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

34 INSTALLATION Installation of Sealed Access Fittings Manholes with Sealed Access Fittings are generally constructed in the same way as traditonal manholes but as watertightness is not critical, unlined brick or concrete manholes may be permitted. Benching of the pipework is essential. 1. Bed all Sealed Access Fittings in cement mortar on a suitable concrete base. Figure 20. Sealed Access Manhole with standpipe Wall not necessarily watertight Concrete benching laid to fall Flow Standpipe Assembly Single seal manhole cover 2. Make pipe connections in the usual way. 3. Allow pipe ends to protrude beyond the edge of the manhole base so that connections can be made after the manhole walls have been built. 4. Slope benching of the pipework so that standing water will drain into the Access Fitting when the cover is opened. The benching must provide adequate clearance for the access cover to be D mm Waste Pipe Access Plug Figure 21. Sealed Access Manhole with shallow invert used internally removed for routine servicing. Nuts should be tightened in a diagonal sequence. Undue force should not be used during the tightening process. 5. When standpipes are specified, fit these to the boss socket on the top of the cover. Open Channel Manholes Open channels provide easy access for rodding in all directions and for the removal of debris. However, construction can be labour-intensive, depending on the amount of haunching and benching necessary. The Wavinsewer system offers a wide choice of open Channel Pipes and Fittings for stepped invert applications and where changes of direction are required, Long Radius Curved Channels are included in the range. It is not recommended that channels be fabricated on site from pipe. In back-drop manholes, the droppipe will normally be outside the chamber and should be surrounded either in concrete or as-dug or granular material. Where the droppipe is positioned inside the chamber, it should be securely supported at intervals not greater than 1 metre. When used as Mid Radius Channel Bends, the D4169 (45 ) and D4112 ( ) Bends are to be drilled and cut on site using a hand drill, pad saw and plain toothed rasp. The cut-out section is marked on both fittings (see Figure 23). Section Plan Finish Floor Flow Flow Concrete Floor 32

35 INSTALLATION Figure 22. Sealed Access Fitting typical installation D4169 D4001 D4032 D4269 Figure 23. Mid Radius Bend cut-out Figure 24. Open Channel Manhole with stepped invert branch entries D4129 D4128 D4002 Installation of Channel Fittings 1. Bed all Straight and Curved Channels in cement mortar on a suitable concrete base. 2. Side entries into the main channel should have an angle of entry not greater than 90 from the internal face of the manhole. For entries greater than 90, a Double Socketed Bend (eg. D4019) should be placed adjacent to the manhole, which should provide a deviation of not more than 45 (see Figure 24). D4002 Concrete benching D

36 INSTALLATION Figure 25. Open Channel Manhole with stepped invert and external backdrop D4077 D4032 D4003 grating and the top level of the water seal. Cut a hole in the grating to allow a pipe up to 75mm diameter to be inserted. 4. Backfill with suitable material. 5. When not protected by paving or concrete at ground level, the crown of the Outlet Bend must be below the level to which garden implements may penetrate. When this is not possible, bed a concrete slab above the Bend. Universal Gully D Bed the Curved Channel Branches in cement mortar and connect them to the main channel so that the discharge from the Branch is in the direction of flow of the main channel. 4. Allow pipe or fitting ends to protrude beyond the edge of the manhole base so that connections can be made after the manhole walls have been built. 5. Provide concrete benching to rise vertically from the top edge of the channel pipe to at least the height of the outlet soffit. 6. Shape the benching around the Channel Branches of the branch drains to guide the flow of sewage in the desired direction. 7. Where practicable, ensure the soffits of the main pipes entering and leaving a manhole maintain a similar gradient. Gullies Traditional Gully D4040 D4128 The Traditional Gully has a Wafix ring-seal joint on the outlet bend which allows flexibility in either lining up the inlet square with the house or substituting the 45 bend supplied with a or to adjust for gradient. A Gully Riser (D4192) can be fitted to the hopper to facilitate the installation of a Traditional Gully at an invert depth greater than 340mm. Installation of Traditional Gully 1. The Gully is supplied fully assembled. Set it on a substantial base such as a precast concrete slab, bricks or in-situ concrete and haunch it with concrete until it is selfstanding. 2. Make connection to the drain via the 45 Bend supplied. 3. Make vertical inlet connections in accordance with Building Regulations which state that a branch pipe should only discharge to a gully between the The Wavin Universal Gully Trap (D4090) is self-standing and has a ring seal socket for connection of the Hopper. Use the appropriate Wavinsewer Bend to form either a P, Q or S outlet. The Universal Hopper (D4145) has a back inlet with Wafix ring seal joint for the connection of 110mm Wavinsewer pipe and inlets either Figure 26. Traditional Gully Figure 27. Universal Gully, Hopper and Outlet Bend 34

