Supply and design a suitable ducting system to Interserve

Interserve –GRREC

Location:             Glasgow

Value:                   £530,782.00

Date:                    June 2015


We were approached by Interserve to supply and design a suitable ducting system with is subjected to excessive pressures both negative and positive for our client’s site in Glasgow.


Each ducting size required individual design which required additional laminates.

Design of the ducting involved the gathering of material TDS and combining the information obtained for and with the manufacture of the duct, i.e. resin, glass fibre matt, duct material (PVC/PP).

Once all the above information was collected, we systematically designed each ducting component from 90mm dia. to 2.7m dia. ducting. The 2.7m ducting created a huge challenge for PFL as this had never been attempted by PFL. With the introduction of a Qualified Chartered Engineer to our team, PFL were able to meet the client’s specifications and duct pressures required in PVC/GRP and PP/GRP.


PFL were awarded the contract in August 2015 to complete the ducting quota. During the project there had been continued design changes which required further design and research form using the correct gaskets, correct fixings, and overcoming anomalies in DRGS from the client sent to PFL for review and agree a useable product.

During the project we invested in an Acetone recovery machine to limit the amount of fresh acetone being purchased, this also showed Interserve our’ green’ research credentials.

What did PFL do to make the material or design meet the bespoke solution / fit for purpose?

PFL engaged in the use of our in house charted engineer to design and construct ducting from 90 mm to 2.7m diameter ducting for a clients waste to energy site in Glasgow.

What testing was done in-house by PFL?

Testing in house of Items of ducting in sections such as Spark Testing, Barcol testing, Acetone testing to comply with the standards required.

Where there any failures during testing? some narrative description of why the failure occurred,  and details of how many iterations of design/materials were tested before the final form was settled.

Testing failures were due to , Inadequate laminate to meet the design of the duct section and flanges,  failures of in the spark testing due to inconsistently of the welding and the product(these where maintain my logging of batch numbers. Testing failures of Raw material such has plastic PP sheet. As mention these were overcome by use of logging individual components and monitoring on a delay basis of the work produced. Records were kept of individual raw materials on each duct section to meet the clients requirements.

How were these failures overcome?

As mention these were overcome by use of logging individual components and monitoring on a daily basis of the work produced. Records were kept of individual raw materials. As mentioned all records were kept on each duct section on each duct section to meet the clients requirements such as Barcol, acetone and spark testing

What was the technological or scientific advance being sought?

The technological advancement is that we produced the manufacture of 2.7m diameter ducting in Plastic to meet the high velocity of extraction system, The use of raw materials to combine and manufacture the product as the requirements, (the customer was considering using Steel but we gave them the confidence that the Plastic ducting would be a more economical advancement in the production and manufacturing field.

Why was the advance being sought not achievable by a competent professional working in the field?

This is type and size of ducting is not readily available and required many hours of work to get it right for the customer, as we are the manufacture, this is what we do, we used our expertise to produce this product and to showcase our skills to a major blue-chip company. Who had no knowledge of this way of manufacturing and design

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