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1 upvc Sewer & Drainage Systems upvc-sewer-n-drainage-sys_v001 Copyright Marley Pipe Systems (Pty) Ltd 2009

2 Marley Pipe Systems is one of South Africa s leading manufacturers and suppliers of Plastic Pipe reticulation systems, meeting the needs of the plumbing, civil, agricultural, industrial and petrochemical industries, primarily in South Africa, but also supplying into Africa, the Indian Ocean Islands, Europe, Australia and America. upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

3 Contents About Standards & Quality 4 Introduction 5 Features and Benefits 5 Products 6 Systems Overview 6 Sewer & Drainage Pipe Overview 7 Marley Underground Sewer & Drainage Fittings 8 Properties and Performance 17 Structural and Mechanical Properties 17 Chemical Properties 18 Pipe Flow Characteristics 19 Design & Installation 20 Pipe Cutting 20 How to Join Socketed Twin Wall Pipe 21 How to Join Twin Wall Pipe using the Push-fit Double Socket (UET402) 22 How to Join Twin Wall and Solid Wall Pipe to Marley Fittings 23 Marley Repair Coupling (Kimberly Socket) 25 Repairs 25 New branch connections 27 Pipe Bedding & Backfill 29 Disclaimer 31 Marley Contact Details 31 Appendix A: Referenced Documents 32 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 3/32

4 About Standards & Quality In most modern homes the owners are very aware of the finishes to their buildings, but less aware of what goes on inside the walls, underneath the floors, in fact almost anywhere out of sight. Yet water supply and sanitation are vital components of convenient living. Standards and the regulating authorities are there to protect consumers; by preparing National Standards - increasingly harmonized with International Standards, by testing products and by certifying products as compliant, ultimately providing assurance of quality and safety. Marley Pipe Systems have been manufacturing SABS approved products since consumer protection was first mandated in the industry. In keeping with international trends, Marley is a market leader in converting to lead free materials. Marley s commitment to quality and safety has all pipe and components manufactured in an ISO9001 accredited facility. SOUTHERN AFRICAN PLASTIC PIPE MANUFACTURERS ASSOCIATION (SAPPMA) upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

5 Introduction The Marley sewer and drainage underground system incorporates Marley Twin Wall Pipe, Solid Wall Pipe and Fittings, all conforming to the relevant South African National Standards (SANS). + + Features and Benefits Ease of installation. Contractors enjoy the ease with which Marley Pipe Systems Underground drainage installations may be undertaken and the increased productivity this offers. Resilient. The system is resilient and offers high resistance to impact. As a result, site breakages and other failures are minimized. A pipe sample undergoes rigorous testing in the Marley lab. Approvals and quality assurance. Specifiers, engineers, contractors and property owners alike can rest assured in knowing that the complete system conforms to the relevant SANS standard and bears the SABS mark. Marley s commitment to quality and safety has all pipe and components manufactured in an ISO9001 accredited facility Standard SANS 1601 SANS 791 Title Structured wall pipes and fittings of unplasticised polyvinyl chloride (upvc) for buried drainage and sewerage systems Unplasticised polyvinyl chloride (upvc) sewer and drain pipes and pipe fittings Performance. The Marley underground drainage system is a upvc solution, beige in colour and offers corrosion resistance with excellent flow rates. Completed installations will provide many years of maintenance free use under normal operating conditions. upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

6 Products Marley Twin Wall and Solid Wall pipes are provided plain ended or with an integral socket on one end. Marley Solid Wall pipe ends are chamfered for simplified installation. In the Twin Wall Pipe system, the corrugated outer wall provides improved strength and increased resistance to radial deformation under load. See Fig 1. All pipe extrusions provide a smooth inner wall ensuring excellent hydraulic performance as detailed in chapter Pipe Flow Characteristics, page 19. Fig 1. Twin Wall pipe illustration; side view with cut-away revealing ribbed pipe wall structure. These extruded systems are supported by a full complement of Marley upvc underground fittings. Systems Overview Diameter (mm) Marley Twinwall Pipe Marley solid wall pipe Moulded fittings Fabricated fittings Note: A list of standard fabricated fittings may be made available on request upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

