Wavinsewer Systems PIONEERS IN PLASTIC WAVINSEWER CONTENTS WAVIN IRELAND LIMITED

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3 PIONEERS IN PLASTIC Wavin is Europe s largest manufacturer of industrial plastic products, and one of the largest producers of plastic pipe and fittings in the world. Owned equally by the Overijssel Water Authority in Holland and Shell, Wavin is credited with inventing and pioneering the use of plastic pipe for water distribution. The company has grown spectacularly since its formation in It now employs over 4,500 people, operating within 25 countries, with a rapidly developing base in Central and Eastern Europe. Constant research and development have put Wavin in the forefront of plastics technology. It has over 17,500 different types of plastics products world-wide and licenses its technology to manufacturers outside the Group in over 30 countries. WAVIN IRELAND LIMITED Wavin has been the leading supplier of plastics pipes and fittings for 40 years. Initial pipe production at Cian Park, Drumcondra in 1957 led to the commissioning of the manufacturing complex at Balbriggan some five years later. Production now extends into a wide range of above and below ground plumbing and drainage systems. Wavin s success in Ireland has been achieved by paying close attention to product quality, innovation and development and by creating a special relationship with suppliers and customers. Ongoing investment in plant and tooling underlines the confidence Wavin place in their future as Ireland s leading plastics pipe and fittings manufacturer. WAVINSEWER Wavinsewer is firmly established as the leading unplasticized Polyvinyl Chloride (PVC-U) house drain and sewer system in Ireland. The system includes pipes and fittings in nine diameters from 110mm to 450mm plus two additional sizes of the new generation of Wavin TRITEC drain and sewer pipes in 160mm and 9 inch diameters. New Wavin TRITEC pipes are manufactured in PVC-U by a unique process which produces three distinct layers to provide strength, durability and a greater flow capacity. They are covered by the Irish Agrément Board Certificate No. 97/0089. All other pipes and fittings in the Wavinsewer range conform with the requirements of Local Government Specification 1977 or IS. 424:1990. The range offers a wide variety of components such as Bends, Branches, Channel Fittings, Gullies, Grease Traps, Access Junctions and Road Gullies. Wavinsewer is designed for buried gravity drain and sewer applications such as foul and domestic drains and sewers, surface and stormwater drains and sewers, sewage treatment and road drainage. CONTENTS Page Pipe Dimensions 2 Abbreviations 2 Product Range 3-18 Design Information Typical Properties of PVC-U 19 Structural Properties of PVC-U 19 Summary of Standard Tests 19 Hydraulic Properties 20 Gradients 20 Grease Traps Design Guidelines 20 Flow Charts Handling, Storage, Transport, Inspection, Installation Handling 24 Storage 24 Transport 25 Inspection 25 Installation Principles 25 Excavation Underbed Pipelaying Backfill 28 Connection into Sewers 28 Connection to Other Materials Jointing Wavin Access Junctions Sealed Access Fittings Open Channel Manholes Gullies Traditional Gully 34 Universal Gully Bottle Gully Yard Gully 36 Road Gully Grease Traps Suspended Drainage Testing Repairs 40 Maintenance 40 Cleaning 40 Appendix 41 General Information 42 1

4 PIPE DIMENSIONS WAVIN TRITEC PIPES (All dimensions are in mm except where inches are indicated) Nominal Mean Individual Pipe Wall Inner Skin OD OD Thickness Wall Thickness OD Min Max Min Max Min Min " WAVIN PIPES TO IS 424:1990 (All dimensions are in mm) Nominal Outside Wall Mean Average Diameter Thickness Internal Weight Min Max Min Max Diameter (kg/m) WAVIN PIPES TO LOCAL GOVERNMENT SPECIFICATION 1977 (All dimensions are in mm except where inches are indicated) Nominal Outside Wall Mean Average Diameter Thickness Internal Weight Min Max Min Max Diameter (kg/m) " ABBREVIATIONS P/E S/S D/S Pipes and Fittings with both ends plain or with one plain end and one special end. Pipe and Fittings with one or more ring-seal or plain socket, but always with one plain or special end. Fittings with ring-seal or plain sockets at all ends. 2

5 PRODUCT RANGE Pipes P/E Pipe 6 metre Nominal Product 110 D D TRITEC D E4513 9" E4503 9" TRITEC E E E E E E4508 S/S Pipe 6 metre Nominal Product A 110 D D TRITEC D E " E " TRITEC E E E Couplers D/S Pipe Coupler (WS 1) for jointing pipes Nominal Product A B 110 D D E E E E E E E Repair Coupler D/S Repair Coupler for repairs and new branch entry connections Nominal Product A 110 D

6 PRODUCT RANGE Branches D/S Branch 45 (WS 2) Nominal Product A B C 110 x 110 D x 160 D x 110 D S/S Branch 45 (WS 2) Nominal Product A B C D E F 200 x 110 E x 160 E " x 110 E " x 160 E x 110 E x 160 E x 200 E x 110 E x 160 E x 200 E P/E x S/S Branch 45 (WS 2) Nominal Product 355 x 160 E x 160 E5045 Fabricated to order 450 x 160 E5121 D/S Branch (WS 2A) Nominal Product A B C 110 x 110 D S/S Branch (WS 2A) Nominal Product A B C D E F 160 x 160 D x 110 D x 200 E " x 9" E x 250 E x 315 E

