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NAYLOR D E N L O K
IR T I B S H O T S T D A E I
N F D
I
A T R
R E D C
BS En60295
BSI
R E
M
G R
II FS T DE ER
NAYLORDRAINAGE LTD
Certificate No. FM1420QAS 2489 2/258PSB SingaporePSB Singapore
MaterialprfungsamtNordrhein-Westfalen
DENLOK
Product ManualandSpecification Data
Vitrified ClayJacking Pipes
e m a i l : s a l e s @ n a y l o r . c o . u k w e b : w w w . n a y l o r . c o . u k
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ContentsCompany
Profile
Development of TrenchlessTechnology
Introduction -Pipelines of the Future
The Need for TrenchlessTechnology
ProductSpecification
ProductionProcess
Product Features andBenefits
ProductData
1
2
4
5
6
7
8
9
NAYLOR D E N L O K
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Naylor Industries PLC is a venture capital
backed fourth generation family business.With its head office in Barnsley UK andfactories in South and West Yorkshire, WestMidlands and Fife the group employs some300 people and sell a wide range of productsacross Britain, Europe, the Middle East,South East Asia, Australasia and North
America generating a 30 million poundannual turnover.
The last decade has seen the companychange dramatically. A 18 million capital
investment programme has been investedover the last 10 years, which has enabledNaylor both to diversify as well as to improvethe productivity of its existing business.
Naylor's has a unique business approachthat builds on long-term relationships withour customers. This is primarily based onopen collaboration with customers, mutualdependency, professional delivery,sustainable profitable growth and innovation.
The world of construction and serviceprovision is changing, public and privatesector organisations are working moreclosely together, joint ventures are expected
Company Profileto deliver end-to-end solutions, new forms of
contract enable collaborative supply chains.From sustainability and communityengagement to technical innovation andsafety we are proud of the many awards thatrecognise Naylor's commitment to setting thehighest standards.
Naylor's have established strongrelationships with supply chain partners inorder to minimise risk and to deliver projectsfault-free, on time and to budget.
Naylor Industries is split into five divisions ofwhich Naylor Drainage Clayware continuesto offer the world's widest range of vitrifiedclay drainage systems.
I N D U S T R I E S P L C
NAYLOR
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Until recently, city administrators and planners believedthat the use of construction techniques involving surfacetrenching was the only option for the construction andrepair of utility services. It was assumed that existingservices were in good condition unless there wasevidence to the contrary. In reality, gradual deteriorationwent unnoticed and failures occurred without warning, in
many cases requiring an urgent response.Over the last 25 years, it became apparent that little wasknown about existing utility services. Installation drawings,where they existed, gave little information on pipecapacity or materials used. Furthermore, the condition ofthe pipe linings was unknown, leakage and infiltrationwere unmeasured and related health issues were oftennot addressed.
The two installation options currently available for accessto underground utility services are Open Cut andTrenchless.
For access by open cut there are four stages:-
Excavation of the trench, removal of spoil andtemporary support of other services.
Laying and jointing the product pipe.
Refilling the trench and compacting the selected spoilor filling material.
Restoring above ground infrastructure.
All four stages are characterised by the amount ofphysical work to be undertaken. Typically, 50 times theamount of spoil to be occupied by the product pipe hasto be moved once during excavation and again inrefilling. Much of the work in all four stages is labourintensive, involving different skills that require co-ordination between several companies and authorities. Alarge project can extend over a long period and be verydisruptive in social, economic and environmental terms.
Access using trenchless techniques also requires surfacework, but not on the scale needed for an open cutapproach.
Trenchless technology projects require carefulconsideration of the existing condition of theunderground pipes and ground conditions in order toselect the most appropriate technique. The technologyand approach must be determined and the surface workmust be conducted using an existing access or bydigging access pits.
The determination of the technique, location of theaccess pits and the route for a new pipe requires an initialsurvey. This is often viewed as an additional expense incomparison to open cut techniques. However, the cost ofthe initial survey stage of a trenchless project is usuallyoffset by a shorter time on site.