7 Sewer & Drainage Pipe Overview Twin Wall Pipe, SABS 1601, Class 34, 400kPA Stiffness * Item code Diam (mm) Length (m) Pipe end Weight (kg/m) UTH Plain ended 0.83 UTHS Socketed 0.85 UTH Plain ended 1.67 UTHS Socketed 1.72 Multi Layer Pipe, SABS 1601, Plain ended Stiffness (kpa) * Item code Diam (mm) Length (m) Weight (kg/m) 100 ULE ULE Solid Wall Pipe, SABS 791, Class 51 (Normal duty) Item code Diam (mm) Length (m) Pipe end Wall thickness (mm) UL Plain ended UZN Socketed UL Plain ended UZN Socketed UL Plain ended UZN Socketed UZN Socketed UZN Socketed UZN Socketed UZN Socketed UZN Socketed UZN Socketed Solid Wall Pipe, SABS 791, Class 34 (Heavy duty) ULH Plain ended UZH Socketed ULH Plain ended UZH Socketed UZF Socketed UZH Socketed UZH Socketed UZH Socketed UZH Socketed UZH Socketed Weight (kg/m) Landrain Slotted Pipe Item code Diam (mm) Length (m) Pipe end Weight (kg/m) UTL Plain ended 0.83 Note* In the pipe tables above, kpa Stiffness is not a pressure rating. kpa Stiffness refers to the pipe s stiffness (crush strength). The pascal (symbol: Pa) or kilopascal (kpa) is the SI derived unit of pressure or stress - in this case, stress. upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

8 Marley Underground Sewer & Drainage Fittings UET402, PUSH FIT TWIN WALL SOCKET, 110mm, PACK QTY= UE401, DOUBLE SOCKET, 110mm, PACK QTY=20 UK40, KIMBERLY SOCKET, 110mm, PACK QTY= UE400, SINGLE SOCKET, 110mm, PACK QTY= UE600, SINGLE SOCKET, 160mm upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

9 UES400, SOLVENT SOCKET, 110mm UBR42, BEND mm, PACK QTY= UBR45, RIBBED BEND 87.5, INSPECTION EYE 110mm, PACK QTY= UBR UBRS40, RIBBED BEND 1/16, 110mm, PACK QTY= upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems /32

10 22.5 UB40, BEND 1/16 SPIGOT/SOCKET, 110mm, PACK QTY= UB41, BEND 1/8, 110mm, PACK QTY= UBR41 BEND 1/8, 110mm UBR43 BEND 1/8, INSPECTION EYE 110mm UBR upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 10/32

11 UB42, BEND 1/4, 110mm, PACK QTY= UYAR41, RIBBED R/H JUNCTION 45, INSPECTION EYE 110mm, PACK QTY= UYAR42, RIBBED L/H JUNCTION 45, INSPECTION EYE, 110mm, PACK QTY= UYR41, RIBBED JUNCTION 45, 110mm, PACK QTY= upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 11/32

12 142.0 UF40, INSPECTION PIPE, 110mm UY41, JUNCTION 45, 110mm, PACK QTY=10 UYA41, JUNCTION 45, R/H, INSPECTION EYE, 110mm PACK QTY= UF UYA42, JUNCTION 45, L/H, INSPECTION EYE, 110mm PACK QTY= upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 12/32

13 213.5 UY42, JUNCTION 90, 110mm, PACK QTY= UY64, JUNCTION 45, 160mm UYA63, REDUCING JUNCTION R/H 45, INSPECTION EYE, 110*160mm UY UYA64, REDUCING JUNCTION L/H 45, INSPECTION EYE, 110*160mm UYA upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 13/32

14 UE41, ADAPTOR PVC/ EW FEMALE, 110mm, PACK QTY= UME41, ADAPTOR PVC/EW MALE, 110mm, PACK QTY= UAP43, RODDING EYE 45, 110mm, PACK QTY= UAP40, STOPEND PLAIN FEMALE, 110mm, PACK QTY= upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 14/32

15 UAP41, STOPEND PLAIN MALE, 110mm, PACK QTY= UAP42, STOPEND ACCESS, 110mm, PACK QTY= UGA40, GULLY HEAD & GRATE, 150mm, PACK QTY= UGG40, GULLY GRATE ROUND, 190mm, PACK QTY= UGB40, GULLY P TRAP, 110mm, PACK QTY= upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 15/32

16 UB61S FABRICATED BEND, 45, 160mm UB62S FABRICATED BEND, 90, 160mm UB61S UB41L FABRICATED LONG RADIUS UB62S BEND 45, 110mm UB42L, FABRICATED LONG RADIUS BEND 90, 110mm UB41L upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 16/32