7 PRODUCT RANGE P/E Branch (WS 2A) Nominal Product 355 x 355 E x 400 E5138 Fabricated to order 450 x 450 E5158 Saddles S/S Unequal Saddle 45 (WS 3) solvent application Nominal Product A B 200 x 110 E x 160 E " x 110 E " x 160 E x 110 E x 160 E x 110 E x 160 E x 110 E x 160 E x 110 E x 160 E Short Radius Bends S/S Short Radius Bend 15 (WS 5) 24 per circle Nominal Product A B C 110 D D S/S Short Radius Bend 30 (WS 5) 12 per circle Nominal Product A B C 110 D D S/S Short Radius Bend 45 (WS 5) 8 per circle Nominal Product A B C 110 D D E E E E

8 PRODUCT RANGE S/S Short Radius Bend (WS 5) per circle Nominal Product A B C 110 D S/S Short Radius Bend (WS 5) 4 per circle approx Nominal Product A B 110 D D E E E E D/S Short Radius Bend 45 (WS 5A) 8 per circle Nominal Product A B C 110 D D/S Short Radius Bend (WS 5A) 4 per circle approx. Nominal Product A B 110 D Short Radius Segmental Bends S/S Short Radius Segmental Bend 15 (WS 5) 24 per circle Nominal Product A B C 9" E S/S Short Radius Segmental Bend 30 (WS 5) 12 per circle Nominal Product A B C 9" E

9 PRODUCT RANGE S/S Short Radius Segmental Bend 45 (WS 5) 8 per circle Nominal Product A B C 9" E E S/S Short Radius Segmental Bend 90 (WS 5) 4 per circle Nominal Product A B 9" E E Adjustable Bends S/S Adjustable Bend 0 to 30 for variable angles up to 30, rotate segments to achieve the right angle. Nominal Product A B C 110 D D/S Adjustable Bend 0 to 30 for variable angles up to 30, rotate segments to achieve the right angle. Nominal Product A B C 110 D Long Radius Bends S/S Long Radius Bend (WS 6) 16 per circle Nominal Product A R 110 D D E " E E E

10 PRODUCT RANGE P/E Long Radius Bend (WS 6) 16 per circle Nominal Product A R 355 E E E S/S Long Radius Bend 45 (WS 6) 8 per circle Nominal Product A R 110 D D E " E E E P/E Long Radius Bend 45 (WS 6) 8 per circle Nominal Product A R 355 E E E S/S Long Radius Bend 90 (WS 6) 4 per circle Nominal Product A R 110 D D E " E E E Mid Radius Bends D/S Moulded Mid Radius Bend 45 (WS 6A) with cut out marks to convert bend to a Channel Bend for use on traditional manholes. Nominal Product A R U 110 D

11 PRODUCT RANGE D/S Moulded Mid Radius Rest Bend (WS 6A) satisfies recommendations of BS 5572:1944 for base of soil stack applications. Manufactured with cut out marks to convert bend to a Channel Bend for use within traditional manholes. Nominal Product A B R U 110 D Channel Fittings S/S Straight Channel (WS 7) Nominal Product A U 110 x 24" D x 36" D x 24" D x 36" D x 48" E " x 48" E x 48" E x 48" E P/E Straight Channel (WS 7) Nominal Product A U 355 x 48" E x 48" E x 48" E S/S Long Radius Curved Invert Channel 45 (WS 8) Nominal Product A R U 110 D D E " E E E P/E Long Radius Curved Invert Channel 45 (WS 8) Nominal Product A R U 355 E E E

12 PRODUCT RANGE S/S Long Radius Curved Invert Channel 90 (WS 8) Nominal Product A B R U 110 D D E " E E E S/S Curved Channel Branch (WS 9) Nominal Product A B C 110 D4129 LH D4128 RH D4131 LH D4130 RH Cleaning Eyes P/E Cleaning Eye (WS 12) with screwed access Nominal Product A D 110 D D Adaptors D/S Spigot Adaptor (WS 13) to cast iron and clay spigot Nominal Product A B C D 110 D D S/S Spigot Adaptor (WS 13) to cast iron and clay spigot Nominal Product A D 200 E " E E E

13 PRODUCT RANGE S/S Socket Adaptor (WS 14) to cast iron and clay socket Nominal Product A B 110 D D S/S Spigot Adaptor to land drainage pipe Nominal Product A B C 110 x 90 D Stoppers P/E Plain Stopper (WS 19) Nominal Product A D 110 D D E " E E Reducers S/S Level Invert Reducer (WS 20A) Nominal Product A B 160 x 110 D x 160 E S/S Concentric Reducer (WS 20A) Nominal Product A B C 200 x 160 E " x 160 E x 160 E x 9" E mm Wavin Access Junctions (WAJ) Cover and Frame for WAJ Nominal Product D1 D2 D3 H A 315 x 315 D For use with 110mm WAJ's Sealed cover option available on request. 11

14 PRODUCT RANGE Riser for WAJ Nominal Product A B C 150 D For use with 110mm WAJ's D/S Straight Through WAJ (WAJ 1) Nominal Product A D 110 D Top of cover to WAJ invert 270mm D/S 90 Bend WAJ (WAJ 2) Nominal Product A D F 110 D4151 LH/RH Top of cover to WAJ invert 270mm D/S 90 WAJ (WAJ 3 & WAJ 13) Nominal Product A B C D F 110 D4152 LH D4157 RH Left hand illustrated Top of cover to WAJ invert 270mm D/S 45 WAJ (WAJ 4 & WAJ 12) Nominal Product A D E 110 D4153 LH D4156 RH Left hand illustrated Top of cover to WAJ invert 270mm 12

