Pre-Insulated Pipe Systems
A UK-produced range of high-performance
pre-insulated pipe systems and services that are helping meet the challenge of heat decarbonisation
The result of many decades of research and development, CPV’s Hiline range of bonded pre-insulated pipe systems offers a safe, secure and efficient means of transporting hot and chilled liquids – whatever the application.
Proven at countless sites throughout the world, each system has been carefully designed and manufactured to deliver outstanding performance and exceptional levels of reliability.
Security, performance and reliability ...
We have spent more than forty years developing our current range of pipe systems and solutions for heat networks. Security, performance and reliability are at the heart of all Hiline systems.
Efficient Insulation
- High-efficiency CFC-free, rigid polyurethane foam insulation
- Different thicknesses available (Series 1, 2 and 3)
- Available with optional trace or maintained heating cables
- Mineral wool insulation layer (Hiline Steam system only)
Tough Outer Casings
- High Density Polyethylene (HDPE) casing on standard systems
- Medium Density Polyethylene (MDPE) casing on flexible systems
- Barrier-pipe casing available for use in contaminated ground
- UV-stable, above-ground casing options available
Strong & Secure Fittings
- Range of secure joints and fittings available
- HDPE electro-fusion, mechanical and heat-shrinkable case jointing options
Surveillance Systems
CPV Hiline systems are compatible with a range of surveillance systems for use with steel or copper service pipes. There's a choice of the Nordic pulse, Brandes resistance or HDW systems which must be specified at the time of enquiry.
The Hiline Range
The table below summarises the range of service pipe options within Hiline. We are also able to create bespoke pre-insulated pipe systems that can satisfy applications way beyond heating and cooling networks - such as those for industrial processes and critical infrastructure. Please contact our sales team should you wish to discuss bespoke requirements.
Off-site fabrication and insulation service
We are able to offer a comprehensive, off-site pre-fabrication service for special pre-insulated pipe sections for heating and cooling networks.
Complementing the Hiline range of pre-insulated pipe systems, we offer what is effectively an ‘emergency service’ for on-site installers of heat networks.
Installers have the option for us to fully pre-fabricate pre-insulated spool pieces in our Hampshire production facility, or for them to fabricate the service pipe themselves on site and send it to us to insulate with bonded polyurethane foam, tough HDPE/LDPE casings and, where required, alarm wires.
This service is proving to be very popular with our clients – particularly when they encounter hidden obstructions underground, such as utilities. Rather than wait for an overseas manufacturer to produce and ship a pre-fabricated spool piece to them – with all the delays that can entail – our clients enjoy access our fast-turnaround service and get their project back on track within a few days. Which when a trench is open and potentially involving a road closure, every hour counts.
This is available for all systems in the Hiline range, covering all choices of service pipe, whether that be steels, copper, polymers or composites.
Please contact us to find out more ...
The true cost of insulation ...
The effects of using a more efficient insulation don’t appear to be much at face value, but factor in a minimum 30-year life-cycle cost of operating the system and the savings – both financial and environmental – mount up significantly.
The Hiline range of pre-insulated pipe systems are available with increased levels of insulation thickness – which for a relatively small additional investment at the time of installation – will yield significant savings during the lifetime of the system.
(*)BASIS OF CALCULATIONS USED FOR EXAMPLE COSTS:
- Gas supply tariff 3p/ kWh
- Gas costs increase by 2.5% per annum for the 30-year calculation
- Gas boiler efficiency 80%
- Carbon factor for natural gas = 0.1836 kgCO2/kWh (source: Ofgem)
To illustrate this point, take an example scenario in which a 5,000-metre long network (flow and return) consisting of DN150mm steel pre-insulated pipes circulating hot water at a flow temperature of 100°C. If fuelled by a natural-gas-fired boiler, constantly operating all-year-round, the system with standard insulation – over its nominal 30-year life – will lose heat to the equivalent of around £3.65 million’s-worth of gas(*) and emit 15,250 tonnes of CO2.
By making a small additional investment – equivalent to around 10 percent of the material cost at the time of installation – in order to upgrade the Hiline pipe system’s insulation thickness to Series Two, the cost of the heat lost would be reduced by some £1.2million – also saving 5,091 tonnes of CO2 from being emitted. The graph shown demonstrate the effects that this can have.
