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www.aquaspira.com Doc: APIG V4 Date: 04/19

Installation Guide for AquaSpira Large Diameter Pipe Systems

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Contents: Please Note:

• This document provides guidelines on the installation of AquaSpira Pipe Systems. It assumes that the installer of the pipes has good general knowledge in construction practices and experience of installing large diameter pipes.

• For design and installation, reference must also be made to the project engineer’s drawings, appropriate text and relevant standards. Wherever there is a variance between information contained in this document and any of the aforementioned project related sources, the project related sources should take precedence over information contained in this document.

• All reasonable efforts have been made to ensure the accuracy of information contained in this document. However, AquaSpira makes no warranty as to the accuracy of this information and disclaims all liability relating to its use.

Subject Page

Pre-Installation Planning 3

Site Preparation 3

Unloading, Handling and Storage 4

Preventing Flotation 5

Shallow Depths and Connecting to Structures 6-7

Bedding, Laying & Jointing 8-9

Preventing Post-Installation Damage 10

Lateral Connections 11-12

Cutting Pipes 13

Removal of Trench Supports 13

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Pre-Installation Planning

Check the site layout drawings and inspect the site to ensure that: o Sufficient access and space for off-loading and storage of large pipes is

available.

o There are no issues in respect of overhead cables or underground services that might affect the movement and installation of the pipes on site.

Identify potential obstructions, including trees that need to be preserved and walls or fences that may be affected by excavation or installation, and define actions for avoiding them.

Assess how the pipe construction programme fits with the rest of the construction programme for the site. In particular:

o Will heavy vehicles be working near the pipeline?

o Will access be needed over the pipeline before construction is finished?

Be aware of the ground conditions you are likely to find, and the type of ground support that will be required.

If groundwater is present, prepare to remove and dispose of this water during installation.

Chemical resistance – AquaSpira pipes are resistant to most contaminants or chemicals that may be present in the ground or the effluent that they are designed to convey. A detailed chemical resistance list is available to download from our website.

Confirm all inspection requirements by external authorities (if required), and whether inspection must be done in sections or for the completed pipeline only.

Site Preparation If pipes are to be stored on site, select appropriately sized, flat areas with safe vehicle access, at locations that will not interfere with other construction work that may be going on at the same time as the pipe installation. Ensure it is possible to safely unload the pipes at the locations you have chosen without disrupting traffic, other construction work, or blocking the access of local residents. In particular, check for overhead powerlines and the locations of other overground services.

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Unloading, Handling and Storage Unloading and Handling AquaSpira pipes are robust, relatively light and easy to handle, however care must be taken to prevent damage during handling and unloading. Pipes should not be dropped, thrown or dragged. Pipes should be inspected upon arrival. AquaSpira cannot accept responsibility for any reported damage to pipes once the delivery vehicle has been offloaded. Where possible pipes should be offloaded using a machine with extended forks, or a machine with a pole attachment – see below. Alternatively, pipes can be safely offloaded with appropriate lifting straps without the need for operatives to mount the trailer. The straps can be thrown over the pack of pipes, drawn underneath and looped together. The external pipe ribs will prevent pipes from slipping.

Safe movement around site Pipes can be safely moved around site whilst retained in their packs, significantly reducing the number of movements around the site to carry pipes from the storage area to the location where they are to be installed.

Storage Pipes should be placed or stacked on a flat surface that is free from protrusions and large debris. They should be positioned on timber supports placed at 2m centres. Stacked pipes should not exceed a height of 3m.

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Preventing flotation

Pipes of any size or material that are empty can float if the trench becomes flooded before backfilling has commenced. In accordance with BS EN1997-1, AquaSpira pipes require the following minimum depth of compacted fill over the crown of the pipe to ensure that flotation cannot occur. Figures are based upon groundwater level at surface level:

Pipe diameter (mm) Depth (m)

900 0.56

1050 0.65

1200 0.75

1350 0.85

1500 0.96

1650 1.06

1800 1.17

1950 1.27

2100 1.38

2250 1.48

If required, the AquaSpira Technical Support Team can produce a project specific flotation calculation.