Trenchless technologies present a number of uniqueadvantages. With new installations, engineers can installpipe in the most favourable stratum, irrespective ofdepth. For gravity sewers, significant savings can berealised by retaining gravity flow and avoiding pumpingstations.
Whichever construction technique is used to installunderground service utilities, the project is greatlyimproved by an understanding of the existingservices and the ground in which they are to beinstalled before work commences. This is particularlyimportant for trenchless projects, where the projectdesign is based on a site investigation report. In opencut projects, the trench itself is often theinvestigation and the plan usually involves solvingproblems as they occur. Advances in the design anduse of CCTV have considerably reduced the cost of
surveying water and sewage networks, andinformation on conditions below the water level canbe obtained by the use of ground penetrating radar. Atraditional rule for most underground projects is thatcost usually rises in direct relationship to the depth ofwork below the surface. As a result, the firstconsideration has been to make any new installationas shallow as practical, and any access to an existingservice as short and direct as possible.
For trenchless projects, experience has shown thatthere is little relationship between cost and depth. Forwork on existing services, the access points already
provided could be used and work can be planned toreduce disruption.
For new projects, the nature of the ground and depthof the water table can influence the chosentechnology and process to be used. By usingtrenchless technologies, project designers can takeadvantage of the most favourable ground conditions,irrespective of depth, allowing for the installation ofnew services in areas where open cut methods werepreviously impossible. The ability to install pipe atgreat depths can help to simplify designs by allowinglonger pipe runs with shallow gradients, thus avoiding
the need for pumping stations and sumps. Thisfacilitates pipe installation below already congestedunderground areas close to the surface in towns andcities.
TheDevelopmentof TrenchlessTechnology
Systems
Installation Options Site Assessment
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In addition to environmental and social factors,financial comparisons can be made betweentrenchless technologies and traditional open cutmethods. However, these comparisons are oftendifficult because there are no universal costcomparison methods. While technically the bestsolution depends upon the ground conditions andthe location of the water table, in practice thefinancial boundaries of a project and the degree ofacceptable financial risk generally play a moresignificant role in the decision-making process.
The question also arises, cost to whom? The clientis responsible for the direct costs of the contract andpossibly for any compensation for the loss of amenityor trade by local residents and businesses. This oftenmeans that the costs are borne by local citizens andfuture generations. Furthermore, certain governmentfinancial policies can distort the real costs ofinstalling, maintaining and repairing utility services.This can lead to the misconception that open cut ischeaper, when in fact a full accounting of the
environmental and social costs may indicateotherwise.
The direct costs of both the trenchless and open cutmethods in the terms of materials, time andequipment can be established relatively easily.Indirect costs such as reinstatement of the surface,long-term repairs to roads and buildings due todelayed settlement, useful life of the service afterwork and a degree of risk for unplanned or additionalemergency work that may arise during the projectcan often exceed direct costs. An advantage of
trenchless methods is that there are generally lessindirect costs because surface access is lessdisruptive, projects are shorter and hence the socialand environmental costs are considerably reduced.
Open cut construction work disrupts roads, buildingsand other infrastructure. The duration of thesedisruptions is a major source of frustration for localresidents, business and the general public. This hasresulted in growing opposition to construction work ingeneral, including concern for the natural environment,as well as an increase in claims for compensation.
Health and safety of workers, equipment operators andthe public is well recognised and has led to theintroduction of legislation requiring the use of safeworking practices. In the case of underground utilities,
the closer workers and operators are to mechanicaland electrical equipment, to moving traffic, or the morethey have to work in confined spaces the greater therisk of accidents. With trenchless projects, surfaceexcavation is confined to relatively small entry and exitpits or shafts, and it is often possible to locate theseaway from hazardous areas and road traffic.
In comparison to the use of open cut methods,trenchless projects are characterised by minimalsurface disruption over a much shorter period of time.For a well-managed trenchless project, the public maynot be aware that major construction work is actually
going on below them.
