Soil &

Waste
Design & installation
Now includes:
• PVCu
• dBlue
• HDPE

marley.co.uk
MARLEY AKATHERM HDPE |
 Innovation & Expertise Marley Soil & Waste systems

Marley Plumbing & Drainage offer a comprehensive

range of soil and waste systems. Available with a
variety of jointing methods, Marley products are
manufactured to exacting UK and European standards
and are designed for use on commercial projects as
well as housing developments.

Product specification information Production information

This guide contains design and installation
information for Marley PVCu soil & waste,
HDPE and dBlue acoustic drainage systems.
Product specification information on these
product ranges is available as a separate
document. All documentation can be
downloaded from marleypd.co.uk
Information on the complete range of
Marley Plumbing and Drainage system
solutions is available to download from
marleypd.co.uk or via the literature hotline
01622 852585.

BS EN ISO 9001:2008
BS EN ISO 14001:2004

Contents
4 PVCu soil & waste systems 18 Marley dBlue
5 Commercial applications 19 Pipe support system
6 Key components 20 Boss branches
20 Boss pipe connections
Design
21 WC connections
8 Stack design
22 WC manifold system
11 Design of waste systems
23 Site work
12 Waste traps
24 HDPE jointing methods
12 WC manifold system
31 HDPE installation
14 Durgo air admittance valve
35 HDPE handling and storage
15 Fire protection
36 British & European Standards
Installation 37 Marley system solutions
16 PVCu jointing techniques
17 Pipe support

2 | MARLEY AKATHERM HDPE MARLEY Soil & Waste Systems | 3

 PVCu soil & waste systems 88½° bend
KB2
Commercial applications
Bottle trap
B040R
Roof terminal
SV42

Weathering slate
SAS45
●● 8
 2, 110 and 160mm push-fit and solvent Marley Akatherm HDPE
weld soil systems incorporating socketed Pipe clip The Marley Akatherm HDPE drainage range is
and plain ended pipe SC45
certified to BS EN 1519: 2000 (licence number
●● 1
 10mm WC connectors for all BS WC pans. Pipe
Pipe KM 545820) An extension of the Marley soil
KP204
SL403 & waste portfolio, the HDPE range offers an
Available with solvent weld or push-fit joints.
alternative solution to cast iron.
●● 1
 10mm WC manifold system allows ranges Branch
SY401 It is particularly suited for commercial
of toilets to be connected horizontally. applications or where a product with high
Ideal for commercial applications. Bent pan connector impact or abrasion resistance is required,
SWCB90 45° tee
●● 5
 0 and 82mm floor outlet components KT21
such as hospitals, hotels, schools, as well as
residential buildings. HDPE will also cope with
are available as separate components or Boss connector temperature variations of -40°C to 100°C.
as an all in one trapped floor outlet. SA421
The combination of the excellent material
●● F ire sleeves and pipe wraps, providing Collar boss
SCB41 properties of HDPE with homogenous welded
up to 4 hours rating. joints provides greater installation flexibility
with a wide range of jointing options
●● 1
 10 and 160mm pipe support
components designed specifically to Low level bath trap
P5040
meet the needs of supporting horizontal
or vertical suspended PVCu pipework. P trap
P040
●● 8
 2, 110 and 160mm pipes and fittings are
also suitable for use as internal and external Waste pipe Key fitting: Akavent aerator
rainwater pipes to drain flat roofs and The need for secondary venting in high-rise The unique shape of the fitting increases
metal gutter systems on commercial and Boss connector
buildings can be eliminated with the Akavent the capacity of the stack. The soil and
Boss pipe SA421 aerator. An Akavent aerator fitting breaks the waste flow from the higher floors smoothly
industrial buildings.
SW40 fall on each floor and as a consequence the converges with the flow of the lower floor.
secondary vent pipe is not required as the
Pipe
SP403
pressure difference stays well within the limit
of 3 mbar.
Slip coupling
SE405 Akavent Aerator

110mm
Underground pipe
Marley dBlue acoustic system
The Marley dBlue acoustic system is a 2 pipe clip diameters*: Secure fixing to the
triple-layer drainage system designed for 50 mm building’s structure.
use where improved levels of soundproofing 110 mm Elimination of the acoustic bridge
between the soil stack and the
are required. Suitable for use in domestic building’s structure
Now available from applications as well as hospitals and hotels,
where reduced noise levels are required.
Solvent waste Push-fit waste Overflow Compression waste Traps Used in conjunction with the acoustic pipe Pipe clip fastening

PVCu ABS Polypropylene PVCu Polypropylene Polypropylene clips, the dBlue system is designed to reduce
noise and acoustic vibrations to a level of 19dB
at 4 l/s discharge rate. It is also lightweight,
resistant to temperature change and is jointed
using the push-fit ring seal method.
The dBlue system is available in 40mm, 50mm,
110mm and 160mm diameters. It is also
compatible with the Marley PVCu soil and waste Acoustic inlays
system for branch connections. Suppression of vibrations between the system section
S uitable for internal Lightweight and cost F or internal use,  complete range of
A  ulti-fit compression
M  range of traps, which
A Three contact surfaces with the pipe
*40 mm and 160 mm pipe clips also available. Special structure on the noise suppression surfaces
and external effective for internal ideally suited to fast pipework and fittings socket, for internal enable quick & easy
applications. installation. Easy to installation. Cost for overflow and use. Easy installation installation to any new
cut joint and install. effective solution where boiler condensate to similar sized new or existing plastic or
systems are being applications. or existing plastic and copper pipework.
installed or modified. copper pipework. Solvent soil
Available in Available in Available in Available in Available in Available in The Marley PVCu soil range has been of 4 top and 4 side entries, allowing for
32, 40 and 50 mm 32, 40 and 50 mm 32, 40 mm 21.5 mm 32, 40 mm 32, 40 and 50 mm extended with the addition of nine 110mm multiple inlet connections. At just 70mm
White & Black White, Black & Grey White, Black & Grey White White & Chrome White & Chrome solvent fittings, offering further options for above the floor slab, the manifold sits
the installer. The range includes the new neatly at finished floor level in most typical
ABS and polypropylene waste pipes and fittings are designed for internal use and should not be fitted externally as they will be subject to ultraviolet light 8-way soil manifold which offers the flexibility applications.
degradation. If fitted externally it is recommended that they are protected by the application of a suitable paint or are boxed in.

4 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 5
 Key components

The Marley soil & waste range offers an extensive choice of standard fittings for
commercial and domestic projects. PVCu Soil – Push-fit
Pictured is a selection of key components within the range. Product specification information on the PVCu, HDPE drainage and dBlue acoustic soil
or solvent weld
ranges is available as a separate document. All documentation can be downloaded from marleypd.co.uk

8-way collar boss Adjustable bends Push-fit soil range

Marley co-ex soil The collar boss offers the flexibility of 4 top
and 4 side entries, allowing multiple inlet
connections. Specifically designed to prevent
Available in 82, 110 and 160mm and can
be adjusted by cutting the fitting at the
required angle and solvent welding the two
The Marley range offers a quick,
straightforward solution. In up to three
colour variants, pipe with a socket or
cross-flow and to allow multiple low level bath sections together.
110mm soil pipe with at least 30% recycled content or shower waste pipes to be connected to the
stack above floor level.
spigot end and a wide range of fittings.
Ideally suited for domestic and small
Code Angle achieved commercial applications.
SB37
Marley 110mm soil pipe now combines the environmental SB46
11° – 87½°
5° – 14°
benefits of using recycled material with the quality and SB47 21° – 90°
SB67 15° – 90°
aesthetic advantages of co-extrusion technology.
• BS EN 1329 certified
• Looks better, with higher gloss levels
• Has improved weathering performance
• Available in grey and black colour only
• Same list price as standard white pipe
• Colour matched to all standard 110mm Marley soil fittings

Solvent Soil range

5 boss branch, 87½° push-fit
sockets/spigot
The Marley range of five boss branches are
designed to allow multiple waste pipe connections
to be made to the discharge stack from different
directions. Four different side entry combinations
are possible together with a rear, if required.
Fire protection systems –
Universal fire collar (UFC1)
& fire sleeves
Fire sleeves and pipe wraps, providing up to 4
hours rating. The universal fire collar is designed
to be surface mounted and is sufficient for 5 x
110mm pipe collars.
WC connectors
Connectors for all BS WC pans to
accommodate a range of outlet sizes
between 84 and 110mm. Available with
solvent weld or push-fit joints.
Durgo air admittance valve
The Durgo valve is designed to reduce the
number of roof penetrations. Suitable for
use in sanitary pipework systems up to ten
storeys high, the valve must be fitted in a
vertical position above the flood level of the
highest appliance connecting to the stack.
Manifold system
For use in sanitary pipework systems in schools,
hospitals, public and commercial buildings,
the manifold system allows ranges of toilets
to be connected to a horizontal float above
floor level and eliminates the need for specially
fabricated fittings.
The Marley range offers a secure method
of jointing and includes the new eight-way
collar boss for multiple connections to the
stack, solvent socket bends, branches and
access fittings. Ideally suited for commercial
and horizontal pipework situations.

