ERF Meter Box Replacement Case Study | Tricel Solutions

ERF Meter Box

About the Project – Replacing ERF Meter Box Systems

This case study focuses on how Tricel's advanced meter box replacement solutions effectively tackled the challenges presented by outdated ERF meter boxes within the ESB Networks infrastructure. Through the deployment of the Tricel Door Frame Kit combined with a specialized adapter transition part, we delivered a solution that not only aligns with current safety standards but also optimizes operational efficiency and drives significant cost savings. The aging ERF meter boxes had become a significant concern for ESB Networks, as they struggled to meet modern safety regulations and posed an increasing financial burden due to maintenance costs. Recognizing these challenges, Tricel developed a solution specifically designed to replace these outdated ERF meter box, ensuring a seamless and reliable upgrade.

Key Project Highlights – Solving for the ERF Meter Box

Assessment and Prototype Development: A comprehensive evaluation of the old ERF meter boxes was conducted, leading to the design and development of a prototype that incorporated the durable K Frame and a custom adapter transition part. This prototype was essential in addressing the unique requirements of ESB Networks while ensuring full compliance with stringent safety standards.

Onsite Implementation: The installation of the prototype was executed with the close collaboration of ESB representatives and Tricel engineers. This hands-on approach ensured that the solution effectively replaced the outdated ERF meter boxes and integrated smoothly into the existing infrastructure. By upgrading the old ERF meter boxes with Tricel’s advanced replacement system, ESB Networks secured a future-proof, compliant solution that surpassed industry standards.

The preassembled Tricel Door Frame Kit facilitated a streamlined installation process, minimizing both downtime and costs. This project highlights Tricel’s commitment to delivering innovative solutions that address the evolving needs of the utilities sector, particularly in modernizing infrastructure like the ERF meter boxes.

Problem Statement – Challenges with the Old ERF Meter Box

The meter boxes in Shannon, installed around 1975 by the now-defunct ERF in the UK, are outdated and nonstandard (See images below). Key issues include the unavailability of ERF meter box replacement doors since ERF is no longer in business, and size and fit issues with the existing Tricel Door Frame Kit (K Frame), which is too large to fit the old boxes properly, resulting in poor sealing. Efforts to retrofit the boxes led to inconsistent and time-consuming installations that failed to meet safety standards. Additionally, sharp edges and the lack of fire-retardant materials posed significant safety hazards.

Solution Overview – Adapting Tricel Kits for the ERF Meter Box

Tricel proposed an innovative solution involving the use of an adapter transition part with the Tricel Door Frame Kit (K Frame) to address the challenges of outdated ERF meter boxes. Initial attempts to replace the ERF boxes with the Tricel Door Frame Kit highlighted several issues: inconsistent installation practices, time-consuming processes, and safety hazards from sharp edges and lack of proper sealing. The proposed solution ensures adaptability by allowing the K Frame to fit the existing ERF meter box perfectly, enhances safety with fire-retardant materials and adhesives, and future-proofs the system by allowing for easy replacement of doors and frames.

Installation Process - Upgrading the ERF Meter Box

Removing the Old Door: The old door was carefully removed to prepare the box for the new installation.
Applying Fire-retardant Silicone: Fire-retardant silicone was applied to the inner lip of the box to ensure a proper seal.
Inserting the New Door Frame Kit: The new Tricel Door Frame Kit and adapter transition part were inserted into place.
Securing the Frame: The frame was secured to the old box with self-tapping screws, making the existing box and the new Door Frame Kit one unit.
Sealing the Outer Frame: The outer frame was sealed to the wall to prevent water ingress.
Closing the Door: The door was closed, completing the installation.

Feedback – A Scalable Solution for the ERF Meter Box Network

All agreed that when we tweaked the prototype, the Shannon Overbox performed well. Tricel is confident in their solution, which can be supplied preassembled in a factory environment. We believe there are approximately 2,000 ERF meter boxes that may need replacing. Oliver Kelly suggested a run of 50 to 100 Shannon Overboxes to validate the above. If successful, another batch could be manufactured and assembled.