Testing the pipeline for water tightnessWhen laying Naylor Densleeve or Denseal pipes, it may be convenient to check that all is in order by applying interim air tests to progressive lengths of pipeline as work proceeds.Once a pipeline has been laid an air or water test may be carried out in accordance with BS EN1610, as detailed below.Air Test1 Fix air-tight stoppers at the ends of the pipeline, after checking that they are clean and well-fitting. Connect a manometer to one of the stoppers.2 Blow or pump air into the pipeline until a pressure slightly more than the required air test pressure is indicated on themanometer. After allowing 5 minutes for the temperature to stabilise, adjust to the required pressure and commence thetest.3(a) If the measured drop is less than the allowable drop then the test is passed (see table).Note: The test pressure LA is the same as that previously used in the UK except that the test period is increased for sizes above DN225, as shown.(b)If the measured drop exceeds the allowable loss, carefully check the testing apparatus and stoppers and examine the pipes and joints for leakage. If a defect is discovered, remedy it and re-test.If this test does not reveal a defect, apply a water test.The above standards do not regard an air test alone as sufficient grounds for rejection and it is recommended that a water test should be applied in the event of apparent failure to meet the air test. An apparent failure of air test can be due to causes other than defects in the pipeline; for example, changes in ambient temperature.Water Test1 At the upstream end of the pipeline to be tested, add a 90 bend and sufficient vertical pipes to provide the required head of water. BS EN1610 requires a minimum 1.0m (10kPa) head of water at the high end with a maximum of 5m (50kPa) at the lower end. Both heads above the pipe crown. In cases of very steep gradients, it may be necessary to test the pipe in stages, in order to comply with these limitations.2.Tighten stoppers at the lower end of the pipeline and at open branches, after checking that they are clean and well-fitting.3.Strut the ends of the pipeline and the 90 bend to prevent movement and then fill the line with water.4Inspect the pipeline for any obvious leaks and remedy any defects. There will be an initial fall of the water level due to absorption and the displacement of trapped air.5 After at least one hour, top up to the maximum test head, a longer period may be allowed in extremely dry conditions. The loss of water over a period of 30 minutes should then be measured by adding water from a measuring vessel at regular intervals of 10 minutes and noting the quantity required to maintain the original water level. The test is accepted if the water added does not exceed 0.15l/m of internal wetted area over a 30 minute period, for pipelines. Higher limits are set for pipelines including manholes and inspection chambers.Further informationSee BS EN1610 and the Clay Pipe Development Association Ltd booklets Specification, Design and Construction and Testing of Drains & Sewers (Water & Air Tests).BackfillingAny selected or granular fill must be carefully hand-compacted in layers not exceeding 150mm to complete the pipeline surround. Place and compact this fill equally on both sides of the pipeline to prevent displacement.Slice with a spade around the barrels to form a cradle for the pipes. This work is important, as the pipeline derives some of its strength from a properly constructed bedding.The trench must be backfilled to at least 300mm above the crown of the pipes before any power-ramming takes place. Backfill should then be well-compacted in layers not exceeding 300mm.As backfilling proceeds withdraw timber and trench sheeting in stages to avoid disturbing the pipeline or the creation of voids within the bedding and surround.Site TrafficSite traffic should not pass over buried pipelines before backfilling has been completed and the final surface constructed.Overloading by unavoidable site traffic can be prevented by bridging the trench with steel plates, timber sleepers or other temporary protection.Prior to Jointing Check the pipes and fittings to ensure that they have not suffered damage. Ensure that the pipe ends, jointing components and lubricant are clean and free from grit, before attempting to make joints.Densleeve Pipes & FittingsDN100 and DN150 assemblies1 Stand the pipe upright on a firm clean base (a 600mm piece of wood is ideal) and lubricate the top end of the pipe paying particular attention to the chamfered lead-in portion.2 Push the sleeve coupling over the lubricated chamfered end of the pipe and ensure that the pipe end is firmly located against the central register of the coupling. The end of any fitting may be pushed into the sleeve coupling - the reverse of the procedure adopted for pipes.3 Ensure that the sleeve coupling on the previously laid pipe is thoroughly cleaned and free from grit or small stones from the bedding material.4 Lower new pipe into trench and check, clean and lubricate the free end. Place the pipe end into the mouth of the previously laid coupling and align the pipe along the central axis of the pipeline. Apply a horizontal forward pressure, in combination with a small side to side movement, and push the pipe home into the sleeve coupling.Densleeve Pipes & FittingsDN200 and above1Lower the pipe into the trench using slings and set in position on the prepared