15 PRODUCT RANGE D/S 45 Twin WAJ (WAJ 5) Nominal Product A D E 110 D Top of cover to WAJ invert 270mm D/S 90 & 45 WAJ (WAJ 7 & WAJ 16) Nominal Product A B C D E F 110 D4158 LH D4154 RH Left hand illustrated Top of cover to WAJ invert 270mm D/S 90 Twin WAJ (WAJ 18) Nominal Product A B C D F 110 D Top of cover to WAJ invert 270mm \ 160mm Wavin Access Junctions (WAJ) Light Cast Iron Cover With PVC-U Skirt Nominal Product D1 F1 F2 H1 H2 D Suitable for light traffic only For use with 160mm WAJ's. P/E Corrugated Riser Shaft Nominal Product D1 D2 H D For use with 160mm WAJ's 13

16 PRODUCT RANGE D/S Straight Through WAJ (WAJ 1) Nominal Product D1 D2 H L Z 160 D H = height overall D/S 45 Left Hand WAJ (WAJ 4) Nominal Product D1 D2 H L Z 160 D H = height overall D/S 45 Twin WAJ (WAJ 4) Nominal Product D1 D2 H L Z 160 D H = height overall D/S 45 Right Hand (WAJ 12) Nominal Product D1 D2 H L Z 160 D H = height overall Sealed Access Junctions D/S Sealed Inspection Pipe with bolted rectangular cover and sealing ring Nominal Product A B C 110 D D

17 PRODUCT RANGE D/S Equal Single Sealed Inspection Junction 45 with bolted rectangular cover and sealing ring. Nominal Product A B C D 110 D4250 RH D4251 RH D4252 LH D4253 LH Right hand illustrated D/S Equal Twin Sealed Inspection Junction 45 with bolted rectangular cover and sealing ring. Nominal Product A B C D 110 D4254 RH D4255 LH Left hand illustrated Gullies Gully Riser grating not included Nominal Product A B 110 D Gully Grating (spare) Nominal Product A 110 D S/S Plain Gully including grating and outlet bend Nominal Product A B C D E 110 D S/S Universal Gully Trap for use with Universal and Adjustable Gully Hoppers Nominal Product A B C D 110 D Overall depth to invert including D4118 Hopper 395mm 15

18 PRODUCT RANGE P/E Universal Gully Hopper with all bosses closed Nominal Product A B C D 110 D P/E Adjustable Gully Hopper Nominal Product A B C D 110 D S/S Bottle Gully with all bosses closed Nominal Product A B C D 110 D Sealed Access Cover for Bottle Gully complete with sealing ring and screws Nominal Product A D P/E Trapped Yard Gully 300mm diameter provides access to surface water drainage system for cleaning, supplied with removable rubber bung. Nominal Product A B C D 110 D Material: Polyethylene Yard Gully Catchment Bucket for use with D4095 Yard Gully Nominal Product A B D Material: Perforated, galvanised mild steel 16

19 PRODUCT RANGE P/E Trapped Road Gully 450mm diameter x 900mm invert Nominal Product A B C D 160 D Capacity: 100 litres Material: Polyethylene S/S Road Gully Adaptor for connection to 160mm WavinSewer Nominal Product A B C 160 D Grease Traps Grease Trap flow rate 1 l/sec Nominal Product A B C D (litres) 40 D E F G H Material: GRP Inlet/outlet: 110mm Grease Trap flow rate 2 l/sec Nominal Product A B C D (litres) 80 D E F G H Material: GRP Inlet/outlet: 110mm 17

20 PRODUCT RANGE Grease Trap flow rate 4 l/sec Nominal Product A B C D (litres) 160 D E F G H Material: GRP Inlet/Outlet: 110mm Grease Trap flow rate 8 l/sec Nominal Product A B C D E (litres) 320 D Material: GRP Inlet/Outlet: 110mm Unless noted otherwise: 1. All dimensions are in mm. 2. Material: unplasticized Polyvinyl Chloride (PVC-U). 3. Colour: Golden brown. 4. Product drawings generally refer to the 110mm size. Larger size fittings are not drawn in proportion. 18

21 DESIGN INFORMATION Typical Properties of PVC-U Property Specific Gravity Specific Heat Thermal Conductivity Coefficient of Linear Expansion Vicat Softening Temperature (Min) Value 1.42 at 20 C 0.24 cal/g C 1.6 W/m C (6-8) x 10-5 / C Pipe: 79 C Fittings: 77 C Modulus of Elasticity 3000 N/mm 2 Poisson's Ratio 1:3 Tensile Strength at Yield at 3mm/minute Elongation at Break at 3 mm/minute 45kN/mm 2 (min) at 20 C 80% (min) at 20 C Structural Properties of PVC-U The material and structural properties required for PVC-U pipes and fittings used for drain and sewer applications are set out in IS.424:1990, Local Government Specification 1977, BS 4660:1973, BS 5481:1977 and ISO/DIS Product testing requires careful control of sampling methods and laboratory conditions. Wavin products are designed and produced to these requirements. Summary of Standard Tests IS ISO/DIS BS BS Product Test Material Deformation Temperature Colour & Colour Fastness Pipes Alkali & Acid Resistance Tensile Strength Elongation at Break Stress Rupture Heat Reversion Impact Strength Hydrostatic Pressure Fittings & Assemblies Elevated Temp. Cycling Stress Relief Drop Test Hydrostatic Pressure Diameter Distortion Angular Deflection Temp. Cycling and Loading Negative Pressure 19