By making a small additional investment – equivalent to around 10 percent of the material cost at the time of installation – in order to upgrade the Hiline pipe system’s insulation thickness to Series Two, the cost of the heat lost would be reduced by some £1.2million – also saving 5,091 tonnes of CO2 from being emitted. The graph shown demonstrate the effects that this can have.
Quality Assured
Hiline systems are manufactured in modern, EN ISO 9001-approved production facilities, using quality-assured materials that comply with all relevant industry standards for district heating and cooling – including EN 253, as well as customers’ bespoke specifications.
Sustainability and the Environment
CPV is working to the requirements of the ISO 14001 Environmental Management System and is currently in the process of certification. The company has also introduced its own renewable energy system with a large-scale solar PV array that will ensure its production process is sustainable as possible.
Sustainability and the Environment
CPV is working to the requirements of the ISO 14001 Environmental Management System and is currently in the process of certification. The company has also introduced its own renewable energy system with a large-scale solar PV array that will ensure its production process is sustainable as possible.
-
Training and Support
As manufacturer, it’s important to us to ensure that our systems deliver exceptional performance throughout their working life. Therefore, we have established an array of world-class support services that help our clients every step of the way. -
CPD Programme
CPV Ltd is CIBSE-accredited provider of CPD courses for Pre-insulated Heat Network Design and Specification -
Electronic Surveillance Systems
We offer full a range of systems and supporting services for the main types of surveillance technologies, including the Nordic, Brandes and HDW systems. -
CarboSeal Relining System
We are the UK representatives of the innovative CarboSeal relining system for buried heat networks. This enables failing networks to be repaired without the need to excavate the entire sections of pipe.
Downloads
Product Catalogues
Paper Manufacture and Conversion
Specialist Polymer Pipe & Tube Extrusion
Alongside our standard range of products, we have developed an enviable reputation for producing custom extrusions - taking advantage of our responsive and flexible production plant based in Hampshire.
Highly-accurate large diameter specialist extrusions
Founded in 1948, CPV was one of the pioneers in the development of thermoplastic pipe systems and, to this day, we remain committed to driving forward innovation in products, services and manufacturing techniques. Alongside our standard range of products, we have developed an enviable reputation for producing custom extrusions to exacting dimensional tolerances - taking advantage of our responsive and flexible production plant based in Hampshire.
A mother reel core specifically designed for paper and tissue manufacturing
Now in its eighth decade at the forefront of technical polymer and composite-based innovation for industry, CPV is supporting the paper and tissue manufacturing industries’ drive to ensure their products are produced in the most sustainable and cost-effective way.
Being incredibly robust, CPV’s UltraCORE offers a significantly extended service life compared to fiber cores. Manufacturers enjoy substantial reductions in operating costs, whilst ensuring greater sustainability and environmental benefits for their business.
Applications
-
Packaging Items
Core Tubes
Available in a variety of materials, including PP, HDPE and ABS, our core tubes are the perfect and long-lasting alternative to the traditional cardboard/paper type. They provide good strength and durability for a multitude of uses, including winding of yarn, thread, plastics, adhesive and insulation tapes, paper, boards, food grade films, fabrics and carpets.
We can manufacture the core tubes to meet specific requirements to diameter, wall thickness and length.
Spools / Bobbins
We can offer a complete custom range of spools and bobbins for a variety of applications. Using materials such as Polypropylene, ABS and Polyethylene – in overall diameters from 25mm up to 450mm with core diameters up to 200mm.
Clear Tubes
We can manufacture crystal-clear tubes for a variety of uses. We can offer food-grade materials or those where high impact strength is required.
Packaging Tubes
To fit a range of applications, such as documents, maps and artwork, our tubes can be manufactured in a range of dimensions and lengths and can be supplied with suitable cap ends to offer complete protection.
-
Environmental
Floating booms and fenders
Constructed to assist in the containment of contaminants and pollution in water, our floating booms can be manufactured to a range of dimensions, lengths and profiles – according to the requirement of the application.
Floating reed islands
Utilising frames constructed from 110mm diameter polypropylene tubes, these reed islands provide buoyancy for reeds and grasses that provide habitat for wildlife in nature reserves – particularly areas that have been reclaimed from former industrial use.
