FMJ Facilities Management magazine providing industry-specific intelligence to FM and property professionals
The Challenge
Ageing pump infrastructure can cause significant operational headaches for facilities managers. One key pump station at a residential care home required a full refurbishment due to outdated components and electrical inefficiencies. The existing system included old pumps, pedestals, floats, and a control panel located in an inaccessible loft space. Additionally, the cabling infrastructure was inadequate, and the rising main pipework showed signs of damage. The confined space and the presence of foul waste further complicated the work. The primary challenge was to complete this essential upgrade safely and efficiently, while maintaining ongoing site operations and access.
The Solution
Our approach was a complete overhaul of the pump station. We installed two new Ama Porter 603 NE 240V pumps, floats, and pedestals, and relocated the control panel to a more accessible position beside the chamber. The power supply was upgraded with a new 400V cable, routed carefully to meet all regulatory standards. To ensure site compliance and safety, confined space equipment was used, and an appropriately sized tanker managed foul waste during the works. We sourced guide rails and brackets locally and proposed installing a new kiosk with beacon functionality, mounted on a freshly poured concrete pad to improve system visibility and control.
The Execution
The project spanned five days and involved two experienced Metro Rod engineers, supported by a subcontracted electrician. After isolating power, the team excavated the site to expose old, corrugated conduit containing the previous pump cabling, clogged with foul waste, requiring additional pumping and clearance. Using CAT and Genny equipment, they traced the correct ducting for the new cable route next to the building, allowing installation of a new armoured 230V power cable.
Concurrently, the old floats, junction boxes, and cabling were removed from the loft, while the new control panel and kiosk were installed on a reinforced concrete base. Once the concrete had cured, new corrugated pipe was laid between the kiosk and pump chamber to house the new cabling.
Mechanical works included removing the damaged pedestal and rising main pipework, fitting new pedestals and a DN65 single rail guide system with brackets, then installing and testing replacement pipework to ensure no leaks. Throughout the process, the team maintained a clean, safe working environment, securing excavated areas before project completion.
The Outcome
The pump station upgrade was completed on schedule and to specification. The new pumps operate reliably, supported by dual float controls and battery backup. The relocated control panel greatly improves accessibility for maintenance, while the new kiosk with beacon functionality enhances operational visibility. The site was handed over fully operational and clean, with no reported issues. This successful project demonstrates how meticulous planning, expert collaboration, and specialist equipment can resolve complex challenges faced by facilities managers, ensuring vital infrastructure remains safe, compliant, and future-ready.
Contact Us
If you’re a facilities manager looking to upgrade or maintain your pump infrastructure with minimal disruption, Metro Rod is here to help. Whether it’s a full refurbishment or targeted maintenance, we provide tailored solutions designed for safety, efficiency, and long-term reliability. Get in touch today to discuss your requirements and find out how Metro Rod can support your site operations. We’re always happy to arrange a free site visit and a no-obligation quote.