6 | MARLEY Soil & Waste Systems All documentation is available to download from marley.co.uk Technical hotline: 01622 852695 MARLEY Soil & Waste Systems | 7
 Design

Bends at the base of stacks

Sanitary pipework design Bends at the base of vertical stacks should be of long radius and have a
All sanitary pipework systems should be designed to satisfy the following regulations and standards where applicable. minimum centre line radius of 200mm on a 110mm nominal size stack.
Two 45° radius bends may also be used as an alternative to provide the
●● The Building Regulations 2010: Approved Document H, Section 1.
change of direction and connection to the building drain. The same
●● The Building Standards Technical Handbook (Scotland) 2010: Part M. design principle should also be adopted where offsets occur in stacks of min 200mm
radius
one or more storey height.
●● The Building Regulations (Northern Ireland) 2000, Technical Handbook N.
Where pipework is suspended in a ceiling void or car park, it is
●● BS EN 12056: 2000, Parts 1 to 5. recommended that two 45° solvent weld bends are used with a short
Regular consultation is essential between Architects and Plumbing Engineers throughout the building design stage as the careful arrangement of piece of pipe between to ensure the radius exceeds that required.
kitchen and bathroom appliances will simplify the final sanitary pipework layout. This will help to ensure that an efficient sanitary pipework system
is installed at minimum cost. long radius bend
UBL488
The design information provided in this catalogue is endorsed in the above publications and while every effort has been made to ensure accuracy,
no responsibility can be accepted for errors or omissions. For detailed guidance please consult the relevant documents referred to above.

Methods of jointing
SWS415/41
While the principal method of jointing 82, 110 and 160mm PVCu pipes and fittings is push-fit, many boss pipe
components in the PCVu range are also available with sockets that allow for solvent weld jointing. Branches at the base of stacks
This particular technique is widely used on smaller diameter waste and overflow pipework although solvent
expansion and copper adaptor couplings include a push-fit joint to allow for thermal movement. weld joint
For single dwellings up to three storeys high, the distance between the
centre line of the lowest branch connection and the invert of the drain
As polypropylene cannot be solvent welded, the push-fit method of jointing is used throughout should be at least 450mm. For multi-storey systems up to five storeys
the system. high, the minimum distance should be 740mm and for systems higher
Marley dBlue is a push-fit acoustic drainage system push-fit than five floors no connections are permissible at ground floor level.
joint Where this occurs a separate stub stack should be provided to serve the UBL488 or
HDPE can be jointed using one of the following methods: Electrofusion; Butt welding; Plug in, ground floor or individual appliances should have their own separate 2 – UB455 bends
L
expansion or flange joints. connection to the building drain.

Thermal movement
The coefficient of linear expansion for PVCu is 0.06mm/m/°C. As a result a 3m length of
pipe will increase in length by approximately 3.6mm when subjected to a 20°C temperature
variation. Therefore, it is important to ensure that any movement is controlled and push-fit L = 450mm up to three storeys high
joints are installed to accommodate any expansion that may occur due to increases in ambient L = 740mm up to five storeys high
temperature or hot water discharges. L = one storey height, over five storeys

Sizing of soil stacks Material and manufacture Dimensions and weights

It is recommended that the guidance given within BS EN 12056, part 2 be adopted when sizing soil Marley Plumbing & Drainage pipes and fittings for domestic sanitary
Pipe BS nominal Wall
stacks. Marley Technical Services Department offer design and installation advice, including the sizing pipework systems are manufactured from different plastics materials Material size (mm/ Min Max thickness
Weight
of soil stacks, for customers who use or specify Marley Plumbing & Drainage products. including PVCu, PVCc, ABS and Polypropylene. kg/metre
Standard inch) (mm) Min

Soil stack capacity The table right details the important dimensions and weights of each Soil PVCu
of the systems together with the relevant British and European Standard. BS 4514 82 82.4 82.8 3.20 1.30
The capacity of a soil stack can be increased by the installation of a secondary ventilated stack. The All pipes are manufactured using a continuous extrusion process and
following information is taken from tables 11 & 12 of BS EN 12056-2: 2000 which illustrates this increase. BS EN 1329 110 110.0 110.3 3.20 1.70
fittings are produced by high-pressure injection moulding.
160 160.0 160.4 3.20 2.50
Waste 36/1¼ 36.10 36.50 1.80 0.33
Chemical and temperature resistance PVC-c 43/1½ 42.70 43.10 1.80 0.41
Primary ventilated stack Secondary ventilated stack Most plastics used for sanitary pipework are highly resistant to those BS EN 1566 55/2 55.70 56.10 1.80 0.57
Stack size Maximum capacity (l/s) Stack size Secondary vent Maximum capacity (l/s) chemicals normally found in domestic waste water and sewerage systems. Waste 36/1¼ 36.10 36.50 1.80 0.20
For applications where chemical discharges are likely to occur, the Marley ABS 43/1½ 42.70 43.10 1.80 0.26
(mm) Swept entries (mm) (mm) Swept entries Akatherm HDPE drainage range may be more suitable. BS EN 1455-1 55/2 55.70 56.10 1.80 0.35
82 2.6 82 50 3.4 Generally the maximum working temperature of Marley PVCu, dBlue Waste
110 5.2 110 50 7.3 & HDPE soil and waste systems when subjected to continuous flow is Polypropylene 34/1¼ 34.40 34.80 1.80 0.21
160 12.4 160 80 18.3 70°C and 75°C respectively. Higher intermittent discharges of up to BS EN 1451 41/1½ 40.80 41.20 1.80 0.26
95°C may be accommodated by PVCu, dBlue & HDPE provided the Overflow
period of discharge does not exceed one minute duration.
PVCu 21.5/¾ 21.55 21.70 1.10 0.11
Alternatively, reference can be made to ISO publications TR10358 BS EN 806-4
& TR7620 which provide comprehensive information on chemical
Secondary ventilated stack
and temperature resistance of plastics and rubber materials.

8 | MARLEY Soil & Waste Systems All documentation is available to download from marley.co.uk Technical hotline: 01622 852695 MARLEY Soil & Waste Systems | 9
 Design

Offsets in stacks
Offsets in the wet portion of a discharge stack
should be avoided wherever possible but
where they have to be fitted a large radius or
two 45° bends should be used to create each
Stub stacks
An unventilated stub stack terminated with an
access fitting may be used to connect a group
of ground floor appliances to the building drain
provided the vertical drop to the invert level
8-way collar boss Branch pipe gradients
The gradient of a branch pipe should be
uniform and adequate to drain the pipe and
appliance efficiently. A minimum gradient of
SY401 Equal Branch
18mm/metre should be adopted for 32, 40 and

Crescent flush actuation plate, Multikwik Sanitary Systems

change of direction. Offsets in lightly loaded of the drain does not exceed 1.5m from a WC 50mm nominal size pipes but larger diameter
stacks up to three storeys high do not require and 2.5m from a waste appliance. Where one 82, 110 and 160mm branch runs may be laid
Top & side waste
offset venting but on multi-storey buildings this or more stub stacks are connected to the same connections flatter at 9mm/metre fall where the discharge
may be necessary depending on the loading drain, the head of the run should be ventilated for maximum flow rate exceeds 2.5litres/second.
of the stack and the numbers of floors above to atmosphere or air admittance valves fitted to flexibility, even
in tight spaces.
the offset. The principles previously described each stub stack arrangement. Design prevents Branch pipe lengths
for bends and branches at the base of a stack any danger of
should also be applied. SE40 cross-flow. The following information is taken from Table 8
access cap of BS EN 12056: 2: 2000 and provides general
SWS415/41 Hole cutter locator
guidance on the recommended lengths of
Stub waste boss pipe
Factory fitted, air unventilated branch pipes for a variety of
This technique is often used to connect isolated tested joint ensuring 61mm sanitary appliances.
long term integrity.
ground floor waste appliances such as basins,
No need for pipe to be cut
baths, shower trays and sinks to eliminate exposed on site, saving installation
pipework or low level ducting. The 110mm time. Comes complete
unventilated PVCu drain is terminated at finished with pre-chamfered spigot
tail for easy jointing.
floor level with a reducer and boss adaptor to suit SY401
the size of waste from the appliance. branch
SCBL41 – 350mm
Long spigot tail,
accommodating virtually Min.trap seal Max. length
Appliances Dia (mm) Pipe gradient (%) Max. bends (No.) Max. drop H (m)
all floor thicknesses. depth (mm) of pipe (m)
SA411/421/420
32mm/40mm
or 50mm SFC44 fire collar, Washbasin or bidet 32 75 1.7 2.2 0 0
2.5m
boss connector max SFW44 pipe wrap can Washbasin or bidet 40 75 3.0 1.8 to 4.4 2 0
be used within the
floor slab. Bath or shower 40 50 No limit 1.8 to 9.0 No limit 1.5
Bowl urinal 40 75 3.0 1.8 to 9.0 No limit 1.5
1.5m SC41 clip fitted Trough urinal 50 75 3.0 1.8 to 9.0 No limit 1.5
SRM402 long radius
max around socket.
eccentric reducer bend UBL488 Kitchen sink 40 75 No limit 1.8 to 9.0 No limit 1.5
Dishwasher or washing
40 75 3.0 1.8 to 4.4 No limit 1.5
machine
UB411
bend WC 110 50 No limit 1.8 min No limit 1.5

The maximum lengths given above may be increased where the branch pipe is ventilated or an air admittance valve is used. For further details refer to
the above standard.