Tree guards
Protecting trees, our tree guard provide much-needed space for a sapling or young tree to develop. Available in a range of sizes and lengths
-
Food
Cheese Production Tubes
We have produced plastic tubes for the manufacture of cheese in fully-approved food-grade thermoplastic materials. Please contact us for further information.
-
Sports and Leisure
Show Jump Poles (Equine and Canine)
Manufactured from a choice of tough polypropylene or HDPE, our show jumping poles are built to be resilient and made to last in the rough and tumble of a show-jumping environment.
We can extrude a variety of sections, including round, square, rectangle and D-shaped – with wall thicknesses and lengths according to specific requirements.
Available in a range of colours, all colour-fast and providing excellent UV stability, our poles have been widely used throughout the equestrian sector.Racecourse Railings
Extruded tubes which are bent to form a curve at one end – they are available in a range of materials.
Fishing Rod Tubes
Protecting fishing rods of various lengths and dimensions, our thermoplastic tubes and ends provide the perfect environment to keep rods safe during transit and storage. Available in a range of colours and materials.
-
Materials Handling
Conveyor Rollers
Available in a choice of durable materials with low-frictional properties and high abrasion resistance, our conveyor rollers provide impressive performance and low cost alternatives to metal-based alternatives.
We also offer selection of extruded tubes with exterior splines for use on conveyor systems. Please contact us to discuss your specific requirements.
-
Fencing and Traffic Management
Traffic posts and Barrier Fences
We can manufacture traffic posts and barrier fence tubes in a choice of sections – including round, square/rectangular and d-shaped – according to the specific requirements.
-
Utilities and Building Services
Gas pipe sleeving
Protecting gas pipes where they pass through building structures, we can manufacture gas pipe sleeving to a range of dimensions and wall thicknesses to meet the specific demands of a site and the relevant building regulations.
Smoke Aspiration Pipes
We can manufacture a system of smoke aspiration pipes and fittings to be used in conjunction with smoke detection systems. Typically using ABS, we can produce tailored dimensions and colours to meet the need of a site’s specific requirements and any relevant building regulations.
-
Size Range
Our modern extruders can produce products ranging from 10mm diameter up to 630mm – with wall thicknesses available from 0.5mm to 50mm. Extrusions can be delivered in straight lengths from 200mm up to 12m and longer lengths subject to the chosen dimensions.
We are also able to provide customised printing directly on to the finished product and can also extrude with integral longitudinal stripes in a wide range of sizes and colours to aid easy identification.
-
Types of products
In essence, if it can be extruded, we can produce it. Offering both tubular and profiled sections, our modern facilities can offer a custom range of dimensions from a wide choice of thermoplastic materials – in any colour. We not only have a vast stock of existing tooling, but our engineers can skilfully produce bespoke tooling to meet individual requirements – enabling our round-the-clock production shifts to manufacture custom orders efficiently and on time. The list detailed below provides just a few examples, however, if your application is not shown, please contact our sales team as it is highly likely that we’ll be able to assist with your requirements. -
Special Material Properties
In addition to standard materials, we can also cater for a client’s special requirements such as UV Stability and fire retardancy.
Downloads
Product Catalogues
Critical Infrastructure
Critical Infrastructure Systems
Off-site fabricated specialist pipe systems for specialist services in mission-critical infrastructure sites
Innovative approach
We have an enviable experience in supporting projects with advanced off-site manufactured specialist pipe systems in covering a variety of different applications for some of the world’s biggest tech giants. Our innovative approach to modular off-site fabrication techniques – coupled with the very latest in BIM-level modelling and advanced manufacturing are ensuring the very best outcome for the end client.
