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Case Study

Corroded 100mm LPHW Pipework Replacement at Southall Police Station

Site

Southall Police Station – London

Job Type

Reactive Mechanical Pipework Repairs

System

Low Pressure Hot Water (LPHW) Heating System

Works Completed

100mm Steel Pipework Replacement & Plant Room Floor Grating Fabrication

BACKGROUND

The Challenge

Aquaflow Services were called to attend a busy operational site at Southall Police Station following concerns surrounding heavily corroded 100mm LPHW steel pipework within the basement boiler plant room.

The affected pipework was located within a floor trench void beneath access grating, with visible corrosion presenting an increasing risk of system failure, water leaks and disruption to the building’s heating infrastructure. Due to the critical nature of the site, all works needed to be completed safely, efficiently and with minimal operational disruption.

Following initial inspection, our engineers identified significant deterioration to sections of the steel pipework and fittings serving the LPHW circuit. Immediate remedial works were recommended to restore system integrity and prevent further asset degradation.

Immediate remedial works were recommended to restore system integrity and prevent further asset degradation. For commercial buildings experiencing similar issues, our specialist me reactive maintenance services  and mechanical engineering teams can help minimise downtime and protect critical building infrastructure.

OUR APPROACH

How We Fixed It

Step 01
Safe Isolation & System Drain Down
Our engineers attended site, obtained access to the basement boiler plant room and safely isolated the affected LPHW circuit. The system was then drained down to allow repair works to proceed safely. Existing floor grating was removed to expose the trench void and provide safe access to the corroded pipework sections.
Step 02
Removal of Corroded Pipework
Working under hot works permit conditions, the damaged 100mm steel pipework and fittings were carefully cut out and removed from the floor void. The surrounding pipework was prepared for welding and fabrication works, ensuring alignment and continuity with the existing system configuration.” Our team regularly carry out commercial pipework repairs and welded steel pipework replacements for plant rooms, heating systems and critical mechanical infrastructure across London and the South East.
Step 03
Fabrication & Coded Welding Works
Replacement steel pipe sections, bends and spool pieces were fabricated on site to suit the existing installation. Our specialist mechanical engineers completed coded welding works to install the new pipework sections, along with new supports and brackets where required. All welded joints were completed in accordance with industry standards and allowed to cool prior to inspection. All welded joints were completed in accordance with industry standards and allowed to cool prior to inspection. You can learn more about commercial heating system pipework standards via the Chartered Institution of Building Services Engineers (CIBSE).
Step 04
Pressure Testing & Recommissioning
Once installation works were completed, the repaired section was pressure tested and visually inspected to verify weld integrity and confirm there were no leaks or defects. The LPHW system was then gradually refilled, vented and returned to normal operating pressure and temperature conditions while engineers monitored system performance.
Step 05
Floor Grating Fabrication & Final Reinstatement
To complete the works, new galvanised floor grating sections were fabricated and installed over the trench void to replace the corroded access covers removed during the repair process. These types of below-ground and trench access works are often completed alongside our specialist excavation services for commercial infrastructure projects. All grating sections were securely fitted, levelled and left suitable for ongoing plant room access and future maintenance activities. Waste materials and redundant pipework were removed from site, with the plant room left clean, safe and fully operational upon completion.
pipework replacement - London (7)
pipework replacement - London (3)
pipework replacement - London - fixed

RESULTS

Outcomes at a Glance

⏱

Response

Reactive attendance and repair works completed efficiently to minimise disruption

🛡

Specialist Works

Hot works permits and coded welding completed safely and compliantly

✓

Pipework

Corroded 100mm LPHW steel pipework fully replaced

📈

Testing

Pressure testing and leak inspections completed successfully

🔌

Safety

System isolated, drained and recommissioned under controlled conditions

👍

Reinstatement

New galvanised floor grating fabricated and installed

✔

LPHW heating system restored to full operation with integrity confirmed under live conditions

The project was completed efficiently under reactive maintenance conditions, helping the client avoid further disruption and maintain safe operation of the site’s heating infrastructure. Aquaflow Services support commercial clients with rapid-response reactive maintenance services across London and the South East.

Contact Aquaflow for a fast response

WHY COMMERCIAL SITES CHOOSE AQUAFLOW SERVICES

Specialist Mechanical & Water System Engineers

Aquaflow Services deliver specialist mechanical services reactive pipework repairs and plant room maintenance for commercial and industrial buildings across London and the South East.

From corroded LPHW pipework and booster set failures to pressurisation units, pumps and critical water infrastructure, our engineers provide safe, compliant and reliable solutions designed to minimise downtime and maintain operational continuity.

We understand the pressures faced by facilities managers, estates teams and commercial property operators when essential systems fail. That’s why we focus on rapid response, clear communication and high-quality workmanship from first attendance through to final commissioning.

All works were completed safely under controlled hot works procedures in line with the current HSE guidance and industry best practice.

Need Specialist Commercial Pipework Repairs?

If you’re experiencing leaks, corrosion or heating system issues within your commercial plant room, Aquaflow Services can help.

Our experienced engineers provide reactive repairs, planned maintenance and specialist mechanical services for commercial buildings across London and the South East.

Get in touch today to discuss your requirements.

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