Chapter 14 - Sewerage Design & Construction Table of Contents

Chapter 14 - Sewerage Design & Construction Table of Contents
Chapter 14:
SEWERAGE DESIGN AND CONSTRUCTION
April 1999
Page 1
14.0
SEWERAGE DESIGN & CONSTRUCTION Table of Contents

Subject Page No
Clause
14.1 14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.1.6 14.1.7 14.2 14.3 14.3.1 14.3.2 14.4 14.4.1 14.4.2 14.4.3 14.4.4 14.4.5 14.4.6 14.4.7 14.4.8 14.4.9 14.4.10 14.4.11 14.4.12 14.4.13 14.4.14 14.4.15 14.4.16 14.4.17 14.4.18 14.5 14.5.1 14.5.2 14.5.3 14.6 14.6.1 14.6.2 14.6.3 14.6.4
GENERAL REQUIREMENTS................................................................................... 14-1 General ..................................................................................................................... 14-1 Definitions ................................................................................................................. 14-1 Works Carried Out by Council .................................................................................. 14-1 Non-Complying Works .............................................................................................. 14-2 Works Affected by Other Authorities......................................................................... 14-2 Site Safety................................................................................................................. 14-2 Works on Private Property........................................................................................ 14-2 MINES SUBSIDENCE .............................................................................................. 14-2 DRAWINGS .............................................................................................................. 14-3 Plan Requirements ................................................................................................... 14-3 Work as Executed Drawings..................................................................................... 14-4 SEWER DESIGN ...................................................................................................... 14-5 Locations Generally .................................................................................................. 14-5 Datum ....................................................................................................................... 14-5 Gravity Mains ............................................................................................................ 14-6 Sewer Manholes ....................................................................................................... 14-6 Dead End Lines and Dead End Treatments............................................................. 14-7 Provision to Service Future Development ................................................................ 14-7 Depth of Servicing Points ......................................................................................... 14-7 Cover Requirements - Gravity Sewers and Rising Mains ........................................ 14-7 Connection Requirements for Torrens Title Subdivision of Dual Occupancies........ 14-8 Lot Connections (Junctions) and Appurtenances..................................................... 14-8 Trench Stops........................................................................................................... 14-10 Concrete Bulkheads................................................................................................ 14-11 Steep Pipelines ....................................................................................................... 14-11 Thrust and Anchor Blocks for Rising Mains............................................................ 14-11 Sewer Protection..................................................................................................... 14-12 Under Boring of Existing Council Roads ................................................................ 14-13 Pipe Crossings - RTA or SRA Property .................................................................. 14-14 Steel Sleeve Encasing Under Trees....................................................................... 14-14 SEWER GRAVITY MAINS ..................................................................................... 14-14 General Requirements - Residential/Commercial Reticulation .............................. 14-14 General Requirements - Industrial Reticulation...................................................... 14-14 General Requirements - Trunk Mains..................................................................... 14-14 SUPPLY OF PIPES, FITTINGS AND MATERIALS GENERALLY......................... 14-15 Quality Assurance................................................................................................... 14-15 Mine Subsidence .................................................................................................... 14-16 Jointing Systems..................................................................................................... 14-17 Slope Riley Fittings ................................................................................................. 14-17
April 1999
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14.0
SEWERAGE DESIGN & CONSTRUCTION Table of Contents (Continued)

Subject Page No
Clause
14.6.5 14.6.6 14.6.7 14.6.8 14.7 14.7.1 14.7.2 14.7.3 14.7.4 14.7.5 14.7.6 14.7.7 14.7.8 14.7.9 14.8 14.8.1 14.8.2 14.8.3 14.8.4 14.8.5 14.8.6 14.9 14.10 14.10.1 14.10.2 14.10.3 14.11 14.11.1 14.11.2 14.11.3 14.11.4 14.12 14.12.1 14.12.2 14.12.3
Manhole Couplings ................................................................................................. 14-17 Witness Marks ........................................................................................................ 14-18 Alternative Pipe Material and Fittings ..................................................................... 14-18 Handling and Storage ............................................................................................. 14-18 SEWAGE RISING MAINS ...................................................................................... 14-19 Pressure Pipe ......................................................................................................... 14-19 Pipe Fittings ............................................................................................................ 14-19 Alternate Pipe and Fittings Materials ...................................................................... 14-19 Joints....................................................................................................................... 14-19 Witness Marks ........................................................................................................ 14-20 Handling and Storage ............................................................................................. 14-20 Rising Main Fittings................................................................................................. 14-20 Connection to Discharge Manholes........................................................................ 14-21 Main and Fittings - Marker Posts and Plates.......................................................... 14-21 EARTHWORKS ...................................................................................................... 14-21 General ................................................................................................................... 14-21 Trench Width........................................................................................................... 14-21 Excavation Depth.................................................................................................... 14-22 Provision for Soft Ground ....................................................................................... 14-22 Dewatering.............................................................................................................. 14-24 Support of Excavations ........................................................................................... 14-24 EROSION AND SEDIMENT CONTROL ................................................................ 14-24 PIPE BEDDING ...................................................................................................... 