Polypipe Civils

Merritts were engaged by Polypipe Civils (leading manufacturer of plastic piping systems) to decommission and relocate 4 Engel injection moulding machines from their plant in Dubai, UAE, to their production facility in Horncastle, UK, and recommission.

MACHINERY & EQUIPMENT

– 2 Engel Duo 1000’s (57 Te per machine).

– 2 Engel Duo 350’s (37 Te per machine) + Viper Robots and peripheral equipment.

PROJECT VALUE

– £420,000

DURATION

Dubai – 3 weeks to decommission, strip, fully export pack and load out

UK- 3 weeks to collect from port, deliver, offload, unpack, position, assemble and recommission.

PERSONNEL REQUIRED

Dubai

  • 1 Engel Engineer
  • 4 Mechanical Engineers
  • 2 Electrician Engineer
  • 2 Lead Riggers

UK

  • 4 HGV Drivers
  • 1 Engel Engineer
  • 4 Mechanical Engineers
  • 2 Electrician Engineer
  • 2 Lead Riggers

LIFTING EQUIPMENT

Dubai

  • 200Te mobile crane
  • 10Te FLT
  • 7Te FLT
  • MEWP
  • Exported Merritts own rigging and lifting equipment

UK

  • SL 125 Super-Lift Gantry
  • Versa-Lift 60/80
  • 2 x 7Te FLT’s
  • MEWP
  • 2 x Tackle Vans

PROJECT DETAILS

Planning Phase:

  • Merritts project managers carried out a site visit in Jebel Ali, Dubai, to fully understand the requirements involved and to create a detailed scope of works for the project.
  • When the scope of works were finalised; method statements, risk assessments and lifting diagrams were issued to the customer for approval.
  • Once the RAMS and lifting methods had been approved, Merritts arranged for their mechanical, electrical and rigging personnel to fly out to Dubai.
  • UAE temporary permits to work were obtained for all members of staff involved in the project.

On Site, Dubai:

  • Merritts ensured machinery was disconnected from mains services and oils were drained.
  • Moving parts on the machinery were locked off with OEM transit brackets.
  • Merritts used the facility’s overhead crane to lift the Viper robots from the machinery and place onto bearers within pre-manufactured timber cases. This process was also used for the machinery’s tie bar pullers.
  • Merritts mechanical and electrical engineers then separated the clamp and injection units on each machine.
  • The clamp and injection units were then skated to an outside position and craned from a specially designed level steel platform and lowered onto pre manufactured steel and timber packing bases.

Engel Injection Moulding Machinery

Export Packing Services:

  • The items were fully vacuum packed in foil bags and cases formed around them.
  • Cases were loaded to flat racks and lashing inspection certificates received.
  • The cargo was shipped ex Jebel Ali, Dubai, to Felixstowe, UK.

Machinery Export Packing Services

Reinstallation at Polypipe, Horncastle:

  • Merritts arranged customs clearance of goods and collected all OOG cases from Felixstowe and delivered to Horncastle (all standard shipping containers delivered by the shipping line).
  • Merritts erected the Enerpac Superlift gantry on site to offload all OOG machinery.
  • All items were offloaded and unpacked to allow positioning, as instructed by the client.
  • Machinery was skated into position with assistance from the Versa-Lift.
  • Merritts mechanical and electrical engineers reassembled and reconnected the machinery.
  • Peripheral equipment, including the Viper robots was positioned using the on site overhead crane.
  • When all machinery had been rebuilt and reconnected, the Engel engineer recommissioned the machinery.

Relocation of Injection moulding machinery

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