17 Properties and Performance Structural and Mechanical Properties upvc Pipes derive their load bearing capacity from a combination of their inherent stiffness and the characteristics of the bedding and sidefill material with which they are used. When a vertical load is imposed on a flexible pipeline it will deform (radial deformation) and the resulting horizontal force is transmitted to the undisturbed trench wall via the sidefill material. A state of equilibrium is reached and any deflection of the pipe ceases when the horizontal reaction of the sidefill corresponds to the transmitted vertical load. The design of a upvc pipeline must therefore take into account the interaction between the pipe and the bedding material. This will enable upvc pipes to withstand imposed loads without excessive deflection whilst also maintaining their ability to cope with possible ground movement without fracturing. The minimum specific tangential initial stiffness of Marley Twin-wall and solid wall drain pipe is given in Table 1 below. Pipe type Nominal Pipe Diameter (mm) Minimum Kn/m² 20 C Twin Wall Pipe Solid Wall Pipe ,200,250 4 Table 1: Specific Tangential Initial Stiffness (STIS) As will be explained on page 29, the correct selection and placing of bedding and backfill materials will prevent the occurrence of an unacceptable level of deformation. upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 17/32

18 Chemical Properties Marley pipes and fittings are highly resistant to acids/alkalis and thus to aggressive soils. Please see Table 2 below. Chemical Type Acids Alkalis Aromatic hydrocarbons and highly polar organic materials such as ketones, esters, cyclic ethers, nitro-compounds and hydrocarbons. Aliphatic hydrocarbons Aliphatic alcohols Halogens - chlorine Halogens - chlorine Halogens - bromine Halogens - fluorine Halogens - iodine Oxidizing agents PVC Reaction/Suitability No attack by concentrated or diluted acids at temperatures up to 60 C, except for oxidizing acids such as concentrated nitric which attacks PVC above 20 C. In stressed applications, design stress,at 20 C, should be reduced by: from 2.5% for 10% sulphuric -to 27.5% for concentrated nitric. No attack at temperatures up to 60 C even by concentrated alkalis. However in stressed applications, design stress must be reduced significantly, e.g. by 40-50% for 10% sodium hydroxide. Not suitable. No effect. No attack at room temperature but design stress must be reduced by half. No attack if dry. Not suitable if moist Not suitable Not suitable Not suitable Reducing agents No effect up to 60 C Detergents Little attack even by the strongest, such as concentrated potassium permanganate, but design stress must be reduced by 25%. No attack Table 2: Chemical Resistance of upvc upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 18/32

19 Pipe Flow Characteristics Marley underground drainage pipe provides low hydraulic resistance and excellent flow characteristics. Table 3 below indicates full bore velocities and capacities for Marley Twin Wall and Solid Wall sewer and drainage pipes at various gradients. The values have been derived from the Colebrook White formula using data supplied by the British Hydraulics Research Station. A minimum self cleansing velocity of 0.76m/s should normally be adhered to (shaded area), taking into account proportional velocities for pipe running part full where necessary. Roughness Height (ks) = 0.6mm (Surface Water Systems). Gradient 110mm Pipe 160mm Pipe Velocity Capacity Velocity Capacity One in: m/s l/s m/s I/s 10 2,42 18,28 3,18 54, ,71 12,89 2,24 38, ,39 10,51 1,83 31, ,20 9,08 1,58 27, ,08 8,11 1,41 24, ,98 7,39 1,29 22, ,91 6,84 1,19 20, ,85 6,39 1,11 19, ,80 6,02 1,05 18, ,76 5,70 0,99 17, ,69 5,20 0,91 15, ,64 4,80 0,84 14, ,60 4,49 0,78 13, ,56 4,22 0,74 12, ,53 4,00 0,70 12, ,47 3,57 0,62 10, ,43 3,25 0,57 9, ,37 2,80 0,49 8, ,33 2,50 0,44 7, ,30 2,27 0,40 6,85 Table 3: upvc Pipe Flow upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 19/32

20 Design & Installation All work should be in accordance with national building regulations and applicable bylaws. Information in this section is intended to highlight and supplement relevant sections of South African National Standards; SANS 10400, SANS 10112, SANS and SANS 1200LD. Consult Appendix A for the SANS title, an abstract and purchase details. For secure joints, only use pipe and fittings from the Marley Sewer & Drainage range. When joining, sockets and seals must be clean and free from swarf or any grit. SANS , section 6.8 details the correct test and inspection procedure to follow before any work is concealed or covered. Local authorities may require tests for drains to be carried out as detailed in SANS Part P, item PP26. The efficiency and effectiveness of rodding is dependant largely on the procedures adopted and the correct choice of properly maintained rodding tools. Poor practices and/or damaged or inappropriate rodding tools could damage sewer pipes. It is advisable to consult a drain cleaning expert to ensure that the correct methods and equipment are used. Pipe Cutting Pipes are easily cut to length on site using a fine tooth saw and a fabricated mitre box (Fig. 6). Saw cuts should be made square to the pipe. Twin Wall saw cuts should be made midway between corrugations (Fig. 7). Solid Wall pipe ends need to be chamfered after cutting (Fig. 8). Remove all swarf from cut ends. Fig. 6 Fig. 8 Fig. 7 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 20/32