22 DESIGN INFORMATION Hydraulic Properties Velocity and Discharge The Colebrook-White Formula should be used for the design of Wavinsewer systems. Where considerable numbers of branch drains are intercepted or other causes of head loss occur, it is suggested that they be allowed for by a reduction in the sewer capacity. In most cases, a reduction of 5% will probably be adequate. The Formula states: ks 2.51v V = 2 2gdi log [3.7d d 2gdi] + For pipes not flowing full, the Colebrook-White formula is expressed as follows: ks 1.256v V = 32gmi log [14.8m + m 32gmi] where V = Mean velocity in m/s d = Internal pipe diameter in metres g = Gravitational acceleration = 9.8 m/s 2 i = Hydraulic gradient k = Pipe wall roughness in metres v = Kinematic viscosity of water at 15 C = x 10-6 m 2 /s m = Hydraulic radius = Wet cross sectional area (m 2 ) Wet perimeter (m) Gradients Minimum drain sizes and gradients for foul water building drainage should be as follows: a) For drains taking small flows or when continuous flows containing solid matter are less than 1 litre per second, or when the drain is long, the gradient for 110mm drains should be 1:40 minimum fall. b) Single dwelling discharging to septic tank or sewer; 110m drain at 1:60 minimum fall. c) One WC in each of up to 5 housing units; 110mm drain at 1:70 minimum fall. d) One WC in each of 5 to 10 housing units; 110mm drain at 1:80 minimum fall. e) One WC in each of 5 to 150 housing units; 160mm drain at 1:150 minimum fall. Maximum gradients giving a velocity of 5m/sec are possible with Wavinsewer as the deposition of solids or pipe erosion are no longer problems. Turbulence at manholes can lead to fouling at high velocities and provision to reduce this should be considered at the design stage. Grease Traps Design Guidelines 1. The rate of flow into the Trap should be calculated in accordance with BS 8301: Proportional Velocity and Discharge chart 2. Average grease/fats produced = litres/head /day Every 1 litre/second inflow to the Trap requires 40 litres of grease storage capacity. Proportional Depth Discharge ( Qp ) Q Velocity ( ) Vp V 4. Rate of Inflow Retention Time Less than 2 litres/sec 2 minutes 2 9 litres /sec 3 minutes litres/sec 4 minutes 20 litres/sec 5 minutes 5. Discharge/Output Flow Up to 400 meals per day 2 litres/sec Every additional 100 meals 0.25 litres/sec Automatic Dishwasher 1 litre/sec Proportional Velocity ( Vp V ) and Discharge ( Qp Q ) 6. The Trap should have a surface area of 0.25 square metres for every litre/sec inflow. 7. The temperature of the inflow to the Trap should not exceed 40 C. 8. The temperature of the effluent from the Trap should not exceed 30 C. 20

23 DESIGN INFORMATION Flow Chart for Wavinsewer in clean water condition k s : 0.06mm Discharge: litres per second Temperature: 15 C Discharge: litres per second Hydraulic Gradient ( H L) Hydraulic Gradient ( H L) Velocity: metres/second pipe size mm

24 DESIGN INFORMATION Flow Chart for Wavinsewer in slimed condition Slimed to about half depth; velocity, when flowing half full, approx. 1.2m/s k s : 0.15mm Discharge: litres per second Temperature: 15 C Discharge: litres per second Hydraulic Gradient ( H L) Hydraulic Gradient ( H L) Velocity: metres/second pipe size mm

25 DESIGN INFORMATION Flow Chart for Wavinsewer in slimed condition Slimed to about half depth; velocity, when flowing half full, approx. 0.75m/s k s : 0.6mm Discharge: litres per second Temperature: 15 C Discharge: litres per second Hydraulic Gradient ( H L) Hydraulic Gradient ( H L) Velocity: metres/second pipe size mm