14-24 General ................................................................................................................... 14-24 Sand Bedding ......................................................................................................... 14-25 Granular Bedding.................................................................................................... 14-25 MANHOLES (ACCESS CHAMBERS) .................................................................... 14-26 Cast In Situ Manholes............................................................................................. 14-26 Concrete Covers and Surrounds ............................................................................ 14-26 Cast Iron Covers and Surrounds ............................................................................ 14-27 Precast Manholes ................................................................................................... 14-27 STEP IRONS .......................................................................................................... 14-30 Specification............................................................................................................ 14-30 Alternative Types .................................................................................................... 14-30 Location .................................................................................................................. 14-30
April 1999
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14.0
SEWERAGE Table of Contents (Continued)

Subject Page No
Clause
14.13 14.13.1 14.13.2 14.13.3 14.13.4 14.13.5 14.13.6 14.13.7 14.13.8 14.14
LAY AND JOINTING............................................................................................... 14-30 General Requirements............................................................................................ 14-30 Pipe Grading and Alignment................................................................................... 14-30 Jointing Details........................................................................................................ 14-31 Rubber Ring Installation ......................................................................................... 14-31 Cutting of Pipes....................................................................................................... 14-31 Polyethylene Wrapping of Pipelines and Fittings - Ductile Iron.............................. 14-31 Tolerances .............................................................................................................. 14-32 Structures and Pipelines at Manholes .................................................................... 14-32 BACKFILLING AND COMPACTION ...................................................................... 14-33
14.14.1 14.14.2 14.14.3 14.15 14.15.1 14.15.2 14.15.3 14.15.4 14.16 14.16.1 14.16.2 14.16.3 14.16.4 14.16.5 14.16.6 14.16.7 14.17 14.17.1 14.17.2 14.17.3 14.17.4 14.18 14.19 14.19.1
General ................................................................................................................... 14-33 Restoration.............................................................................................................. 14-34 Maintenance ........................................................................................................... 14-34 CONCRETE............................................................................................................ 14-34 General ................................................................................................................... 14-34 Finish ...................................................................................................................... 14-35 Cement ................................................................................................................... 14-35 Concrete Criteria..................................................................................................... 14-35 TESTING OF GRAVITY SEWERS......................................................................... 14-36 General ................................................................................................................... 14-36 Initial Test of Gravitation Sewers ............................................................................ 14-36 Initial Test of Manholes........................................................................................... 14-37 Acceptance Test of Gravitation Sewers and Manholes.......................................... 14-37 Testing with Compressed Air.................................................................................. 14-38 Hydrostatic Testing ................................................................................................. 14-39 Visual Inspection and Measurement of Infiltration.................................................. 14-40 TESTING OF RISING MAINS ................................................................................ 14-40 General ................................................................................................................... 14-40 Method of Carrying Out Test .................................................................................. 14-41 Allowable Leakage Tolerances............................................................................... 14-41 Repair of Leaks....................................................................................................... 14-42 COUNCIL ACCEPTANCE ...................................................................................... 14-42 MISCELLANEOUS ................................................................................................. 14-42 Treatment of Redundant Sewer Systems............................................................... 14-42
April 1999
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Chapter 14 - Design & Construction
14.0
14.1 14.1.1
SEWERAGE
GENERAL REQUIREMENTS General This specification outlines requirements for the supply and delivery of sewer pipes and fittings and the design and construction of reticulation sewers, sidelines, manholes and sewer rising mains. This specification is intended to: 1 2 Outline all requirements for general development work; and Form a Schedule to Specification (detailing technical requirements) to accompany specifications for Contractor constructed works.
All works are to be carried out in accordance with this specification, the regulations of the relevant statutory authorities and manufacturers recommended procedures where appropriate. 14.1.2 Definitions The term "The Engineer" shall refer to the Director of Engineering Services or the appointed representative. Refer Clause 2.3 for additional definitions. 14.1.3 Works Carried Out by Council Connections to Council's existing sewerage system shall be carried out by Council where the execution of such works may result in a sewerage surcharge, disruption to other customers or additional work to Council, resulting from debris entering the sewerage system. Council will provide the connection of the size, type and at the location as detailed on the approved plans. It will be the responsibility of the Developer to connect the new works to the connection point provided by Council following acceptance of the works in accordance with Clause 14.16.4. All designs for connection/s and main adjustments shall be prepared by the Developer. The design shall be submitted to the Engineer for approval. The Developers attention is drawn to Clause 14.1.7 regarding connections that are required within private property. At the Developers written request the Engineer shall provide estimated costs for works to be carried out by Council. No Developer supplied materials will be accepted by Council for use in the works. The payment is based upon an estimate only, actual costs will be charged to the Developer on completion of the works. Pre-payment of the estimated amount will be required prior to Council ordering materials and programming works. The work will be commenced within twenty (20) working days from the date of receipt of payment, of delivery of material or upon written notification by the Developer to commence work whichever is later.
