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Alton Towers, Staffordshire

Client: Alton Towers, Staffordshire

Cost: £70,000

Dung Heap Play Area is a Tower-ing Success

Brief

The world-famous Alton Towers theme park has installed some popular alternatives to its formidable selection of hair-raising rides by working in partnership with West Yorkshire-based children’s play specialist, Sutcliffe Play.

Alton Towers has unveiled a new £450,000 children’s play area – affectionately entitled ‘There’s Something in the Dung Heap’ – to enhance the popular Old MacDonald’s Farm area of the Staffordshire theme park.

The Dung Heap contains around £70,000 worth of play equipment manufactured or supplied by Sutcliffe Play.

Sutcliffe Play was commissioned by Scott Desborough, London-based project manager for Tussaud Studios, which makes wax figures for Madame Tussauds, and also manages projects for other parts of the Merlin Entertainments Group empire – including Alton Towers.

Client

“The Dung Heap has met with a really positive response,” said Scott. “Alton Towers is dedicated to ensuring that new rides and attractions are specifically designed to exceed customer expectations. Within the brief, a customer satisfaction score is included and it is our objective to ensure this is met and exceeded. Recent feedback suggests we’re performing extremely well!”

Design and Build

The new play area is split into four different sections aimed at different heights and age groups. These are connected by a central plaza in which parents can relax and take the weight off their feet while youngsters enjoy themselves.

The four areas begin with the underground Soil Albug Hall, which has flies buzzing around this entrance to the Dung Heap! Nearby is Mr Mushroom’s Magic Maze, which sits just outside the Soil Albug Hall.

Equipment supplied by Sutcliffe Play features prominently in The Toxic Bog, which is aimed at toddlers aged 3-6, and in the Cobweb Capers area, designed for youngsters aged around 6-10.

“It’s a really nice area. The parents seem to like it as much as the children because they can sit and eat, or drink coffee, and leave the kids to it,” said Mr Desborough. “It’s like a little refuge from the rest of the park, which can often be quite manic in places!”

The Cobweb Capers area includes a spider’s Springy Cobweb Climbing Zone; alternatively, children can test their airborne agility going across a silken zip wire. For this area Sutcliffe Play installed two 1.8m cone climbers, plus a 25m cableway, and a 4m high space net.

The Toxic Bog is ideal for children who love to slip, slide, bounce, or balance. It features a bunch of Teetering Toadstool Boingupons, as well as Jumping Gerberas and a slide into the bog itself. It is also home to the Wobbly Walk rotating beam!

Equipment manufactured by Sutcliffe Play for this area comprises two 1.4m square trampolines built into the ground; two sets of curvy seats; and a 3m rotating beam which forms the Wobbly Walk!

Sutcliffe Play also supplied and installed the toadstool-shaped stepping pods, with their brightly coloured spots. And, acting in its role as the sole UK distributor for German playground equipment firm Kaiser & Kuhne, Sutcliffe Play supplied a double-width slide on a timber structure.

Playground Equipment:

“Alton Towers is constantly evolving, and each year we invest in a new attraction or area of the Park. On this occasion, we wanted to increase our product offering for families with younger children,” said Scott.

“As part of the same project we also added a walk through a wooded area, which appeals to the children and can be themed for events such as Halloween.”

Scott had never previously worked with Sutcliffe Play, but was impressed by the firm’s willingness and ability to tailor its equipment to meet Alton Towers’ specific requirements.

Another major consideration surrounding the Dung Heap project was to create a playground that would blend in harmoniously with its surroundings.

“We use a range of consultants to ensure that any new builds are sympathetic with the natural environment, even down to the type of foliage used to compliment the backdrop of the attraction,” said Scott.

“Everything has to be considered in some depth, but Sutcliffe Play helped us to create an area which is deliberately intended to encourage the children to use their imagination without going over the top in making things look unnecessarily wild and wonderful. Meanwhile the parents know their kids can only go in and out of one gate, so it’s all self-contained!”