37 INSTALLATION side to suit either 110mm Wavinsewer pipe, 68mm Wavin Osma rainwater downpipe or 40mm Wavin White Waste. Alternatively, the Adjustable Hopper (D4138) may be used in place of the Universal Hopper. Installation of Universal Gully 1. Assemble the Trap, Hopper and suitable Outlet Bend out of the ground. 2. Set it on a substantial base such as a precast concrete slab, bricks or in-situ concrete and haunch it with concrete to the level where the supporting feet meet the body. Make sure the concrete does not enter any ring seal joints. 3. Make connection to drain via a suitable Outlet Bend. 4. When using the Universal Hopper, make any required horizontal connections for 110mm Wavinsewer, 68mm Wavin Osma rainwater downpipe or 40 mm Wavin White Waste. 5. Make vertical connections in accordance with Building Regulations as previously described. 6. Backfill with suitable material. 7. When not protected by paving or concrete at ground level, the crown of the Outlet Bend must be below the level to which garden implements penetrate. When this is not possible, bed a concrete slab above the Bend. Bottle Gully installer considerably with unpredictable conditions on site. Three blanked-off inlets, one either side, and one at the back of the gully, may be used to connect pipes from 32mm to 110mm. Easy access for rodding the system is provided by means of a removable rubber access plug. The Gully is supplied with a polypropylene grating. A Sealed Access Cover (D4311), which is secured to the gully by means of four self-tapping screws, is also available. Figure 28. Bottle Gully, typical assembly Polypropylene Grating PVC-U Frame Ring Seal Socket Figure 29. Bottle Gully installation with vertical inlet. Installation of Bottle Gully 1. Position and level the Gully on a suitable base, such as precast concrete slab, bricks or in-situ concrete. 2. Haunch it with concrete 25-30mm from the base. This will ensure that the base is firmly located. 3. Make any horizontal connections from 32mm to 110mm to either left, right or back sockets. 4. Make vertical connections for waste or rainwater pipes by cutting the grating to the necessary diameter and insert Sealing Ring Access Access Plug The Bottle Gully is a neat, compact and practical alternative to traditional gullies. Its advanced design features incorporate a fixed baffle, having a removable access plug, three 110mm side bosses and a square cover and frame, which ensures a perfect fit when used alongside paving slabs. The Bottle Gully has a number of installation and maintenance advantages. The body of the gully can rotate by means of a push-fit joint, connecting the body with the cover. This facility assists the Rainwater/Waste Pipe D4308 D

38 INSTALLATION Figure 30. Yard Gully - typical installation Suitable Grating and frame the pipe (see Figure 29). 5. Backfill with suitable material. It is not necessary to surround the Gully with concrete. Yard Gully The Yard Gully (D4095) is manufactured from polyethylene, a robust material, offering both high impact with good chemical resistance. The unit is available as a single component, being 300mm diameter by 600mm invert depth and incorporates an integral trap, with a removable rubber plug, allowing easy access for rodding. A perforated mild steel Catchment Bucket (D4097) is available as an optional extra. D4097 Figure 31. Yard Gully - typical installation Bed the grating and frame in a suitable concrete mix D4095 Installation of Yard Gully 1. When excavating the Gully pit, allow an additional 100mm under the unit and 150mm around the unit. 2. Sit the Gully on a minimum of 100mm as-dug or granular material and surround it with similar material 150mm wide, up to the underside of its 110mm spigoted outlet. 3. Connect the Gully to the branch drain in the appropriate way. 4. Pour 150mm x 250mm invert of concrete around the Gully up to its lip. 5. Where required, insert the Galvanised Mild Steel Catchment Bucket (D4097). 6. Bed a Ductile Iron Grating and Frame in a suitable concrete mix (see Figures 30 & 31). Wavin Trapped Road Gully Pour 150mm by 250mm invert of concrete around gully Bed and surround the gully in a minimum of 110mm under and 150mm around the unit of granular material Connect 110mm WavinSewer in the appropriate way When excavating the gully pit allow an additional 100mm under and 150mm around the unit The Wavin Road Gully offers high impact resistance with light weight. A series of external reinforcing ribs give the unit its strength and also act as anti-flotation collars during installation. The Gully s flexible outlet allows movement of up to 15 thus offering greater scope and flexibility during installation. 36