26 HANDLING, STORAGE, TRANSPORT, INSPECTION AND INSTALLATION HANDLING Care should be exercised at all times in handling pipes to avoid damage to the pipe surface or to pipe ends which have been chamfered or otherwise prepared for jointing. On no account should pipes be dragged along the ground. The impact strength of PVC-U is reduced somewhat at temperatures below 10 C, therefore even more care in handling should be exercised in cold conditions. Loading and Unloading When loading and unloading bundles mechanically, use either nylon belt type slings or fork lift trucks with smooth forks. Metal slings, hooks or chains must not come into direct contact with the pipe. Pipes should always be laid down gently and should never be dropped onto a hard surface. Pipes at the top of a stack should always be the first to be removed. Where pipes have been transported one inside another, the innermost pipe should be removed first. Figure 1. Handling of block bundles supported throughout its length. This can be achieved by bedding on a layer of sand. Side supports should be provided at intervals of not more than 2 metres and should preferably consist of battens not less than 75 mm wide. Pipes should not be stacked more than 2.5m high and pipes of different sizes should be stacked separately. Pipes should not be stored one pipe inside another. Socketed pipes should be stacked in layers with the sockets protruding and pointing in opposite directions in alternate layers so that each pipe has an even bearing throughout its entire barrel length. Care should be taken to ensure that no load is carried by the sockets. Pipes should at all times be stored in such a manner that the ends are not exposed to the danger of damage. On no account should pipes be stored in a stressed or bent condition or near a heat source. Pipes of different sizes should be stacked separately. Figure 2. Storage of loose pipes on the ground On site, stacks of pipe should not be climbed upon. Pipes should not be walked on or dropped on the ground, but should be carefully handled at all times. On exposed sites where unauthorised interference may occur, the stacks should be suitably secured to prevent dislodgement. Fittings and Lubricant Rubber rings, gaskets and all fittings should be stored so as to avoid damage to them, or contamination by oils, petrol or greases. It is most important that all rubber items be stored in a cool, dry, dark place so as not to be exposed to the light. Storage of fittings on site or in long term storage should be retained in their original containers or in suitable bins until required for use. Contamination by earth, mud, dirty water, oils and greases should be avoided. When not in use, lubricant containers should be kept shut to prevent the entry of dirt and dust. 2m or 7 layers max. 2m Figure 3. Storage of loose pipes on bearers STORAGE Pipes Pipes should be given adequate support at all times. They should be stored on a reasonably flat surface, free from stones and sharp projections so that the pipe is 24 75mm bearing width 1m spacing maximum

27 TRANSPORT, INSPECTION AND INSTALLATION TRANSPORT Vehicle A flat floored vehicle should be used to transport pipes. Its floor should be free from nails or other sharp projections. It is particularly stressed that there should be no projecting battens at the end or elsewhere on the truck floor which would prevent the pipe being evenly supported. Loading and Transport In no case should pipes overhang the vehicle by more than 0.6m. Socketed pipes should be stacked in layers with the sockets protruding and pointing in opposite directions in alternate layers. Care should be taken to ensure that no load is carried by the sockets in the bottom layer. Pipe loads stacked higher than 2.5m are not recommended. In the case of mixed loads, thick walled pipes should be located beneath the lighter pipes. Pipes may be transported one inside another provided that: a) the pipes are clean and free from grit, b) suitable covering be provided over the exposed ends of the pipes to prevent the entry of grit during transport, c) the pipes in the lower layers are not excessively loaded, ie., to such a degree as would cause damage or undue distortion, and d) the pipes be off-loaded on arrival, the smaller diameter pipes being removed first. During transport, the pipes should be protected from damage at all times. Small lots of pipe should be secured in bundles which may be easily handled manually. The pipes should be provided with adequate side support and should be effectively secured to avoid relative movement during transport. Side supports should be provided at not more than 1.2m intervals. These uprights should be flat and free from sharp edges. Where timber framed bundles of pipe are transported one on top of another, care should be taken to ensure that the frames are so secured that they cannot move relative to one another throughout transport. It is important that the vehicle be driven at all times in such a manner that no damage to the pipes may occur during transport. Figure 4. Transport of loose pipes Transport and Off-loading on Site Efficient means for transporting the pipes on site should be provided. These should be such that the pipe is adequately supported at all times and that it is not subjected to excessive stresses. Care should be taken that damage to pipes by vibration, knocks and scratches does not occur. Similar care should be exercised in offloading and ensuring that there is adequate support and protection for the pipes when placed along the trench or road margin prior to laying. On site, no pipe should be transported one inside another. INSPECTION ON DELIVERY General All deliveries and off-loading at site should be supervised by the purchaser s representative. Pipes and fittings should be examined for signs of damage before acceptance. The markings on the pipes should be checked to ensure that they comply with the requirements of the specification against which the pipes were purchased. Inspection If there is any evidence that the load has shifted or shows signs of rough treatment or has not been handled and stacked as recommended, then each pipe should be inspected for damage before acceptance. Otherwise, ordinary inspection while unloading should be adequate to ensure that pipes and fittings have arrived in acceptable condition. INSTALLATION Principles Flexible pipes such as those made from PVC-U do not readily fracture under load, but are liable to deformation. They rely considerably on the immediate surrounding fill to resist circumferential deformation. Accordingly, PVC-U flexible pipelines should be surrounded by noncohesive material as specified in these recommendations and it is of prime importance that the fill material be properly compacted to prevent excessive deformation of the pipe. In order to avoid interference with flow, deformation should be limited to 5% on completion of the backfilling which can only be achieved by proper compaction of the backfill. It is essential to avoid high stress concentrations and so sharp objects or large stones should not be allowed to come into contact with the surface of the pipe. The flexible nature of PVC-U enables it to accommodate most longitudinal deformations resulting from ground movement or from differential settlement. Excavation, underbed and pipelaying Excavation Trench As a general rule, trenching should not be carried out too far ahead of pipe laying. Backfilling should take place as soon as possible. 25

