Spigot & Socket Pipes Product Range

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1 Product Range 1. All S&S Pipes designed and meet the requirements of BS 5911pt.100 Irish Standard IS All dimensions in mm. 3. All weights in Kgs based on density of concrete at 2450 kg/m3 Spigot End also known as male end Arrow indicates flow direction G = Overall Length F = Effective Length H C A=DN B D Socket End also known as bell end or female end 4. Indicates pipe reinforced E Flexible Jointed Spigot and Socket Pipe A DN:Inside diam of pipe Minimum Light = L B Wall Medium = M Thickness Heavy = M C Overall pipe diam D Overall socket diam E Projection of socket F Effective length G Overall pipe length H Circumference on centre line I Approx weight/pipe in kgs J Approx no off pipes/21 ton load K No of meters /21 ton load Length varies Length varies Effective Length Effective Length BUTT END SPIGOT BUTT END SOCKET ROCKER PIPE DOUBLE SPIGOT Butt End or square end pipes can be cut on site or supplied if requested. Rocker pipes are as full length pipes except length. Made only to order. Rocker Pipe D.N Effective length of S&S Rocker Rockers not recommended see C.P.S.A. Article on use of Rockers Ref: TC11/1 Arrow indicates flow direction BUTT END SPIGOT or double spigot only where M/H base used BUTT END SOCKET Full length pipes Old Rossorry TYPICAL MANHOLE DETAIL (where rocker pipes may be used) ROCKER MANHOLE RING CHANNEL BENCHING ROCKER As short as possible, but not exceed 600 mm Minimum 100 mm

2 Bends and Junctions Bends The centre line effective length on bends vary depending on diameter of pipe. 11 1/ / Bends are manufactured by cutting pipes into two or three segments and joining them together at the required angle using an epoxy resin. Although manufactured from class H pipes, Bends are not load bearing structures and should be encased in concrete surround to carry any applied load. 11 1/ 4 0 degree bend 22 1/ 2 0 degree bend 45 0 degree bend 90 0 degree bend Manholes are normally required for inspection purposes over bends in sewers, however, there may be occasions where bends are permitted without a manhole. Offset Distance per meter Angle mm 1 0 deflection mm 2 0 deflection mm 5 5 /8 0 deflection mm 11 1 /4 0 deflection mm 22 1 /2 0 deflection mm 45 0 deflection e.g. 90º or 45º bends immediately outside a drop manhole 11 1 /4 º Bend placed immediately outside a manhole Various Bends in Drains carrying only rainwater 150 Diameter Bends on pipes from road gully to main drain. Junctions Inlet pipe may be PVC, clay or concrete. D1 Not more than D Square or T junction Junctions are normally attached to full length pipes, inlet part always being the female or socket end. Concrete surround should always be placed around a junction D1 Not more than D D = Inside Diam D = Inside Diam Manholes are normally required at intersection of junctions for inspection purposes, however there may be occasions where junctions are permitted without the use of a manhole e.g. smaller diameter pipes from road gullies or one off houses to main drain which are usually 100 or 150 Diameter and may be P.V.C. clay pipe, or concrete pipe. Oblique or Y junction Tumbling Bay Junctions Used in drop manholes. Tumbling Bay Junctions which are used outside Drop Manholes are normally attached to full length pipes which can be provided with Butt End if requested. D Square or T tumbling bay junction D Butt End if requested Oblique or Y tumbling bay junction 45 0 as D as D The male or spigot end is always used as outlet on Tumbling Bay junctions. The Outlet Diameter Pipe is always the same as the main pipe. Tumbling Bay Junctions and associated bends, used to transfer drain from incoming invert to lower invert level, must be surrounded in concrete. Customers are asked to give adequate notice of their requirements for junctions or bends as they are usually made to order, this is due to the vast range and type for each diameter of pipe. Ref: TC11/2 Old Rossory