Financial Considerations Strategic Considerations
DN600 x 2min Hungery
Auger Boring in the UK
DN700 x 2m in the UK
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The Need for Trenchless Technology
For a company with its origins in clay pipes it isnatural that Naylor Drainage Limited is in theforefront of product development and innovation.
With over 100 years of constant production of pipesand fittings throughout the development of water-borne sewerage systems with their associatedimprovements, the Naylor company has developeda product that is a core requirement for thetrenchless construction industry.
With worldwide operational activities, NaylorDrainage has become the worlds leadinginternational supplier of specialist pipes fortrenchless technology and many prestigiousprojects have been supplied throughout thecompanys UK home base as well as manycontinents overseas.
Reputation for product reliability and customerservice is part of the Naylor tradition.
Water and sewerage infrastructures have represented asignificant asset investment on the part of mostmunicipal organisations and water authorities for wellover 100 years. The distribution networks for utilityservices have been located underground in pipes thatare laid, repaired or replaced by trenching from thesurface. In cities and urban areas, these distributionnetworks are located underneath roads. This oftenmakes access difficult, particularly in areas congestedwith traffic and buildings.
When pipeline infrastructures are not well maintainedthen inefficiencies arise. For example, in waterdistribution systems, leakages occur and watershortages are possible. However, in seweragesystems, cracked and damaged pipes can cause
wastewater seepage, leading to contamination ofgroundwater. These problems often give rise to relatedhealth and environmental impacts.
The oldest underground utility services are usuallyfound close to the surface. Services installed later aremost often found below or interwoven with the initialinstallations. Construction and repair carried out fromthe surface inevitably disrupts traffic, business andother services. This disruption has a negative impact onthe local environment in terms of air quality, noise andother pollution, as well as on local vegetation andbuildings. This in turn diminishes the quality of life forlocal residents.
Trenchless technologies, which minimise therequirements for surface excavation, can significantlyreduce the environmental impacts of undergroundutility service installation, maintenance and repair. Byminimising surface disruption, traffic congestion is
significantly reduced.
The companys trenchless technology product -Denlok - is a specially-developed vitrified clay pipesystem to meet the requirements of pipe installation
by trenchless construction methods which include:- Microtunnelling
Guided Auger Boring
Pipe Bursting
Pipe Eating
Slip Lining
The Naylor approach to its development of productsfor the trenchless construction industry has resultedin new manufacturing equipment and productiontechniques. These progressive steps have led to
reductions in specialist product costs and thesesavings have been passed onto the customer toenable the use of a first-class product at affordableprices.
Pipelines of the Future
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Trenchless TechnologyThe trenchless sector is continually being refined and developed. Improvements cover bothlarge and small diameters, longer drives, greater accuracy, faster and curve driving, differentsoil conditions and the ability to work deeper into water tables.
There are many variants of Pipe jacking, during which the product pipe is forced into theground by hydraulic cylinders mounted horizontal in a launch shaft. The run is completedwhen the pipe string reaches an exit shaft. Both shafts are used later as service accesspoints.
The various systems for new installations can be broadly categorised into:-
Pipe Jacking in which the spoil and water is removedby pumping as slurry.
Guided Auger Boring where the spoil is removed by anauger through a steel casing. Specially designedpipes are then hydraulically jacked in by the machine.
Pipe Bursting where the existing pipeline is forced intothe pipeline bedding by the means of an expandinghydraulic cone controlled from the surface. The new
Applicationsfor newinstallations
pipe pushes the expanding head through the pipelinewhich is being replaced.
Pipe Eating where the existing pipe line is ground usinga cutting head and the fragments of the pipeline areremoved by augers through the new incoming pipe.
Slip Lining where pipes are winched through an existingpipe system and the voids between new system and oldsystem are filled with grout.
Guided AugerBoring
PipeJacking
PipeBursting
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Product SpecificationNaylor Drainage manufactures its products under thecontrol of an approved Quality Assurance Systemcomplying with the requirements of BS EN9002: 2008.Naylor Drainage Ltd is a Registered Firm of AssessedCapability (BSI Certificate No. FM1420).
