stirling Unit
0-1.2 metres
Weight: 28kg
Standard Base Unit for every
day use.
Pads code: 057/100740
Watford Unit
Standard GRP
Rodding Ledge
Weight: 6kg
Pads code: 057/100656
Mini-Stirling Unit
Weight: 21kg
For use in the 6 foot or in
narrow excavations
Pads code: 004/103023
To be installed in either the CESS
1.2 metres +
Weight: 28kg
For use in deep installations
1.2 metres
plus with space for Standard
Rodding Ledge.
Pads code: 057/100741
Watford Unit
Network Rail Approved

The Watford/Stirling GRP Catch-pit range is fully
product accepted. Approval No PA05/02850
Rubber Sealing Ring
Product selections
Stirling Unit
or the 6 foot location at up to 1.2
metres deep ideally to suit 225mm
TDK and below, with a 225mm deep
sump, but can also accommodate up
to 300mm TDK with sump depth
reduced to 182mm.
Installed in applications deeper
than 1.2 metre in CESS or the 6

foot. Ideal to suit 300 TDK and
below with 225mm deep sump,
but can accommodate 375 TDK
with a sump depth of 175mm.
x2
Fully approved for use in the CESS

or the 6-0, proven and tested by
Network Rail at the Railway section
of the University of Birmingham.
Mini-Stirling Unit
EW
designed for installation in tight 6

foots. Can accept up to a 300 TDK
pipe with sump depth up to 300mm.
Luton Mini Unit
A full length GRP mini base unit
08
Stirling
Watford
Mini-Stirling
Rodding Ledge
Luton Mini Unit
N
EW
Can be installed in CESS but mainly
Catch-Pit Base Units
Pads code: - 057/100740

Pads code: - 057/100741
Pads code: - 057/103023
Pads code: - 057/100656
Pads code: - TBA
N.B. Extra Deep Watfords are available on request
1
Catch-Pit Rings
Derby GRP Catch-Pits Rings
115
Innovation by Aqua
3 x stronger than concrete

1 man installation
Interchange with concrete rings

Approved for use in 6 foot
Weight 16Kg
1270 x 735
Standard Derby frame
Derby full
sized rings
115
Weight 16Kg
EW
1270 x 575
Luton full length mini frame
115
Mini Derby unit for use in

6 foot and tight installations
Proof test of Derby unit
The Derby unit was
tested by independent
Test House EXOVA
and was proved to
withstand a UDL of
390(KN)
Maintenance
1035 x 575
Weight 13Kg
Mini Derby frame
Derby GRP Unit
Mini-Derby Unit
Pads code: - 057/100650
Pads code: - 057/100654
Lid installation
Derby frames
interlock together
to form a solid
catch-pit
The top frame is fitted with a cut-out to

accept the locking assembly, this
system firmly locks
lid and frame
together. Note:
Only the top ring
has this facility.
York adaptor
Derby rings can be used instead of the heavy concrete rings
in maintenance programmes.
A transition ring is used to lock concrete and GRP rings into
a single unit.
Network Rail Product Accepted

approval no PA05/04178
Derby units are subject to registered community

design No 001945775
York Adaptor
09
SE Range of fabricated Double Skinned

Tubular Section Units
The SE50 (20 diameter), SE60 (24 diameter) and SE80 (30
diameter) circular catch-pits are a one piece catch-pit in any
required depth and usually supplied with either a metal or GRP lid,
fitted base and entry holes (Sockets available on request).
This section can

be removable to
aid maintenance
2m
Optional
Advantages of the SE Unit
Standard depth 2 metre but can be manufactured to any depth.

Lock-on lid can be removed during installation and refitted when
required catch-pit depth has been established.
225mm
Fixed 225 sump.
Diameter I/D can be - 400mm, 500mm, 600mm, 750mm,
Dia I/D
900mm, 1050mm.
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depths and to within 1000mm of the running rail (closer subject

to ground conditions).
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Can be supplied in sections for breakdown during ballast cleaning.

Fully approved for use in the CESS
or the 6-0, proven and tested by
Network Rail at the Railway section
of the University of Birmingham.
Sockets can be fitted if required.

Extremely strong, can be installed in CESS and 6 - 0 and at great
GRAN
Catch-Pit Base Units
Unit
SE50(Orp)
SE60
SE80
SE100
SE120
500mm dia
600mm dia
800mm dia
1000mm dia
1200mm dia
Stafford large diameter

Catch-Pit for large diameter
Permanent-way Drains
For engineers who prefer
Catch-Pit rings
Unit
Pads Code
S80
S100
057/101219
057/101220
800mm dia
1000mm dia
The Stafford unit is designed for use

with large diameter Permanent-way
drainage pipes in either the CESS or
the 6-0. The unit can be supplied
with step irons for extra deep
locations, drains from 400mm to
800mm diameter.

10
Stone guard
Sump unit
(225mm deep sump)
Pads Code
057/100754
057/100748
1
Specialist Permanent-Way Drainage Products

Crewe Adaptor - Patent App
The Crewe Adaptor is designed as a transition piece between
standard railway catch-pit rings and the narrow catch pit rings.
The unit is for use where a full sized catch-pit is desired
but surface projection prevents the
catch pit maintaining its full size to
the surface.
Concentric
Eccentric
Crewe Adaptor
Pads code: 057/1006409
Crewe Adaptor

Unit
Pads Code
Crewe Adaptor
057/100640
Carlisle Joint Box

The Carlisle joint box is designed for use as a transmission piece to
accept cross drains, were they occur at heights that vary from the
position of the lower catch-pit base.
Carlisle Box
Cross Drain
11
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Catch-Pit Base Units and Lids
PP R O
5mm
Nouva Moulded Units Patent No. 2150953
See list
The NOUVA MOULDED UNITS were introduced

during 1983 in response to engineers demands for a
system which allows partial dismantlement to enable
ballast cleaning procedures and maintenance.
600mm
The range of extensions are fixed together and onto the sump
unit by a simple interlocking mechanism, alternatively the units can
be riveted together to give a complete unit.
225mm
630mm
Product
BR code/ Pads 2000
E52/100 Lid (Metal)
004/103022
E52/050P Lid (Plastic)
004/103002
E52/150 Extension 6
004/103004
E52/300 Extension 12
004/103005
Guaranteed to 30C, will not crack
E52/450 Extension 18
004/103006
Will not float during or after
E52/600 SUMP and

Connection Pan
004/103007
The 630 mm dia. high-performance

catch-pit offers and incorporates the
following facilities:
Resistant to impact damage

moulded HDPE
at low temperatures
installation
Needs no special installation

techniques
Blow-up detail of our

registered design of
interlocking device.
Lids to suit catch-pits

Solid anti-vandal lid
(galvanised).
Ashford anti-vandal GRP grated lid

for use with concrete frames.
Pads Code 057/100834
Solid lockable two-piececover & frame lid (galvanised)

cam-lock system.
Solid lid (galvanised). Locked

by self tapping screws.
Mini Ashford GRP lid for use with

mini-stirling.
Solid anti-vandal catch-pit lid for
use with concrete frames.
Grated anti-vandal catch-pit lid for
use with concrete frames.
Solid lid (HDPE plastic) for

lines with live third rail.
Locked by self tapping screws.
Matisa anti-vandal catch-pit lid for

use with Matisa frames.
Galvanised steel half lid for use
with concrete frames.
12
1
Pre-cast Concrete Catch-Pit Rings and Sections
50mm
Traditionally B.R. developed and manufactured its own range of concrete

catch-pits in its YORK, TAUNTON & THORNTON HEATH depots.
The system has proven both robust and durable in its performance
and the very same moulds designed during those early years are still
used today. The unit is site assembled from its individual units and has
a proven track record. Installation deeper than 1.2 metres must have
supported or correctly battened sides.
Typical B.R.
Concrete Catch-pit
115mm
230mm
75mm
1270mm
735mm
Solid Anti-Vandal Lid (Galvanised)