3 WATER Laboratory Tests in Brief 14 m Ref: TC11/3 Old Rossorry Tracey Concrete Ltd have their own modern 14 laboratory m where our technicians carry out the various tests WATER briefly 14 m described below, to ensure the products meet the strict requirements of BS 5911 pt 100. WATER Hydrostatic Test Fill pipe with water and pressurize to 20psi. Hold for one minute, Pipe to show no signs of leaks Joint Straight Draw Test After pressurizing hold for 5 minutes, Joint to show no sign of leaks Joint Deflection Test After pressurising hold for 5 minutes, Joint to show no sign of leaks Joint Shear Test After pressurizing and load applied, hold for 5 minutes. Joint to show no sign of leaks Held Ridget Balance 14m Head of = 1.4 BAR = 0.14N/mm 2 Point = 20 P.S.I. Held Ridget Balance Point All of the above tests This are Pipe carried out with Support pipeat Held Ridget Balance Point filled water and pressurized, the pipe or joint should withstand this test with no sign of leaks. Bending Moment Resistance Test For pipes up to and including DN 300 which are longer than 1.25m Crushing Test See crushing table for applied loads per metre, pipe to sustain its applied work load for 1 minute without developing a crack width greater than 0.25mm. Joint Withdrawn 20mm Joint Withdrawn 20mm Joint Withdrawn 20mm Refer to BS 5911 Pt100 for full details of above tests. 14 m WATER Expanding Joint Withdrawn Stoppers 20mm To Seal Ends Of Pipes Expanding Stoppers To Seal Ends Of Pipes Expanding Stoppers To Seal Ends Of Pipes 2 0 Up to DN DN DN Up to DN DN Up 675 to - DN DN DN Up to DN DN DN This Pipe 14 m Expanding Stoppers To Seal Ends Of Pipes This Pipe Held Ridget This Pipe Load Load Load Load Support At Balance Point Support At Support At LOAD LOAD WATER List of tests to be carried out on Spigot pipes to meet the requirements of BS 5911 Pt100 Pipe diam Test Normal Type Routine Test Test All sizes Surface voids absorption Hydrostatic Works proof load Maximum load Cover to reinforcement Straightness Surface evenness Joint deflection Joint straight draw Joint sheer up to and Bending moment incl. DN 300 resistance (BMR) Normal routine tests: carried out on samples for each batch whilst manufacturing, refer to BS 5911 Pt100 Type test: Carried out initially on new joint design or if any changes occur due to wear or new design, but in any case at least once per year. Crushing Test Loads in kn/m L = Light M = Medium H = Heavy DN = Works Max Work Max Work Max Diam Load Load Load Load Load Load Note: For information on the application of the above pipe crushing test load to design of pipelines, reference should be made to Simplified tables of external loads on buried pipelines (HMSO 1986) and A guide to design loadings for buried rigid pipes (HMSO 1983).

4 test General Site Testing Air and water tests All lengths of sewer drain up to DN 750 should be tested for leakage by means of air or water tests. These tests should be applied after laying and before backfilling. Some backfill may be placed at the centre of each pipe to prevent movement during testing. We strongly recommend that air testing be undertaken periodically during the laying process, say every fourth pipe, so as to facilitate rectification if any defect is found. Short branch drains connected to a main sewer between manholes should be tested as one system with the mains sewer. Long branches should be separately tested. Man entry sizes of pipeline can be physically inspected while smaller diameters can be visually inspected from manholes by means of T.V. cameras. Visual inspection: Check for- 1. obstructions and debris, 2. structural soundness of pipes, 3. joints properly sealed, 4. line and level within tolerance Pipeline under Test (diagram) Level of water for test Test A water test is the more logical and conclusive method of testing a completed pipeline but problems of availability and disposal of the quantity of water involved may cause difficulty. Before backfilling, leakage can be clearly located, its amount assessed and where necessary appropriate remedies applied. To test the pipeline:- 1. Insert plugs in both ends of the drain or sewer and in connections if necessary. Precautions should be taken by strutting or otherwise to prevent movement of the drain or sewer during testing. 2. Fill the system with water ensuring all the air has been expelled. 3. Allow at least two hours before test readings are taken to allow conditions to stabilise, adding water to maintain the test head. It may be necessary to extend this period for large diameter pipes, up to twenty-four hours or more before a stable condition is reached. 4. Apply required test head at the upper end by means of a flexible pipe leading from a graduated container or stand pipe. 5. Apply the test pressure of 1.2m head of water above the soffit of the drain or sewer at the high end with a maximum of 6m head at the low end. If it exceeds 6m test the drain or sewer in stages. 6. Measure the loss of water over a period of 30 minutes by adding and metering quantities of water at intervals of 5 minutes to maintain original water level in the standpipe. Over this 30 minute period the quantity of water added should not exceed 0.05 litre per 100 linear meters per millimetre of nominal size of the drain or sewer, i.e. for a 150m length of DN 800 the allowable leakage would be: 1.2m Head of (6.0m Max at lower end) 0.05 x 150 x 800 = 60 litres Should the pipeline not comply with these requirements it will probably be attributable to one of the following:- 1. leakage from test equipment 2. trapped air, 3. leakage from joints, e.g., displaced ring, 4. leakage from damaged or defective pipe. Pipeline Under Test Ref: TC11/4 1.2m 6.0m Max Old Rossory Plug Strutted if necessary