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Sutcliffe Play Ltd
Waggon Lane
Upton
Pontefract
WF9 1JS
United Kingdom

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Anti-Slip Surfacing

Many of our products, especially our multi-play units, are designed to enable fast, thrilling, kinetic play for all ages and abilities. This is why durable, hard-wearing anti-slip surfacing is another key material used in our factory, to deliver the safest, highest quality playing experience for children.

The two most commonly used materials in this regard are Hexastrong panels and WISA®-Multifloor panels. The former is found primarily on the walking decks and steps on many of our multi-play units, including in our MiniTown, Toddlerzone and Playzone ranges. With their hard-wearing nature and excellent strength to weight ratio, these panels are ideally suited for use on playground equipment, and as they are produced primarily from timber, they can be considered a renewable resource.

Durable WISA®-Multifloor panels are also utilised most prominently in our Toddlerzone and Playzone ranges. Constructed from birch veneers bonded together with weather-resistant glue and coated with an elastic overlay, they deliver a strong, safe surface on walking decks and steps, upon which children can play freely.

As with all materials involved in the manufacture of our products, we work hard to ensure we deal with responsible suppliers at every stage, and participate in a sustainable supply chain with environmental consideration at its heart:

Both of our Hexastrong suppliers are UK-based, reducing emissions from overseas freight, and the materials we source from both are FSC (Forest Stewardship Certification) approved, ensuring they are derived from well-managed forests and tracked throughout their manufacturing journey. Both suppliers also fully comply with the Timber and Timber Products Regulations (UKTR), which requires them to conduct all necessary due diligence on their supply chains, to ensure the materials they use have been legally sourced and traded.

One of our suppliers also utilises a Carbon Calculator, to inform every customer of the overall carbon footprint of their order, taking in manufacture, delivery of the product to the supplier’s warehouse, and storage, all the way up to the moment it leaves the supplier’s premises. This information allows us to easily understand the carbon impact of the Hexastrong panels we purchase, and assess the results accordingly.

Our supplier of WISA®-Multifloor panels, meanwhile, is based like us in West Yorkshire, again reducing freight emissions, and as with our Hexastrong supplier, is FSC (Forest Stewardship Certification) approved and fully complies with the Timber and Timber Products Regulations (UKTR).

Both our Hexastrong and Wisa®-Multifloor panels are covered by a 2-year warranty against material degradation.

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Paint/Finishing

Although originating from our West Yorkshire factory, our equipment delivers fun across the country every day – and beneath the colourful surface, its fundamentals are high quality, durable, and sustainable.

When it comes to safeguarding our environment, however, we know the surface itself has a part to play, too. We utilise a range of different treatments and finishes, including galvanising, powder coating and zinc priming for mild steel, and anodising for aluminium. These processes provide the materials with the best chance of enduring heavy usage, whilst sealing the surface’s prime coating, and adding further durability through a UV stable colourfast finish.

The manner of application is also crucial with regards to sustainability. Our preferred method, electrostatic spraying, involves the use of a spray gun to powder coat the metal. This leads to an exceptionally even particle distribution when compared with traditional airless methods, which can result in significant overspray and insufficient coverage. The improved transfer then translates to reduced paint consumption, which in turn reduces waste, and saves on any cleaning agents required to remove excess.

Our UK-based supplier practices sustainable delivery methods, including utilising cardboard packaging in place of plastic, as well as biodegradable packing peanuts made from natural, nontoxic sources (such as wheat and corn starch) which can be used in compost piles after use. 

Our paint, anodising and galvanising are all covered by a 10-year warranty against significant corrosion due to faulty materials or finishing.

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Rubber

With its inherent flexibility and array of bright colours, rubber is ideal for use in play equipment.

In our case, it is the main material used in many of our swing seats, whose design and production originally helped to make Sutcliffe Play a leading name in the playground market.

Rubber is derived from the sap of the rubber tree, which, when farmed responsibly, can be tapped for latex production over a period of many years before requiring replacement. Not only does this make the rubber itself a sustainable resource, it is also a great benefit for the wider ecosystem, as rubber trees have a significant capacity to absorb carbon dioxide.

