CLIENT OVERVIEW
Derngate Theatre is a major regional venue hosting thousands of visitors each week. With constant performances and extremely limited downtime, the theatre places heavy demands on its water systems. Their existing cold-water storage tanks (approx. 16,000 litres) were more than 30 years old, repeatedly flagged in risk assessments, and had reached end-of-life despite multiple cleans.
Water hygiene, resilience, and compliance were the driving priorities for this project.
THE CHALLENGE
This project presented several unique logistical and technical challenges:
- Strict installation window during the theatre’s two‑week dark period, the only time no shows were scheduled.
- Tanks located on the fourth floor, only accessible via a ladder and a small hatch.
- The old tanks had to be cut into pieces to be removed from the plant room.
- New GRP sectional tank panels had to be supplied in half-size sections to fit through the access hatch.
- All waste material had to be transported down four floors and into an external skip.
- New panels and materials had to be lifted up four levels using a temporary pulley system.
- The theatre experiences extreme fluctuations in water demand, from thousands of guests during shows to almost zero usage at quiet times, leading to temperature and stagnation issues.
- Hot water expansion from the calorifiers was incorrectly returning into the cold-water tank, creating a compliance issue.
Despite all these restrictions, the new system had to be installed, tested, chlorinated, and commissioned before the dark period ended.
OUR SOLUTION
Infinity Water delivered a full turnkey tank replacement solution, including:
- Isolation and installation of a full bypass system to maintain water continuity if ever required.
- Dismantling and removal of the old sectional tanks panel by panel.
- Inspection of the base and support structure to confirm suitability for the new build.
- Installation of a new insulated GRP sectional tank, supplied in reduced‑size panels for access.
- Enhanced insulation to improve energy efficiency and reduce temperature stratification.
- Installation of new Keraflo float valves, adjustable for varying tank turnover based on theatre usage.
- Reconfiguration of all associated pipework, including correction of the non‑compliant hot water expansion return.
- Installation of a new water meter to allow the theatre to monitor tank input volumes.
- Full chlorination and disinfection of the tank and associated pipework.
The design ensured reliable operation during both peak and quiet periods, while improving compliance and long‑term serviceability.
THE PROCESS
1. Access Planning & Bypass Installation
- Installed a bypass line to allow continued supply should the tank ever need to be isolated.
- Established safe access routes and lifting methods.
- Prepared a pulley system for lifting tank components up four floors.
2. Removal of Existing Tanks
- Drained, isolated, and cut the old tanks into manageable sections.
- Transported all debris through the restricted access route and down to ground level.
3. Base Inspection & Preparation
- Assessed the concrete base and upstands to ensure suitability for the new sectional tank.
4. Installation of the New Tank
- Hoisted new panels into the plant room using the pulley system.
- Assembled the GRP tank using half‑size panels.
- Installed all stays, bracing, roof panels, and insulation.
5. Pipework Rectification & Improvements
- Reconfigured all supply and distribution pipework.
- Installed adjustable Keraflo float valves to manage turnover.
- Rerouted hot water expansion pipework to prevent return into the cold tank.
- Installed new isolation valves, fittings, and a water meter.
6. Chlorination, Testing & Commissioning
- Fully disinfected the tank and associated pipework.
- Checked for leaks, correct float operation, efficient turnover, and temperature control.
- Delivered the installation on time — just within the dark period window.
THE RESULTS
- Fully compliant water storage system replacing a severely deteriorated tank.
- Improved water hygiene and reduced risk of stagnation due to adjustable turnover controls.
- Better temperature stability thanks to upgraded insulation and panel design.
- Simplified maintenance and increased system reliability.
- Corrected compliance issues, including the improper hot water expansion return.
- Completed within the theatre’s strict two‑week shutdown, ensuring zero operational impact.
The Derngate team were extremely happy with the installation and have since requested additional support for other parts of their building.
CLIENT FEEDBACK
“Infinity Water were fantastic. The access challenges and the deadline were tough, but the team handled it all professionally and delivered a brilliant installation. The new tank works perfectly and we’re fully compliant once again.”