5 Air testing Ref: TC11/5 Old Rossorry Air Test The air test is very searching and is more convenient than the water test, but the leakage rate cannot be measured accurately. An excessive drop in pressure in the air test may indicate a fault in line such as a displaced sealing ring. It may be due to faults in the testing apparatus. Therefore the first check must be on the apparatus, especially the seals of the stop ends and all connections. The point of any leakage may be difficult to detect but spraying with soap solution could indicate such leakage by the presence of bubbles. Failure to pass this test in not conclusive and, when marginal failure does occur, a water test as described should be made and the leakage rate determined before a decision as to rejection is made. Air test requirements are currently specified in British Standard Codes of Practice BS 8301 Building Drainage and BS 8005 Sewerage. (5 minute test 100mm on U tube to drop no more than 25mm). However current practice in many other European Countries confirms the research by CPA that the introduction of a higher pressure test to 1000mm rather than the current 100mm would overcome most of the shortcomings in BS test. These may be summarised as follows:- 1. The BS air test specifies a constant requirement regardless of diameter and length of the pipeline. 2. The air test is relatively more severe on smaller pipe diameters. 3. Pipe wall dampness affects air test results, particularly on smaller diameter pipes and at the low pressure specified. Nominal size of pipe (DN) Minimum time for head to fall from 900mm to 800mm minutes To test the pipeline, fit strutted plugs at each end and pump air until a pressure of 1m head is shown on the U tube. Allow the pressure to drop recording the time for the head to fall from 900mm to 800mm. This time should not be less than that shown in the table above for the appropriate nominal pipe size. These modifications to the BS test incorporating these higher pressures are illustrated above. The following air test procedure is consistent with that described in BS 8301 and the Authorities Association publication Sewers for Adoption. 1. Seal the ends of the pipeline by means of expanding or inflatable drain stoppers. 2. Connect a U gauge (manometer) to the test nipple of the drain stopper by means of rubber tubing. 3. Raise the internal pressure of the system until the U gauge indicates slightly more than 100mm. Purpose made drain testing equipment is so calibrated that the scale indicates the actual pressure in mm water gauge. (See figure below) 4. Allow about 5 minutes for stabilisation of the air temperature (a 1º change in temperature is reflected in a change in pressure of about 38mm on the gauge). 5. Adjust the pressure to 100mm by either introducing further air or by bleeding off any excess pressure. 6. Observe the fall in indicated pressure over a 5 minute test period. The residual pressure should be not less than 75mm. Air pump or Compressor 'U' Gauge (Manometer) EXPANDING STOPPERS Inflatable stoppers etc available from Causeway Equipment, Belfast Road, Saintfield, Co. Down. Fax/Phone (028) mm 100mm