Denlok is Third Party Certified by:
BSI Quality Assurance under Licence No 20173.
CE07 in accordance with Directive 93/68/EC.
MPA NRW Germany - Licence No 210001169-01-01
PSB Singapore - Licence No 02235
CPRU Brunei - Licence No STD3/003
All Denlok pipes and assemblies are manufactured inaccordance withBS EN295-7
Requirements for vitrified clay pipes and joints forpipe jacking.Denlok pipes and joint assemblies aremanufactured in accordance with
BS EN12889: 2000 Trenchless construction and testing of drains andsewers.
Quality Assurance
Component Specification
LoknSlip 4.5 Bar Seal
Third Party Assurance
CE Conformity
1
2
3
MAX
NORM
MIN
29
35
41
11.31
18.33
38.07
0.85
1.20
1.87
13.3
15.3
20.4
LoknSlip is available in either EPDM or Nitrile certified toEN681- 1
Root InfestationDue to the high contact pressure LoknSlip reduces therisk of root infestation through the joint allowing for pipeinstallation under mature trees
Naylor Drainage Vitrified Clay Pipe conforms toEuropean Standard: EN 295-10.
Denlok and Revit pipes above diameters DN300 in corporate the new LoknSlip NS pipe seal.
Seal Design and FunctionLoknSlip is designed as a sliding seal that is located in the pipe endrebate. No lubricant is required on either the seal or stainless steel
sleeve as lubricant is enclosed within the sliding mantel. As the malespigot is inserted into the female sleeve the seal is compressedcreating a positive 4.5 bar internal and external pressure.
The mantel rolls over the seal during jointing reducing friction to aminimum and acts as a cushion between the spigot and sleevelimiting differential movement under transverse shear loads once thejoint is completed. The design optimises joint performance andprovides an exceptionally high level of operational reliability.
Item Gap Compression%Deformation Force
N/mmContact Pressure
MPAContact Width
mm
6
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Locally-quarried raw materialsare accurately blended beforebeing ground to a fine form toenable subsequent extrusion.
Clay raw material is mixed withwater to give plasticity for extrusion.
High-pressure extrusion ensures thata strong dense pipe body is produced.
Close attention to drying to removemoisture is undertaken prior to firing underaccurate temperature control.
2 4
3
6
5
Use of special highly-insulated kilns isemployed for attaining accurate firing.The special qualities of vitrification of thepipe body are attained at a firingtemperature in excess of 1050C.
After the firing and subsequentgrading processes the pipe ends areaccurately machined with computer-
controlled diamond profile cutters. Accurate production of parallel ends is
also achieved.
Intermediate inspection takes placeas well as pipe ends being pressure
tested to ensure integrity of pipematerial. The joint components are
then applied and materials arepacked for shipment.
Naylor Denlok Pipes readyfor despatch.
1
Production Process
7
Delivery of pipes is to the customersrequest, consignee to be responsible foroffloading all packs, which are designedto be offloaded by forklifts.
If there is no forklift available on site amoffat off-load vehicle can be arrangedat the time of order placement.
Close attention to packing fortransportation and overseas shipment is
part of the Naylor delivery service.
It is a major recommendation that allunit packs must be kept assembledwith all protection intact until the pipe isready for use.
All Denlok pipes and elastomercomponents are resistant to heat, ozone
and ultra violet light.
Delivery and Site Handling
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Product Features and Benefits
Denlok is covered by and fully certified to EN295,the international standard for clay jacking pipes.
High-axial strength for jacking force assurance.
High crushing strength for load bearingcapabilities.
Smooth wall surface with very minimal frictionalresistance.
Excellent chemical resistance, Denlok handles
domestic, industrial and chemical effluents.
Accurately machined pipe ends for easy loadtransference of jacking force.
EPDM elastomer sealing components and particleboard thrust rings factory fitted. Particle boardcomponents tested as best material for loadtransference.
Wide range of diameters available.
Worldwide international project-supply references.
International Technical and Commercial support.