BR code/Pads 2000 057/100743
Grated Anti-Vandal Lid

Galvanised M.S. mesh lid for use in areas liable to vandalism
BR code/Pads 2000 057/100742
Standard Catchpit Cover

BR code/Pads 2000 004/13508
Standard Catchpit Frame

BR code/Pads 2000 004/13501
Stone Guard
Slips over Permanent Way pipe to stop ballast falling into pit
BR code/Pads 2000 057/100744
Standard Rodding Ledge

BR code/Pads 2000 004/13510
Standard Catchpit Half Frame

BR code/Pads 2000 004/13502
Standard Catchpit Corner

BR code/Pads 2000 R/H 004/13507, L/H 004/13506
Standard Catchpit Base

BR code/Pads 2000 004/13509
Matisa Concrete System
Matisa Catch-pit Cover

BR code/Pads 041/104512
Matisa Catch-pit Frame

Matisa Catch-pit Base

13
1
Permanent-Way Pipe Performance
Porosity
Please note the figures given in the
adjacent specification are for halfperforated pipes.
Slotting Configurations
Comply to B.S. 65 and B.S. 540 Part 1: 1971 1000mm2 per
metre length of pipe ingress.
Aqua supply pipes, both half and/or fully

perforated depending on the customers
technical requirement.
110mm 1250mm2 per metre run of pipe
The orientation of half perforated pipes

in a trench is a debatable issue. Aquas
opinion in that should an engineer
require maximum lowering of the water
table - slots down. Should an impervious
invert be required - slots up.

All pipes radially slotted to spec. 191047
Installation
Invert levels and pipe depths
Gradient
The invert level of a pipe drain should be below the level to which
it is desired to lower the free water surface. Recommended pipe
depths are:
The absolute minimum gradient of track side drains should be

considered to be 1 in 1000 with the desirable minimum gradient
being 1 in 500.
Minimum - that necessary to give 150mm cover to the pipes or
Where gradients flatter than 1 in 500 must be adopted then the

size of the pipe should be increased accordingly. Some caution is
advised, however, since the flow rate of the larger pipe will be less
than that of the smaller pipe and silting up may occur more rapidly.
over the collars of socketed pipes, where used.
Desirable - such that the invert is approximately 100mm below

the bottom of the ballast.
Maximum - the invert should not be more than 1050mm below

ground level, although this may be exceeded by small amounts
and/or short lengths.
Geotextiles
When a pipe drain is being installed where a permeable geotextile
is provided (on a formation renewal site for example), then this
should be carried over the side of the drain trench to the bottom,
or even extended under the pipe.
The table to the right may be used as a guide to the effect of pipe
diameter and gradient on the discharge and velocity of flow of
a pipe drain. The lines across the lower portions of the columns
divide the nominally self-cleaning drains from the nominally silting
ones, as assessed at maximum discharge.
Geotextiles shall accord with Railtrack line specification

RT/CE/S/010 Geotextiles.
Deep drains
Some forms of membranes are manufactured with a sleeve

along one edge through which the pipes can be threaded. This
arrangement will provide some of the function of the filter medium
described in para. 7.3.10 but the provision of the graded filter
material in addition to the membrane sleeve is recommended.
Pipe diameter
The minimum internal diameter of single pipe runs should be
200mm. For short drains (less than approximately 10 metres)
where a fall of 1 in 250 or steeper can be obtained, then pipes of
150mm diameter may be used.
14
The faster the flow, the better the self-cleaning action, so as

steep a gradient as possible should be used. For a drain to be self
cleaning the flow velocity should be a minimum of about 0.75m/sec
(approximately 2.5 ft/sec).
If the minimum permissible gradient results in the depth of

1050mm being exceeded then the pipe should be continued as
a carrier drain and shallower surface water drains laid above and
connected to the carrier at each catchpit.
The diameter of the carrier drain should be increased as necessary
to take the flow from the surface water drains.
Installation
Pipes should be laid to the design line and level and bedded
on 75mm - 150mm of a graded filter medium to take up the
irregularities of the trench bottom.
1
Pipe dia 150mm 225mm 300mm 375mm 450mm 525mm

D
V D V D V D V D V D V
Gradient
Nominally self-cleaning Damaging

1 in
50
23.3 1.32
68.8 1.73
148.2 2.10
268.6 2.43
436.8 2.75
658.9 3.04
100
16.5 0.93
48.6 1.22
104.8 1.48
189.9 1.72
308.9 1.94
465.9 2.15
150
13.5 0.76
39.7 1.00
85.5 1.21
155.1 1.40
252.2 1.59
380.4 1.76
200
11.7 0.66
34.4 0.87
74.1 1.05
134.3 1.22
218.4 1.37
329.4 1.52
240
31.4
67.6
122.6 1.11
199.4
300.7
0.79
0.96
1.25
1.39
300
- -
28.1 0.71
60.5 0.86
109.7 0.99
178.3 1.12
269.0 1.24
350
- -
26.0 0.65
56.0 0.79
101.5 0.92
165.1 1.04
249.0 1.15
400
- -
52.4 0.74
95.0 0.86
154.4 0.97
232.9 0.08
450
- -
49.4 0.70
89.5 0.81
145.6 0.92
219.6 1.01
500
- -
46.8 0.66
84.9 0.77
138.1 0.87
208.4 0.96
600
- -
42.8 0.61
77.5 0.70
126.1 0.79
190.2 0.88
- -
- -
700
- -
- -
116.7
0.73 176.1
0.81
Nominally silting
Notes
1 D = maximum discharge in litres/second.
2 V = velocity of flow in metres/second at maximum discharge.
3 Pipes of 525mm diameter installed on a gradient of 1 in 50 or

steeper will be subject to scour damage. For pipes larger than
525mm diameter other values of critical gradient will apply and
the reader is advised to refer to Tables for the design of pipes
(see references).
Standard Installation suggestions
Minimum 500mm overlap

at joint of Geotextile
separator & Geotextile
trench liner
Filter medium 6mm
nominal single size Pea gravel
Trench lined with non-woven Geotextile
aperture ,0.06mm.
Standard Formation
150 min
200
Non-woven Geotextile
separator aperture
<0.06mm. TERRATEX.
Surface of
prepared subgrade
Wrapped Drain
Ballast
Geotextile trench liner held in place

just below ground surface.
(5) ALL JOINTS OF GEOTEXTILE

TRENCH LINER TO BE MADE WITH
500mm MIN OVERLAP.
(6) ALL GEOTEXTILES TO BE LAID
CAREFULLY & WITH MINIMUM OF
JOINTS.
(7) PIPE JOINTS TO BE SEALED
WITH SUITABLE CEMENT OR
JOINTING COMPOUND.
1 in 30 crossfall
Impermeable
Geoblanket Reforme.
Surface of
prepared subgrade
Minimum 500mm overlap
at joint of Geotextile
separator & Geotextile
trench liner
Filter medium 6mm
nominal single size Pea gravel
(1) LONGITUDINAL FALL . 1 IN 240

PIPE TO BE WRAPPED WITH A
NON-WOVEN GEOTEXTILE
APERTURE <0.06mm.
(2) AS NOTES N(2)-(*) OF FIG. 4..
VARIES
(3) TRENCH TO BE SQUARE CUT &

CLEAN FROM DEBRIS BEFORE
GEOTEXTILE TRENCH LINER IS
INSTALLED.
(4) GRAVEL & PIPE TO BE
INSTALLED IMMEDIATELY AFTER
LAYING OF TRENCH LINER TO
MAINTAIN INTEGRITY OF TRENCH
& GEOTEXTILE.
NOTES:-
(3) WRAP JOIN TO BE

