21 February 2025
From under pressure drilling equipment and electrofusion tooling to advanced materials, recent innovation in the utilities sector has brought with it a significant shift in the way we install, connect, repair and maintain our key distribution networks. And evolving challenges for the utilities sector require the right solutions. That’s where our leading distribution pipeline equipment comes in.
At Hy-Ram, we don’t just supply equipment. We design and manufacture industry-leading solutions for distribution pipelines. Our UK-based and manufacturing facility is a hub of innovation, where our expert research and development team address our clients’ biggest challenges with high-performance products used globally.
With more than 45+ years of experience, we’ve established ourselves as a pioneering force in pipeline equipment design and manufacturing. In this blog, we’ll share an insider look into the manufacturing process at Hy-Ram and how some of our flagship pipeline tooling came to be.
The manufacturing process at Hy-Ram: how our distribution pipeline equipment is made
We manage the entire product development process and manufacturing in-house at our head office in Nottinghamshire. Whether we’re designing a new product line to roll out across our range or working with a client on something bespoke, we follow the same tried-and-tested process…
1. Planning & scoping
Before we put pen to paper (or mouse to digital design), we need to fully understand the scope.
What challenge does the product need to overcome? What standards or accreditations does it need to meet? Is there a new technology, material or technique we need to consider? What are the key factors to consider? This step is key to successfully producing our range of market-leading solutions.
2. Specifying the right materials
Our engineers are experts in metallurgy, which is essentially understanding the science behind why metals and alloys react to different levels of pressure and exposure to chemicals. Thanks to this knowledge and experience, we can manufacture our products to the right levels of durability and quality required for the job. As well as meet key industry standards!
3. Design and Research & Development Cell
Our in-house research and development team uses the latest CAD design software, which allows us to visualise the product before development begins. In conjunction with our dedicated R&D cell, we can rapidly produce prototypes for testing and inspection.
This means we can evolve concepts and designs quickly without having to waste materials, cost and time savings that we then pass on to our clients through our hire and sales prices. When it comes to manufacturing bespoke distribution pipeline equipment, it also helps us meet our clients’ stringent timescales and budgetary requirements.
4. Machining & production
Step inside our facility and you’ll find our state-of-the-art CNC machines, precision welding equipment and automation technologies. This video footage from within our machines shows the incredible precision and our engineering capabilities at the heart of every Hy-Ram product.
5. Testing
Having full product development capabilities in house means we’re able to control all aspects of the product design, including prototyping and testing. We can create a controlled environment to test the product, which allows us to work to key industry standards. Depending on your project or industry, that may include ISO, GIS, WIS, DIN, BS, EN and more.
Leading the industry with specialist distribution pipeline equipment & tooling
Utilities companies across the globe rely on the equipment and tooling we manufacture in-house. Here are just a few of the flagship products we’re known for, and how we implemented innovative design features to help our customers deliver.
The WeldMaster Butt Fusion Machine
Our butt fusion machines are trusted by industry professionals worldwide for welding 63-400mm polyethylene (PE) pipes, and have been since the early 1980s. That know-how and experience has culminated in the development of our latest WeldMaster range. With a focus on robust and quality capabilities, our fusion machines are built to handle the most demanding infrastructure projects, whilst providing added value in quality assurance.
One of the key considerations during development and manufacturing for this product was that it maintained the same durability and efficiency our customers know our butt fusion machines for. Not only did we achieve this, but we also packed it with advanced software features, including bluetooth connectivity and GPS, all accessible through a simple, intuitive touchscreen interface, which also offers real-time animated welder guidance. Believed to be the first in the world to offer this, at its initial launch in 2016.
We knew that the WeldMaster needed to work for both in-trench and trenchless welding, which is why our design features the controller, chassis, trimmer and hotplate as separate modular units, all with high specification military grade connections.
PE Pipe Squeeze Off Tools
Hy-Ram has been at the leading edge of PE pipe squeeze off design and manufacture for over 30 years, and we’re proud to supply one of the largest offerings of squeeze tools in the world, in terms of capacity and quantity manufactured annually.
Our range includes both manual and hydraulic units, ranging from 16mm to 500mm, offering safe and effective flow reduction/isolation solutions to suit most applications. For ease of use and effectiveness, all of our squeeze off tools are designed to be compact and lightweight. Plus, their zinc plated or powder coated finish ensures maximum durability.
One of the many benefits of manufacturing our squeeze off range in house means we’re able to offer a complete repair service for your tools. On top of this, our high volume of stock combined with our hire service means you’ll never be stuck without the essentials.
The DrillMaster Under-Pressure Drilling Equipment
Our under-pressure drilling equipment is revolutionising hot tapping, allowing operators to create new mains and service connections and carry out repairs without disrupting flow.
Engineered for accuracy and reliability, the DrillMaster drills deliver clean, precise cuts across various pipe materials, reducing the risk of leaks. Designed for ease of use, they’re lightweight and compact, ensuring smooth operation – even in tight spaces.
With our latest designs, we’ve made sure to prioritise operator comfort and safety, eliminating manual ratchet drilling and reducing musculoskeletal strain. Plus, our DrillMaster tools can now complete drilling connections in as little as 30 seconds for a more efficient, compliant and safer way to complete connections to pipelines.
Our commitment to quality and aftercare
Our commitment to quality extends beyond our manufacturing capabilities. Our friendly team of experts is on hand to provide ongoing maintenance, repairs and support to keep your distribution pipeline equipment operating at peak performance.
Watch our short video clips to see how we service and maintain our industry-leading products.
Discover our manufacturing capabilities today
For UK manufacturing excellence with a global reach, look no further than our distribution pipeline equipment. Our largest export markets rely on our high-quality equipment to maintain and expand their critical pipeline networks. By continually refining our technology, we remain at the forefront of the pipeline equipment industry, delivering solutions that stand the test of time.
Ready to experience Hy-Ram’s commitment to excellence firsthand? Explore our range of products, find out more about our manufacturing capabilities or get in touch for a no-obligation quote for your requirements today.