Prevention of cross-flow To prevent cross-flow from a large diameter The Marley Collar Boss was specifically designed to overcome installation problems imposed
branch to a smaller waste connection, the latter by the 200mm restricted zone and to allow multiple low level bath or shower waste pipes to be
Where small diameter branch waste pipes
should be made to the stack at or above the connected to the stack above floor level. Cross-flow is prevented as the circular annular chamber
connect to a discharge stack they must be
centre line of the larger protects the small diameter waste connections from the WC discharge allowing waste water to
arranged to eliminate the risk of cross-flow from
branch, at right angles or flow freely and merge below the critical zone.
one branch to the other. A branch creates a
at least 200mm below the
no entry zone for opposing waste connections, Different combinations of 110mm branches can be used with the collar boss to accommodate
restricted zone. Entry is
which varies depending on the stack diameter. various WC positions which may be up to 3 metres from the vertical stack. SY401
permissible on the boundary
No connections should be made within the branch
SWS40 centre line directly opposite
restricted zone although entry is permissible
boss pipe or at right angles.
on the centre line of the boundary directly
opposite or at right angles.

H
Stack size Height of zone 'H'
H
(mm) (mm)
SA421 SCB41
boss adaptor SY405 collar boss
82 90 branch
SA421
110 110 boss connector
160 250

‘H’ = 200mm irrespective of stack diameter

10 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 11
 Design

Combined branch waste WC manifold system

A combined branch waste is often used to
connect a bath and/or shower and basin to the
discharge stack as this allows waste pipework
to be neatly concealed in a low level duct.
Where this technique is adopted a 45° entry tee
must be used to ensure the basin discharge is
swept in the direction of flow towards the stack.
The minimum distance between the bath or
shower and basin connection should not be less
than 500mm and it is recommended that an
anti-syphon bottle trap is fitted to the basin or
a vent provided to protect the appliance from
self-syphonage.
It is recommended that the distance of the
combined waste does not exceed 3 metres,
however, experience has shown that longer runs
using 40 or 50mm pipework has proved successful
provided adequate fall can be obtained to ensure
self-cleansing velocity is maintained
Waste traps
Generally appliances such as sinks, baths and
showers do not suffer from self-syphonage
as the trap seal is replenished at the end
of the discharge due to the flat bottom
design of the appliance. Tubular traps are
recommended for such appliances as they
ensure unrestricted discharge and reduce the
risk of blockage and prevent the accumulation
of sediment.
●● C
 ompression jointed polypropylene traps
can be taken apart to remove a blockage
or gain access to the waste system
●● R ange includes P-traps, S-traps, bottle
traps, bath & shower traps and different
configurations for washing machines,
dishwashers, 1½ or 2 bowl sinks
●● White with multiple seal depths
●● Sizes: 32, 40 and 50mm
B040V
anti-vac
bottle trap
Developed for use in sanitary pipework systems the minimum distance between the end of the To accommodate different dimensions
The Multikwik anti-vac bottle trap, B032V
in schools, hospitals, public and commercial WC spigot and the face of the wall is 150mm. between the WC spigot and horizontal float,
/ B040V, was specially developed to prevent
buildings, the manifold system allows ranges To facilitate varying angles and gradients the the adjustable spigot bend SM43W may be
self-syphonage from basins, which can occur
of toilets to be connected to a horizontal float 110 x 90mm manifold branch has a radial trimmed by up to 35mm or the extension pipe
particularly where the waste pipe drops
above floor level and eliminate the need for socket to match both options of adjustable SM45W can be used with the pan connector
vertically from the appliance before falling at
specially fabricated fittings. WC bend. When the selected bend is cut to SM44W and SA323W cap & seal.
an even gradient to the discharge stack.
the appropriate line and solvent welded into
The components are suitable for installation in The WC socket on both the SM42W and
The trap also eliminates the need for a the socket on the manifold branch a uniform
a duct, or for fitting on the surface of the wall SM44W must be trimmed to suit the length
secondary vent pipe where basins are located fall is obtained between each toilet on the
directly behind the pan. Where the manifold of pan spigot before the SA323W is fitted.
further than the recommended 3m maximum horizontal float.
is fitted directly behind the range of toilets,
from the stack. Non-mechanical, the trap For installation details see page 18.
operates as air is drawn in through a by-pass
tube to eliminate any syphonic action and
ensure the trap seal is maintained.
The P1940 low level shallow trap has a
SM42W
19mm water seal and is supplied to satisfy & SA323W
customer demand.
It is recommended its use is restricted
to ground floor baths and showers that centre line of WC outlet SM41W
discharge directly to an external trapped from finished floor level
gully. It should not be fitted to a bath or
shower where the waste pipe is connected
to a soil stack.

190mm
Now available from

P1940 low
level trap 110mm float at
KT21W entry tee
SWS41 9mm/metre fall SY401/SY405
KBA22W branch
bath/ boss pipe
45º bend
shower

A
40mm
500mm min
SM42W
adjustable bend

30
215mm minimum

35
duct width B
Manifold branch SM41W with SM42W Adjustable wall fixing
Manifold branch SM41W with SM43W
Cut line 50° 55° 60° 65° 70° 75° 80° 85° 90° Cut line SA323W 50° 55° 60° 65° 70° 75° 80° 85° 90°
cap & seal
Flush plate
A – projection (mm) 93 93 92 91 90 87 84 80 75 A – projection (mm) 180 180 179 178 177 174 171 167 162
W.C. cistern SM41W
B – drop (mm) 69 77 85 93 101 109 116 123 130 B – drop (mm) 69 77 85 93 manifold
101 109 116 123branch
130
front panel

W.C. frame

W.C. seal & cap

SA323W Flush pipe SA323W cap & seal
A
A
A
SM42W
adjustable SM43W WC SM43W
SM43W
WC bend SM42W
SM42W spigot bend adjustable spigot bend
adjustable
adjustable
adjustablebend
WC bend WC bend
SM41W
Manifold branch SM41W
manifold branch

30
35
30

JB42 two peice pipe 110mm float

35

B
bracket with SC621 B
barrel clip collar
SA323W
SA323W SM41W
SA323W
SA323W capcap & seal
& seal SM44W
cap
cap&&seal
seal manifold
110 x 90mm branch SM41W Adjustable bend SM42W with socket SM41W JB42 two peice pipe bracket Adjustable bend SM42W with socket pan connector branch
trimmed to suit 50mm pan spigot manifold with SC621 barrel clip collar trimmed to suit 50mm pan spigot SM44W
SM41W
branch pan connector SM41W
manifold branch manifold branch

12 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 13
 Design

Durgo air admittance valve Fire protection

The Durgo valve is designed to reduce the
number of ventilating pipes and subsequent roof
penetrations in domestic, commercial and public
buildings. Suitable for use in sanitary pipework
systems up to ten storeys high, the valve must
be fitted in a vertical position above the flood
level of the highest appliance connecting to
the stack. Valves should be installed within
the building in a ventilated duct or roof space
where there is no risk of freezing and must be
accessible for inspection and testing.
The 50, 82 and 110mm size valves have been
assessed by the British Board of Agrément and
awarded Certificate No 06/4325 which permits
their use in accordance with the Building
Regulations. A copy of the full certificate
is available and provides comprehensive
information on their use and installation.
11 to 20 dwellings SVP at head and mid point
SVP Durgo SVP
20th 11th 10th
Indicative row of 20 dwellings 3 storeys high (maximum) fitted with Durgo valves
When installed the valve will remain closed
unless the system is subject to negative
pressure whereby the diaphragm will lift and
allow air to be drawn in to eliminate syphonic
action. Positive pressure ensures the valve
closes and prevents foul air escaping from the
system. Each valve is supplied boxed with a
polystyrene insulation cover that should remain
in position after installation, as this will protect
the valve against freezing, particularly when
installed in a roof space.
To ventilate the underground drainage system
and to minimise the effects of back pressure
should a blockage occur, the branch or main
drain serving a stack or stacks fitted with Durgo
valves may require conventional venting at a
point upstream of the stack connection.
5 to 10 dwellings SVP at head
Up to 4 dwellings no SVP required
Durgo Durgo Durgo
5th 4th 1st
For up to and including four dwellings, 1, 2, or
3 storeys in height, additional drain venting is
not required. Where a drain serves more than
four such dwellings equipped with the valve,
the drain should be vented according to the
following rules:
5 to 10 such dwelling – conventional ventilation
to be provided at the head of the system.
11 to 20 such dwellings – conventional
ventilation to be provided at the mid-point and
at the head of the system.
For multi-storey domestic dwellings (other than
those referred to previously) and non-domestic
buildings, conventional drain venting should
be provided if more than one such building,
each equipped with the valves, is connected
to a common drain which itself is not vented
by means of a ventilating stack or a discharge
stack not fitted with a valve.
Stacks should not be fitted with valves when
the connecting drain is subject to periodic
surcharging or is fitted with an intercepting
trap. An open vent must be provided and
this also applies to stacks that discharge to a
cesspool or septic tank.
The Building Regulations 1991 (as amended) 2 hours integrity. The test work and technical The construction illustrated below achieved a
require that a building shall be sub-divided into evaluation was independently assessed by 1½ hour fire resistance rating without the need
compartments where necessary to inhibit the the British Board of Agrément who issued an for a fire resistance enclosure. The enclosure is
spread of fire. Plastics pipework is permitted Agrément Certificate. Copies of this original necessary to achieve a 2 hour rating.
to penetrate separating walls, compartment certificate and the detail sheets are available
walls and floors provided the appropriate from Marley Plumbing & Drainage.
measures are taken to prevent the spread of
fire in accordance with Part B of the Approved
Document (2010).
To comply with this, pipes must be enclosed
SVD4 Durgo air
within a fire resistant enclosure which extends admittance valve
from floor to ceiling within each storey. The
enclosure must have a class ‘O’ internal surface SE400 pipe
socket
and have each side formed by a separating
wall, external wall or by casing. Any casing must
have a minimum ½ hour fire resistance and
penetrations of the duct must be limited to
160mm vertical and 110mm horizontal. SGS41/SA323W
WC pan connector
Where longer periods of fire resistance are
SW40
required, Marley fire collars or pipe wraps can boss pipe
be fitted to provide a fire rating of up to 4
hours depending on the actual construction
detail. Tests carried out at the Warrington Fire
Research Centre in accordance with BS 476:
Part 20: 1987 verified the integrity of each
construction detail shown opposite in respect SY401
branch
of fire spread.
In addition to the above, tests carried out at
FIRTO on a variety of typical sanitary pipework
arrangements proved that it was possible to
achieve up to 1½ hour fire rating through a
compartment floor without a fire collar or pipe
wrap where the stack was terminated by an air
admittance valve. Various other arrangements Floor and enclosure fire stopped at all openings using
were also tested and achieved a minimum of materials meeting building regulation requirements