28 INSTALLATION The trench should be kept as narrow as practicable but must allow adequate room for jointing the pipes and placing and compacting the backfill. Trenches should be excavated with vertical sides to a height of 300mm above the top of the pipe. The trench bottom should comply with the limiting widths set out in Table 1. Table 1. Trench widths Nominal Width of Trench Pipe (mm) (mm) Min Max " Trench Bottom In all cases, the trench should be excavated to a depth which will allow for laying the pipes on a prepared underbed. The trench bottom should be carefully examined for the presence of soft spots and hard objects such as stones, rock projections or tree roots, which should be removed and filled with well tamped bedding material. Where a delay in pipe laying is envisaged, the bottom layer of 300mm should not be removed until the permanent material is about to be placed in order to avoid deterioration of the formation. Spoil The excavated spoil should be kept at least 0.5m back from the edge of the trench and all loose stones removed from the side of the spoil heap remote from the trench. Depth of Cover Normally, pipes should be laid with a cover, measured from the top of the pipe to the surface of the ground, of not less than: 1.2m under roads, 1.0m in agricultural land, 0.5m in gardens within curtilage of dwellings. Where such cover is not practicable, the designer should specify alternative methods of protection. The designer should take into consideration in his design any conditions, existing or envisaged, which might adversely affect the performance of the pipes. When future landscaping or other development works are envisaged, sufficient depth should be allowed over the pipes to ensure that the loadbearing capacity of the pipeline will not be exceeded due to surcharge and/or surface loads. Underbed General The prepared underbed should consist of bedding material laid to the correct gradient and depth over the full width of the trench as excavated and should give uniform support to the pipe over its entire length. Depth of Bedding In normal clay excavation, the thickness of the bedding under the barrel of the pipe should be not less than 100mm. In rock, a thickness of at least 150mm should be allowed. In very soft conditions, the thickness of the bedding should be as directed by the designer. Bedding Material Bedding material may be either: a) Granular Aggregate Complying with the requirements of Table 1 of IS. 5 Aggregates for Concrete as follows: Pipe Material 110mm to 250mm: 10mm nominal single-sized aggregate. Pipe Material 315mm and greater: 10, 14 or 20mm nominal single-sized aggregate or 14-5 or 20-5mm nominal size graded aggregate. When using the above material, no special compaction is required. Figure 5. Pipes bedded in granular material Sidefill 150mm wide each side of pipe regardless of diameter 100mm granular bedding Granular sidefill As-dug backfill Granular material extended for at least 100mm over crown of pipe b) Imported Sand or Sand/Gravel Mixture In special cases when approved by the designer and client, imported sand or sand/gravel mixture not complying with the grading in a) but which, when determined in accordance with the Appendix (page 41), would have a compaction fraction not greater than 0.3 may be used. The maximum particle size should not exceed 20mm. When using material of this quality, it should be so compacted as to attain not less than 90% of the maximum dry density at optimum moisture content when determined in accordance with Test 12 of British Standard 1377 Methods of test for soil for engineering purposes, and provision should be made for field testing accordingly. British Standards are published by the British Standards Institution, 2 Park Street, London W1A 2BS. 26

29 INSTALLATION Figure 6. Pipes bedded in granular material and covered with as dug material which is free from stones exceeding 40mm Sidefill 150mm wide each side of pipe regardless of diameter c) As Dug Material In the case of single houses, and when approved by the designer and client, as-dug material excavated from the trench may be used provided it complies in all other aspects with the requirements above. Figure 7. Pipes bedded in suitable as-dug material Sidefill 150mm wide each side of pipe regardless of diameter Pipelaying Compacted in 300mm layers as-dug backfill Granular sidefill 100mm granular bedding Compacted as-dug backfill As-dug sidefill 100mm as-dug bedding General Pipes should be lowered into the trench with tackle suitable for the weight of the pipes using suitable lifting slings, preferably flat. On no account should chains or wire ropes be used. The position of the slings to ensure a proper balance should be checked when the pipe is clear of the ground. Any construction debris inside the pipe should be removed using a pull-through. Laying Practice Pipes should be joined in the trench and laid on the prepared bed so that they maintain substantially continuous contact with the bed. Small depressions should be made in the bed to accommodate the pipe joints. When the pipe socket or pipe and coupler have been bedded, the depressions should be filled carefully, taking care that no voids remain under or around the joint. Levelling devices such as bricks or pegs should be removed and any resulting voids filled before backfilling is commenced. Steep Gradient If due to steep gradient or waterlogged conditions, the bedding tends to act as a drain for subsoil water, the insertion of waterstops of puddleclay dams across the trench may be necessary to resist the passage of water. Flooding If the trench becomes flooded, buoyancy may occur, in which case the pipes may be held down by partial backfilling or by suitable anchors. Such a situation may arise overnight, when at the cessation of work, the ends of the pipes should be plugged to prevent the entry of dirt or vermin. Special Precautions Pipes Passing Through Walls Where a pipe is required to pass through a wall or foundation of a building or other rigid structure, it should be enclosed in a suitable sleeve having a minimum radial clearance of 25mm. Alternatively, a lintel or relieving arch may be formed in the structure. Care should be taken to prevent water passing along the barrel of the pipe and through the wall, or the entry of surrounding granular material. Movement Allowance Where a pipe is rigidly fixed to a structure, two flexible joints should be used, one on each side, as close to the structure as possible. Where substantial subsidence is anticipated, it is desirable to provide a short length of pipe (ie. a rocker pipe) with a flexible coupler on each end to allow movement. Pipelaying at Low Temperature Particular care should be exercised when installing pipes at temperatures below 10 C. Pipelaying should not be carried out when the temperature of the pipes is below 0 C. Pipelaying Above Natural Ground Level Expert advice should be sought in cases where pipes are to be laid above the natural ground level. Pipelaying in Unstable Ground The soft relatively unstable conditions of the trench bottom that can occur with softened clays, silts, very fine sands or peat are unfavourable to flexible pipes because of the buttressing effect of the sidefill, which normally helps the pipe keep its shape, may be considerably reduced; and this effect is aggravated if there is a high water table. In such situations, care is needed depending on the severity of the conditions and advice sought from the Technical Department of Wavin Ireland Limited. Use of Concrete General Principles Normally, flexible pipes should not be bedded in or surrounded by concrete; its use converts a flexible pipe into a rigid one which is more liable to fracture under ground movement. However, in certain circumstances, a designer or local authority may require the use of concrete bedding or surround and in such cases, special precautions should be taken. Flexibility Some flexibility can be maintained in a pipeline bedded and surrounded in concrete if the continuity of the bedding is broken by forming joints incorporating a flexible material. Such joints should 27