39 INSTALLATION Gully Connection to 160mm Wavinsewer 1. Ensure that the pre-fitted flexible outlet is correctly seated. 2. Lubricate the whole of the inside of the outlet. 3. Ensure that the spigot end of the Wavin Adaptor (D4147) is clean and the ring is correctly seated. Align and push home. 4. Insert 160mm Wavinsewer pipe into the socket following the standard jointing sequence for Wavinsewer pipe (see Figure 33). Figure 32. Road Gully - typical installation Gully grating and frame to conform to BS497 Class B Engineering brickwork Installation of Road Gully 1. When excavating the gully pit, allow an additional 150mm under and around the unit. 2. Lay a concrete base 750 x 750 x 150mm overall. Set Gully in position and haunch up to its second rib. 3. Connect the Gully, trapped to the branch drain in the appropriate way (see Figure 33). 4. Pour 150mm of concrete around the Gully up to its lip. 5. Where required, build a brick or concrete kerb on top of the Gully to suit the grating and frame. 6. Bed the grating frame in a suitable concrete mix and fit grating (see Figure 32). Figure 33. Road Gully - connection to 160mm WavinSewer Bed and surround gully in 150mm of C20 concrete Grease Traps The discharge of grease into sewers is now acknowledged as a major problem, causing blockage in pipes and problems at locations such as sewage treatment works and septic tanks. Grease is a normal constituent of water borne wastes from kitchens and food preparation rooms where quantities arise from the washing of Figure 34. Installation of Grease Trap used crockery and utensils. Where waste macerators are installed, the quantities of grease and fats discharged are likely to be greater. Facilities must be available at restaurant kitchens for the bulk collection and removal of grease, fats and oil and to prohibit their discharge into the drainage system. Specific points to note are: 1. It is necessary to provide a Grease Trap on the outlet from D4147 Concrete surround separated by shuttering to prevent load transfer Manhole covers Finished ground level As dug or granular material. Concrete suitably reinforced, in areas of vehicular traffic Access shaft. Height variable. Max 1000mm Inlet Outlet WavinSewer 160mm pipe Flexible joint to allow for differential shifting Concrete surround Concrete base with suitable reinforcement 37

40 INSTALLATION the kitchen before it discharges into the drainage system. 2. The Trap should have sufficient capacity to accommodate the grease. 3. The Trap should be so sited that it will receive sewage-free waste from the kitchen and is convenient for maintenance. 4. Regular and frequent cleaning is essential if grease is not to discharge through the Trap and should include the removal of settled solids to avoid putrification. Wavinsewer includes a range of four Grease Traps with capacities ranging from 40 litres to 320 litres. 6. Connect the inlet and outlet pipes using 110mm adaptors. Incorporate a short length of pipe to allow for differential movement. 7. Where installed in areas subject to traffic loads, the design, construction and installation of the top slab is important. The slab should be appropriately reinforced such that the superimposed loads are not transmitted to the top or side walls of the Grease Trap. 8. When installed in areas subject to loading from vehicles, the cover and frame selected should be capable of withstanding the loads likely to be imposed upon them. 9. It is essential to take precautions to prevent damage to the Grease Trap during installation. Suspended Drainage Drainage pipes may have to be suspended just below floor or ceiling level in basement or similar situations. Wavinsewer Pipes, Couplers, Bends, Branches and Sealed Access Fittings are suitable for suspended installations. However, although PVC-U pipes and fittings are lightweight, they must be suspended by a robust Installation of Grease Traps 1. A suitable location for the Trap should be selected and this will vary from site to site. The location should be such that the wastes entering the Grease Trap should have cooled to 45 C before entering the Trap. The recommended distance from the waste source to the Grease Trap is 4 metres minimum. 2. The location of the Grease Trap must be upstream of foul waste entering the system. 3. Excavate a hole for the Trap allowing an extra 200mm on all sides and 200mm for the base. The actual depth of the hole will be determined by the invert levels of the pipes connected to it. 4. Construct the base using 20N concrete with suitable reinforcement where necessary to a depth of 200 mm. The concrete must be flat and level. In areas of saturation, appropriate measures should be taken to ensure the structural integrity of the base. 5. When the concrete has sufficiently cured, lower the Grease Trap onto the base and line-up the inlet and outlet Connectors with their respective pipes. Fill the Grease Trap with water. Backfill the excavation with gravel or concrete depending on the location. Figure 35. Suspended Bracketing - intermediate pipe support Threaded Bracket Threaded Rod Bracket plate Pipe/Socket bracket Figure 36. Suspended Bracketing - socket support Threaded Bracket Threaded Rod Adjustable Brace Bracket plate Pipe/Socket bracket 38