Available Systems
-
Pre-insulated Pipes
We offer the widest possible range of service pipe and casing options – to ensure we can satisfy every application and media. From chilled water through to higher temperatures and pressures, our bonded pre-insulated pipe systems offer exceptional levels of performance and reliability. -
Hazardous and Process Drainage
We have both above- and below-ground chemical and hazardous drainage systems - including dual-contained/pipe-in-pipe solutions - for a wide array of applications, including laboratories in schools, universities and hospitals, as well as medical, pharmaceutical, chemical, petrochemical and biotechnology research facilities. -
Storage Tanks
We have a long history of manufacturing polymer storage tanks from a wide array of material choices. We can also include all valves, fittings and other associated equipment to create completed solutions ready for fitting at a project site. -
Bespoke Solutions
Whilst the above list is comprehensive, we’re flexible enough to adapt our offerings to meet every possible application. Please contact us to discuss your requirements. -
Chambers and Vestibules
We can produce an array of chambers and vestibules – from a wide array of polymer materials. We can also include all valves, fittings and other associated equipment to create completed solutions ready for fitting at a project site. -
Mechanical Building Services
We can provide our off-site fabrication services for all types of mechanical building services (single wall and dual-contained), regardless of their materials and applications. This can include, but not limited to: heating, chilled water, potable water, hot water, gases, compressed air, etc.
Why off-site?
-
Lowers Costs
Faster installation, less labour and minimal waste all help to lower costs. -
Saves Time on Site
A carefully-planned modularised approach saves time on site. -
Reduces Waste
Precise work from detailed designs makes the fabrication process less wasteful. -
Improves Quality
Working in a controlled, clean environment makes for better quality. -
More Sustainable
A modularised approach makes projects more sustainable with a lower environmental impact. -
Safer Sites
Factory-based construction provides a safer working environment for personnel.
Downloads
Product Catalogues
Off-Site Fabrication
Off-Site Fabrication
CPV’s pre-fabricated multi-service solutions will give you a decisive advantage in today’s ever-changing and competitive built environment.
How we do this...
Drawing on seven decades of experience in producing specialist pipe solutions, our technically-advanced team can engineer the perfect off-site solution for your project. From simple single pipe systems through to pre-insulated and secondary containment systems, we can help you deliver your project on time and within budget with the benefits that our techniques offer…
Why off-site?
-
Lowers Costs
Faster installation, less labour and minimal waste all help to lower costs. -
Saves Time on Site
A carefully-planned modularised approach saves time on site. -
Reduces Waste
Precise work from detailed designs makes the fabrication process less wasteful. -
Improves Quality
Working in a controlled, clean environment makes for better quality. -
More Sustainable
A modularised approach makes projects more sustainable with a lower environmental impact. -
Safer Sites
Factory-based construction provides a safer working environment for personnel.
Related Case Studies
Our portfolio of projects includes data centres, hospitals, commercial and government facilities through to pharmaceutical, power generation, water treatment and industrial sites
-
Renewable Energy Plant
£650m Tees Renewable Energy Plant is a 299MW biomass-powered, combined heat and power (CHP)
Location
Teesport, Teeside, Middlesbrough, UKProducts
Copolymer Polypropylene pre-fabricated pipe sections 160mm up to 400mmServices
Belowground Drainage PipeworkOverview
Below-ground drainage PP pipework for its chemical resistance and ability to work at higher temperatures -
Data Centre, Denmark
Confidential turnkey solutions offered for a data centre being constructed for one of the world's leading companies
Location
Odense, DenmarkProducts
PE100 with an integral leak detection systemServices
Vestibule cabinetsOverview
110mm PE100 bespoke vestibule cabinets manufactured with complete off-site fabrication and design to BIM level 2 -
Boldrewood Southampton University
Innovation Campus, Maritime Centre of Excellence, Lloyds Register Group Technology Centre and Airbus Noise Technology Centre ANTC
Location
Boldrewood Southampton University, UKProducts
Pre-insulated 250mm PPR-CT pipe, fittings and special pre-fabricated building entry pipeworkServices
Low Temperature Hot Water ServicesOverview
Pre–fabricated building entry sections installed via two pre-drilled entry holes to avoid existing drains and foundations -
Data Centre, Ireland
Confidential turnkey solutions offered for a data centre being constructed for one of the world's leading companies
Location
Clonee, Dublin, IrelandProducts
PE100 in high density polyethylene casing - with an integral leak detection systemServices
Internal rainwater systemsOverview