LONGITUDINAL FORMED BY
DOWNWARD FACING OVERLAP
(250mm MIN) HELD TIGHTLY IN
PLACE BY CIRCUMFERENTIAL
WIRING AT 2.0m INTERVALS.
150 min
(2) GEOTEXTILE TRENCH LINER &

GEOTEXTILE SEPARATOR JOINED
WITH 500mm MIN OVERLAP, NO
STITCHING OR STAPLING
REQUIRED.
150
1 in 30 crossfall
(1) LONGITUDINAL FALL . 1 IN 240

PIPE NOT TO BE WRAPPED TO
ACHIEVE SELF CLEANSING FLOW.
200
Geotextile trench liner held in place

just below ground surface.
VARIES
Ballast
NOTES:-
150
Unwrapped Drain
NON-WOVEN GEOTEXTILE
WRAP APERTURE <0.06mm.
AQUA-SOK
Trench lined with non-woven Geotextile

aperture ,0.06mm.
Clay Formation
15
1
Permanent Way Installations
16
Aqua S & TS
Signalling and Power Installation Systems

Product selections
Solution:
Car Park and Station Lighting
2
Chamber Designs
Chamber Selection
Ancillary Products
Car Park Lighting

CCTV Access
Platform Lids
Solution:
Ducting and Conduits
TDE Heavy Duty Ducting

TDK Normal Duty Ducting
Solution, Thieel:
Under track Crossing Chambers (UTX)
Solution:
Concrete + GRP Troughing
TPG uPVC Ductings

Split Ductings
Concrete
troughings
and lid
17
Undertrack Crossing Chambers (UTXs), Thieel

The Aqua UTX chamber range was developed to
fill the need for an engineering solution to enable
signalling cables to be efficiently diverted under the
track in a UTX situation.
The chambers are available in a wide range of sizes and
depths and can accommodate an individual ducted UTX
arrangement, or the multi-duct system.
2
The product can be produced as watertight as possible and is

quick and easy to install.
UTX to suit individual

duct systems
UTX to suit multiduct systems
Detail of a UTX assembly

In its basic form the body of the UTX chamber can simply be drilled
with the required number of holes to give access to ducting. Spigots
are fitted to allow for a socketed system to be used and are factory
fitted in a controlled environment. These spigot / socket assemblies
can be simply push fit or fitted with O rings to seal the connection.
Accepted for use on Railtrack

infrastructure within the scope
defined below and subject to the
discretion of Railtrack zones.
Frame
Removable
access pole
(optional)
Trough cut-out
Lid with cam-lock

UTX Chamber
Capping plate exterior

fitted (optional)
Concrete
Troughing
Optional spigots
Sockets
Oversized base plate for

anti-floatation in locations
with high water level
AquaDucts
18
Fit for Purpose
Proven Performance
To ensure the confidence of Network

Rail, its designers and specifiers
of the product performance, we
commissioned Scientifics of Derby,
to examine our product and report
their findings. They found that the
Aqua UTX units are fit for purpose for todays rail industry.
It is right and correct that the

performance of Aqua UTX units be
examined. Therefore GGP of Hull
were commissioned to produce a
mathematical model of the unit in
track condition. Several units were
examined and successfully proven.
Copies of their calculation are available on request.
A full copy of this report can be supplied on request.
2

Designed for taking cables under the track,

Aqua manufacture their UTX chambers to any
dimensions required by the client.
C 1/8 Troughing set at
G.L into chamber unit
Two piece lockable

safety Lid. Galvanised
Additional Items include:

Single piece units
Extensions to suit
Step Irons
Pulling eyes
160mm T.D.E
High impact
polythene
pipes
Dia/Depth

Pads Code Pads Code Pads Code Pads Code

900mm
1000mm
1200mm
1350mm
Up to 1.5m
057/100748
057/100772
057/100773
057/100641
Up to 2m
057/101036
057/101023
057/101026
057/100642
Up to 2.5m
057/101037
057/101024
057/101027
057/100643
Spigots
Pads Code
Anti-float base Pads Code
4 way
057/101028
800 057/101032
6 way
057/101029
1000 057/101033
9 way
057/101030
120 057/101034
12 way
057/101031
Ancillary Products:
Drawcord
Detectable Warning Tape
Sockets/Spigots
Anti-floatation bases
Sealed systems
Larger diameters available
Specialist Ducting
Larger diameter UTX units 1500 - 3000 will be locally

approved by Network Rail.
19
Chamber selection
Chambers
Product Internal External

Diameter Diameter
Generally the size of the UTX Chamber

used will be governed by the space
required to ensure easy looping of cables
can be achieved. In addition the number of
inlet/outlet sockets will additionally govern
the size of the chamber to be selected.
2
To establish the latter, calculate the surface

area of the ducts you require and divide
them into the surface area of a 1 metre
deep section of the size of UTX chamber
you prefer. If the total area of the ducts is
20% or less than that of the surface area of
the chamber, then the size is OK.
This is also important when double entry
UTX units are required.
To estimate the size of the UTX you need,
Aqua can supply a sizing matrix on request
via the website.
500 UTX
450
506-511
550 UTX
500
548-560
600 UTX
600
670-680
800 UTX
750
826-835
1000 UTX
900
993-1000
1200 UTX
1050
1161-1169
1350 UTX
1200
1308-1315
1500 UTX
1350
1501-1511
1650 UTX
1500
1658-1664
1800 UTX
1650
1805-1815
2000 UTX
1800
1970-1981
2200 UTX
2000
2175-2201
2300 UTX
2100
2310-2320
2500 UTX
2200
2435-2445
2700 UTX
2400
2659-2669
2800 UTX
2500
2759-2769
2900 UTX
2600
2859-2869
3000 UTX
2800
3059-3069
3300 UTX
3000
3283-3323
Chamber Connection and Duct Selection

Both TDE and TDK ducting can be selected based
on performance requirement (see section below)
and can achieve a waterproof connection to the
body of the UTX chamber.
duct spigot
pre assembled as illustrated in B
socket
Duct connection
For TDK duct an o-ring jointing system is
supplied. The o-ring will be fitted into a
corrugation of the TDK duct, the socket
will then be pushed onto the duct. The
socket will then be offered up to the
chamber spigot, this spigot will also have
an o-ring fitted, and the system pushed
together to form a waterproof joint.
20
duct
O rings
situate O ring in position
Installation Suggestions for Aqua UTX Chambers

Aqua UTX Chambers are supplied c/w cover and frame. Each
frame (800 and above)has 3 x lifting lugs equally spaced around
the perimeter.
Manual lifting regulations may limit single person lifts to 25 kg.
UTX Chamber weights

It is important to consider the weight of the UTX Chamber.
Refer to the chart below for weights. For diameters not on
list please contact Aqua sales desk on 01695 51933.
Lifting lugs
Weight per 500mm

depth (Kg)
Lid (Kg)
600
13
30
800
18
43
1000
24
62
1200
28
76
1350
45
92
1500
47
131
1650
70
200
1800
75
250
82
300
2000
Size of UTX
On site positioning
Tracks up to 80mph
The movement and positioning of UTX Chambers on site can

best be handled by making use of the lifting lugs with straps
fitted with D links.
The UTX Chamber must sit on a 150mm deep bed of TYPE 1

material. The same material will be used as backfill to the chamber
in 150mm deep compacted layers.
The excavated hole must be as directed by the supervisor or

person in charge of lift.
Tracks over 80mph

The UTX Chamber will be as above. The cable duct will be
surrounded by ST5 dry mix concrete.
200mm*
The cable ducts will be

surrounded in pea gravel, 145mm BS882-NR/SP/CIV/404,
with a minimum of 75mm
between ducts.
200mm*
* 100mm diameter ducts. For