41 INSTALLATION, TESTING support and anchorage system which can accommodate the expansion and contraction of PVC-U imposed on the system should it become blocked. The Suspended Bracketing system available in the Wavin Soil system is designed to meet these specific requirements. It will support any 110mm PVC-U system in the correct way for any given situation. There are two packs of Suspended Bracketing components, the C8738 pack contains the same components as the C8736 pack plus two Adjustable Braces. These Braces are used to secure a socket and prevent any lateral or horizontal movement. Installation of Suspended Drainage Position access doors at the top or side of the installation depending on the room available. For intermediate pipe support, use the Adjustable Pipe Bracket Assembly (C8736). For socket support, use the Adjustable Socket Bracket and Brace Assembly (C8738). Intermediate Pipe Support 1. Fix the Threaded Bracket from the Adjustable Pipe Bracketing Assembly to the ceiling using bolts appropriate to the ceiling material. 2. Screw the Threaded Rod into the Threaded Bracket. 3. Fix the Bracket Plate on to the Threaded Rod using the two nuts and washers provided. Adjust the height of the Bracket Plate to fall. Cut the Rod below the lower nut. 4. Fix the Pipe/Socket Bracket over the pipe to be supported. Fix the Pipe/Socket Bracket to the Bracket Plate using the two bolts provided. 5. Make pipe connections in the same way as the standard ring seal jointing of fittings. Socket Support 1. Using components from the Adjustable Socket Bracket and Brace Assembly (C8738), follow steps 1 and 2 as outlined for the intermediate pipe support. 2. Fix Adjustable Braces and Bracket Plate onto the Threaded Rod (see Figure 36). Adjust to fall. Cut Rod below the lower nut. 3. Adjust the length of the Braces using the nuts on the Braces themselves. 4. Fit the Pipe/Socket Bracket over the socket to be supported, directly behind the socket shoulder. Fix the Pipe/Socket Bracket to the Bracket Plate using the two bolts provided. 5. Fix the Braces to the ceiling at the side of and behind the socket using bolts appropriate to the ceiling material. 6. Make pipe connections in the same way as the standard ring seal jointing of fittings. Support any 110mm Wavinsewer suspended drainage installation at 0.9m centres maximum and at every socket. As a general rule, the maximum centres can be doubled for vertical installations. Testing Wherever possible, testing should be carried out from manhole to manhole. Short branch drains connected to a main sewer between manholes should be tested as one system with the main sewer. Long branches and manholes should be tested separately. Water Test This test should be carried out after laying and before backfilling. Drains and sewers should be generally subjected to an internal pressure test of 1.2 m head of water above the crown of the pipe at the high end but not more than 6 m at the low end. Steeply graded sewers should be tested in stages if the maximum head would be exceeded were the whole section tested at once. The test should be carried out by inserting suitable plugs in the low end of the sewer and in the connections, if necessary, and by filling the system with water. For small pipes, a short radius bend may be temporarily jointed-in at the top end and a sufficient length of vertical pipe jointed to it so so as to provide the required test head. For both large and small diameter pipes, it may be preferable to connect a hose pipe to a plug with a pressure gauge or stand-pipe. Allowance should be made for initial losses such as those caused by air entrapment or expansion by adding water as required to maintain the test head for not more than one hour before commencing the test proper. The loss of water over a period of 30 minutes should be measured by adding water from a measuring vessel at regular intervals of 10 minutes and noting the quantity required to maintain the original water level. For the purpose of this test, the average quantity required should not exceed 1 litre per hour per linear kilometre per millimetre of pipe diameter. Any leakage which causes a drop in the test water level should be investigated and the defective part of the work removed and made good. Air Test It is sometimes more convenient to test sewers by means of internal air pressure. However, while an excessive drop in pressure when employing the air test may indicate a defective line, the location of the leakage may be difficult to detect and the leakage rate cannot be measured. The air pressure is also affected by temperature changes. Consequently, failure to pass this test is not necessarily conclusive, and when failure does occur, a water test as previously described should be carried out, and the leakage rate determined before a decision as to acceptance or rejection is made. Failure to pass an air test is very often attributable to faults in the plugs or testing apparatus. 39