160mm & 200mm PE100 in a 250mm & 315mm outer casing supported with complete off-site fabrication and design to BIM level 2 -
Commercial Laboratory
Laboratory drainage system for Alfred H Knight working in metal and mineral industry
Location
St Helens, Merseyside, UKProducts
Polypropylene in Polypropylene casing Safeflo – with integral leak detection systemServices
Dual-contained laboratory drainageOverview
110mm in a 200mm outer casing supported with complete off-site fabrication of pipe, tees and bends -
Automotive Manufacturer
£200m Noise, Vibration & Harshness Building for Jaguar Land Rover, Gaydon
Location
Gaydon, Warwickshire, UKProducts
Polypropylene in Polypropylene casing Safeflo – with integral leak detection systemServices:
Chilled Water F&R and Condensate F&R PipeworkOverview:
355mm HDPE pre-insulated chilled water feed and 180mm Polypropylene condensate lines -
Pharmaceutical Sector
Chemical drainage system for the University of Cambridge research laboratory buildings
Location
Cambridge, UKProducts CPV Floway polypropylene in 100mm and 150mm
Services
Chemical drainageOverview:
Standard and custom-made manholes, pipe and fittings to create a fully-fused system for two new research laboratory buildings -
Mount Pleasant, Falkland Islands
Corrosion-free upgrade for a district heating network
Location
Mount Pleasant, Falkland IslandsProducts
Hybrid pre-insulated network with GRE, stainless steel and composite polymersServices
District heating networkOverview
Range of different diameters of the three Hiline pre-insulated pipe systems
Available Systems
-
Pre-insulated Pipes
We offer the widest possible range of service pipe and casing options – to ensure we can satisfy every application and media. From chilled water through to higher temperatures and pressures, our bonded pre-insulated pipe systems offer exceptional levels of performance and reliability. -
Hazardous and Process Drainage
We have both above- and below-ground chemical and hazardous drainage systems - including dual-contained/pipe-in-pipe solutions - for a wide array of applications, including laboratories in schools, universities and hospitals, as well as medical, pharmaceutical, chemical, petrochemical and biotechnology research facilities. -
Storage Tanks
We have a long history of manufacturing polymer storage tanks from a wide array of material choices. We can also include all valves, fittings and other associated equipment to create completed solutions ready for fitting at a project site. -
Bespoke Solutions
Whilst the above list is comprehensive, we’re flexible enough to adapt our offerings to meet every possible application. Please contact us to discuss your requirements. -
Chambers and Vestibules
We can produce an array of chambers and vestibules – from a wide array of polymer materials. We can also include all valves, fittings and other associated equipment to create completed solutions ready for fitting at a project site. -
Mechanical Building Services
We can provide our off-site fabrication services for all types of mechanical building services (single wall and dual-contained), regardless of their materials and applications. This can include, but not limited to: heating, chilled water, potable water, hot water, gases, compressed air, etc.
Downloads
Product Catalogues
Chemical and Laboratory Drainage
Chemical & Hazardous Drainage
A complete range of solutions for the safe transportation of hazardous chemicals above
and below ground
Introduction
The letters CPV in our company name come from our origins as the Chemical Pipe and Vessel company. We were a pioneer in the extrusion of thermoplastic pipe systems for chemical applications. This spirit of innovation and technical advancement is still at the core of our company and as such, we have developed multiple solutions that are serving chemical drainage and storage applications – both above and below ground.
Our systems have been used in a wide variety of laboratory applications in schools, universities and hospitals as well as medical, pharmaceutical, chemical, petrochemical and biotechnology research facilities.
Our systems can operate at high temperatures and offer excellent reliability and service life due to exceptional resistance to most organic and mineral acids, alkalis, alcohols and salt solutions. The system can also be used for conveying low-level radioactive waste liquids.
Chemflo
A complete laboratory and chemical drainage system for for above and below-ground drainage. This includes the FUSEAL® system along with a wide range of fittings and components
Chemflo Plus
Dual-containment chemical drainage for the safe and effective containment of service pipes conveying hazardous and high temperature fluids
Chemflo Pressure
A pressure pipe system consisting of a range of pipes and fittings manufactured in a standard choice of block copolymer polypropylene (PP-B), natural polypropylene and PVDF
Our Solutions
Our Chemflo range of pipe solutions for chemical drainage applications encompasses three variants: Chemflo - for traditional gravity-fed above and below-ground drainage applications (featuring FUSEAL®), Chemflo Plus – as Chemflo, but with the added security of a secondary containment system and finally Chemflo Pressure – our pressure pipe system.
