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Clay Drainage Instructions

Clay Drainage Testing

MetroDrain Instructions

Prior to Jointing

Testing the pipeline for water tightness

Preparation

Check the pipes and fittings to ensure that they have not
suffered damage.

When laying Naylor Densleeve or Denseal pipes, it may be


convenient to check that all is in order by applying interim air tests to
progressive lengths of pipeline as work proceeds.

Ensure that the pipe ends, jointing components and lubricant are
clean and free from grit, before attempting to make joints.
Densleeve Pipes & Fittings

Air Test
1

DN100 and DN150 assemblies


1 Stand the pipe upright on a firm clean
base (a 600mm piece of wood is ideal)
and lubricate the top end of the pipe
paying particular attention to the
chamfered lead-in portion.
2 Push the sleeve coupling over the
lubricated chamfered end of the pipe
2
and ensure that the pipe end is firmly
located against the central register of
the coupling. The end of any fitting may
be pushed into the sleeve coupling - the
reverse of the procedure adopted for
pipes.
3 Ensure that the sleeve coupling on the
previously laid pipe is thoroughly
cleaned and free
from grit or small
stones from the
bedding material.

Once a pipeline has been laid an air or water test may be carried out
in accordance with BS EN1610, as detailed below.
1

Fix air-tight stoppers at the ends of the pipeline, after checking


that they are clean and well-fitting. Connect a manometer to one
of the stoppers.

Blow or pump air into the pipeline until a pressure slightly more
than the required air test pressure is indicated on the
manometer. After allowing 5 minutes for the temperature to
stabilise, adjust to the required pressure and commence the
test.

Densleeve Pipes & Fittings


DN200 and above
1 Lower the pipe into
1
the trench using
slings and set in
position on the
prepared bedding.
Form coupling
recess in the
bedding.
2 Lubricate the pipe
end to be jointed.
Centralise a
2
sleeve coupling to
the pipe end and
push home. A
bar may be
used against a
timber block.
3 Lower the next
pipe into the
trench and
3
lubricate the end
to be jointed,
Ensure that the
coupling on the
previously laid
pipe is
thoroughly clean
and free from grit
or stones.
Centralise the pipe and push fully home into the coupling.
A bar may be used against a timber block. Ensure coupling
recess is filled with bedding material after making the joint.

Test Method

Test Pressure mbar (kPa)

LA

10 (1)

All Naylor pipes can easily be cut


to accurate length with a disc
blade power tool (safety
precautions such as goggles,
dust mask, etc should be worn).
It is essential that sharp edges
are removed from cut pipes to
provide a satisfactory lead-in for
the rubber seals on sleeve
couplings. This can be achieved
by rasping, using a trimming tool
or a light hammer.

Ensure the inside of the connector or

The connector or fitting should then be pushed


over the seal and on to the pipe ensuring all
surfaces are kept clean during this process. It
is often easier to start this process with the
pipe at a slight angle.

The connection

Allowable Drop mbar (kPa)

The pipe should be pushed fully onto


the connector or fitting until it
reaches the stays within the
connector or fitting. This can be done
by hand or using timber as shown on
the larger diameters.
Ensure that the alignment of the
pipes is correct and that there is no
excessive angular deflection.

2.5 (0.25)

Test period in minutes


DN100

DN200

DN300

DN400

DN600

10

14

(b) If the measured drop exceeds the allowable loss, carefully check
the testing apparatus and stoppers and examine the pipes and
joints for leakage. If a defect is discovered, remedy it and re-test.
If this test does not reveal a defect, apply a water test.
The above standards do not regard an air test alone as sufficient
grounds for rejection and it is recommended that a water test should
be applied in the event of apparent failure to meet the air test. An
apparent failure of air test can be due to causes other than defects in
the pipeline; for example, changes in ambient temperature.
Water Test
1

At the upstream end of the pipeline to be tested, add a 90 bend


and sufficient vertical pipes to provide the required head of
water. BS EN1610 requires a minimum 1.0m (10kPa) head of
water at the high end with a maximum of 5m (50kPa) at the
lower end. Both heads above the pipe crown. In cases of very
steep gradients, it may be necessary to test the pipe in stages,
in order to comply with these limitations.