30 INSTALLATION be not less than 25mm in width and should be coincident with the pipe joint. Encasement (Reinforced) Where a pipeline is encased in concrete, it should be wrapped in a membrane such as felt or plastic sheeting. As differential movement is likely to occur at the ends of the concrete surround, the adjacent pipeline should comprise one or more short lengths of pipe jointed by couplers. Protecting PVC-U Pipe from Loads As PVC-U pipes are flexible, they can accommodate ground movement and pressure without damage. However, if the pipe needs protection, eg., when laid with a cover of less than 1.2 metre under a road, concrete may be used above the pipeline as a protective raft, provided a cushion of fill is laid between the pipe crown and the raft (see Figure 8). This will prevent unacceptable deflection of the pipe. Figure 8. Protecting underground pipe from loads The material should be placed and compacted by hand in layers not more than 100mm thick and should extend over the crown of the pipe to a depth of 100mm for 110mm pipe and 150mm for pipes of larger diameter. It should extend over the full width of the trench as excavated. Remainder of Backfill The next 300mm of backfill may consist of material excavated from the trench provided it is free from stones exceeding 40mm. The remainder of the backfill may also be material excavated from the trench but only if it is free from heavy stones or other objects which could protrude through the special initial backfill during the backfilling or compacting process. Mechanical compactors, other than hand vibrators, should not be used until the total depth of backfill over the pipe is 450mm. Trench Sheeting Trench sheeting if used, should be withdrawn in stages as sidefilling and backfilling proceeds and the spaces between the pipe and the sides of the trench completely filled with sidefill and firmly compacted. insertion, after which the new branch connection may be made. Alternatively, a saddle connection may be made. The saddle should be placed in its intended location and its position marked. The position of the inlet hole should be marked on the outside of the pipe using either the saddle or a purpose-made template. The inlet hole is made by drilling a small hole and cutting out the profile with a keyhole saw. Remove all swarf and rough edges. The surface of the pipe and the saddle should be cleaned, roughened and coated with cement and jointed. Figure 9. Assembly of a solvent saddle joint a. b. Mark position of connection using inside of saddle branch as guide and cut out hole. Apply a liberal coat of Solvent Cement to the mating surfaces. 100mm cushion of fill Backfill Sidefill and Initial Backfill The material used for sidefill and initial backfill should comply with the requirements for bedding material. For the protection of the pipe, the sidefilling and initial backfilling operations should be carried out as soon as possible after the pipes have been laid and tested. 28 Reinforced Concrete raft Connection into Sewers Connection into Existing Drains and Sewers Connections to sewers should be made only as directed by the drainage authority. Wavin Adaptors should be used for connecting to junctions or saddles on existing pipelines. Connection into PVC-U Drains and Sewers A connection into PVC-U pipe may be effected by inserting a branch into the line. This is achieved by cutting out the appropriate length of PVC-U pipe, preparing the cut ends for jointing and placing repair couplers into position on the prepared ends. The branch is fitted into position and repair couplers slipped into position to complete the c. Strap the Saddle temorarily to ensure firm all-round contact. The joint should be held in position with tying wire until sufficient strength has been achieved. In general, 15 minutes should be allowed before making connection to the saddle. Connection to Other Materials The Wavinsewer system includes Adaptors to connect to clay or iron spigots or sockets. Connection to Clay or Iron Spigot Apply mastic to the spigot face of the clay or cast iron pipe and insert it into the socket of the PVC-U

31 INSTALLATION Adaptor (WS 13). Caulk firmly with a layer of gaskin and complete with a sand and cement joint (see Figure 10). Figure 10. Connection to clay or iron spigot Connection to Clay Socket Apply a bead of mastic to the face of a PVC-U Adaptor (WS 14). Position the Adaptor in the socket and caulk with yarn followed by cement mortar. Then insert the PVC- U pipe spigot in the standard way (see Figure 11). Clay or Cast Iron Spigot Flow D4079/4080 (WS13) WavinSewer Pipe Connection to Cast iron Socket Apply a bead of mastic to the face of a PVC-U Adaptor (WS 14). Position the Adaptor in the cast iron socket and caulk with gaskin followed by well caulked lead wool. Do not use hot lead. Alternatively, use gaskin and cement mortar in a similar way to that used for jointing PVC-U to a clay socket (see Figure 12). Figure 11. Connection to clay socket Flow WavinSewer Pipe Clay Socket Jointing Preparing Pipe Ends All spigots on fittings and the ends of standard lengths of pipe are chamfered approximately 15. Pipes cut on site must be clean cut at right angles to their horizontal axis. Chamfer the cut end to approximately half the pipe wall thickness and deburr it with a scraper. Figure 12. Connection to cast iron socket Flow WavinSewer Pipe D4081/82 (WS14) Cast Iron Socket Depth of Entry Mark Some plain ended fittings have a depth of entry mark moulded on the spigot. This depth of entry allows the pipe to expand into the fitting socket. Insert the spigot into the socket until the depth of entry mark is just visible. All pipes - whether cut on site or otherwise - and other plain ended fittings must be inserted to the full depth of the socket, marked at the socket face, and then withdrawn at least 6mm (see Figure 14). Figure 13. Pipe preparation D4081/82 (WS14) a. Cut pipe square b. Chamfer spigot ends 15 equal equal 29