150mm duct 255 centres.
21
Permanent-Way Pipe Performance (cont...)

nditions
ing (UTX) soft ground co
ck cross
Typical underground tra
see size range
All chambers
to be 50mm
above finished
ground level
xxxxxxxxxxx
Track ballast
xxxxxxxxxxx
Railtrack line
Track ballast in accordance with
NR/sP/civ/102.
standard NR/sP/civ/006 and
in 100mm layers.
existing ballast recompacted
depth to match existing.
Circular galv. M.S. lid is

secured by a simple
cam-lock method
'allen-key' operated in
o
a 90 action, see note 9
Lid locking device
Fillet weld
und conditions
gro
of
rpro
watek
) nroc
Whe
ck crossing (UTX
UTX's are needed
350 deep one pipe
500 deep two pipe
engineer
a respo
fitted
level ets
arensible
to achive sound bedrock sock
ded
to be recor
Friable material to be removed
Levelpt
er
rubb
to identify sound bedrock level.
to hacce
sides
(chartered mice/struct, eng)
both
and
trenc
points of
finish
and
start
at
er
to
s
sleep
of
joint
'O' ring
from underside
of excavation.
selected ducts
3000 Preferred
see note 3
selection of ducting available
Track ballast
Joints in accordance with

NR/sP/civ/044 section 5.4
see note 15
Railtrack line
Track ballast in accordance with
NR/sP/civ/102.
standard NR/sP/civ/006 and
in 100mm
existing ballast recompacted
ng.
layers. depth to match existi
Aqua 'Thieel' uTX
xxxxxxxxxxx
Chamber wall
Base unit
xxxxxxxx
Base unit
Bedrock level
350 deep one pipe

500 deep two pipe
see size range
Circular galv. M.S. lid is

secured by a simple
cam-lock method
'allen-key' operated in
o
a 90 action, see note 9
Isometric view of step iron
Backfill using a
suitable uniform
material compacted
in 150mm max layers
er und dependent on duct type,

Wash
surro
Pipe
see note 15,16 and 17
Chamber wall
to the approval of the

selected excavated material
d to the underside
NR engineer to be recompacte
y material to be
of existing ballast. All poor qualit
ed with MoT type2
discarded (ash, silts) and replac
400mm deep
compacted in 75 to sump option - A
granular fill. All material to be
be
x 400mm dia sump base can
. EN 1562 bolt on
100mm layersBS
allowed for sump pump
step iron galv coated
Option 2
Option 1
Chamber wall
Option 3
rectangular
Aqua UTX's are made from
n spirally welded
hollow section extrusioion
4 w section
Opt
tural hollo
p
together into a struc
NRS-S preference with sum
112mm
Top 300mm can

be made removable
350 deep one pipe

500 deep two pipe
900 to underside
of sleeper minimum
153mm
28mm
BS EN 1562 bolt on
coated step irons at
step iron galv
300
d
Anti-floatation option skirt adde
itions
to base. size to suit ground cond
and dia of uTX
300mm cRs
rectangular
lly welded
spira
n
usio
extr
on
hollow secti
w section
together into a structural hollo
Base unit
step irons at
300mm cRs
300
300
bers
step trims can fit all uTX cham
300
350 deep one pipe

500 deep two pipe
Top 300mm can

be made removable
Base unit
see chart
92mm
Washer
see chart
22
153mm
28mm
Single unit
Section a unit
400mm deep
sump option - A
112mm
be
BS EN 1562 bolt on
rectangular
ly welded
hollow section extrusion spiral
section
hollow
together into a structural
Xs
Aqua Range of Thieel UT
Washer
92mm
Typical underground tra
900 to underside
of sleeper minimum
When waterproof
UTX's are needed
sockets are fitted
to accept rubber
'O' ring joints to
selected ducts
on duct
dependant
Pipe surround When
waterproof
15, 16 and 17
tape. see note UTX'
s are needed
ts are fitted
socke
to the approval of the
selected excavated matertoialaccept rubbeunder
r
side
pacted to the
NR engineer to be recom
toial to be
ring joints
'O' qualit
y mater
of existing ballast. All poor
ducts
ed
type2
select
MoT
ed with
discarded (ash, silts) and replac
compacted in 75 to
granular fill. All material to be
.
layers
100mm
Joints in accordance with

NR/sP/civ/044 section 5.4
see note 15
Fillet weld
Backfill using a
suitable uniform
material compacted
in150mm max layers
Fillet weld
selection of ducting available
Socket detail
Aqua 'Thieel' uTX
3000 Preferred
see note 3
bers
step trims can fit all uTX cham
sump option - A 400mm deep

adde
cand be
base
n skirt
dia sump
ation
m optio
x 400m
Anti-float
nd conditions
grou
pump
sump
. size
forsuit
ed to
to base
allow
and dia of uTX
sump option - A 400mm deep

be
l and
Cross section of UTX wal
ail
det
step iron
Chamber wall
Washer
BS EN 1562 bolt on
rectangular
lly welded
hollow section extrusion spira
w section
hollo
al
ctur
stru
a
into
together
16. Pipe Backfill

sized pea gravel,
1000g/m2 two piece frame and
TDE and TDK compacted single
9. L ids, galvanized to BS 5493
sand (6.1) ratio, refer to
lly tilted to the Thieel UTX
max dia 14mm; TDT dry mix
lockable non-slip lid, mechanica
note 17.
chamber.
shall be C28/30; Slump 2;
BS 8301 and BS 1247 part1.1990
17. Concrete duct surround
10. S tep irons to comply with
sion
corro
2
ers
wash
and
Bolts
to BS 8500.
2
CEM
Galvanised to BS 5493 1000g/m
is by Aqua S&TS.
to form the slot to allow
are stainless steel. Setting out
ormally Aqua would expect
18. N
lts can be provided fitted
trough. However where
eyebo
rete
g
conc
pullin
the
of
cable
steel
lation
less
instal
11.Stain
clients requirements.
the access hole, due to site
installation takes place on site
inside the UTX chamber to meet
the ingress of
mayisbe oversized. This may allow
, lid
tions
be in accordance with NR/Circular limita
shall
M.S.
units
galv.
UTX
the
of
Aqua have produced
ber.
12. Installation
cham
in
UTX
acted
the
comp
into
rial
spoil
or le
rm mate
ballas
a tsimp
SP/CIV/044 using a suitable unifo
secured by
retro-fitted to the chamber
a capping plate which can be
ol applied
(max) 150mm layers.
od
meth
-lock
ng voids can be filled with aeros
cam
existi
Any
site.
for
on
bed
ing
rete to form levell
in area.
ated
the
oper
'
linding layer of dry-lean conc
seal
-key
to
13. B
'allen
foam
d.
state
s otherwise
o
9 on site can be difficult. Aqua can supply
chamber (150mm thick) unles
n, see
actio
a UTX
intonote
A
ccess
od a 90 19.
will
ructed using open cut meth
the body of the chamber, which
to
fitted
t
14. Undertrack crossing const
of
socke
a
level
the
to
surround and up
to allow sufficient
backfilling above the concrete
t a dismountable access pole
with
accep
dance
accor
in
t
ber.
ballas
track
ion into the cham
the formation shall consist of
purchase from a standing posit
m layers.
dures
NR/SP/CIV/006 in (max) 100m
advise all correct lifting proce
20. All lids will be marked to
deration.
dance with Health & Safety consi
15. Ducts shall be:
accor
in
red
track crossing pipe manufactu
approved lifting keys.
(1) TDE - Duct heavy duty
21. For lifting lids, use only Aqua
DIN 8074 supplied in 5m
from de-stressed H.D.P.E to
lengths smooth walled.
twin wall pipe manufactured
(11) TDK - Duct reinforced
supplied in 6m lengths c/w
from H.D.P.E to BBA 02/HO69
use with a sealed duct
coupling. Seals are available for
system.
manufactured from UPVC
(111) TDT - Duct BS 4660
1401 supplied in 6m lengths
complying with BS 4660/EN
c/w rubber seal.
2
unless otherwise stated.