2.

Tighten stoppers at the lower end of the pipeline and at open


branches, after checking that they are clean and well-fitting.

3.

Strut the ends of the pipeline and the 90 bend to prevent


movement and then fill the line with water.

Inspect the pipeline for any obvious leaks and remedy any
defects. There will be an initial fall of the water level due to
absorption and the displacement of trapped air.

After at least one hour, top up to the maximum test head, a


longer period may be allowed in extremely dry conditions. The
loss of water over a period of 30 minutes should then 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. The test is accepted if the water
added does not exceed 0.15l/m of internal wetted area over a
30 minute period, for pipelines. Higher limits are set for pipelines
including manholes and inspection chambers.

Further information
See BS EN1610 and the Clay Pipe Development Association Ltd
booklets Specification, Design and Construction and Testing of
Drains & Sewers (Water & Air Tests).
Backfilling
Any selected or granular fill must be carefully hand-compacted in
layers not exceeding 150mm to complete the pipeline surround.
Place and compact this fill equally on both sides of the pipeline to
prevent displacement.
Slice with a spade around the barrels to form a cradle for the pipes.
This work is important, as the pipeline derives some of its strength
from a properly constructed bedding.

Cut Pipes can be jointed by


similar means

Naylor lubricant should be


applied to the sealing ring and
pipe end. The sealing ring is
then located between the first
and second corrugation on the
pipe.

Connector or fitting fitting is clean and then apply Naylor lubricant.

Note: The test pressure LA is the same as that previously used in the
UK except that the test period is increased for sizes above DN225,
as shown.

4 Lower new pipe


into trench and
check, clean and lubricate the free end.
Place the pipe end into the mouth of the previously
laid coupling and align the pipe along the central axis
of the pipeline. Apply a horizontal forward pressure, in
combination with a small side to side movement, and
push the pipe home into the sleeve coupling.

(a) If the measured drop is less than the allowable drop then the
test is passed (see table).

Sealing

The Naylor MetroDrain Premium Drainage


System is easily cut to length using a coarse
toothed saw or jigsaw. Cuts should be made
between the corrugations on the pipe. Before
jointing, the pipe ends should be
cleared of all sharp edges and
dirt.

The trench must be backfilled to at least 300mm above the crown of


the pipes before any power-ramming takes place. Backfill should
then be well-compacted in layers not exceeding 300mm.
As backfilling proceeds withdraw timber and trench sheeting in
stages to avoid disturbing the pipeline or the creation of voids within
the bedding and surround.
Site Traffic
Site traffic should not pass over buried pipelines before backfilling
has been completed and the final surface constructed.
Overloading by unavoidable site traffic can be prevented by bridging
the trench with steel plates, timber sleepers or other temporary
protection.

If this procedure is not followed and Naylor Lubricant is not used,


the airtight system guarantee is invalid.
Pressure Testing (Air test) - Test inline with current Highway
Specifications, ensuring that the correct test equipment is used
(4" U Guage).
1. Seal the ends of the pipe and connectors or fittings with
expanding stoppers.
2. Fill a U-tube manometer with water to the required level without
any trapped air bubbles.
3. Connect the manometer to the port of one of the sealed
stoppers.
4. Increase the pressure until 100mm of water (0.01 Bar) is
achieved.
5. Let the pressure stabilise for 5 minutes and then increase the
pressure to 100mm head of water if it drops.
6. Record the pressure after 5 minutes. Larger diameters may
require a longer test period, please refer to BS EN 1610 for
details. It should not drop below 75mm head of water without
any additional pumping.