bedding. Form coupling recess in the bedding.2 Lubricate the pipe end to be jointed. Centralise a sleeve coupling to the pipe end and push home. A bar may be used against a timber block.3 Lower the next pipe into the trench and lubricate the end to be jointed, Ensure that the coupling on the previously laid pipe is thoroughly clean and free from grit or stones. Centralise the pipe and push fully home into the coupling.A bar may be used against a timber block. Ensure coupling recess is filled with bedding material after making the joint.123Clay Drainage Instructions Clay Drainage Testing MetroDrain InstructionsTwinwall Jointing InstructionsCut Pipes can be jointed by similar meansAll Naylor pipes can easily be cut to accurate length with a disc blade power tool (safety precautions such as goggles, dust mask, etc should be worn).It is essential that sharp edges are removed from cut pipes to provide a satisfactory lead-in for the rubber seals on sleeve couplings. This can be achieved by rasping, using a trimming tool or a light hammer.Pressure Testing (Air test) - Test inline with current Highway Specifications, ensuring that the correct test equipment is used (4" U Guage).1. Seal the ends of the pipe and connectors or fittings with expanding stoppers.2.Fill a U-tube manometer with water to the required level without any trapped air bubbles. 3.Connect the manometer to the port of one of the sealed stoppers.4. Increase the pressure until 100mm of water (0.01 Bar) is achieved.5.Let the pressure stabilise for 5 minutes and then increase the pressure to 100mm head of water if it drops. 6.Record the pressure after 5 minutes. Larger diameters may require a longer test period, please refer to BS EN 1610 for details. It should not drop below 75mm head of water without any additional pumping.If this procedure is not followed and Naylor Lubricant is not used, the airtight system guarantee is invalid.PreparationSealingConnector or fittingThe connectionThe Naylor MetroDrain Premium Drainage System is easily cut to length using a coarse toothed saw or jigsaw. Cuts should be made between the corrugations on the pipe. Before jointing, the pipe ends should be cleared of all sharp edges and dirt.Naylor lubricant should be applied to the sealing ring and pipe end. The sealing ring is then located between the first and second corrugation on the pipe.Ensure the inside of the connector or fitting is clean and then apply Naylor lubricant. The connector or fitting should then be pushed over the seal and on to the pipe ensuring all surfaces are kept clean during this process. It is often easier to start this process with the pipe at a slight angle.The pipe should be pushed fully onto the connector or fitting until it reaches the stays within the connector or fitting. This can be done by hand or using timber as shown on the larger diameters. Ensure that the alignment of the pipes is correct and that there is no excessive angular deflection. (Sealed System)For 63mm,110mm,120mm,145mm, 160mm and 178mm DUCT1) Always ensure that the pipe end is free from dirt, grit, soil etc. Remove any damaged end sections of the pipe. 2) Place the seal within the 3rd valley of the twinwall corrugated pipe. (2nd valley for 160/137 and 178/150mm pipe)Ensure both pipe ends are raised off the ground before lubricating to ensure no grit or dirt is picked up when lubricant is applied.3) To help place the seal in the valley lubricate valley before fitting.Lubricate around the outside edge of the seal and pipe, also lubricate both internal sides of the coupler using Naylor lubricant.4) Push the coupler onto the pipe with seal, ensuring the pipe end is flush with the central stop positioned within the middle of the coupler.5) Place the next pipe inside the coupler and push the pipe with seal into the coupler.6) Air test - Test inline with current Highway specifications, ensuring that the correct test equipment is used (4" U Gauge).7) Installation - Follow all current Highway specifications, ensuring that the correct bedding material is used.8) Pipes which require cutting to size, should be cut using a course toothed saw. Cuts should be made in the valley section of the pipe and should be square to the axis of the pipe. Beforejointing, ensure the pipe ends are free of sharp edges, swarf, grit and handling damage.9) If this procedure is not followed and Naylor lubricant is not used, the air tight system guarantee is invalid.Test MethodTest period in minutesDN100 DN200 DN300DN400DN600Test Pressure mbar (kPa) Allowable Drop mbar (kPa)LA5 5 7 101410 (1) 2.5 (0.25)123Band-Seal InstructionsINSERTION of JUNCTION or REPLACEMENT pipeinto existing pipelineCut section from sewer using pipe cutter or disc saw. The section should be about 20 mm longer than the junction or replacement pipe.Remove cut section and slide BAND-SEAL couplings onto each end of the existing pipe line. No lubricant required.Position new junction/new pipe into the pipeline. Place a pencil mark half the BAND-SEAL width from each joint. Using the pencil marks, centre a BAND-SEAL over one joint at a time and tighten clamp bands. The clamp bands should be tightened first and then the shear band.After BAND-SEAL assembly carefully tamp bedding under the exposed pipe line.14532CONNECTION between PIPES USING BUSHESAs an example, the illustrations detail the connection between DN300 vitrified clay and DN300 ribbed plastic pipes. A bush is used to take up the differences in