ll dimensions are in millimetres
1. A
ing and agreed
t draw
layou
the
weld
on
n
Fillet
2. L ocation of UTX as show
s
cross the track at right angle
by Network Rail. The UTX shall
the layouts.
on
wise
other
ted
indica
s
unles
the running
positioned at least 3m from waterproof
3. Chambers are preferably
up ton a metre
lationWhe
instal
for
ved
appro
are
s
rail. Aqua UTX
needed
appro
areval.
Rail 's
UTX
r with Network
from the running rail and close
sockets are fitted
Nominal 1380.
black er
acceeptin rubb
to profil
factured from a box
4. Aqua Thieel UTXs are manu
and outer
inner joint
th ring
s to
ly winding a smoo
'O'
polyethylene formed by spiral
ed together. The
ent profiles weldselec
duct.E.s
tedH.D.P
pre-formed profile with adjac
using
weld
sion
extru
an
with
fitted
chamber is factory
with
h of chamber is to be agreed
welding rod to the base. Dept
Aqua S&TS prior to order.
be
ized chamber base plate shall
5. Anti-floatation ring, the overs
ing to mobilise fill material to
weld
sion
extru
with
fitted
factory
water table.
resist floatation in areas of high
ry
el UTX incorporates a facto
Thie
Aqua
the
6. Sump option using
m
with aperture to suit the 400m
base
ed
weld
fully
d
secon
fitted
are extrusion welded using
I.D. sump 400mm deep. All joints
H.D.P.E welding rod.
are to
systems, number and position
7. Duct sockets for sealed duct
y
prior to order which will be factor
be confirmed with Aqua S&TS
hot
wall using an externally applied
fitted, welded into the chamber
only
ction
s to the socket conne
air plastic fillet weld. This seal relate
.
not the UTX chamber us a whole
with
position are to be confirmed
8. Duct entries, number and
will be factory fitted in the
Aqua S&TS prior to order which
.
installation
chamber wall ensuring parallel
l External
xternal Product Interna
Product Internal E iameter Diameter Diameter
Diameter D
1805-1815
1650

500 UTX
550 UTX
600 UTX
800 UTX
1000 UTX
1200 UTX
1350 UTX
1500 UTX
1650 UTX
450
500
600
750
900
10 50
1200
1350
1500
92mm
Notes
506-511
548-560
670-680
826-835
993-1000
1161-1169
1308-1315
1501-1511
1658-1664
1800 UTX
2000 UTX
2200 UTX
2300 UTX
112mm
2500 UTX

2700 UTX
2800 UTX
2900 UTX
3000 UTX
3300 UTX
153mm
1970-1981
2175-2201
2310-2320
2435-2445
2659-2669
2759-2769
2859-2869
3059-3069
3283-3323
1800
2000
2100
2200
2400
2500
2600
2800
3000
28mm
Chamber size
ulate the
of duct ways required. To calc
is dependent on the number
duct
by
up
n
take
The Minimum size of chamber
per metre can be
20% of the UTX surface area
minimum size consider that only
ctural integrity of the chamber.
entries without effecting the stru
9 way
6 way
4 way
3 way
200
200
200
200
Double Entry
s on two faces
Intermediate chamber with duct
Single Entry
chamber
Ducts entry on one face of the
Systems Ltd
Aqua Signal & Telegraphic
Skelmersdale, Lancs WN8 9UB
Belmont House, Garnett Place,
1
T: 01695 51933 F: 01695 5189
www.aquafab.co.uk
E: sales@aquafab.co.uk W:
S
UTX ASSEMBLY & OPTION
THIEEL UTX
23
UTX Chamber Accessories

Restricted Access
In tight 6 - 0 locations or any other restricted space applications.
Aqua have developed the Restricted Access UTX unit. This
modified THIEEL UTX affords the ability to have large numbers of
ducts entering and exiting the UTX chambers, below traffic when
surface access is required. The system has been used extensively
on the East London Line tight gauges.
2
This unit can be supplied with:
Single or double duct entry

Can be fitted with antifloatation skirt
False floor for sump pump

facility can be fitted
Installation
Typical installation suggestion, extracted from our scientifics
Fit For Purpose report.
Diagram showing forces acting on undertrack crossing installed by excavation
Notes:
1000
1. Under track crossings installed by excavation should be the

following standards:
GC/RT 5171
GC/RT 5200
GS/IH 0001
and the manufacturers guidance notes.
Possible 15 ton
vehicle loading
Straight track
800
1000
900 absolute min
Pipe
18KN/m
Max possible force
TDK pipe
surround
450 min
Soil must withstand

transferred vehicle
load if required
24
Sub-grade
Passive pressure from

pipe surround and
sub-grade
Skinfriction
Skinfriction
3. Infill to excavation should be of granular material approved

by Railtrack.
350 min
Minimum force in gravel

blanketing sand infill on
concrete haunching
elope
or infill
nv
load e
Turning
chamber body
Minimum force in
granular sub-ballast
1 in 0.5
Minimum force in good

clean ballast
2. Ground investigation/ground improvement may be required

in the following circumstances:
Vehicle loading is anticipated on turning chambers
Turning chamber is to be positioned within 1.6
of running edge
Where loads in excess of 15KN/m are anticipated
at pipe level
Buried Route Chamber & Ducting

Cable theft is a major problem effecting railways
causing great expense and disruption of timetables and
delays for passengers.
2
Mini-Stirling
Clover Chamber
Mini-Stirling Clover Chamber

Pads code: - 057/103023
Network Rail Approved

The Clover Chamber is fully accepted.
Approval No PA05/02850
Fully approved for installations in

the CESS or the 6-0.Birmingham.
Clover Duct
TS
H
RIG
ED
Pads code: - 004/103119
ATHER
DF
Clover Duct
GRAN
Clover duct is an innovative method of

installing multi-ducts in formations of 4 or 6
way packs of 100mm TDK. The ducts packs
are supplied in 3 metre sections (longer on
request) for ease of handling and installation.
A PP R O V
25
Cable Ducts and Conduits
TDE Heavy Duty Track Crossing Pipe
Aqua Mean Mean BR CODE/

Code I.D. O.D.
Pads 2000 Nos
AQUA TDE is manufactured from de-stressed high density polyethylene which

gives the pipe great strength and rigidity yet remains lightweight and manoeuvrable.
4TDE
110mm
6TDE 152mm 160mm 057/100749
TDE can be used in very severe applications and will withstand great physical
abuse.
8TDE 190mm 200mm 057/100750
Can be installed in shallow position with cover just to crown.