Twinwall Jointing Instructions


(Sealed System)
For 63mm,110mm,120mm,145mm, 160mm and 178mm DUCT
1) Always ensure that the pipe end is free from dirt, grit, soil etc.
Remove any damaged end sections of the pipe.
2) Place the seal within the 3rd valley of the twinwall corrugated
pipe. (2nd valley for 160/137 and
178/150mm pipe)
Ensure both pipe ends are
raised off the ground before
lubricating to ensure no grit or
dirt is picked up when lubricant
is applied.
3) To help place the seal in the valley
lubricate valley before fitting.
Lubricate around the outside
edge of the seal and pipe, also
lubricate both internal sides of the
coupler using Naylor lubricant.
4) Push the coupler onto the pipe with seal,
ensuring the pipe end is flush with the
central stop positioned within the
middle of the coupler.
5) Place the next pipe inside the coupler
and push the pipe with seal into the
coupler.
6) Air test - Test inline with current
Highway specifications,
ensuring that the correct test
equipment is used (4" U
Gauge).
7) Installation - Follow all current
Highway specifications, ensuring that the correct bedding
material is used.
8) Pipes which require cutting to size, should be cut using a course
toothed saw. Cuts should be made in the valley section of the
pipe and should be square to the axis of the pipe. Before
jointing, ensure the pipe ends are free of sharp edges, swarf, grit
and handling damage.
9) If this procedure is not followed and Naylor lubricant is not
used, the air tight system guarantee is invalid.

Band-Seal Instructions

Access Chamber Instructions

INSERTION of JUNCTION or REPLACEMENT pipe


into existing pipeline

Installation

Cut section from sewer using pipe cutter or


disc saw. The section should be about 20
mm longer than the junction or replacement
pipe.

Installation Instructions

cut
2 Remove
section and slide
BAND-SEAL
couplings onto
each end of the
existing pipe line.
No lubricant
required.

+ Excavate the required specified location, to the depth of appropriate


number of chambers required, (maximum 3 chambers), plus
additional 40mm for depth of base.
+ Install chamber centrally within the specified trench/location.
+ Base of excavated area to be well compacted granular material or
concrete slab is preferred. Drainage runs within the slab are required
to allow excess water to drain freely from the constructed chamber.
+ Before duct connection takes place, the trepanned holes located on
each chamber will require cutting out to specified diameter. Naylor
Access Chambers take from 63mm to 160mm OD duct pipes.
+ Allow minimum of 150mm surrounding the chamber for solid
concrete support, which should be of a semi-dry workable mixture.
+ Ensure concrete fill is evenly distributed around the chamber and
level with the top surface. Concrete the frame in at the appropriate
height.

Access Chamber
Side and End Elevation
All covers and frames
must be supported on the
concrete surround or on a
concrete bedding mortar of
sufficient thickness

TOP

Composite Cover (B125) with


locking frame

Position new junction/new pipe into the

3 pipeline. Place a pencil mark half the


BAND-SEAL width from each joint.

TOP

Each section fits directly into


each other
High-Strength HDPE
TOP

Handling and Unloading


Unloading

Access to site must be over a hard road capable of supporting a fully


laden vehicle. The delivery vehicle must be parked on firm, flat ground.
Naylor pipes are delivered to site in packs weighing between 1 and
1.9 tonnes. Fittings are usually supplied in crates. Any loose fittings
should be removed by hand from the delivery vehicle before other
goods are unloaded.
There is usually a choice between:
1 Use of Naylor Moffatt self-loading vehicle

Using the pencil


marks, centre a
BAND-SEAL over
one joint at a
time and tighten
clamp bands.
The clamp bands
should be
tightened first
and then the
shear band.

If you require this service, please request when making delivery


arrangements.
The Moffatt is detached from the trailer-load and is operated as a
fork-lift to unload the packs and crates. For this purpose, approx.
10 metres of firm level ground space is required along each side
of the trailer.
If conditions allow, packs may be placed around the site in order
to reduce subsequently handling.