Major advantages of Denlok Vitrified Clay Jacking Pipes are:
Pipe underresearchat a UK materiallaboratory
Pipe beingtype tested
in accordancewith EN295-7
Clause 4.8Strength
Installedpipeline
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DN150 jacking pipe with EPDM seals and aninjection moulded polypropylene sleeve and integralthrust ring, all elastomer conforms to therequirements of EN681 1.
A vitrified clay jacking pipe which is suitable for theconstruction of house connection installed bytrenchless technology.
Naylor DN150 Denlok can be connected directly to
Naylor DN150 Densleeve using the factory fittedDenlok coupling removing the need for any specialconnections.
Jacking Strengths1. F1 = permissible jacking force for manual recorded safety factors 2/2 (for standard dimensioning)2. F2 = permissible jacking force for automatic and control, recorded safety factors 2/1.6)
ProductData
Pipe Dimensions Strength
NominalSize
DN
mm
InternalDiameter
d1
mm
ExternalDiameter
d2
mm
Pipe EndDiameter
d3
0.5mm
EffectiveLength
L
0.5mm
ManualSteering
F1(2)
sf=2.0kN
CrushingStrength
kN/mFN
AutomaticSteering
F2(3)
sf=1.6kN
ApproxWeight
kg/m
45183 228150 9961493.0 2083.0 186
d2 d1 d3
L
64
NC RangeDN150
Naylor Denlok
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Pipe Dimensions Strength
NominalSize
DN
mm
InternalDiameter
d1
mm
200
225
250
300
2003.0
2254.0
2534.0
3055.0
ExternalDiameter
d2
mm
2713.0
2934.0
3574.0
4125.0
Pipe EndDiameter
d3
0.5mm
246
272
332
388
EffectiveLength
L
0.5mm
996
996
996
996
ManualSteering
F1(2)
sf=2.0kN
CrushingStrength
kN/mFN
AutomaticSteering
F2(3)
sf=1.6kN
ApproxWeight
kg/m
350
358
815
938
438
447
1019
1172
60
80
100
120
Pipes up to and including DN300 are generally supplied in 1.0m lengths. DN300 are available in 2.0m lengths.
Other lengths available as special requirements.
d2 d1 d3
L
Naylor Denlok NC range of jacking pipes consists of avitrified clay pipe with parallel end faces and a squareaccurate machined seal interface.
All pipes have a factory fitted 316 stainless steelcoupling which incorporates a moulded EPDMelastomer seal, each seal has an integral EPDM thrustring, which transmits the jacking forces during pipeinstallation, all elastomer conforms to the requirementsof EN681 1.
By precision machining of the seal interface thecoupling will with stand a 2.4 bar internal and externalpressure allowing installation below the water table andprotection from lubrication systems during pipeinstallation.
Naylor Denlok
80
80
100
120
From DN200 to DN300NC Range
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Pipe Dimensions
NominalSize
DN
mm
InternalDiameter
d1
mm
400
450
500
525
600
700800
900
1000
1100
1200
4065.0
4505.0
5045.0
5245.0
6097.0
7159.07909.0
8909.0
9919.0
108512.0
118312.0
ExternalDiameter
d2
mm
5525.0
5855.0
6395.0
6605.0
7587.0
8559.09649.0
10809.0
11939.0
130712.0
143012.0
PipeEnd
d3
0.5mm
526.5
564.0
612.5
633.0
730.5
819.0964.0
1051.0
1164.0
1276.0
1393.0
EffectiveLength
L
0.5mm
9841984
9841984
9841984
9841984
9841984
9841984984
1984
9841984
9841984
9841984
9841984
ManualSteeringStrength
F1(2)
sf=2.0kN
CrushingStrength
kN/mFN
AutomaticSteeringStrength
F2(3)
sf=1.6kN
Strength
ApproxWeight
kg/m
1575
1625
1700
1780
2260
25003077
4350
5210
6237
7527
1969
2031
2125
2225
2825
31263846
5437
6512
7797
9408
240
250
260
280
338
430508
680
800
967
1170
Jacking Strengths1. F1 = permissible jacking force for manual recorded safety factors 2/2 (for standard dimensioning)2. F2 = permissible jacking force for automatic and control, recorded safety factors 2/1.6)
From DN400 to DN1200
d2 d1 d3
L
Naylor Denlok NS range of jacking pipes consists a
vitrified clay jacking pipe with parallel ends and arebated accurate joint interface.