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Shallow Cover Depths On installations in trafficked areas where the finished cover level is less than 900mm above the crown of the pipe (1200mm for adoptable estate roads), it may be necessary to construct a reinforced concrete slab over the pipe – see standard detail below.

Connecting to Structures When connecting pipes to a rigid structure such as an access chamber, the pipe should be cast in-situ into the concrete wall. The steel reinforced ribs of the pipe act as flanges to provide restraint and prevent longitudinal movement. It is important to use fine sized aggregate (15 – 20mm) and vibrate the concrete to ensure that all voids are filled and a watertight joint is achieved.

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Rocker Pipes BS 9295 2010 – Section A.13.3 states: “Pipe materials with a high degree of longitudinal continuity and flexibility, such as welded polyethylene and welded steel, do not typically require rocker pipes at structures but other engineering solutions might be required where settlements are large”.

Rocker and Short Pipes are therefore not ordinarily required. However, it can often be more practical to build away from manholes with shorter pipes. The detail below shows how this can be simply achieved using 1.3m* long Spigot/Plain End and Socket/Plain End pipes. These pipes are available to order or can be formed on site by simply cutting a standard 2.6m** long pipe in half. For further information please refer to the ‘Cutting Pipes’ section on p.13 of this guide. *or 1.5m for pipe sizes up to 1350mmØ ** or 3m for pipe sizes up to 1350mmØ

Similar construction details for each individual pipe diameter are available for download in .pdf or .dwg format from the Typical Construction Drawings section on our website www.aquaspira.com

Structural Design Calculations A sample Structural Design Calculation to BS EN1295 is available to download from the Structural page on our website. If required, the AquaSpira Technical Support Team can produce a project specific structural design calculation.

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Bedding, Laying and Jointing

Trench Preparation For trench dimensions please refer to the standard detail drawing above. Maximum unsupported trench depth must be determined by the site engineer on completion of site-specific risk assessment and method statement however, according to Section 6.4 (p.15) of BS EN1610, this should not exceed 1.4m

Bedding Bedding material should be laid evenly along the trench bottom. For depth of bedding and material types see the standard detail drawing above.

Complete Construction Detail & Data Sheets for each pipe size are available at www.aquaspira.com

Typical Detail – Pipe diameter varies. Detailed drawings for each pipe diameter are available on our website.

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Jointing Spigot/Socket Joint (900 - 2250mmØ)

1. Ensure that the first pipe to be laid is placed in the correct direction with the spigot end facing

downstream.

2. The receiving pipe should be anchored with 75% of backfill in place.

3. The spigot and socket ends of the pipe should be clean and free from significant debris.

4. The rubber ring seal around the spigot is factory fitted but should be checked immediately

prior to installation to ensure that it has not been damaged.

5. Slacken the stainless steel creep band, such that it is relatively loose. Also, prior to jointing,

make sure that the tightening bolts are at, or towards the top of the pipe.

6. Apply lubricant around the inner bore of the socket end of the adjoining (receiving) pipe.

7. Lay the pipe up to the adjoining (receiving) pipe and locate the spigot inside the socket.

8. Using the AquaSpira Jointing Frame, position the frame inside the socket of the pipe to be

jointed, and with the arm of the machine, gently nudge the pipe home.

9. Check alignment of the pipe (1° maximum angle). The pipe is fully inserted when the bright

red section on the spigot is fully inside the socket and is no longer visible.

Tighten up the creep bands until they are hand tight, approximately 8Nm torque, but no more

than 12Nm.

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Protecting the pipeline until completion of the project All types of pipes can be damaged by being trafficked with heavy construction equipment before adequate cover has been built up. Rigid pipes, such as reinforced concrete can be cracked, while semi-rigid or flexible pipes, such as AquaSpira, can become deflected. It is therefore very important that heavy loads are kept away from the pipes unless sufficient compacted fill has been placed over them. The following diagram shows the minimum cover that should be placed and compacted over an AquaSpira Pipe before the types of construction equipment listed are allowed to pass over the pipe. This diagram assumes that the fill above the pipe has been compacted before the construction equipment is used above it. It assumes the recommended bedding material around the pipe has been used and has been well compacted. This diagram is only intended to provide an indication, as the weights and individual wheel loads of construction equipment can vary substantially. On construction sites where heavy machinery is operating, such as highway construction sites, it may be necessary to temporarily ramp fill above the pipe.