42 TESTING, REPAIRS, MAINTENANCE AND CLEANING The length of pipe under air test should be effectively plugged as previously described and air pumped in by suitable means (eg., hand pump) until a pressure of 100mm of water is indicated in a glass U-tube connected to the system. The air pressure should not fall to less than 75mm during a period of five minutes without further pumping, after allowing a suitable time for stabilisation of the air temperature. Infiltration Check All inlets to the system should be effectively closed. Visual inspection should then be made at manholes or inspection chambers to ascertain the presence of leakage flow. If the rate of infiltration leakage exceeds 0.8 litres per hour per linear kilometre per millimetre of nominal diameter of the pipe, the source of this leakage flow should be investigated and remedial measures taken. Test for Straightness, Gradient and Obstruction Tests for line, gradient and freedom from obstruction should be applied. and removed. 2. The residual pipe-ends must be cut square and prepared for jointing. 3. Repair Couplers should be placed in position, the replacement pipe length laid on a suitably prepared bed and the Couplers moved to their final position. 4. After testing, the sidefilling and backfilling should be replaced in accordance with appropriate sections of this manual, in order to give compaction values approximately equal to those immediately adjacent to the repair. MAINTENANCE Building Regulations and Local Authority Byelaws state that: Manholes, inspection chambers and rodding eyes must be provided to give ready access to underground Figure 37. Rodding through Bottle Gully drains and sewers for maintenance and cleaning. Remove inspection chamber covers periodically to clean the housing and to check and clean the benching. Check the complete drainage system periodically and clean, making good any necessary defects. CLEANING The smooth bore of PVC-U pipes combined with their longer lengths reduce the risk of blockages. However, if a blockage does occur, use only flexible or roller type rods. Pointed or boring type metal fittings are NOT recommended. Tests have been carried out on PVC-U pipes and fittings using equipment from specialist drain cleaning contractors and their normal equipment is suitable. Do not use specialist cutting attachments. Flexible Rod Bottle Gully with sccess plug and grating removed Inspection Chambers and Manholes Inspection chambers and manholes should be watertight. If the ground water level is likely to be seasonally above the crown of the pipe, chambers and manholes should be inspected for watertightness against infiltration when the water table is at its highest. Records Complete records should be kept of all tests carried out on sewers and drains, both during construction and after being put into service. Figure 38. Access to Bottle Gully for rodding REPAIRS With the Wavinsewer system, it is relatively easy to carry out repairs using Wavinsewer Repair Couplers. The following general points apply: 1. The full extent of the damaged or failed section must be identified 40