21 How to Join Socketed Twin Wall Pipe Relocate the seal into the second or third notch of the pipe, making sure that the seal is correctly seated and not twisted (Fig. 9). Apply lubricant around the pipe seal and inside the socket (Fig. 10 and 11). Align the pipe lengths and push the pipe fully into the socket (Fig. 12 and 13). Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 21/32

22 How to Join Twin Wall Pipe using the Push-fit Double Socket (UET402) Fit the seal ring into the second or third notch of each pipe end to be joined (Fig. 14). Apply lubricant to pipe seal and inside the socket. Note that this is not necessary where Marley pre-lubricated seals are being used (Fig. 15 and 16). Align the pipe lengths and push pipes fully into the double socket (Fig. 17 and 18). Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 22/32

23 How to Join Twin Wall and Solid Wall Pipe to Marley Fittings The lip-seal system of joining is simple yet effective. Solid Wall pipes and all spigot ended Marley Sewer & Drainage Fittings have a chamfered edge to assist joint assembly. Determine the insertion depth mark and transfer this to the pipe using a permanent marker. Follow the same procedure when joining a spigot ended fitting. The insertion depth may be determined by measuring the depth from the fitting s outside face to maximum insertion depth less a 10mm allowance for pipe movement. See Fig. 19 and 20. Ensure that the rubber seal ring is correctly positioned in the socket recess of the fitting or pipe socket. Apply a small amount of Marley lube to the chamfered spigot end and to the rubber seal ring (Fig. 21 and 22). Fig. 19 Fig. 20 Continue on next page. Fig. 21 Fig. 22 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 23/32

24 Continued from previous page. Line the pipe (or spigot) end up with the socket and push firmly through the ring seal until the insertion depth mark is level with the face of the socket (Fig. 23 and 24). Where Marley Twin wall pipe is being joined, push until you should feel the lip seal engage a pipe corrugation; stopping just short of the insertion depth mark. Fig. 23 Fig. 24 Joining Marley Solid Wall socketed pipe lengths may be accomplished in a similar manner. upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 24/32

25 Marley Repair Coupling (Kimberly Socket) The Marley Repair Socket has been designed to permit additional branch connections or repair to an existing Marley soil pipe installation, without causing major and costly alteration. Repairs You will need 2 Repair Sockets (UK40) and a section of pipe long enough to repair the damaged section. The first task concerns the accurate marking of the portion of pipe to be cut and removed from the system. Carefully cut away the damaged section with a hacksaw or other fine tooth saw. Cuts should be made square to the pipe axis. Chamfer and deburr the pipe ends. See Fig. 25 and 26. Measure the length of pipe required to repair the damaged section and cut a new section of pipe for this purpose. Cuts should be made square to the pipe axis. Chamfer and deburr the pipe ends. See Fig. 27. Determine the insertion depth mark from the Repair Socket by halving the total socket length (Fig. 28). Fig. 25 Fig. 26 Fig. 27 Continue on next page. Fig. 28 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 25/32

26 Continued from previous page. Using a black permanent marker, transfer this length onto both ends of the repair pipe section (Fig. 29). Lube the Repair Sockets and all pipe ends. Insert a Kimberley socket to the fullest extent over each end of the repair pipe section (Fig. 30). Alternatively insert a Kimberley socket to the fullest extent over each end of the existing pipe line. The repair pipe section is then inserted into the gap. All that remains to complete the installation is to slide the Kimberley sockets over the ends up to the insertion depth marks. See Fig. 31 and 32. Fig. 29 Fig. 30 Fig. 31 Fig. 32 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 26/32

27 New branch connections For new branch connections, cut two small sections of pipe long enough to form a spigot ended branch section. Prepare the sections, taking care to chamfer and deburr all pipe ends. Establish the spigot ended branch section. See Fig. 33 and 34. Now measure the piece from spigot end to spigot end (Fig. 35). Transfer this dimension to the existing pipe section and carefully cut away with a hacksaw or other fine tooth saw. Chamfer and deburr both cut ends. See Fig. 36. Determine the insertion depth mark from the Kimberly socket by halving the total socket length (Fig. 37). Fig. 33 Fig. 34 Fig. 35 Continue on next page. Fig. 36 Fig. 37 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 27/32