Pipes in greenfield or landscaped areas We would recommend that suitable markers are placed above the pipe to indicate its presence.

Bedding, surround and cover as typical detail on p.8

Construction Equipment Cover

1000mm Heavy construction equipment

Remote roller

Heavy roller, grader

Wacker/Vibration Plate

Firmly compact the area above the sidefill on each side before compacting over the top of the pipe.

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Lateral Connections into AquaSpira pipe Lateral connections can be created quickly and easily into AquaSpira pipes with our purpose made Lateral Connectors (LTC). The LTC is placed inside a pre-drilled hole and the lateral pipe is then inserted and clamped into position, providing a neat, sealed connection in a matter of minutes. The LTC’s are manufactured from 9mm thick, high quality EPDM rubber in accordance with BS EN 681: Part 1-1996 ‘Specifications for elastomeric joint rings for pipework and pipelines – drainage’ and are fitted with a stainless steel clamping band. Complete product, dimensional and installation details are set out below.

Product Description: LTC 110 Lateral Connector for 110mm pipe

LTC 160 Lateral Connector for 160mm pipe

Product Code: ZS0542 ZS0540

OD of incoming lateral pipe (a) 110mm 160mm

OD of LTC sleeve and Ø of hole required (b) 127mm 177mm

Overall height of LTC sleeve (c) 90mm 90mm

Insertion depth of incoming pipe (d) 80mm 80mm

Height of LTC sleeve from outer pipe wall (e) 74mm 74mm

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Lateral Connections – Installation procedure 110mm and 160mm connections can be made into AquaSpira pipes quickly and easily with our Lateral Connectors (LTC). 1. Hole saw blades and LTC’s to the correct

specification should be obtained from AquaSpira.

2. Drill hole 90° to the pipe axis. Where possible it is

better to drill holes from inside the pipe

however, holes can also be drilled from the

outside.

3. Ensure hole is clean.

4. Fit the LTC into the hole such that the steel band

remains above the level of the ribs, whilst

ensuring that the bottom of the LTC protrudes

into the pipe by 2-3mm (in line with small non-

return flange).

5. Mark the pipe/bend to be connected with a line

80mm from the end of the pipe/bend to indicate

correct depth insertion.

6. Lubricate the inside of the LTC and the

pipe/bend.

7. Insert the pipe/bend into the LTC until the depth

insertion marker is level with the top of the LTC.

8. Tighten the clamp on the steel band to approx.

6Nm.

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Cutting Pipes Pipes can be cut quite easily using a manual or powered saw/cutter. Prior to cutting, the pipe should be clearly marked with a cutting line that is square to the pipe. Whenever a pipe is cut there will always be 3 or more sections of exposed steel ribs that have been cut. In most applications, the cut end will be cast into a concrete chamber and no further action is required. However, if the end is not surrounded with concrete, whilst these exposed ends are on the outer element of the pipe and do not form any part of the internal water-way bore, it is recommended that they should be sealed off with a small bead of CT1 sealant.

Removal of Trench Supports Vertical loading should not be applied to the pipe until the backfill has been fully placed on

each side of the pipe and compacted between the pipe and the trench wall. The method to

achieve this is as follows:

• Where trench support systems are in

use, the support should be progressively

raised as the surround material is placed

in accordance with section A1 of

BS9295.

• Backfill material should not be placed

above the crown of the pipe until the

trench support and backfill material has

been raised to the crown of the pipe.

AquaSpira Limited Profile Park Junction Street Nelson Lancashire BB9 8AH Tel: 01282 608510 www.aquaspira.com Doc: APIG V4 Date: 04/19