32 INSTALLATION Figure 14. Ring seal jointing Ring seal Depth of entry mark Ring seal Depth of entry mark Ring Seal Joints Pipe Couplers and most Bends and Branches, particularly in the 110mm and 160mm sizes, are supplied with sockets on all ends. These sockets are fitted with ring seals which act as both seals and expansion joints. The correct sequence for ring seal jointing is as follows: 1. Check that the pipe chamfer is correct (see Figure 13) and that the ring seal is properly seated in its housing. 2. Make sure that both the pipe or fitting spigot and the ring seal socket are dry, clean and free from grit or dust. 3. Lubricate evenly around the spigot and Wafix seal with Wavintite Lubricant (see Table 2). 4. Make sure that the components to be joined are correctly aligned. 5. Push the spigot fully into the socket. Mark the spigot at the socket face and then withdraw the spigot by a minimum of 6mm. If the spigot is already marked with the depth of entry, push it into the socket until the mark is just visible. Make a subsequent check to ensure that the expansion gap is not lost during further installation work (see Figure 14). 6. Do not cut back the straight leg sections of Long Radius Bends or Channel Bends as only the spigot end provided is suitable for jointing. 7. Make jointing of large pipes easier by levering them into position. Protect the pipe end (or socket mouth in the case of single pipes) from the levering by placing a block of wood between the pipe and the lever (see Figure 15). Figure 15. Jointing large pipes Table 2. Lubricant allowance Pipe Number of Joints (mm unless noted) (per 500g) Table 3. Depths of WAJ assemblies Wavin Access Junctions The Wavin Access Junction is designed to provide the method of collecting 110mm drains at invert depths up to 600mm by the use of WAJ Risers. The total assembly comprising Base, Riser and Frame Unit provides a completely sealed system up to ground level. Considerable savings in installed costs may be achieved by using WAJ s compared to traditional manholes. WAJ s may be installed relatively quickly, since no additional excavation is required other than that for normal drain laying, and the need for wet trades is eliminated. The depths of WAJ assemblies from the top of the Cover to the Channel Invert are given in Table 3. The design incorporates telescopic, tilt and swivel facilities which give all the flexibility required on site. A choice of 9 configurations provide a comprehensive, level invert system with excellent flow characteristics. The PVC-U Cover is normally unsealed for external use but a sealed and bolted cover is available for internal use on request. Installation of Wavin Access Junctions 1. Lay suitable bedding material (as used for the drain line). 2. Make pipe connections in the same way as the standard ring seal jointing of fittings. Assembly A B (mm) (mm) WAJ without Riser WAJ with one Riser WAJ with two Risers

33 INSTALLATION Figure 16. Wavin Access Junction assembly Figure 17. Wavin Access Junction typical application Gully 45 (LH) Wavin Access Junction 45 (RH) Wavin Access Junction 45 Branch 45 Bend 110mm Pipe Figure 18. WAJ, non-load installation 150mm sidefill of suitable as-dug or granular material continued to ground level D4492 Cover and Frame 3. Place the WAJ on a minimum 100 mm bed of as-dug or granular material and surround it with similar material 150 mm wide. Installations suitable for wheel loads up to Class C (250 kgs) require a 150 mm thick concrete plinth around the top of the WAJ (see Figure 19). 4. Depending on the depth of invert required (see Table 3), either: a) Use the WAJ complete with Frame Unit as supplied. b) Push-fit one or two WAJ Risers (D4183) directly into the WAJ and fit the Frame Unit. Intermediate depths may easily be obtained by cutting the Riser to the required depth. 90 Wavin Access Junction Figure 19. WAJ installation suitable for wheel loads up to Class C (250 kgs) 90 Wavin Access Junction 150mm sidefill of suitable as-dug or granular sidefill around WAJ to underside concrete plinth D4492 Cover and Frame 110mm WavinSewer 150mm concrete plinth 110mm WavinSewer Sealed Access Fittings Sealed Access Fittings with removable covers are available as an alternative to open channels in traditionally built manholes. The haunching around Sealed Access Fittings does not have to be as precise as that around open channels. Sealed Access Fittings are particularly suitable for areas that have a high water table and where it is difficult and uneconomical to construct a watertight manhole. Sealed Access Fittings may be used internally. A sealing ring between the cover and the main body of the fitting gives an airtight joint. This makes the specification of a more expensive double sealed manhole cover unnecessary. The opening area available when the cover is removed is large enough to permit rodding in all directions including branch arms and for the removal of debris. The sealing ring fits into a recess in the cover. The cover is secured via studs, washers and nuts which are all stainless steel. An additional feature is the 50mm boss socket on the cover to which a standpipe can be fitted. This enables standing water to be drained from the manhole and also indicates the presence of a blockage below the manhole. Sealed Access Fittings may also be used within back-drop manholes and for Suspended Drainage. 31