All NS range of pipes consists of a couplingmanufactured from 316 stainless steel a LoknSlip seal
160
144
120
126
120
96128
108
120
132
114
and MDF load transferee ring.
Each pipe supplied will have all seals and a stainlesssteel sleeve factory fitted with the thrust ring suppliedseparate in a cover to protect the material from theweather elements.
NS Range
Naylor Denlok
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All information correct at time of print.
d2 d1 d3
Naylor Revit the special designed pipe for use by the '3'Pass Guided Auger Boring Installation Technique.
Naylor Denlok NS range of jacking pipes consists avitrified clay jacking pipe with parallel ends and arebated accurate joint interface.
All Revit NS range of pipes consists of a couplingmanufactured from 316 stainless steel a LoknSlip sealand MDF load transferee ring.
Each pipe supplied will have all seals and a stainlesssteel sleeve factory fitted with the thrust ring suppliedseparate in a cover to protect the material from theweather elements.
Naylor
From DN225 to DN500Revit Range
Pipe Dimensions Strength
NominalSize
DN
mm
InternalDiameter
d1
mm
ExternalDiameter
d2
mm
Pipe EndDiameter
d3
mm
CrushingStrength
kN/mFN
JackingStrength
kN
ApproxWeight
kg/m
225
300
375
400
450
500
225 +/-3
300 +/-3
375 +/-5
400 +/-5
450 +/-5
500 +/-5
277 +/-3
380 +/-5
455 +/-5
482 +/-5
548 +/-5
610 +/-5
260
360
445
468
534
586
54
60
45
64
54
60
360
580
610
650
745
815
40
80
125
150
200
235
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For pipelines needing to operate at hightemperatures - up to 130C - the DenChemrange is ideally suitable. Special ceramic pipescapable of withstanding higher temperaturesand full resistance to Alkaline and Acid attackcan now be offered for microtunnelling.
Applications within the chemical,pharmaceutical, food and dairy processing aswell as brewing industries can beaccommodated. High temperature chemicaleffluents resulting from process or cleaningoperations can be handled with confidence.
d2 d1 d3 c1
L
Naylor
From DN150 to DN300DenChem Range
150
200
225
300
400
450
150+/-3
200+/-3
225 +/-3
300 +/-3
400 +/-5
450 +/-5
208+/-3
271+/-3
277 +/-3
380 +/-5
482 +/-5
548 +/-5
186
246
260
360
468
534
64
80
54
60
64
54
183
350
360
580
650
745
45
45
50
85
160
210
Pipe Dimensions Strength
NominalSize
DN
mm
InternalDiameter
d1
mm
ExternalDiameter
d2
mm
Pipe EndDiameter
d3
mm
CrushingStrength
kN/mFN
JackingStrength
kN/mFN
ApproxWeight
kg/m
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Vitrified clay pipe systems for trench andtrenchless installation
Hathernware Thermachem - ChemicalDrainage and Industrial Ceramics
Band-Seal couplings for the repair of andconnections into existing pipelines
Plastic Land Drainage, Twinwall DuctingSystems and Access Boxes
Lintels - Prestressed Concrete Lintels
Yorkshire Flowerpots, a range of frostproofplant pots
Naylor Industries plc - morethan 100 years of productionand supply to theConstruction Industry
K 0 4 1 1
CLOUGH GREENCAWTHORNEBARNSLEY, SOUTH YORKSHIRES75 4AD
NAYLOR DRAINAGELIMITEDNAYLOR
D E N L O K
TELEPHONE: 01226 790591FACSIMILE: 01226 790531EMAIL: [email protected]: WWW.NAYLOR.CO.UK
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