Our Solutions
Our Chemflo range of pipe solutions for chemical drainage applications encompasses three variants: Chemflo - for traditional gravity-fed above and below-ground drainage applications (featuring FUSEAL®), Chemflo Plus – as Chemflo, but with the added security of a secondary containment system and finally Chemflo Pressure – our pressure pipe system.
Legacy Systems
Chemflo is now the single brand range that covers many of our legacy systems for above and below-ground systems.
- CPV Zurn
This range of above ground chemical drainage systems is now covered by Chemflo - CPV Floway
This below-ground drainage system is now covered by Chemflo - CPV Safeflo
Secondary containment system is now covered by Chemflo Plus
Downloads
Product Catalogues
District Heating and Cooling Networks
District Heating & Cooling Networks
A range of pre-insulated pipe systems for district heating, cooling and special applications
Preparing for a Net Zero Future
Heat networks are vital to making net zero a reality in the UK. Offering the flexibility to utilise a wide range of heat sources, they are set to play a leading role as we transition to a sustainable energy landscape.
CPV is supporting this drive to decarbonise heat by its ongoing research and development. Having been at the forefront of the design and development of specialist pipe systems CPV’s Hiline range is no exception. Not content with merely accepting current industry best practice, the company is constantly looking into ways in which it can improve a system’s performance, life expectancy and capital and operating costs.
This approach has resulted in the development of CPV’s next generation of pre-insulated pipe systems to meet the challenge of decarbonising heat.
Heat sources and flow temperatures are evolving
With the drive to decarbonisation and changes in the way that new buildings operate, temperatures in heat networks are dropping. Whilst Hiline caters for all types of systems, we are evolving our pipe solutions to ensure maximum benefits to both the installation and operation.
Manufactured and stocked in the UK
CPV is proud to be the UK’s longest-serving manufacturer of pre-insulated pipe systems for heating and cooling networks. Over four decades of experience have defined the company’s current Hiline range of solutions that are being used on heat networks far and wide. With its comprehensive choice of service pipe options, the company has developed an enviable range that is backed up by world-class service and support.
Over 40 Years of UK Pre-Insulated Pipe Production
2023 marked forty years since we started manufacturing pre-insulated pipe systems for heating and cooling networks in the UK. Being one of the pioneers of polymer pipe extrusion in the late 1940s when the company was founded, the production of pre-insulated pipe was an obvious addition to the business and helped satisfy a growing demand for heat networks at that time.
-
Training and Support
As manufacturer, it’s important to us to ensure that our systems deliver exceptional performance throughout their working life. Therefore, we have established an array of world-class support services that help our clients every step of the way. -
CPD Programme
CPV Ltd is CIBSE-accredited provider of CPD courses for Pre-insulated Heat Network Design and Specification -
Electronic Surveillance Systems
We offer full a range of systems and supporting services for the main types of surveillance technologies, including the Nordic, Brandes and HDW systems. -
BIM Modelling Services
We work with our clients' engineering, BIM and construction teams to develop optimal solutions with the latest in fully-coordinated LOD 400 BIM modelling techniques.
The Hiline Range
The table below summarises the range of service pipe options within Hiline. We are also able to create bespoke pre-insulated pipe systems that can satisfy applications way beyond heating and cooling networks - such as those for industrial processes and critical infrastructure. Please contact our sales team should you wish to discuss bespoke requirements.
Off-site fabrication and insulation service
We are able to offer a comprehensive, off-site pre-fabrication service for special pre-insulated pipe sections for heating and cooling networks.
Complementing the Hiline range of pre-insulated pipe systems, we offer what is effectively an ‘emergency service’ for on-site installers of heat networks.
Installers have the option for us to fully pre-fabricate pre-insulated spool pieces in our Hampshire production facility, or for them to fabricate the service pipe themselves on site and send it to us to insulate with bonded polyurethane foam, tough HDPE/LDPE casings and, where required, alarm wires.
This service is proving to be very popular with our clients – particularly when they encounter hidden obstructions underground, such as utilities. Rather than wait for an overseas manufacturer to produce and ship a pre-fabricated spool piece to them – with all the delays that can entail – our clients enjoy access our fast-turnaround service and get their project back on track within a few days. Which when a trench is open and potentially involving a road closure, every hour counts.
This is available for all systems in the Hiline range, covering all choices of service pipe, whether that be steels, copper, polymers or composites.
Please contact us to find out more ...