BASIN FLOOD LEVEL SVD4-110mm

B1 rated valve
Fire protection
fitted above
SE400 Coupling flood level of Marley Fire Protection Products provide up to 4 hours resistance. Suitable for use with all Marley plastic drainage systems
or pipe socket basin

SC45 Pipe clip

B032V 110mm PVCu pipe 55-160mm 110mm 110mm

anti syphon bottle trap 110mm 110mm
KR210 reducer SVD3-82mm
A1 rated valve
fitted below
flood level of
SWCB90 SRM304 110x82mm basin
90° connector Level invert reducer

40mm dia

BATH/SHOWER SYS415
87.5° Branch
UFC SFC44 SFW44 SFC44 SFW44
P1940 KBA22
Universal fire collar pipe wrap fire sleeve pipe wrap
low level 'p' trap 45º bend
40mm dia fire collar

F.F.L.
Universal fire collar Fire collar Pipe wrap Fire collar Pipe wrap
KT21 2no 45° Bend SA421 SCBL41 fixed to soffit of fixed to soffit of fixed within concrete floor fixed to exposed side of fixed within fire
45º tee KBA22/KB22 Boss connector Collar boss
concrete floor concrete floor fire compartment wall compartment wall

14 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 15
 Installation data

Jointing techniques
The ring seal has been successfully employed as Solvent soil stack installation Push-fit soil stack installation
the principal method of jointing large diameter
The addition of the SE409 ring seal adaptor allows for thermal
PVCu pipes and fittings since their introduction
movement required in a solvent soil installation
over thirty years ago. This particular technique
has proved extremely reliable as the joint can
accommodate thermal movement that will
occur as a result of temperature variations. An SES401 SC41
expansion gap of between 5-10mm should be Double solvent coupling Socket/support clip
SC41 Anchor point
allowed within each ring seal socket as each full SES401
Socket/support clip SC41
length of pipe is installed and fixed using socket Double point
Anchor solvent coupling Socket/support clip
SC41 Anchor point
and barrel pipe clips. Socket/support clip
Anchor point
Solvent weld jointing is also widely used and
many components in the range are available
with this facility to provide an effective
alternative. By selecting these fittings a solvent
weld system can be installed, however, ring
seal joints must be incorporated to control
thermal movement.
While the most popular method of jointing

MAX 2000mm

MAX 2000mm
larger size PVCu pipes and fittings is by ring
seal, with small diameter waste pipework the ring seal joint solvent weld joint

MAX 2000mm

MAX 2000mm
principal choice is usually solvent weld. Where
this technique is used expansion couplings
must be introduced where pipe lengths exceed
2 metres or between fixed points. The same
40mm waste pipe expansion coupling KEC2
principle should also be adopted when the
polypropylene push-fit waste system is installed.
It should be noted that polypropylene cannot SFS41 SFS41
Access pipe Access pipe
be solvent welded and together with the ABS
waste system must not be fitted externally SFS41 SFS41
Access pipe Access pipe
unless painted to protect it from ultra-violet pipe clips
degradation.
5 to 10mm 5 to 10mm
Expansion gap Expansion gap
SC45 SC45
Pipe/barrel clip 5 to 10mm Pipe/barrel clip
5 to 10mm
Guide bracket Expansion gap Guide bracket
Pipe support Expansion gap SC45
SE409
Pipe/barrel clip
SC45
Pipe/barrel clip
Experience has proved that an efficient and Ring
Guideseal adaptor
bracket Guide bracket
reliable PVCu sanitary pipework system depends SE409
SYS405 SY401
Connection Connection
considerably on the attention that is placed from W.C
Ring sealbranch
110mm adaptor
from W.C
110mm branch
on the correct provision of pipe support SCB41
SYS405 SC41SY401
Connection Connection
brackets. This is particularly important in multi- Connection from
from W.C
Collar boss branch
110mm Connection from
from W.C
Collar boss branch
110mm
bath/shower bath/shower
storey buildings where care must be taken to SCB41 SC41
ensure clips are positioned to control thermal Connection from Collar boss Connection from Collar boss
bath/shower bath/shower
movement at each floor level.
Plastic coated metal socket clips are designed
to fit ring seal sockets and act as anchor
brackets. These used in conjunction with PVCu
intermediate pipe clips, control expansion and
contraction and maintain the vertical alignment
of the stack.
Pipe material BS Nominal pipe size Horizontal support (m) Vertical support (m)
Two piece socket clips SC41/61 may be adapted
to suit the appropriate pipe size by using a
section of barrel clip collar SC621 to provide PVCu 21.5 0.50 1.20
the necessary spacer sleeve. The table opposite Polypropylene 32 0.50 1.20
indicates the maximum recommended support 40 0.50 1.20
centres of different size plastic pipe systems. PVCc 32 0.50 1.20
barrel pipe clip SC45 socket pipe clip SC41
ABS 40 0.50 1.20
50 0.60 1.20
PVCu 82 1.00 2.00
110 1.00 2.00
160 1.20 2.00

16 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 17
 Installation data

Marley dBlue Marley pipe support system

Marley dBlue is a push-fit system and is installed The Marley pipe support range was developed to meet the specific requirements of PVCu
in the same way as PVCu soil pipe. The only suspended sanitary pipework and drainage systems. Manufactured in zinc electro plated mild
minor difference is type of clips used, which are steel for internal use, the versatile range of components can be assembled to provide a robust,
integral to the effectiveness of the system. lightweight system suitable for most applications. The system also provides suitable control of
expansion and contraction.
The arrangements of brackets and channel supports have been extensively tested and the assembly
techniques used have been successfully employed on many domestic and commercial installations.

Single support
Recommended for waste or larger diameter pipework fixed within 500mm of the floor soffit.
see table
Double support
Drill holes applicable for the diameter of the Developed for use with larger diameter pipework fixed within 1.0m of the floor soffit. angle brace

fixing. Fix a rawlbolt into the wall and insert the

pipe clip, rotating it clockwise until it is flush
Pipe brackets
500mm max.
with the wall and secure. The 110mm two piece pipe brackets are designed to fit round the ring seal socket ofora600mm
pipe with
or
fitting. Where intermediate support brackets are located, the SC621 PVC barrel clip collar is used as
side bracing
110mm pipe
a spacer sleeve between the pipe and bracket.
anchor bracket
Angle and side bracing
Angle braces should be provided at 6m centres to prevent lineal and thermal movement. Side
intermediate bracket
bracing may also be necessary on long runs where there are no side connections to eliminate
lateral movement.

Vertical pipes
The transition between vertical and horizontal pipework should be achieved using two 45° bends
or a single 87½° long radius bend with a support bracket positioned as close as possible.