28 Continued from previous page. Using a black permanent marker, transfer this length onto both ends of the spigot ended branch section (Fig. 38). Lube the Kimberly sockets and all pipe ends. Insert a Kimberley socket to the fullest extent over each end of the spigot branch section (Fig. 39). Alternatively insert a Kimberley socket to the fullest extent over each end of the existing pipe line. The new branch section is then inserted into the gap. All that remains to complete the installation is to slide the Kimberley sockets over the ends up to the insertion depth marks. See Fig. 40 and 41. Fig. 38 Fig. 39 Fig. 40 Fig. 41 upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 28/32

29 Pipe Bedding & Backfill E C D A B Fig. 42, Trench cross-sectional view The width of the trench should be as narrow as possible but at least 300mm greater than the outside diameter of the pipe (Dimension A plus B). Trenches deeper than 900mm (Dimension C) should be stepped and suitably shuttered so as to prevent accidental injury from collapsing sidewalls. The bottom of the trench should be free from stones, projections, soft spots, be reasonably uniform and graded to fall. Bedding should be to a class as specified by an engineer. In the absence of engineering instructions, it is advisable to use a bedding class for flexible pipes in accordance with SANS 1200LB where under traffic load and a Class C bedding elsewhere. The initial backfill should be of selected granular material compacted to a depth of 100mm (Dimension D) and covering the full width of the trench. It is good practice to backfill as the pipe laying progresses, leaving 300mm exposed on either side of joints for testing. Generally the use of concrete with flexible pipes in trenches is considered wasteful since it converts a flexible pipeline into a beam of negligible flexural strength. At depths of 700mm (Dimension E) and more, protection by normal well upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 29/32

30 compacted granular surround is generally adequate. At shallow cover depths where pipes may be subject to heavy traffic loadings, protection is best achieved by the use of concrete slabs on a cushion of hand compacted granular fill. Alternatively the pipeline may be protected by a reinforced pipe duct of greater diameter. Where the 160 by 110mm reducing junction (UY64) is used to create a branch connection leading to the ground level, care should be exercised in the backfill and compaction surrounding the joint so as to avoid excessive joint leverage. Branch access should be adequately supported. See Fig. 43 Fig. 43, UY64 Connection to Ground Level Caution upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 30/32

31 Disclaimer Whilst every care has been taken in the preparation of this instruction manual, neither Marley Pipe Systems nor any of their agencies can be held liable for any errors in this publication. It should also be noted that this manual is intended for reference only. Due consultation is required when designing for particular applications, and no liability will be entertained in this regard. Marley Contact Details Head Office: 1 Bickley Road, Pretoriusstad, Nigel P.O. Box 67, Nigel, 1490 Tel: (011) Fax: (011) Bloemfontein (051) /5 Cape Town (021) Durban (031) East London (043) George (044) Nelspruit (013) Polokwane (015) Port Elizabeth (041) Also available from: Marley (Namibia) (Pty) Ltd. (00264) Contract Supplies (Botswana) (00267) Marley Export Division (011) upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 31/32

32 Appendix A: Referenced Documents SANS (South African National Standards) documentation may be purchased online or at any of the SABS regional offices. Please visit for more information. South African National Standard Abstract (when applicable) SANS Description The installation of polyethylene and poly(vinyl chloride)(pvc-u and PVC-M) pipes Is intended to present (in sufficient detail for general use) the comparative physical, chemical, and mechanical properties of 2 types of plastics pipe in common use, to provide guidance in their selection for the conveyance of potable water (and other applications) and to define sound practice in the assembly and installation of such pipework. SANS Water supply and drainage for buildings Part 2: Drainage installations for buildings Establishes general principles for the design, installation and testing of sanitary drainage installations. Does not cover any special requirements for drainage installations in health care, laboratory or industrial buildings. SANS The application of the National Building Regulations Covers provisions for building site operations and building design and construction that are deemed to satisfy the provisions of the national building regulations. In certain cases, commentry and illustrations to amplify and explain the application of the deemed-to-satisfy rules are included. Information on standardization of the application of the regulations is contained in a commentary to Part A of the regulations. SANS 1200LD Standardized specification for civil engineering construction Section LD: Sewers Covers the general construction requirements for sewerage systems including manholes and the like but excluding pump stations, treatment works and ancillary works. SANS 1601 (SABS 1601) SANS 791 (SABS 791) ISO9001 Structured wall pipes and fittings of unplasticised polyvinyl chloride (upvc) for buried drainage and sewerage systems Unplasticised polyvinyl chloride (upvc) sewer and drain pipes and pipe fittings Quality management systems upvc-sewer-n-drainage-sys_v001 upvc Sewer & Drainage Systems 32/32

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