High impact performance.
Will not fracture under crushing loads.
Will withstand dropped ballast.
104mm
9TDE 214mm 225mm 057/100997
10TDE 238mm 250mm 057/100751

12TDE 300mm 315mm 057/100752
16TDE 380mm 400mm 057/100753
TDE - manufactured from de-stressed P80

H.D.P.E. to DIN 8074 in 5 metre lengths.
Twin Wall TDK Ducting

Twin Wall Ducting is a first class alternative to
PVC Duct where extra strength is needed.
Twin wall ducting has B.B.A. 91/65 approval.
Conforms to ESI volumes 12-24 + BS EN
50086 1,2 & 4. Standard 6 metre length fitted
with coupling.
TDK - manufactured from

H.D.P.E. to BBA 02/H069 in
6 metre lengths.
Type

Nom size
Mean
Mean
mm inches I.D. O.D.
Pads 2000 Nos
100 4
100
120
004/103119
TwinWall
150
150
180
004/103122
200
200
230
004/103125
225 9
225
268
004/103127
300 12
300
355
004/103129
375
15
375
426
450
18
450
510
600
24
600
675
Rigid UPVC TPGDucting

AQUAS range of civil and electrical ductings give quick solutions to many
engineering problems. In particular our range of ductings provide ideal
sleeve or protection ducts for all manner of services.
BR CODE/
Nom size
Mean
mm inches O.D.
Mean Class
Wall
Radius
55 2
2.1 D56-0 300mm
53.9
96
3.5 96.5 3.05 D54-0 400mm
Generally manufactured to BS 3505/3506 - Class O Standards and BS

4660. BA 5750 Quality Assurance.
114 4
114.3
2.1
500mm
110 4
110.0
2.9
4660
500mm
Colours - To customer requirements.
168 6
168.3
2.7
600mm
6 metre lengths complete with socket although 2/3/4 metre lengths and
internal sockets can be provided.
160 6
160.0
4.1
4660
600mm
Full range of Fittings and Drawcord.

TD6 - manufactured in UPVCBS4660 standard.
Not preferred for UTX work as it must be
encased in concrete, for such works.
26
Bend
Split Duct
Split Ductings
TDK Heavy Duty Split Ducting
In certain installations power cables and

signalling cables are already installed and
cannot readily be moved.
4 - 100mm I.Dia
6 - 150mm I.Dia
3 & 6m lengths
In such instances we can offer a range of

split ductings which can be readily slipped
over existing cables thereby giving them
the protection they require.
uPVC Split Ducting

Aqua TDS duct is a plastic moulded
system of split ducting. Unlike other types
of split ducting TDS is a designed system.
With its tongue and grooved design that
clips together and is then locked in place
using approved cable straps.
TDS Duct
uPVC Aqua TDS Duct General Information

Design Type
TDS Split Ducting
Nominal Diameter
TDS 3A 96.5mm / TDS 4A 110mm
TDS Coupler
Colour Grey or Black

Print N/A
Duct 54 & 57 Spec Compliant
Length 3m
Aqua TDS is supplied in two sizes TDS 3A (96.5mm

Duct 54) & TDS 4A (110mm Duct 57) both come in
3 metre lengths.
27
Station and Car Park Lighting Schemes
Scheme advantages
Multiple duct entry to allow lighting, CCTV and electronic

signalling cables.
Improved access for maintenance and system improvement

or extension.
2
Rapid installation times.

One off cost - no need to re-excavate for system extension
or improvement.
Recessed lids to suit block paving slabs.
Typical Railway Product Installation

Medium or light duty lids and also recessed lids for high quality
paved areas.
Standard 600 deep Lyan unit with inlet/ outlet holes for 4 Aqua
duct and fitted 80mm diameter flexi duct fixed to chamber for
sleeving cables to lighting column sleeve.
Lighting column sleeve 300 diameter x 800 deep allowing installation
of system prior to availability of lighting columns.
Typical lighting column foundation for
3m, 8m and 10m columns
Free Standing Structure in High Impact HDPE
Tough moulded plastic body resistant to impact and
guaranteed not to crack at temperatures as low as -30c.
Interlocking device which gives extra depth with no loss in

strength and also protection against vandals.
Chamber and extensions can be riveted together to form a

single unit.
Lightweight and able to withstand extreme manhandling.

Applications
Note 3:
r 3m, 5m
3 O.D. fo
= 168.
S
RL
8m
d
an
r 8m, and
1 O.D. fo
= 219.
H
10m RL
Note 2:
g Depth
1862 &
ax. Plantin
11 / RLS
P.D. = M
Note 1:
ound
m for M05
gr
0m
80
om
fr
=
P.D.
e.
Distance
lin
Z
/
re
Note 4:
Z&
e supplied
RLH
nge cent
1 / RLS /
ambers ar
M0511 /
level to hi
ts.
2m
m for M08
AQUA ch
n RLS 29
= 1200m
lets / outle
P
in
um
D
ol
-in
P.
C
ilt
5m
2m
quest.
with bu
/Z
Z
n RLH 29
lets on re
7 / RLN /
086 / RLH
in
M
10
al
M
on
r
5m Colum
e.
iti
fo
2m
Add
an abov
00mm
n RLS 29
P.D. = 15
mm less th
8m Colum
3m
. MIN is 50
n RLH 74
N.B. - P.D
8m Colum RLH 743m
n
10m Colum
28
Street Lighting Schemes.

TV Cable & CCTV Security Systems.
Car Park, Station & Subway Lighting Schemes.
Motorway Lighting and Bridge Projects.
Petrol Station Forecourt Power & Signalling Cable
Distribution Systems.
HDPE is a cost effective alternative to concrete or brick chambers,

being lightweight and in a finished condition it can be installed
by unskilled labour in any weather with no need for mechanical
assistance.
GRP and Concrete Troughings

Aqua Troughing Systems
To compliment their range of Signal and Telegraphic systems, Aqua
have introduced an extensive range of GRP troughings to be used
alongside their existing concrete range.
2
Aqua are now able to offer the engineer a complete range of

options in his quest to find solutions to various engineering
problems. He now has at his disposal complete solutions to both
everyday projects and also to major engineering schemes.
Link-up certificate
Possess B.R. purchasing codes
B.R. qualified vendor certificate (now superseded by Link-up)
Aqua Trough and Lid Units, used extensively throughout the UK
and Overseas, provide the most economical form of cable and
pipeline protection. A wide range of troughs to satisfy all forms of
application and installation. With a national distribution network
available and guaranteed quality, Aqua have become the natural
choice for the contractor.
For details of Aqua troughing accessories, i.e. ballast boards, tee
pieces, bends, mitres, transitions, apparatus case bases, please
contact our sales office.
Dimensions
BR CODE/ Pads 2000
Trough
B C
Lid
C/1/6 1000 100 90 4/105351 004/105282

C/1/7 1000 130 130 4/105353 004/105285
C/1/8 1000 150 200 4/105355 004/105288
C/1/9 1000 190 130 4/105357 004/105291
C/1/10 1000 250 130 4/105359 004/105294
C/1/29 1000 350 130 4/105361 004/105297
C/1/43 1000 350 300 4/105363 004/105297
Reinforced lids to suit.
29
Signalling and Lighting Installations
30
Aqua Products
GRP Products and bespoke items

GRP products
GRP is a strong and versatile product enabling the production of a
variety of goods in a material of no intrinsic value.
The materials used are lightweight but as strong as steel or concrete
and prove to be ideal replacements for traditional products.
Handrails and Stairs

We can alter any assembly either in GRP or metal. Already we have
supplied several solutions to railway based projects,
3
GRP Products and Bespoke Items
Loading and Access Platforms

The Health and Safety considerations of personnel involved with
the handling of heavy construction materials prompted Aqua to
introduce a range of lightweight loading and access platforms
that can easily be manhandled into position and provide a safe
environment for your work force.
Grating and Walkways

To any application for such items Aqua can give you a range of
options, contact us direct with your requirements on 01695 51933.
31
Special Projects
Blackfriars Station
As part of the Thameslink Programme, Blackfrairs Station was given
a facelift with the installation of the new platforms. The new design
called for the installation of trash screens within the castillations
of the stations platform walls. Aqua suggested the installation of a
bespoke GRP grating system, with each grating shaped to suit each
individual castellations.
The result led to Aqua supplying 6777 trapezoidal and 300 square
GRP gratings, which proved to be a great success.
3
Project management
Tinsley Yard - Sheffield
This was a new drainage scheme and to assist in speeding up
installation, Aqua was supplied with all site drawings and put
together a manufacturing programme where all catch-pits, where
numbered in order, with full descriptions of inlet and outlet.
This programme speeded up installation and enabled the project
to be completed on schedule.
Other project managed schemes
Airdrie to Bathgate
Northfleet
Felixstowe Port
Acton Diveunder
32
Paisley Corridor
Project Evergreen
Rugby Realignment
Sewage and Foul Water Disposal