Branch connections
All branch connections into horizontal pipework should be made at 45° to ensure the discharge is 1.2m max.
swept in the direction of flow.
angle brace

Structural fixings
Put the pipe or fitting inside the pipe clip under
socket and connect the two parts of the open It is recommended that 6mm rawlbolt or similar proprietary fixings are used to secure base 750mm
plate max.
or 1.0m with
pipe clip with a drill. and angle cleats to the structure. side bracing

intermediate
bracket 110mm pipe

anchor bracket

1.0m

Marley dBlue boss connections Single support Double support

Marley boss connectors are available in white,
black & grey. The blue colour variant is not
only a different colour, but it is a different size, SW40BL SW40BL
which should be used to connect to dBlue boss branch boss branch
metric waste pipe only. see table
SA421BL (40mm) / SA420BL SA411/421/420 see table
Please note that this applies to the boss (50mm) dBlue boss connector boss connector
angle brace
connections on all Marley dBlue fittings,
including the collar boss, branches and boss angle brace

pipe. For integrity, all boss adaptors must 500mm max.

or 600mm with
be solvent welded into boss upstands. side bracing 1.0m max.
40mm dBlue pipe (PPA-040-018-300D) or 32, 40 or 50mm pipe 110mm pipe or 1.2m with
50mm dBlue pipe (PPA-050-018-300D) side bracing
ABS or PVCc waste pipe 110mm pipe
anchor bracket
anchor bracket

intermediate bracket

intermediate bracket

To connect a Marley dBlue soil stack to To connect a Marley dBlue soil stack to
Marley dBlue waste pipe, use the SA421BL Marley ABS & PVCc waste systems use
(40mm) or SA420BL (50mm) the SA411 (32mm), SA421 (40mm) or
SA420 (50mm) in white, black or grey.

1.2m max.

angle brace
18 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 19
 Installation data

Boss branches
The Marley range of five boss branches 110mm SWCB
32, 40 or SA411/421/420 ST40W 110mm
push-
are designed to allow multiple waste pipe 50mm pipe boss connector solvent
conn
connections to be made to the discharge WC connector
stack from different directions. Four different
side entry combinations are possible together
with a rear if required. Staggered waste
pipe connections, directly opposite are not
permitted as cross-flow could occur.

Compatibility
Boss pipes, boss connectors and strap-on
bosses fitted with multi-fit ‘T’ ring seals are
suitable for use with PVCc or ABS waste systems
WC connections 110mm ST40W
SWCB90
110mmSGS41W
Two different types of connectors are available push-fit WC
to BS EN 1566 or BS EN 1455-1, polypropylene solvent 110mm solvent connector 110mm
SY405 SA411/421/420 SY405 KBK25 or KBK35 to allow connection to vitreous china or stainless WC connector WC connector
to BS EN 1451-1 and metric size copper to branch boss connector branch knuckle bend
BS EN 16090. steel WC pans, slop hoppers and other similar
sanitary equipment. Manufactured in PVC and
Un-perforated boss upstands on boss pipes, eva (ethylene vinyl acetate) to accommodate a
branches and reducers may be drilled to accept range of outlet sizes between 84 and 110mm
32, 40 and 50mm boss connectors SA411, SA411/421/420 SA411/421/420
sanitary pipework or undergound drainage.
boss connector boss connector SWC11
SA421 and SA420 using a 51mm diameter hole SA323W push-f
saw. Knuckle bends KBK25 and KBK35 may also The 90º ST40W, ST41W and SG40W connectors WC seal and WC co
be used as 90° boss connectors for 40 and are supplied complete with flexible seal and retaining cap
50mm PVCc or ABS waste pipework. retaining cap. Where the SGS41W or STS41W
pan connectors are used, the WC socket must be
trimmed to suit the length of pan spigot before
Horizontal connections the SA323W is solvent welded in position.
SGS41W
110mm solvent 110mm
The SWS4135 boss pipe is recommended for WC connector
Ground floor toilets often have their own
use in horizontal situations where connections
connection to the building drain to eliminate
to 110mm diameter pipe is made at 45°. This
pipework and ducting. Where this occurs both
fitting has a 50mm solvent weld socket to SWCB90
types of connector are suitable for push-fit or 110mm ST40W 110mm
accept PVCc or ABS waste pipes. push-fit WC
solvent weld jointing to the 110mm PVC drain. solvent
connector
WC connector
SWC11
SY405 SY405 32, 40 or
SA323W push-fit
branch branch 50mm pipe WC seal and WC connector
retaining cap

110mm SWCB90
ST40W 110mm
push-fit WC
solvent ST40W SWCB90
Boss pipe connections WC connector
connector
solvent WC connector push-fit WC conne
Four different types of fitting are available to provide alternative methods of connecting small diameter waste pipes to 82, 110 and 160mm vertical
110mm SWCB90 SGS41W
discharge stacks. ST40W 110mm
push-fit WCsolvent
110mm 110mm
solvent
connector WC connector
110mm 110mm WC connector
Single boss pipes. Strap-on-bosses.
Available with ring seal or solvent Primarily designed to permit 32, 40
weld sockets for push-fit or solvent and 50mm waste pipe connections
weld jointing, single boss pipes to be made to existing 110mm PVCu
SWC11
allow 32, 40 and 50mm waste pipe discharge stacks, strap-on-bosses SA323W
110mm 11
push-fit
connections to be made at 87½° SWS415/ can also be used on new systems to SWS4150 PVCu drain PV
WC seal and WC connector
SWS41 /410/420 retaining cap
direct to the vertical stack. provide flexibility of installation during
SGS41W
different stages of construction. 110mm solvent 110mm ST40W SWCB90
110mm SWCB90 WC connector solvent WC connector push-fit WC connector
ST40W 110mm
push-fit WC
solvent
SW30/40 connector
82mm WC connector
boss branch SGS41W
Multiple entry boss pipes. Patch bosses. 110mm solvent 110mm
Supplied in ring seal or solvent weld Suitable for solvent weld jointing to WC connector
SA411/421/420 SWS332
options, all have 90° boss upstands boss connector new and existing 82mm diameter /340/350
SWC11
moulded on each fitting with one PVCu discharge stacks to accept SA323W push-fit
inlet port open. Connection is made 32, 40 and 50mm size PVCc or ABS WC seal and WC connector
using the appropriate size Marley waste pipework. retaining cap
boss connector to suit 32, 40 or SWC11 110mm 110mm
SA323W push-fit PVCu drain PVCu drain
50mm waste pipes. 32, 40 or 50mm pipe WC seal and WC connector
retaining cap

SGS41W
20 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 21
110mm solvent 110mm
WC connector
 

 

 

 

 

 





 Installation data




 
  
  
  
  

Site Work  





WC manifold system Inspection and testing Handling Safety

Inspection and testing should be carried out in PVCu pipes are strong, though lightweight The relevant regulations are outlined in the


 

 

 

 

 accordance with BS 12056: 2000 and Building and therefore very easily handled. However, Health and Safety At Work Act 1974 and
Up to six WCs can be connected to a soil stack using the WC manifold system and a single branch NUMBER ANGLE OF MANIFOLD BRANCH Regulations noting especially the details given reasonable care should be exercised while The Construction (Design and Management)


 connection. By using a double
  six
 connection, an additional
branch 

WCs can be connected.  

OF WCs 4 
  

WC 1 WC 2 WC 3 WC WC 5 WC 6 in respect of air testing and the fact that smoke handling, particularly in extremely cold conditions. Regulations 1994 and should be followed.
The table, right, details the angles of the manifolds for this installation.
testing of plastics pipework should be avoided Pipes should preferably be loaded and unloaded Hazard sheets, dealing with the correct





6 80° 75° 70° 65° 60° 55°

5 75° 70° 65° 60° 55° as the materials can be adversely affected. by hand but if mechanical handling is used, storage, use, and any hazards of working with
protected slings are recommended. solvent cement, silicone lubricant and fire
4 70° 65° 60° 55° Air test protection products are available from Marley

 Maintenance
3 65° 60° 55° The installation should be capable of Plumbing & Drainage.
2 60° 55° withstanding an air test of positive pressure Provided that the system is designed and installed
of at least 38mm water gauge for at least 3 correctly, no maintenance will be required.
minutes. During this time every trap should
If blockage does occur, use only flexible or roller
maintain a water seal of at least 25mm.


 

 

 

 type rods. Pointed or bearing type metal fittings
are not recommended. Tests have been carried


  
  
  
  
 out on PVCu pipes and fittings using equipment
from specialist drain cleaning contractors and





their standard equipment is suitable.



Dimension (*) based on 230mm centre outlet WC pans and SM43W adjustable spigot bends cut to the angles shown.

Storage


 

 


Pipes should be stacked on a reasonably flat, sockets at alternate ends protruding to ensure


  
  
  
 level surface on timber battens not less than pipes are evenly supported along their length.
75mm wide spaced at a maximum of 1m
Pipes should not be stacked more than 7 high





1. Select the adjustable bend angle required 2. File away any rough edges from the face 3. Apply a uniform coat of Marley solvent centres. Side support should also be provided
and when stored in the open for long periods,
from the above diagram according to the of the fitting and wipe clean the bend and cement, to the short branch radial at intervals of not more than 1.5m.
or exposed to strong sunlight, they should be
WC position. Cut the bend with a hacksaw, branch, with a dry cloth. Before jointing, socket and to the external surface of
Different size pipes should be stacked separately. covered with an opaque sheet. Fittings supplied
removing the unwanted portion.
 the bend and branch should be checked for the bend body.
However, where this is not possible, larger in cardboard boxes or polythene bags should
position and alignment, both parts being
diameter pipes should be placed at the bottom. be stored under cover and kept packed until
marked to ensure accurate assembly.
required. Solvent cement should be stored in a
Spigot and socket pipes should be stacked
cool place out of direct sunlight and away from
SM41 separately. However, where this is not possible,
any heat source.