43 APPENDIX Determination of Suitability of Imported Material Compaction Fraction Visual Examination Examine the material and reject any which contains pieces with sharp edges. Particle The maximum particle size should not exceed 20mm The following test will ensure compliance with this requirement: A weighed representative sample of material (about 2kg) should be sieved, using a test sieve of 20mm nominal size (see Irish Standard 24:1973, Test Sieves ). Note 1: To obtain a representative sample, about 50kg of the proposed material should be heaped on a clean surface and divided with a spade down the middle. One of these halves should then be similarly divided, and so on until the required mass is left. Note 2: In the sieving, clumps of material that break up under light finger pressure may be helped through the sieve, but considerable force should not be used to squeeze oversize lumps through the mesh. The material is not recommended if any particles are left in the sieve. moisture content of the sample should not differ materially from that of the main body of material at the time of its use in the trench. Place the cylinder on a firm flat surface and gently pour the sample material into it, loosely and without tamping. Strike off the top surface level with the top of the cylinder and remove all surplus spilled material. Lift the cylinder clear of its contents and place on a fresh area of flat surface. Place about one quarter of the contents back in the cylinder and tamp vigorously with a metal rammer until no further compaction can be obtained. Repeat with the second quarter, tamping as before, and so on for the third and fourth quarters, tamping the final surface as level as possible. Measure down from the top of the cylinder to the surface of the compacted material. This distance in millimetres divided by the height of the cylinder (250mm) is referred to as the compaction fraction. Interpretation of Results Compaction Fraction Less than 0.15 Greater than 0.15 but less than 0.3 Greater than 0.3 Suitability for Use Material suitable Material suitable but requires extra care in compaction. Not suitable if the line is subject to waterlogged conditions after laying. Not suitable Ease of Compaction Apparatus [1] Open-ended cylinder 250mm long and 150mm ± 6mm internal diameter (160mm diameter Wavinsewer is suitable). [2] Metal rammer with striking face 40 mm diameter and weighing 1.0 ± 0.1kg. [3] Measuring rule. Procedure Obtain a representative sample (see Note 1 above) more than sufficient to fill the cylinder (about 11kg). It is important that the 41

44 GENERAL INFORMATION ACCEPTANCE Irish Standards Wavinsewer Pipes and Fittings meet the requirements of the Local Government Specification 1977 or IS. 424:1990. British Standards Wavinsewer pipes and fittings comply, where applicable, with the requirements of the following standards: BS 4660:1989 Unplasticized polyvinyl chloride (PVC-U) pipes and fittings of nominal sizes 110mm and 160mm for below ground gravity drainage and sewerage. BS 5481:1977 Unplasticized polyvinyl chloride (PVC-U) pipe and fittings for gravity sewers. Irish Agrément Board Wavin TRITEC pipes are covererd by Certificate No. 97/0089. British Board of Agrément A number of fittings are covered by Agrément Certificates issued by the British Board of Agrément. Wavin is a Registered Firm with the National Standards Authority of Ireland for IS.EN/ISO 9002:1994 Quality Systems. 42 Wavin holds the Irish Quality Mark for the production of all products. Wavinsewer Pipes and Fittings conform with the requirements of the Building Regulations MANUFACTURE Most Wavinsewer Pipes and Fittings are produced by Wavin at their factory in Balbriggan, Co Dublin. Production is a highly automated process using the most up-to-date technology and precision engineered equipment. Pipes are extruded and fittings injection moulded. Certain fittings such as some of the Long Radius Bends and Channel Access fittings are fabricated. Wavin will be pleased to consider the fabrication of items not offered as standard. MATERIALS Generally, unplasticized Polyvinyl Chloride (PVC-U) is used for pipes and fittings. Exceptions are noted in the Product Range List. SEALING RINGS Where applicable, sealing rings are supplied fitted to each component and are included in the price. COLOUR Pipes and Fittings are generally golden brown. Exceptions are noted. DIMENSIONS Unless otherwise stated, dimensions are in millimetres (mm). CHEMICAL RESISTANCE PVC-U drains and sewers are particularly resistant to chemical attack in the form of household detergents, effluent liquids and gases. Acids and alkalis normally occuring in the ground, as well as concentrated fertilizer have no effect on PVC-U. DESIGN & INSTALLATION The design and installation of Wavinsewer systems should comply with the recommendations set out SR 7:1981, published by the National Standards Authority of Ireland and/or Local Authority requirements where applicable. SUPPLY Wavinsewer Systems are available from stock from Builders Merchants throughout Ireland. TECHNICAL SERVICE Further information, on-site advice and assistance is freely available from Wavin Ireland Ltd at Balbriggan, Co. Dublin. Tel: Fax: DESCRIPTIONS Descriptions and illustrations in this publication are for guidance only. No responsibility can be accepted for any errors, ommissions or incorrect assumptions. Refer to the product itself if more detailed information is required. Due to the continuing programme of product improvement, the Company reserves the right to amend any published information or to modify any product without prior notice. CONDITIONS OF SALE The Company will not accept responsibility for the malfunction of any installation which includes components not supplied by Wavin Ireland Limited. Goods are sold subject to Company Conditions of Sale. HEAD OFFICE, ADMIN & SALES ENQUIRIES Wavin Ireland Limited, Balbriggan, Co. Dublin. Telephone: Fax (admin): Fax (sales):