6 Jointing & Laying Jointing Procedure Forsheda 140 Lamell Sliding Rubber seal permits installation with very little force as there is lubricant enclosed within the seals sliding layer, thus there is no friction between concrete pipe and rubberseal. The sliding layer, when in final position locates itself in the gap between spigot and socket and then prevents concrete to concrete contact if pipe is deflected. Installation Fit the seal onto spigot as shown on Fig.1. Centre the spigot in the socket as Fig. 1. Slide the pipes together and the lubricated flap will move over top of the compressed rubber seal as Fig. 2 and finish as shown on Fig. 3. SOCKET rings are compatible with the pipes to be laid, then the following procedure should be followed: Clean the Pipe Ends Brush or wipe with rag to remove adhering part or water. Ice may be removed with methylated or a gas torch. Take care not to damage the concrete. Inspect Joint Surfaces Inspect the joint faces for damage which may affect the performance of the joint. Handle Pipes with Care Use only proper lifting equipment, eg woven slings. Make sure the pipe is balanced so that it is horizontal. Fig 1 Fig 2 SPIGOT Fit the Ring Fit the correct ring in the correct position and equalise the tension by lifting out intervals at its length and letting it snap back against the socket (see Joint details) Clean the Socket End Brush and wipe the end of the pipe fitted previously to remove any particles or water, ensure that the receiving socket is clean and undamaged. Prepare the Trench Bed Make a recess in the bed to accommodate the pipe. Line Up the Pipes Carefully centre the spigot within the socket. Fig 3 The relevant pipe diameter is stamped on each rubber ring. Rubber rings should be carefully stored and protected from sunlight, oils, greases and heat, if rings have been tied they should be separated a few days before using in order to eliminate minor impressions the tying may have caused. Joint rings are normally Styrene Butadiene Rubber (SBR) complying with EN Nitrile and Ethylene Propylene Rubber (EPDM) can be supplied if specifically ordered to meet special conditions, but are not normally available from stock. Laying Pipes After ensuring that you are using the correct bedding, Diameter and class of pipe as specified and that jointing Make the Joint The jointing procedure should develop a steady controlled push or pull until joint is in final position. Method of jointing will depend on size of pipe. Ensure timber blocks are used to prevent damage to socket of pipe. Mechanical plant should not be used to push pipes down to their correct level. When jointing pipes the last pipe laid sometimes has a tendency to reassert therefore it should be proped and checked before laying commences. Ref: TC11/6 Old Rossory

7 Recommended Trench width and Bedding pipes When laying pipes, to attain its full potential as a load bearing structure, trench width, proper bedding and backfilling are equally as important as the actual pipe strength. In fact, almost 50% of the completed structure is attributed to proper design and good workmanship. Any increase in trench Recommended Maximum Trench Widths measured at crown of pipe = Bd width above that specified will increase the load on the pipe and a narrower trench may impede the Pipe Diam. Trench Width proper placing and consolidation of bedding The trench should be dug so that the line, gradient and dimensions are as specifications or as agreed with site engineer. The bedding is intended to level out any irregularities in the formation and ensure uniform support along the barrell of pipe. The drawing below generally shows a typically bedding detail, however contractors should adhere to the type of bedding details specified which will vary depending on certain conditions for a particular project. Typical Bedding Detail Cover to pipe H Surface finishing Ground level 300 Lightly Compacted 300 above crown of pipe Trench width maintained to 300 above crown of pipe Lightly compacted under pipe Bd Normal backfill, degree of compression will depend on surface design requirements Well compacted in layers especially under haunches of pipes It is recommended that were pipes have to be airtested, it should be done every fourth pipe and prior to back filling. Cover to pipes (H) laid in fields for agricultural purposes only = 600mm. However, it is advisable that pipes laid under roads carrying traffic or grass verges adjacent to such roads, should have a minimum 1200mm cover. Y Temporary drain where necessary H = Cover to pipe Y Y Never drive across a pipeline with minimum cover unless at prepared crossings. Ground water should be kept below the bottom of trench by use of temporary drains and not allowed to rise before backfilling is complete. Ref: TC11/7 Old Rossorry Y = min of 100 under Barrells and 50 under sockets. In rock, 200 min under Barrell and 150 under socket The selections of bedding material and bedding class is influenced by many factors which include the nature of the ground, the loads acting on pipeline, availability of a particular type of bedding material. The ideal is crushed rock or gravel that is compatible and provides stable embedment. For more details on bedding and pipe specifications see C.P.S.A. (Concrete Pipe Systems Association) publications. Special care should be taken with the bedding material immediately surrounding the pipes to minimise the possibility of lumps or others coming into direct contact with pipes thus causing point loading. Never bulldose backfill directly into trench.