 

 larger diameter pipes should be stacked with


  
 
 






 SM42/SM43
4. Assemble the branch immediately, insuring
that the marked lines on the fitting coincide.
Do not twist the two parts of the branch
during this operation, but maintain steady
pressure until the spigot of the bend comes
to rest against the internal surface of the
branch socket. Quickly wipe off any surplus
solvent cement from the inside and outside
of the completed joint and hold in position
for approximately 15 seconds.
SM41
SM42/SM43
SM42/SM43
5. Trim the WC socket to suit the toilet pan
spigot length and remove any swarf with
a file. Place the seal in the socket, apply a
uniform coat of solvent cement about 15mm
wide to the outside of the socket and inside
the retaining cap. Push onto the socket and
wipe off any surplus solvent cement.
SM41
SA323
cap and seal
SM42/SM43




SM42/SM43





To accommodate varying dimensions between
the WC spigot and the centre line of the
horizontal pipe run, the adjustable spigot bend
SM43 or extension pipe SM45 can be used with
WC connector SM44.
Packing, storage and transportation specific to Marley dBlue
In order to facilitate transport and storage, Never throw, drag or bend pipes and fittings
all the fittings are packed in cardboard boxes. when unloading them.
Pipes are packed in bundles on pallets.
Pipes should be stored horizontally on even
Marley dBlue pipes and fittings must not be surfaces up to 1.5m high. All products should
transported unpacked (in bulk) along with be protected against sunlight.
other construction materials to prevent
Their outdoor storage time should not exceed
damage during transportation. The pipes
12 months.
must be transported in a horizontal position.
During unloading they must be protected
against damage, particularly at temperatures
below freezing.

22 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 23
 HDPE jointing methods


Electrofusion Jointing procedure 7. Prevent misalignment Butt-welding
1. Cut the pipe square
The pipe ends must be cut square to ensure that the heating element
✗ 

in the coupler is completely covered by the pipe or fitting.

✔ 

 vertical
 down when installed
8. Prevent coupler from sliding
 
✗ KG

2. Mark insertion depth + 10 mm  Butt-welding is a very economical and reliable jointing technique for
KG making welded joints, requiring only butt-welding equipment.
Electrofusion, the most simple and rapid jointing technique, is mainly
used on construction sites for a highly efficient method of assembly for This is to ensure that across the full welding zone the oxidised
layer All Akatherm pipes and fittings can be joined by this welding method.
will be removed. 

pipes, fittings and prefabricated sections.
 
Fittings for which a k-dimension is shown in the table can be shortened
by not more than this amount. Butt-welding is extremely suitable for
Electrofusion couplers ✔ 10 mm  prefabricating pipe sections and for making special fittings.
The PE range includes couplers in the diameters 40 to 315 mm. The
10 mm Preparations
couplers are extremely suitable for applications in waste water and
rainwater drainage, with the following features: 2x 
The following guidelines are of importance when making a proper
 butt-weld:
1. Injection molded with excellent dimensional accuracy and stability.
3. Scrape pipe and mark
10 mm insertion depth again 
2. One welding indicator on each welding surface for checking both
The outer surface of the pipe (approx. 0.2 mm deep) must be

scraped
●● E stablish a work space where the jointing can be done without being
welding connections. 10 mm effected by major weather conditions.
for the full distance
10 mmthat will be covered by the coupler to remove any 9. Prevent load on vertical pipesystem
3. Centre stops easy to remove in order to use the coupler as a slide- 10 mm
surface 'oxidation'.    ●● C
 heck the equipment functions properly. Welding equipment used
over coupler.
The insertion depth should be marked again to safeguard full insertion.
✗ 2x 
on site deserves special attention.
4. Resistance wires fixed to the surface for an optimal heat transfer ●● T he fittings and or pipes need to be aligned in the welding machine.
KG
and therefore a high quality welding connection. Mis-alignment can be up to 10% of the wall thickness.
✔ 
5. Yellow edge surrounding the welding indicators of the diameters ●● C
 lean the heating element before each jointing operation with a lint-
200, 250 and 315 mm for better visibility.  free cloth and suitable cleaner (see instructions welding machine).


 ●● Cut the pipe and/or fitting with a pipe cutter to make the end square.
Electrofusion control box
The Akafusion control box CB315 can not only weld Akatherm electro-   ●● M
 ake sure that once the pipe and/or fitting ends have been
fusion couplers in the diameter range 40 to 160 mm but also the 4. Clean coupler machined, they do not get dirty. Do not touch them with your hands.
diameters 200, 250 and 315 mm. The new techniques applied in the The surface needs to be clear of oil, grease and dirt.
electronics (such as integrated circuit boards) and the case material Before assembling the pipes into the coupler ensure that all surfaces
●● P ut the pipe parts into the welding machine to facilitate a firm hold
make it a solid and reliable control box. are clean and dry.
 during the jointing process.

Multiple welding
✔  After connecting the cables of the control box the welding process ●● A
 digital thermometer can be used to check the temperature of


 can be commenced42
by pushing the start button. The CB315 control the heating plate. The temperature should be checked at several
box adapts the welding time to the ambient temperature. When it is points around the plate and should be between 200ºC and 220ºC.
 colder than 20°C the welding time is extended and
2x when the ambient Maximum deviation between points is given in the table.
temperature exceeds 20°C the welding time is shortened. For welding
times and cooling down time seetable below. 
5. Insert pipe and/or fitting up to pipe stop

Ensure that the pipe is pushed as straight as possible into the fitting.
The joint assembly should not be disturbed during the fusion cycle and
for the specified cooling time afterwards. KG

✔  Used surface of heating element

Δttot


 weld
for welding diameter d1

The CB315 is capable of welding several electrofusion couplers dimension d1 system cooling time d1 = 40-160 8ºC
simultaneously in the same time that is needed for producing one  time
d1 = 200-315 10ºC
mm sec min
electrofusion weld. The combined diameters of the couplers to be
joined should not exceed 200 mm. For example in the case of a 45° 40-160 Constant current 5A 80 20
75/50 mm tee, both the diameters 75 mm and the branch 50 mm can Constant voltage
200-315 420 30
be welded at once. 6. Prevent joint movement during welding  220V
Maximum temperature variation heating element

✗ 


10. Don't weld coupler
42
twice

✗ 2x 

24 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 25
 HDPE jointing methods

Welding process
The butt-welding of Akatherm HDPE operates according to the pressure N/mm2
following steps:
(PE)
HDPE
preheating pressure (F o) welding pressure (F L)
Machining the surface Heating up with less pressure
0,15
Both sides should be machined until they run parallel. When the machining
HDPE is a good insulator, therefore at this stage it is necessary that the
is finished, open the carriages (the plastic shavings must be continuous and
correct heating depth of the pipe ends is obtained. Only a small amount of
uniform in both sides to weld). Take off the milling cutter.
pressure 0.01 N/mm2 is required to maintain the contact of the pipe ends
Verify the alignment between the machined surfaces. Remove the plastic with the heating element. The heat will gradually spread through the pipe/
shaving. Do not dirty or touch the machined surfaces. fitting end. The size of the bead will increase a little. The time and pressure
needed for this phase can be found in the table on the next page.

heating pressure (F d)
0,01
time

pressure time
changeover

building-up
time
preheating time heating time cooling time
Machining the surface

Obtaining correct heating depth

total welding time
Preheating under pressure
height welding bead
Press the two ends to be jointed gradually to the heating element until
Change over
a bead is created. The size of the bead is a good indication that the
appropriate pressure and time is used. For pressure and bead size see the Remove the heating element from the jointing areas and immediately total time welding process
table on the next page. make those areas touch each other. Do not push the pipe ends abruptly
onto each other. Preheating
pressure /
The removal of the heating element needs to be done quickly to prevent welding Heating
Diameter Wall thickness pressure pressure Height Changeover Building-up
the pipe ends from cooling down. The times for changing over can be
d1 e (0,15 N/mm2) (0,01 N/mm2) welding bead Heating time time pressure time Cooling time
found in the table on the next page.
mm mm FO/FL N Fd N mm sec sec sec min

40 3.0 55 4 0.2 29 4 4 4
Welding and cooling 50 3.0 70 5 0.5 30 4 4 4
56 3.0 75 5 0.5 30 4 4 4
After the jointing areas have made contact they should be joined with a
gradual increase in pressure up to the specified value. Keep the specified 63 3.0 85 6 0.5 31 4 4 4
welding pressure at a constant level during the cooling period. Do not 75 3.0 105 7 0.5 32 5 5 4
Preheating under pressure 90 3.5 145 10 0.5 35 5 5 4
cool artificially.
110 4.2 210 14 0.5 42 5 5 6
125 4.8 275 18 1.0 48 5 5 6
160 6.2 450 30 1.0 62 6 6 9
110 3.4 175 12 0.5 35 5 5 4
125 3.9 225 15 0.5 39 5 5 5
160 4.9 370 25 1.0 49 5 5 7
200 6.2 570 38 1.0 62 6 6 9
250 7.8 900 60 1.5 77 6 6 11
315 9.7 1400 93 1.5 77 6 6 11
200 7.7 700 47 1.5 77 6 6 11
250 9.6 1090 73 1.5 97 7 7 13
Welding and cooling 315 12.1 1730 115 2.0 121 6 8 16

The welded components can be removed from the machine when 50% of
the cooling period has elapsed, providing that this is done carefully, with
no load or strain being placed on the joint. The joint must then be left
undisturbed for the remainder of the cooling period.
Welding parameters Akatherm HDPE drainage
In this table the welding parameters can be found for Akatherm HDPE.
The exact regulation of the welding machine depends on its mechanical
resistance. The tables provided with the machine are to be used for
regulating the machine.