Chambers
These can be produced to any desired specification fully
benched to facilitate quick disposal of waste materials.
General water handling or attenuation chambers can

be supplied.
Ventilation systems to Water Treatment plants
Aqua has the manufacturing facilities to suit any requirement
TFI/London Underground and Turbines - a large

attenuation chamber fitted with access facilities.
3
Example of large diameter brown water benched

chamber - Aquas heavy duty plastics allowed a large
chamber with multiple entry and exits to be made in a tough
yet light weight product rather than the traditional heavy and
time consuming concrete.
Project Engineering - Aqua can help manage your projects
by producing your drainage scheme from design drawings, ask
the office 01695 51933 for details.
33
Bespoke Chambers
Aquas fabrication facility can also manufacture

chambers for other civil engineering applications.
Water treatment
Sewage disposal
Foul water removal
Housing
Water attenuation
Pumping stations
Specialist fabrications
East London Line - a large diameter chamber to be

installed in a care depot on a backwash scheme.
3
Cambridge Station - multi-cable chamber for installation in

the station lighting system.
East London Line - example of a foul water

channelling manhole.
34
Bespoke and Special Installations
3
35
Aqua Geocomposites
Geotextiles and Geocomposites

Standard solutions No2: 4 options available
Enhancement of Existing Blanket with Geotextile Separator
Criteria
Satisfactory drainage (for poor drainage, see note b)

Adequate depth of trackbed layers (see notes)
No ballast contamination by cohesive materials
Functioning blanket, may be less than 100mm thick in places
Network Rail
Product Accepted
700mm (min)
700mm (min)
Clean ballast to aid

good drainage
Existing
p-way
formation
with drain
Min 1:30
Separating Geotextile - this should extend for

700mm beyond sleeper end or as far as possible
with excess Geotextiles run up sides of excavations
Existing formation
Notes
a) Where blanket is formed of sand and small percentage of coarse
particles > 14mm and low abrasion risk - Terratex 70. If there is a
significant amount of coarse particles and a risk of high abrasion Terratex 4050.
4
b) If drainage is unsatisfactory or an existing high water table use - TED2.

c) If trackbed layers are insufficiently deep to achieve desired dynamic
sleeper support stiffness but achieves absolute minimum value lay a 3
metre wide Geogrid before placing ballast.
These rules are essential when making your

selection for the facing page.
36
Separating Geotextile to run

down into p-way formations
Product selections - Standard solutions 2a to 2d

Solution 2a: Terratex 70
Low-Medium Abrasion Risk
Description
Needle punched, non woven, continuous long

fibre Geotextile
Size range 4m x 50m rolls although other widths

available on request
Terratex 70
Padsnet Cat No: 057/100821
Medium abrasion resistance

Very high elongation
Solution 2b: Terratex 4050

High Abrasion Risk
Description
Needle punched, non woven, staple fibre

Geotextile
Size range 4m x 50m but other widths available

on request
Highest abrasion resistance

Available in 2 metre width as Terratex
Terratex 2050
2050
Terratex 4050
Solution 2c: TED 2

High Water Table/Poor Drainage
Description
Drainage composite/separator or an extended

PE mesh encapsulated in Terratex
Size range 3.9m x 25m but other widths

Robust separator
High lateral drainage performance
TED 2
4
Solution 2d: TED 4

Poor Track Stiffness
Description
Geogrid 65mm aperture, fixed onto a Terratex

Geotextile
Size range 3.9m x 25m but other widths

High puncture and abrasion resistant

High ballast interlock
TED 4
37

Enhancement of Existing Formation prone to Pumping using a Geocomposite
Criteria
Well established subgrade erosion problem

700mm (min)
700mm (min)
Existing
p-way
formation
with drain
Min 1:30
Geocomposite, this should extend 700mm beyond

sleeper end or as far as possible with excess
Geocomposite to run up sides of excavations
Existing Pumping
formation
See opposite
page
Notes
a) If the total depth of tracked layers is not sufficient to
give the desired dynamic sleeper support stiffness, but
provides the absolute minimum value, a Geogrid may be
placed on the Geocomposite before ballast is installed.
These rules are essential when making your
selection for the facing page.
4
38
Geocomposite turned down

into p-way formation
Product selections - Standard solutions 3a and 3b

Solution 3a: Geofloe MicroSand
Formation Pumping
Network Rail Specified
Extensively used in WCML
Clean water passing into
ballast and into p-way drain
Clear water flowing

into the ballast
Geofloe in action
Description
Geofloe 6mm permeable double

cuspated core sandwiched between
two needle punched, non-woven
Geotextiles laid on a 50mm bed of
sand. The Geofloe forms a highly
permeable protective layer that
protects the sand beneath, permitting
a thin sand layer to be installed.
Size range 5.0m x 25m but other
Geofloe
50mm Sand
Formation
Ballast
widths available on request
Very high transmissivity

Very cost effective system
Balllast
Geotextile
Contaminated water/slurry forced

up into sand layer above
Clay particles held by

the sand layer
Ballast
Sand
Tracktex
Formation
Formation
Solution 3b: Tracktex

Formation Pumping
Ballast
Tracktex
Ballast
Geotextile
Sand
Tracktex
Formation
Formation
Water passing through

under pressure
Tracktex in action
Micro-porous (<5 micron)
4
Description
Force from
passing train
water
movement
breathable fitter sandwiched

between two needle punched,
non-woven Geotextiles
Size range 3.9m x 25m but other
Balllast
widths available on request
Tracktex
Tracktex conforms to any surface

depressions in the formation
preventing the creation of localised
voids which can create slurry pockets.
Formation
Section through track
Slurry particles prevented

from ingress through the
micro porous filter
39
Solutions for specialist applications: 2 options available

Solution No4:
High Water Environment (Hydrology)
Criteria
Deep cutting with steep gradient

Localised high water discharge areas
Outflow from tunnels
School
Supermarkets
Downpour
Run-off from car

park or roads
Precipitation directed
into p-way drains
Drainage in Cess
or single large dia
drain in 6 foot
Impermeable high draining barrier directing

supercharge of water away to discharge point
Solution No4:
Formation Polluted
Impermeable
Geomembrane to
extend at least 0.7m
beyond sleeper ends,
or as far as possible,
with excess material
run up side of
excavation
Criteria
Blanket formation heavily contaminated with oils, chemicals

and noxious materials
700mm (min)
700mm (min)
Geomembrane
turned down over
trench liner
Precipitation
prevented from
mixing with the
contaminated
formation
Impermeable membrane seals in contaminated formation
40
Existing p-way drain in Cess
Product selections - Specialist solutions

Solution: Reforme
Hydrology problems
Description
Impermeable double cuspated HDPE core

wrapped in needle punched Geotextiles
Sizes up to 5m wide x 25m long

High impact resistance
Very high in-plane flow 1.4 I/S/M
Positive Barrier between water and formation
Ground waters
into p-way drain
Ballast (dry)
1 in 40 fall
Reforme
Ground waters drain away

from below subgrade via
Geoblanket
Subgrade (dry)
Solution: Reforme
Water contamination
Details as above
Right angle flow
100.6 l/m2/s
Profiles membrane
Permeable - Reforme
Ballast
4
6.75mm
Water run-off is clear

of pollutants so can be
freely discharged into
nearby water course. In
plane flow 1.440 l/s/m
Formation
Needle punched
Geotextile
Right angle flow

