ATK was born because of the frustration of Shaun Gallagher, a plumbing contractor of 20 years experience. “I got so fed up with having to send teams of guys back to jobs that have failed their ‘air tests’.
I decided to do something about it. Re-visiting finished jobs was proving costly and disruptive to my company and there wasn’t a satisfactory solution available, so I began developing a unique cost-effective solution to ‘air-tightness’ around pipework.
“I had always traditionally fitted soil pipes and waste pipes by using the appropriate pipework through the cavity, and sealing with tape and foam. Increasingly I was being called back to jobs to re-seal the pipework that had been moved slightly as the external brick work was added. This contributed to the job failing the ‘air test’ that is part of the L1 Building Regulations. With the new 2010 amendments I could only see the situation getting worse.”
Re-sealing for a re-test can prove very expensive; at best it involves using foam-based sealants, at worst the pipework has to be re-sealed which, involving fitting new plasterboard and re-tiling, adds literally hundreds of pounds to a job.
There are membranes and grommets that are currently available which, if used properly, go some way towards improving the air-tightness around pipework. Shaun’s vision was to develop a connector and seal that formed an integral part of the pipe by solvent welding the connector to traditional pipework. His first prototype was made out of traditional piping with a plastic square collar, sonic welded at one end. He realised he was on the right lines and this provided a rigid seal, but the connector would be very difficult to manufacture.
He then called on lifelong friends Paul Smith and Andrew Mason, who are experts in plastic manufacturing, to advise him. After a great deal of research the guys decided that a ‘connector’ was a unique viable solution. They decided that the connector would be manufactured in high grade ABS by Andrew’s company Champion Mouldings, which was already manufacturing for Rolls Royce, Honda and Marley.
High grade ABS was chosen for the connector as its properties are ideal for the application and, coupled with the galvanized rubber seal, will provide an affordable product with the necessary longevity.
After researching the market, the guys then invested in tooling, patented the product, trademarked their company logo, and launched ATK Limited UK.
ATK’s unique airtight kit is manufactured in three sizes that fit the industry standard pipework – 21mm, 42mm and 110mm: each kit consists of a connector and gasket with four screws and rawl plugs.
Next ATK embarked on extensive field tests. New City Vision, a high profile developer, was approached to ‘test’ the product on their prestigious Ellergreen development in Liverpool. Air tests were carried out on houses with and without the airtight kits.
Alan Wilson, project director for New City Vision, says: “We believe that installing this product has assisted us in exceeding our target Level 7, and in fact we are achieving an average of 3.22 throughout our development.”
The proof of success is that Alan Wilson has since re-ordered the product and is committed to using ATK products in all future developments.
This field test also created a further use for the 110mm kit: it is ideal for using around extractor fans to seal the inner membrane from the cavity.
Gareth Thomas, project director at Grimwood-Dix Electrical Contractors commented: “The ATK 110mm connector kit provides added rigidity and stability to the fan installation.”
Continuing on the electrical uses, ATK are currently developing a foam insert for sealing the inside of the 21mm connector, making it ideal for sealing holes for cabling (BT, Sky, Virgin etc.).
Energy saving is high on the eco agenda; however, the industry still tends to focus on cost benefits. When weighed against the costly business of re-testing and all of the associated disruption to a development, installing the airtight kits, at a cost of around £60 per typical house, is a no-brainer.
ATK is currently working with Salford University and BRE to further test the system, as well as speaking to air testing companies and investigating future stockists. Currently, the product is available direct from ATK Limited UK.
Finally, Andrew Mason, a director at ATK, explains: “The future is bright for our unique airtight kits.
If designed into any new build, whether industrial or domestic, not only does it fulfil a need to provide a cost-effective solution to assist in meeting L1 Building Regulations, it saves energy, which in the long-term will become increasingly more important.”
To find out more, visit www.airtightkit.co.uk.