26 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 27
 HDPE jointing methods

Evaluating the butt-weld joint Plug-in joint Expansion joint

The butt-weld can be evaluated using destructive and non destructive When there is either insufficient heating up or too low welding pressure
evaluation methods. For these evaluations special equipment has to be there are hardly any beads. In cases like this thick walled pipes often form
used. Butt-welds can easily be judged by a visual inspection making this the shrinking cavities. The weld must be classified as "not acceptable".
recommended method for a first evaluation.
Butt-weld (not acceptable)
The shape of the welding bead is an indication for the proper operation
of the welding process. Both welding beads should have the same shape
and size. The width of the welding bead should approximately be 0.5 x the
✗
A plug-in joint is an easy to make, detachable and non pull-tight Expansion sockets can absorb length changes of pipes with a maximum
height. Differences between the beads can be caused by the difference in
jointing method. length of 5 m.
HDPE material used in the welded components. Despite the differences in
welding bead the butt can be of sufficient strength.

In the next illustration a good weld is shown with a uniform welding bead.
Jointing process: Jointing process:
At a visual inspection this would be classified as an "acceptable" weld.
Cut pipe square and remove burr Cut pipe square and remove burr
Butt-weld with even welding beads (acceptable)

✔ In the next illustration a cross-section of a regular, round fusion bead, free

✔ ✔
of notches or sagging is shown. Special attention should be paid to the
fact that the collar value 'K' is greater than 0.

Cross section of a good butt-weld

✔
Mark insertion depth Mark insertion depth

Mis-alignment between fittings and pipe can occur for several reasons. ✔ ✔
Oval pipe ends or irregular necking of the pipe can cause an incomplete fit. Plug in socket: An expansion socket counteracts
If this is less than 10% of the wall thickness the weld can still be clas- sified the variation in length caused by the
as "acceptable"(see next illustration). The pipe needs to be inserted in thermal expansion and shrinkage of
the plug in socket using the full the pipe.
Butt-weld with mis-alignment of pipe (acceptable) insertion depth.
Depending on the ambient
✔ A plug-in joint is not to be used to temperature the insertion depth
accommodate the expansion and varies. The right insertion depth
contraction of a pipe system. for both 0°C and 20°C is indicated
on the expansion socket.

Chamfer pipe end

Chamfer pipe end
✔
The pipe-end needs to be chamfered
✔
under an angle of 15°. To get an even The pipe-end needs to be chamfered
cut and chamfer a chamfering tool under an angle of 15°. To get an even
The next illustration shows a joint with beads that are too big. The
should be used. cut and chamfer a chamfering tool
uniformity indicates a good joint preparation. Heat supply and jointing
should be used.
pressure settings, however, are too high. A purely visual assessment would
still classify the weld as "acceptable".

Butt-weld with big welding beads (acceptable)

✔
Make joint
Make joint
Lubricate the pipe end and insert the pipe up to the marked
insertion depth. Lubricate the pipe end and insert the pipe up to the marked
insertion depth.

28 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 29
 HDPE jointing methods HDPE installation

Flange joint Contraction sleeve Tempered Pipe
The Marley Akatherm HDPE pipe is tempered. This pipe is produced
according to the standards EN 1519 and ISO 8770 but has undergone a
heat treatment after extrusion. The result is less shrinkage when cooled
down from high operational temperature. This gives less stress on joints
resulting in a longer life for the pipe system.
For the installation of Akatherm PE pipe systems several bracketing
systems can be used:
Anchor point bracket
This method of bracketing is used for rigid installations. The expansion
forces are transferred to the building structure.

Shrinkage according to EN 1519 (3%)

Maximum shrinkage tempered Akatherm pipe (1%)

The flanged joint is a detachable joint not that common in soil and waste
systems. It is the ideal jointing method to connect the system onto
flanged equipment and to install valves. The joint can be made by the
Support bracket fixed to building Electrofusion coupler either side of
following steps: structure- brackets must be of sufficient support bracket
strength to resist forces generated by
●● Mount backing ring over pipe or fitting Pipe length after production thermal movement of the PE pipes

●● Weld stub flange to fitting or pipe Anchor bracket with 2 electrofusion couplers Art. Nr. 41xx95
Linear expansion
●● Apply seal
The Marley Akatherm HDPE material has a linear expansion coefficient of
●● M
 ount bolts, nuts and washers and tighten nuts with the bolt torque A simple transition to other materials than HDPE can be made using the 0.13-0.19 mm/mK. We calculate with an expansion of 0.2 mm per meter
mentioned in the next table. contraction sleeve. pipe for every °C temperature difference. The total length variation can Anchor bracket with expansion socket
be calculated as follows:
The sleeve provides a non pull-tight connection and is installed as follows: This method of installation is used for flexible installations where
d1 (mm) Bolt torque (Nm)
Δl = L x λ x Δt the expansion force is not transferred to the building structure.
●● Mark insertion depth on the connecting pipe. Only the force caused by the internal resistance of the expansion
40 20 Δl = length change in mm socket is transferred.
●● C
 onnect contraction sleeve to HDPE pipe or fitting using
50 30 L = total length of pipe
electrofusion or butt fusion.
56 35 λ = linear expansion coefficient
●● Mount the O-ring in the middle of the insertion zone.
63 35 Δt = temperature difference in °C
75 40 ●● H
 eat up the contraction sleeve evenly with a torch or an industrial
heater. Diameters above 125 mm are best heated up using a second Example:
90 40
heat source.
110 40 Pipe 10 metres with a maximum temperature of 60°C and a minimum
125 40 temperature of -20°C. This results in an expansion of:
160 60 Support bracket fixed to building Thermal movement of PE pipework
Δl = 10 x 0,2 x 80 = 160 mm structure-brackets to be of sufficient
200 70
strength to resist forces caused by the
250 80 Length changes can be accommodated by the expansion socket which internal resistance of the expansion socket
315 100 can take up the expansion and contraction of a 5 meter length of pipe
Anchor with expansion socket
for temperatures between -20°C and 70°C.

Bolt torque for non-pressure applications Electrofusion

The Marley Akatherm products can be welded by electrofusion unless
stated differently in the product table. This is the preferred method of
on-site jointing.
Butt welding and k-dimension
Guide bracket
The guide bracket is used to support the pipe and to prevent the pipe
from buckling sideways when in a rigid installation. The pipe can freely
move in the bracket.

All Marley Akatherm products can be welded using this jointing

method. Fittings can be shortened by up to the k-dimension
(indicated in the specification guide), still allowing butt-welding
on a standard butt-welding machine.

The sliding bracket is used to support the

pipe and to prevent the pipe from buckling
sideways (snaking). The pipe should be able
to move freely in the bracket

Guide bracket

30 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 31
 HDPE installation

Bracket distance Horizontal installation with expansion sockets Vertical installation: to the wall
The bracket distances for Akatherm PE pipes are largely dependent on and support trays For the vertical installation the bracketing
the working temperature of the pipe system. Also the filling rate of the In this kind of installation the pipe is extra supported by support trays. distance is in general 1,5 times the
pipe plays a role. A fully filled pipe has a different bracket distance. The distance between the brackets can be larger. The support shells are distance of the horizontal bracketing.
installed on to the pipe with straps. For distances see table below. There is no separate bracketing distance
for immediately in front of the expansion
socket because there is no sagging of the
pipe and the insertion is always in line.

Horizontal pipework with support tray

GB= guide bracket LA= bracket distance Vertical installation

FP= fixed point LA*= bracket distance for expansion unit
GB = guide bracket FP = fixed point
B= tray band LBA = spacing for bands
LV = vertical support distance

d1 LA LA* LBA

75 1.2 m 0.6 m 0.5 m

90 1.4 m 0.7 m 0.5 m
110 1.7 m 0.9 m 0.5 m d1 LV
125 1.9 m 1.0 m 0.5 m
160 2.4 m 1.2 m 0.5 m 50 1.0 m
200 3.0 m 1.5 m 0.5 m 56 1.0 m
250 3.0 m 1.5 m 0.5 m 63 1.0 m
315 3.0 m 1.5 m 0.5 m 75 1.2 m
90 1.4 m
Bracket distances horizontal installation with expansion sockets and 110 1.7 m
Bracket distances for vertical and horizontal PE pipe systems with standard filling 125 1.9 m
support trays
160 2.4 m
200 3.0 m
250 3.0 m
315 3.0 m

Horizontal installation with expansion sockets without Bracket distances vertical installation with expansion sockets
support trays
The bracket directly in front of the expansion socket has a shorter
bracket distance (LA*) This makes a better guidance into the expansion d1 LA LA*
socket possible (see image). The bracketing distances for this application
can be found in table below. The maximum distance between 2 75 0.8 m 0.4 m
expansion sockets is 5 m.
90 0.9 m 0.5 m
110 1.1 m 0.6 m
125 1.3 m 0.7 m
160 1.6 m 0.8 m
200 2.0 m 1.0 m
250 2.0 m 1.0 m
315 2.0 m 1.0 m

Bracket distances horizontal installation with expansion sockets

32 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 33
 HDPE expansion socket insertion depths HDPE handling and storage

Fittings Storage of loose pipes

The fittings and electrofusion couplers need to be stored at a dry place.
To prevent oxidation and contamination it is recommended to leave the
40mm Expansion fittings in their original packaging as long as possible.
Socket (S400420)
75mm Expansion Socket
Pipes
(S420720)*
The high impact strength of Akatherm HDPE provides some protection
against damage but care should be taken at all stages of handling,
transportation and storage.