8 Specification, Handling and Storage Specifying Spigot & Socket pipes and accessories are manufactured in accordance with BS 5911 pt 100. This is the relevant British Standard which sets out the complete specification including manufacturing tolerances and the various strength and hydrostatic tests which the final product must comply with. However it does not include guidelines on the use if pipes for particular situations. For Guidelines on specifying the use of pipes including Diameter, Class, Bedding details etc. refer to Concrete Pipe Systems Association Publications or your engineers details. C.P.S.A. 60 Charles Street, Leicester England LE1 1FB Phone: +44 (0) Fax: +44 (0) Website: 1. Loads on Buried pipelines in trenches simplified tables. 2. Hydraulic calculations for sewer and surface water. 3. Laying concrete pipelines in trenches. 4. Jacking Concrete Pipes. Below describes the markings which the manufacturer puts on pipes to identify them. L = Light Duty see the crushing tables which M = Medium Duty } shows the load a particular H= Heavy Duty diameter of pipe or class should sustain R = Reinforced } pipes below DN 900 do not Unreinforced have to be reinforced is not identified provided they sustain the relevant loads applied SR = Sulphate Resistant Cement PC = Portland Cement is not identified BS5911 pt100 = British Kitemark = this may be specified for certain ground conditions. The British Standard to which the pipe is manufactured. This indicates that the BS institution, following initial on site tests and continuous site assessments, have been satisfied that the product meets the relevant standard and grant the manufacturer a licence to use the Kitemark on product. Manufacturers name, date of manufacture and internal diam are also marked on pipes There may be other marking on pipes such as colours or batch number which is solely for the manufacturers purposes. } EQUAL 80mm EQUAL BALANCE POINT FOR LIFTING PURPOSES Handling & Storage Time and place of loading should be agreed before units arrive on site. The pipe line contractor should provide suitable equipment for offloading, stacking and stringing out pipes and other accessories on site. Offloading should take place at the nearest hard road to the point of installation provided it is accessible for delivery trucks. All units must be left in a stable condition well clear of the edge of trench. Pipes should be handled horizontally using a properly designed c hook or other purpose designed equipment, but not unprotected chains. For safety reasons always know the weight of pipe to be lifted. Fig. 1 Fig. 2 Fig. 3 Never Lift pipes or accessories as shown in Fig. 3 which is likely to cause damage to spigot or socket. Where stacking is necessary, this must be on level ground and the bottom layer of pipes securely chocked to prevent pipes from rolling or stack from collapsing. Pipes should be supported under the barrell of the pipe so that the sockets are free from load, they should preferably be stacked barrell to barrell with sockets overhanging alternative sides. 2.0M MAX. Fig. 4 CHOCKES Mainly for safety reasons pipes should not be stacked in greater numbers of layers than shown in table. Generally the height of stack should not exceed 2.0m high. Fig. 5 SOCKET CLEAR OF GROUND Diam of Pipe No. of layers and above 1 Carefully inspect during off loading to verify that products comply with order and are not damaged. If a product fails to meet these conditions notify the company immediately and record details on delivery docket. Pipes or other units which have to be moved, should never be dragged. If pipes have to be rolled, beware of rocks or boulders which may damage joint profiles. See joint details for storage of rubber rings. Ref: TC11/8 Old Rossory

Polysewer Gravity Sewer System SPECIFICATION

Polysewer Gravity Sewer System SPECIFICATION July 2014 SCOPE OF WORKS To meet the specific performance criteria detailed within this specification and accompanying drawings. The completed drainage systems