outside pipe diameter.NOTE:When jointing certain types of concrete pipes, particularly ones which have been vertically cast, it may be necessary to apply a neat cement grout to small areas on the exterior of the pipe barrel to obtain sufficient smoothness to ensure an airtight seal. It may also be necessary to smooth out the barrel mould joint line on the barrel of some concrete and iron pipes.Install bushes onto the square cut end of the plastic pipe.Place BAND-SEAL on the clay pipe and butt pipes together. Slide BAND-SEAL over bushes until edge of bush is level with edge of BAND-SEAL. No lubricant required.Tighten clamp bands first, then the shear band. After BAND-SEAL assembly, carefully tamp bedding under and around pipes.123Installation InstructionsHandling and UnloadingNAYLOR DRAINAGE LTDAccess Chamber InstructionsInstallation+ Excavate the required specified location, to the depth of appropriate number of chambers required, (maximum 3 chambers), plus additional 40mm for depth of base.+ Install chamber centrally within the specified trench/location.+ Base of excavated area to be well compacted granular material or concrete slab is preferred. Drainage runs within the slab are required to allow excess water to drain freely from the constructed chamber.+ Before duct connection takes place, the trepanned holes located on each chamber will require cutting out to specified diameter. Naylor Access Chambers take from 63mm to 160mm OD duct pipes.+ Allow minimum of 150mm surrounding the chamber for solid concrete support, which should be of a semi-dry workable mixture.+ Ensure concrete fill is evenly distributed around the chamber and level with the top surface. Concrete the frame in at the appropriate height.Composite Cover (B125) with locking frameAll covers and frames must be supported on the concrete surround or on a concrete bedding mortar ofsufficient thicknessEach section fits directly into each otherTOPTOPTOP150mm50mm Drain hole through concrete100mm150mmAccess ChamberSide and End ElevationNOTE Chambers, when completed, must be internally free from any debris.High-Strength HDPETrepanned holes to accept 63, 90, 110, 120, 145 and 160mm duct pipe Surrounded by minimum 150mm concrete surroundStand on well compacted base or concrete slab, complete with drainage channels to allow excess water to drain awayInstallation+ Excavate the required specified location, to the depth of appropriate number of chambers required, (maximum 3 chambers), plus additional 40mm for depth of base.+ Install chamber centrally within the specified trench/location.+ Base of excavated area to be well compacted granular material or concrete slab is preferred. Drainage runs within the slab are required to allow excess water to drain freely from the constructed chamber.+ Before duct connection takes place, the trepanned holes located on each chamber will require cutting out to specified diameter. Naylor Access Chambers take from 63mm to 160mm OD duct pipes.+ Allow minimum of 150mm surrounding the chamber for solid concrete support, which should be of a semi-dry workable mixture.+ Ensure concrete fill is evenly distributed around the chamber and level with the top surface. Concrete the frame in at the appropriate height.Chamber Sizes Chambers will be specified as AC / 1 / LengthsDimension Item Code Pack Size Colour300 x 300 x 335 PAC6 6912142 Black300 x 450 x 335 PAC3 6912435 Black450 x 450 x 335 PAC1 6901228 Black450 x 600 x 335 PAC5 6912324 Black600 x 600 x 335 PAC12 6912213 Black450 x 900 x 250 PAC4 6903618 Black150mm150mmWe cannot guarantee the performance of the product if Naylor Lubricant is not used.UnloadingAccess to site must be over a hard road capable of supporting a fully laden vehicle. The delivery vehicle must be parked on firm, flat ground. Naylor pipes are delivered to site in packs weighing between 1 and 1.9 tonnes. Fittings are usually supplied in crates. Any loose fittings should be removed by hand from the delivery vehicle before other goods are unloaded.There is usually a choice between:1Use of Naylor Moffatt self-loading vehicle If you require this service, please request when making delivery arrangements.The Moffatt is detached from the trailer-load and is operated as a fork-lift to unload the packs and crates. For this purpose, approx. 10 metres of firm level ground space is required along each side of the trailer.If conditions allow, packs may be placed around the site in order to reduce subsequently handling.2Using site equipment to unload - (This is the responsibility of the Contractor.)The packs and crates can be offloaded by fork-lift, or by suitable crane, or other machine using a proven or test-certified sling.3Hand offloading by site personnelCheck that the pack is stable and that the pipes and packing woods are undamaged before cutting the straps and manually unloading.Stacking1Pipes delivered in packsSet the packs down on a firm and level surface.2Storage of loose pipesRest the bottom row of pipes on battens to keep them clear of the ground and stake the end pipes in order to prevent movement of the stack.3Sleeve couplings and lubricantStore indoors in a clean area, away from sunlight. Extremes of temperature must be avoided. Winter conditions, in particular, can affect the ability to make a joint if items have been left outdoors.CLOUGH GREEN, CAWTHORNEBARNSLEY, SOUTH YORKSHIRE, S75 4AD, ENGLANDTELEPHONE: 01226 790591 FAX: 01226 791531info@naylor.co.uk www.naylor.co.uk