200mm Expansion Socket Pipe must be transported by a suitable vehicle and properly loaded and
(S402020) Without Protection Plug unloaded, e.g. wherever possible moved by hand or mechanical lifting
equipment. It must not be dragged across the ground. The storage
50mm Expansion
90mm Expansion Socket should be flat, level and free from sharp stones. Tools
Socket (S400520)
(S420920)* Tools need to be protected against moisture.
Bundles
Bundled packs of pipe should be stored on clear, level ground with the Health and safety at work act and COSHH regulations
battens supported from the outside by timber or concrete blocks. For Attention is drawn to the requirement in the UK of this act and to the
safety, bundled packs should not be stacked more than three high. 1988 Control of Substances Hazardous to Health (COSHH) Regulations.
Marley cannot accept responsibility for accidents arising from the misuse
Smaller pipes may be nested inside larger pipes. Side bracing should be
of its products because of bad installation or incorrect application.
provided to prevent stack collapse.
110mm Expansion Socket 56mm Expansion Handling of HDPE has no detrimental health impact. It is recommended,
Similar precautions should be taken with fittings and these should be
(S421120)* Socket (S405620) kept packaged until required for use.
however, that HDPE is not ingested or dust inhaled.

Personal Protective Equipment (PPE)

250mm Expansion Socket Storage of bundles
When welding HDPE, molten material is formed, which can cause burns
(S402520) Without Protection Plug
to skin. Appropriated PPE should be worn.

Physical contact
HDPE is not considered to be a skin irritant. Where HDPE dust is
generated by cutting of machining pipe of fittings, powder particles of
125mm Expansion Socket 63mm Expansion HDPE dust may cause eye irritation by abrasion.
(S421220)* Socket (S400620)
Butt Weld Only Behaviour in Fire
HDPE is a flammable material. It has, however, been installed throughout
Europe for over 35 years and presents no greater risk of fire propogation
than similar plastic based systems when installed in accordance with local
regulations. Marley Unicollar firecollars are suitable for use with Akatherm
HDPE (up to 200mm) and these should be installed in accordance with
the instructions provided.

315mm Expansion Socket 160mm Expansion Socket * Insertion depth and expansion
(S403120) Without Protection Plug (S421620)* details indicated on fitting
Lengths
HDPE Expansion Details Pipe lengths stored individually should be stacked in a pyramid not more
Type A Type B that one metre high, with the bottom layer fully restrained by wedges.
Min. Insertion
Diameter Total Length Max. Expansion (No White Retaining Ring) (With White Retaining Ring) Where possible, the bottom layer of pipes should be laid on timber
Depth @ 20°C
battens at one-metre centres. On site, pipes may be laid out individually
40mm 132mm 76mm 56mm Type B in strings (where appropriate, protective barriers should be placed with
50mm 132mm 76mm 56mm Type B adequate warning signs and lamps).
56mm 132mm 76mm 56mm Type B
63mm 132mm 76mm 56mm Type B
75mm – On Fitting On Fitting Type A
90mm – On Fitting On Fitting Type A
110mm – On Fitting On Fitting Type A
125mm – On Fitting On Fitting Type A
160mm – On Fitting On Fitting Type A
200mm 230mm 120mm 110mm Type A
250mm 250mm 125mm 125mm Type A
315mm 270mm 126mm 144mm Type A

34 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 35
 Standards Marley system solutions

British & European Standards

BS EN 1329-1: 2014 BS EN 1566-1: 2000 BS EN 14680: 2006

Plastics piping systems for soil and waste
discharge (low and high temperature)
within the building structure – PVCu.
BS EN 1451-1: 2000
Plastics piping systems for soil and waste
discharge (low and high temperature) within
the building structure – polypropylene.
BS EN 1519-1: 2000
Plastics piping systems for soil and waste
discharge (low and high temperature) within
the building structure – polyethylene.
BS 4514: 2001
Specification for PVCu soil and ventilating
pipes, fittings and accessories.
Specification for thermoplastics waste pipe
and fittings.
BS 5255: 1989
Specification for thermoplastics waste pipe
and fittings.
BS EN 1455-1: 2000
Plastics piping systems for soil and waste
(low and high temperature) within the
building structure – ABS.
BS 5627: 1984
Specification for plastics connectors
for use with horizontal outlet vitreous
china WC pans.
Specification for adhesives for non-pressure
thermoplastics pipe systems.
BS EN 681-1: 1996
Elastomeric seals. Material requirements for
pipe joint seals used in water and drainage
applications. Part 1 vulcanised rubber.
BS EN ISO 9001: 2008
Quality systems. Model for Quality
Assurance in Design, Development,
Production, Installation and Servicing.
BS EN ISO 14001: 2004
Environmental management systems.
Requirements with guidance for use.
Marley HDPE
Marley Akatherm HDPE is a drainage system
which offers an alternative solution to cast
iron. It is particularly suited for commercial
applications or where a product with high
impact or abrasion resistance is required,
such as hospitals, hotels, schools, as well as
residential buildings. HDPE will also cope
with temperature variations of -40°C to
100°C making it ideal for external as well as
internal installations.
Marley dBlue
An acoustic soil and waste range with a triple
layered pipe providing quick, hygienic removal
of sanitary waste water. The noise generated
by the flow of water is dramatically reduced
– making it perfect for multi-occupancy
apartment blocks and high specification
developments.
Marley waste systems
A wide range of PVC-u, ABS and polypropylene
waste ranges from 32mm to 50mm and
in a variety of colours. Available with
polypropylene solvent weld and push
fit jointing.

Marley rainwater Marley underground systems Marley sustainable drainage

Five gutter profiles and three downpipe
options provide a rainwater solution
for any application. Advanced Life4
technology on four of the key profiles,
coupled with the benefits of the Easyclip
and notching capability combine to make
the Marley rainwater range the most
comprehensive available.
The Marley Plumbing & Drainage range
of underground systems include the
solid wall range, predominately for
round the house drainage and Quantum
structured wall range for sewer and
highway drainage applications.
The Waterloc250 cell is ideal for use in either
an underground infiltration or attenuation
system. 96% of the cell volume is available
to store water, minimising the extent of
excavation required for the installation.
The range includes Flowloc, a vortex control
device, which controls the rate at which water
is discharged to a surface water drain or
water course.

Accreditations
ER INDUSTR
AT
TIFIE TO W

Y
SP
ECIFICAT
D

Marley Equator Alutec Multikwik

ER

ON
I

C
Certificate No. 06/4325 BS EN 1329-1 : 2000
BS 4514 : 2001
BS EN 1566-1: 2000
BS 5255: 1989
BS EN 1455-1: 2000
BS EN 1451-1: 2000
BS EN 1519-1: 2000
Equator is ideal for hot & cold water or
BS EN ISO 9001: 2008
BS EN ISO 14001: 2004 central heating installations. A tamperproof
fitting with a unique grip release mechanism
ensuring that the system can only be
disassembled through the use of a special
de-mounting tool. Equator has been designed
to meet the requirements of BS 7291: Parts 1
& 3; Class S. The complete Equator system is
backed by a 30 year guarantee.
Alutec offer modern and traditional
aluminium rainwater profiles, providing
solutions for any type of building. Aluminium
has high visual appeal and durability, lasting
for 50 years or more. The product portfolio
includes Evolve; easy to install, low cost gutter
systems in four profiles. The rainwater ranges
are complemented by aluminium soffit and
fascia systems and roof & floor outlets.
The Multikwik brand is known and trusted
by plumbers for its sanitary frames, cisterns,
traps, compression waste systems and
market leading range of pan connectors.
Complementing the Marley range it provides
an excellent solution to modern bathroom
design with a wide choice of product options.

36 | MARLEY Soil & Waste Systems MARLEY Soil & Waste Systems | 37
Notes Notes
marley.co.uk
For general enquiries and details of your
nearest stockist please call the customer
services department:
Tel: 01622 852585
email: marketing@marleypd.com

To place an order
For delivery to England & Wales
Email: orders.lenham@marleypd.co.uk
Fax: 01622 851111
For delivery to Scotland
Email: orders.uddingston@marleypd.co.uk
Fax: 01698 810307

For all estimate requests

Email: estimates@marleypd.co.uk

For Technical advice please call

01622 852695

Head Office
Lenham, Maidstone
Kent ME17 2DE
Tel: 01622 858888
Fax: 01622 858725

Scotland
Birkenshaw Industrial Estate
Uddingston, Glasgow G71 5PA
Tel: 01698 815231
Fax: 01698 810307

Export Division
Lenham, Maidstone
Kent ME17 2DE England
Tel: +44 (0)1622 858888
Fax: +44 (0)1622 850778

April 2014