Likewise, natural rubber is also extremely biodegradable, giving it a major advantage over plastic (which can take decades or even centuries to decompose); the higher the percentage of pure latex rubber in the compound, the faster it breaks down upon disposal.

Our north-west based supplier is a leading enterprise that operates a Sustainable Procurement Policy, which seeks to monitor and manage the business’s environmental impact, whilst ensuring social, environmental and economic factors are fully considered by employees and suppliers.

Our rubber is covered by a 2-year warranty against material degradation.

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Aluminium

Sustainability and durability run through our equipment quite literally from top to bottom, as the supporting uprights on our popular Toddlerzone, Playzone, Neo and Mission ranges are constructed from high-quality, responsibly sourced aluminium.

Three of our four main aluminium suppliers are based locally in West Yorkshire, reducing freight emissions, and all seek to work within a sustainable supply chain, with one certified to the Environmental 14001 standard.

This highly durable material is the most recyclable metal in the world, and can be continually re-melted and refashioned into new products without losing its properties. This process also uses up to 95% less energy than the production of new aluminium from raw materials.

Its unique combination of versatile properties, including low weight, high strength, corrosion resistance and recyclability make it a perfect match for heavy usage playgrounds. Its hardened anodised finish is also maintenance free and requires no touch-up or finish during its life cycle, saving on wastage and the use of new top up materials.

Our aluminium is covered by a 25-year warranty against structural strength, and our anodising is covered by a 10-year warranty against significant corrosion due to faulty materials or finishing. 

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Mild Steel

Mild steel is another essential material which is a perfect fit for our durable product range, used to create the supporting components of our multi play units, as well as rotators such as our inclusive dish roundabouts.

As with stainless steel, our supplier is an established enterprise in the local West Yorkshire area. They create mild steel from raw materials sourced from UK and Belgian foundries which are BES6001 certified, and as of April 2023, their activity was estimated to produce 1.39 tonnes of carbon emissions per tonne of steel, well below one of the major estimated industry averages (1.85 tonnes), and on par with another (1.40).

This high-quality material is painted using a sustainable electrostatic process, and gains added protection through a UV stable colourfast finish. It has been proven to withstand not only the rigours of daily usage but the harshest of outdoor environments, including those with high salinity – this is well-evidenced by the fact that there has never been a customer claim against its structural guarantee.

Our mild steel is covered by a 25-year warranty against structural strength.

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Stainless Steel

Another material that helps us to offer the most robust equipment on the market is stainless steel, used in the manufacture of our chute, bedway and bannister slides.

Our supplier is local, based like us in Yorkshire (reducing freight-based carbon emissions), and they utilise only materials from approved and highly reputable mills. They also work to ensure their supply chains are free from any unacceptable labour practices, are aligned to the UN 2040 Net Zero Target, and are beginning to roll out the use of Hydrotreated Vegetable Oil to replace diesel at all of their service centres, leading to a reduction in carbon emissions and nitrogen oxide.

The stainless steel in our products is maintenance free, easy clean, and suitable for all environments. It conforms to EN10088 specifications, and it is austenitic – making it stronger, more durable, and less electrically and thermally conductive than carbon steel, as well having a greater corrosion resistance. This durable, robust composition greatly extends the material’s lifespan, deferring waste creation (and steel is already the most recycled material used in manufacturing overall, so is far less likely to create waste at all).

Our stainless steel is covered by a 25-year warranty against structural strength.

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HPL

HPL is a high-performance, external grade, self-supporting laminate utilised in versatile ways throughout our product range, such as the colourful panelling on many of our multi-play units.

The two key components in its creation are paper (technically called cellulose fibres) and thermosetting resin, with the former representing 60-70% of the finished material.