100.6 l/m2/s
41

Ballast Reinforcement
Criteria
T he total depth of tracked layers is not sufficient to give absolute minimum value of stiffness
Product selections - Specialist solutions
Solution: Railgrid
Description
Extruded biaxial polypropylene geogrid,

65mm aperture, tensile strength 30N/mm2
Advantages
Improved track geometry

Large aperture grid promotes optimum
Railgrid
Pad No: 057/100852
ballast interlock
Can also be used at mid layer to improve
stiffness particularly where ballast

depths exceed 300mm e.g. on adverse
cant curves
Formation
Solution: Geoweb
Description
Polythene Honey-comb, structural cellular
confinement panels. 100, 150 and 200mm

deep cells, 2.5 metres wide and from 3.5 to
8 metres long
4
Advantages
Greatly improved sub-ballast stiffening of
ATHER
DF
GRAN
formation over soft or cohesive soils
Use with additional geotextile/Geocomposite

Filled with sand or pea gravel
T
IGH
ED
RAPPR OV
42

Geoweb
Pad No: 057/100722
057/100723
Specialist geotextiles - drain enhancement

Criteria
Network Rail require all Cess and 6 foot trenches to be lined with a geotextile
Product selections
Solution: Aquatex Trench Liner
Description
Product range
ED
Aquatex
Trench-Liner
Pads Codes Size
Trenchliner
057/101020
4.4 x 150m
Trenchliner
057/101021
3.8 x 150m
Trenchliner
057/100998
2.2 x 150m
Trenchliner
057/101022
1.9 x 150m
T
IGH
RAPPR OV
2.2 metre wide by 150 metre long rolls
Product
ATHER
DF
from 100% UV stabilised polypropylene.

Characterised by a high resistance to
installed damage, high water permeability and
increased UV resistance
GRAN
Needle punched non-woven geotextile, made
Trench-liner min 500mm overlap with

formation geotextile
Trench-liner fixed in place
by spikes at 2m spaces
ss fall
1:40 cro
Prepared surface
of subgrade
Geotextile
Various sizes available
Drainage Trench
Geotextile trench-liner
Criteria
Increasing the effective drainage of p-way drains

Product selections
Solution: Aqua-Soks
Description
Needle punched, non

woven geotextile
4 Perforated pipe
without sock
(1% perforated area)
Heat bonded
geotextile sock
Ideally required
water table not
achieved
Effective drainage area calculations

U = p Re = p . 14 = .44 (3.5in2/foot)
4 Perforated pipe
with sock
U = p . R = p . 2 = 6.3 (75.6in2/Foot)
4 Perforated pipe
without sock
U = p Re = p . 14 = .44 (3.5in2/foot)
4 Perforated pipe
with sock
With Aqua-Sok
Ideally required
water table achieved
43
Specialist geotextiles
Criteria
Mechanical installation of a geotextile during re-ballasting operations

Product selection
Solution: Mobci Roll
Application
Installing geotextiles during ballast cleaning operations using

medium or high output ballast cleaning units
Mobci geotextiles (Terratex) and geocomposite (TED 2)

mini-rolls

Mobci (Terratex)
New ballast
Old ballast removed
4
Formation
Terratex geotextile
Pad No: 057/100846
MOBCI rolls - Terratex geotextile

supplied in 3.0 or 3.2 metre wide rolls
carrying 20 to 21 metres of geotextile
per roll and cable tied ready for
immediate use.
MOBCI roll
Product
Installation
Mobci (Terratex) Rolls
The MOBCI roll is trailed between cutter bar and new

ballast bar and discharges geotextile under the new ballast as
operations proceed. Use on West Coast Main Line has achieved
installation rates of 100 yards/hour with roll change over time
of 1.5 minutes. Only Aquas products are tough enough for this
type of installation.
Installing geotextiles during ballast cleaning operations
Belmont House, Garnett Place,

Skelmersdale, Lancashire,
WN8 9UB
S & TS Ltd
Geocomposites Ltd
Telephone: 01695 51933

Email: sales@aquafab.co.uk
Fax:
01695 51891
Web:
www.aquafab.co.uk
using medium (high output ballast cleaning units)
Mobci (TED2) Rolls
Product is as above, but due to the robustness of
TED 2 only 12 - 13 metres long rolls are possible
Permanent-way Drainage, Signalling,

Power and GRP & Bespoke Products
Geotextiles, Geocomposite and
Geomembranes
Product
Acceptance
Trademark
0338
All information contained herein is given in good faith without any guarantees or responsibility
on the part of Aqua Geocomposits Ltd. Final Determination of the suitability of any information
or material for the use contemplated, of its manner of use, and whether the suggested use
infringes any patents, is the sole responsibility of the user.
All rights reserved. No parts of the document may be reproduced in any form or by any
means without permission in writing from Aqua Geocomposites Ltd.
Designed by www.ashcroftcreative.com

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Integrated Railway Design Solutions

Permanent-Way Drainage Systems 1

GRP Products and Bespoke Items 3

Signalling and Power Installation Systems 2

Geotextiles and Geocomposites 4

Innovation, safety and support right down the line

Working with the Railways

Product tested and approved in Europes

Signalling and Power

GRP Products and

To assist in the design of railways, Aqua have

Permanent-Way Drainage Systems

TDX Extreme Duty Large Bore Pipe

TDK Reinforced Wall Pipe

This is the workhorse for permanent-way drainage. It can be installed in

TDE Heavy Duty Pipe

This is selected where a more robust product is preferred, where pipes

TDS Helical Wound Steel Pipe

Min 0.85m top of

Trench to be back filled with

Typical Cross Section

CESS Drainage Applications

Trench to be back filled with

Aqua-Tex trench liner

Typical Cross Section

6-0 Drainage Applications

Note: Suggested details of CESS installations are available in

AQUA TDK is a corrugated outside wall with a reinforced smooth

In 6 metre length or less to suit

TDK Reinforced-Wall x 6 Mtr

Permanent-Way Drainage Systems

TDK Reinforced-Wall Pipe

BR/Pads 2000 Code

Larger sizes available on request.

High Stress Performance

Installation suggestions, porosity details and hydraulic

Network Rail approval for use

TDK pipe is environmentally friendly,

TDE Heavy Duty Track Crossing Pipe

Dia I/D O/D

BR/Pads 2000 Code

AQUA TDE is manufactured from de-stressed high density

High impact performance

High Stress Performance

Technical and performance histories confirm the ability of TDE to

High Impact Performance

TDE can be used in very severe applications and

Network Rail approval for use

TDE pipe is environmentally friendly,

Specialist Drainage Pipes (plain and perforated)

TDS Helical Wound Steel Pipe

AQUA TDS helical zinc-coated steel pipes have spiral corrugations

N.B. TDS can be supplied without holes.

TDX Extreme Duty Large Bore Pipe

In 6 metre length or less to suit

TDX Large Bore Extreme Duty x 6 Mtr

4TDKC 100mm 004/130306

Network Rail Product

Working with railway engineers Aqua has developed a

Derby GRP Catch-pit rings

Catch-pit application suggestions

Derby GRP rings

6-0 drain incorporating an SE60 circular catch-pit

CESS drain showing an S80 Stafford circular base

High impact performance

Derby GRP Catch-pit rings

3 x stronger than concrete

Interchange with concrete rings

Standard depth 2 metre but can be manufactured to any depth.

Fixed 225 sump.

Diameter I/D can be - 400mm, 500mm, 600mm, 750mm,

Can be supplied in sections for breakdown during ballast cleaning.

Sockets can be fitted if required.

Guaranteed to 30C, will not crack

Will not float during or after

E52/600 SUMP and

Resistant to impact damage

Needs no special installation