Trepanned holes to
accept 63, 90, 110, 120, 145
and 160mm duct pipe
Surrounded by minimum
150mm concrete surround
Stand on well compacted
base or concrete slab,
complete with drainage
channels to allow excess
water to drain away

3 Hand offloading by site personnel


Check that the pack is stable and that the pipes and packing
woods are undamaged before cutting the straps and manually
unloading.
Stacking
1 Pipes delivered in packs

100mm
150mm

50mm Drain hole through concrete

150mm

NOTE Chambers, when


completed, must be internally
free from any debris.

Installation
+

5 After BAND-SEAL assembly carefully tamp


bedding under the exposed pipe line.

2 Using site equipment to unload - (This is the responsibility of the


Contractor.)
The packs and crates can be offloaded by fork-lift, or by suitable
crane, or other machine using a proven or test-certified sling.

150mm

CONNECTION between PIPES USING BUSHES

As an example, the illustrations detail the connection between DN300


vitrified clay and DN300 ribbed plastic pipes. A bush is used to take
up the differences in outside pipe diameter.

Set the packs down on a firm and level surface.

Install bushes onto the


square cut end of the
plastic pipe.

2 Storage of loose pipes


Rest the bottom row of pipes on battens to keep them clear of
the ground and stake the end pipes in order to prevent
movement of the stack.

Excavate the required


specified location, to
the depth of
appropriate number
of chambers required,
(maximum 3
chambers), plus
additional 40mm for
150mm
depth of base.
Install chamber
centrally within the
specified trench/location.
Base of excavated area to be well compacted granular material or
concrete slab is preferred. Drainage runs within the slab are
required to allow excess water to drain freely from the constructed
chamber.
Before duct connection takes place, the trepanned holes located on
each chamber will require cutting out to specified diameter. Naylor
Access Chambers take from 63mm to 160mm OD duct pipes.
Allow minimum of 150mm surrounding the chamber for solid
concrete support, which should be of a semi-dry workable mixture.
Ensure concrete fill is evenly distributed around the chamber and
level with the top surface. Concrete the frame in at the appropriate
height.

3 Sleeve couplings and lubricant


Store indoors in a clean area, away from sunlight. Extremes of
temperature must be avoided. Winter conditions, in particular,
can affect the ability to make a joint if items have been left
outdoors.

Chamber Sizes
Chambers will be specified as AC / 1 / Lengths

Place BAND-SEAL on the


clay pipe and butt pipes
together. Slide BANDSEAL over bushes until
edge of bush is level with
edge of BAND-SEAL. No
lubricant required.

Dimension

Item

Code

300 x 300 x 335

PAC6

69121

Pack Size Colour


42

Black

300 x 450 x 335

PAC3

69124

35

Black

450 x 450 x 335

PAC1

69012

28

Black

450 x 600 x 335

PAC5

69123

24

Black

600 x 600 x 335

PAC12

69122

13

Black

450 x 900 x 250

PAC4

69036

18

Black

Tighten clamp bands first,


then the shear band. After
BAND-SEAL assembly,
carefully tamp bedding
under and around pipes.

NAYLOR DRAINAGE LTD

We cannot guarantee the performance of the product if


Naylor Lubricant is not used.

NOTE: When jointing certain types of concrete pipes, particularly


ones which have been vertically cast, it may be necessary to apply a
neat cement grout to small areas on the exterior of the pipe barrel to
obtain sufficient smoothness to ensure an airtight seal. It may also
be necessary to smooth out the barrel mould joint line on the barrel
of some concrete and iron pipes.

CLOUGH GREEN, CAWTHORNE


BARNSLEY, SOUTH YORKSHIRE, S75 4AD, ENGLAND
TELEPHONE: 01226 790591 FAX: 01226 791531
info@naylor.co.uk www.naylor.co.uk