Our supplier is an Environmental Management Systems ISO 14001:2015 certified business, which holds both of the voluntary ‘Chain of Custody’ certifications according to FSC (Forest Stewardship Council) and PEFC (Programme for the Endorsement of Forest Certification) schemes. These certifications guarantee that the final product is made of material from well-managed, FSC or PEFC-Certified forests, and other controlled sources.

No organic solvents, asbestos or heavy metals are used during HPL’s production cycle, and it doesn’t release any gases, vapours, solvents or fluids. Its processing waste can be handled in a manner equivalent to household waste at controlled landfills, and it is estimated that 80% of the waste generated by our supplier is recovered.

Once created, HPL’s standout durability (it is fire-retardant, scratch and shock resistant, and non-porous) ensures that it will resist a great deal of wear and tear, and endure for long periods before requiring replacement.

Our HPL panels are covered by a 10-year warranty against non-structural failure due to faulty workmanship or materials.

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HDPE

HDPE (High-Density Polyethylene) is an extremely versatile thermoplastic polymer used in the freestanding play panels which feature in many of our play spaces, as well as for various components across our product range.

Offering an excellent strength-to-density ratio, and a very high impact resistance and melting point, products utilising HDPE are sure to enjoy a very long life.

Our HDPE is sustainably sourced, with our supplier having recycled 99% of their waste material and off-cuts from their formation, and offering HDPE recycling services to customers for products which are no longer required.

Unlike natural, porous materials such as wood (which can feature fissures or grooves that harbour moisture or bacteria) HDPE resists mould and rotting as well as most strong mineral acids and naturally occurring chemicals. HDPE is also easily recyclable, helping to keep non-biodegradable waste out of landfill. 

Our freestanding play panels are also accompanied by a selection of sustainably sourced supporting posts, including recycled plastic, galvanised metal, and timber. As with HDPE, these enjoy a far longer lifespan due to their environmental resistance (with none of the rotting, cracking, or splitting that may come with traditional timber posts), and they also help to reduce non-biodegradable landfill waste.

Our HDPE is covered by a 10-year warranty against non-structural failure due to faulty workmanship or materials.

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Glulam

Our Treetops multi-play equipment is well-known for its naturalistic aesthetic, with striking wooden support beams bringing an eye-catching look to the entire range.

These are constructed from Glued Laminated (Glulam) Larch, a structurally engineered wood comprised of layers of dimensioned lumber, bonded together with durable, moisture-resistant structural adhesives.

Our well-established supplier of Glulam is based very locally to our factory in West Yorkshire, reducing freight emissions – and as with all of our materials, Glulam’s great durability minimises waste and the need for replacement in the long term. Its design delivers greater dimensional stability than that of whole log sections, with no shakes, twisting or warping, and all Glulam beams within the Treetops range have an oblique cut top to prevent water ingress, as well as galvanized steel shoes to protect the base of each post from the elements.

As well as having no known negative environmental effects, repairability of Glulam is high, and once it reaches the end of its natural life, it can be repurposed as an excellent biofuel.

Our Glulam is covered by a 10-year warranty against structural strength.

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Timber

Timber is an essential material in our work, used primarily in our naturalistic Orchard range – and we strive to ensure not only that it is sustainably sourced, but smartly applied to ensure maximum longevity.

Our FSC (Forest Stewardship Council) certified supplier handles slow grown pine logs derived from strictly controlled sources, either through government body approved felling licences or forest/woodland management plans. They also encourage the recycling of their products during manufacturing, with all wastage repurposed – including in a local biomass plant that produces electricity and heat.

The timber we purchase for use in our Orchard posts has been pressure treated against wet rot, dry rot and insect infestation, carried out after it has been cut and drilled (ensuring the coverage of all exposed timber). It has also been preservative pressure-treated with high-quality Tanalith 9000, which is proven at providing unrivalled protection.

A UK-sourced aluminium protective shoe maintains the timber above ground level, protecting the base of each post throughout its lifetime, and side ventilation holes allow the posts to breathe and stay dry. At the other end, a special rubber cap completely seals the post top, preventing moisture from entering the top grain.

Our Timber is covered by a 10-year warranty against structural strength.

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