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Chapter 14 - Sewerage Design & Construction
In selected situations as determined by the Engineer work carried out by Council may be undertaken on a "do and charge" sundry debt basis. Those situations will be restricted to minor works using stock material and requiring no design. These works will be completed within one (1) week upon notification of the Developer to commence work. The Developer is advised that several weeks lead time after payment may be required for the supply of non-stock materials. Council will not accept responsibility for any delays incurred by the Developer or their agents through their failure to obtain a timely quotation, make payment or make written notification for the connection works. 14.1.4 Non-Complying Works a General The Engineer may carry out random CCTV (close circuit television) inspections of the completed works prior to issue of the linen. If defective work is identified, the work shall be rectified by the Developer with the Developer also bearing the cost of the CCTV inspection. b Levels and Grades If work as executed levels and grades exceed the nominated tolerances of Clause 14.13.7 the requirements of Clause 2.33 shall apply. 14.1.5 Works Affected by Other Authorities Where proposed sewer works crosses, or is located within a main road, creek, or construction of the work affects plant, assets or property under the control of any other Authority, the work will be carried out in accordance with the requirements of that Authority. The Developer will obtain all necessary approvals for the work from the Authority concerned and it will be the Developer's responsibility to notify the Authority of their intention to construct and to complete any written notification so required. 14.1.6 Site Safety The Developer shall comply with all relevant Occupational Health and Safety Acts and exercise all necessary precautions for the safety of site personnel. Refer Chapter 16. 14.1.7 Works on Private Property The Developer shall arrange all necessary permits and agreements to facilitate works on private property prior to entry and commencement. 14.2 MINES SUBSIDENCE The Developer is advised that parts of Wyong Shire fall within proclaimed Mine Subsidence areas. All pipe jointing systems for sewer works must be capable of accommodating movement associated with the mine subsidence design ground strain as advised by the Mine Subsidence Board for the nominated development area.
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April 1999
It is the responsibility of the Developer to check if the proposed work lies within a proclaimed Mines Subsidence area and (if applicable) obtain the design ground strain for the associated development site from the Mine Subsidence Board for design of the works. The design ground strain is to be clearly detailed on the design drawings. In addition the relevant calculations (Refer Clause 14.6.2), specific pipe type and length, joint type and socket depth, fitting type and socket depth shall be submitted for approval by the Engineer. It will be the Developer's responsibility to ensure that any pipe jointing system supplied and incorporated with the works comply with the requirements of Clause 14.6.2 for the nominated design ground strain. Failure to comply with Mines Subsidence requirements shall result in a direction by the Engineer to remove all non complying material. All costs associated with removal of the faulty work and supply of new pipe materials shall be borne by the Developer. For information regarding ground strains for Wyong Shire the Developer should contact the District Inspector, Mines Subsidence Board, Wyong. 14.3 14.3.1 DRAWINGS Plan Requirements a Reduction Ratio Drawings that are submitted for approval shall be prepared to the following scales: a Detail Plans Scale - 1:500 (or 1:1000 if previously approved by the Engineer). - Vertical - 1:200 - Horizontal - 1:1000
Long Section
Scale
Plans Plan sheets shall include but not be limited to the following:1 The location of the proposed sewer shall be shown on a separate sewer reticulation plan to be easily identifiable. All existing services and stormwater systems. Proposed services and stormwater systems adjacent to the proposed sewer. All existing features, ie trees, rock outcrops, kerb and gutter. Contours at intervals that accurately represent the final surface. Proposed lot boundaries and kerb alignments.
2 3
4 5 6
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7 c
The area of lots not served if applicable.
Longitudinal Sections Longitudinal sections shall include but not be limited to the following:1 2 Design invert. Finished surface levels and finished manhole levels where different to the adjacent finished surface. Sewer main size, class, type, grade and contributing ET's. Depth of sewer. Chainage of sewermain, manholes etc. Spacing of bulkheads or trenchstops. Details of special bedding if required. Drops through manholes, manhole types, lids and surrounds where non standards. Chainage and extent of concrete encasement, location of concrete cradles supporting drainage pipes or similar.
3 4 5 6 7 8
Miscellaneous All easements for sewer rising mains are to be arranged and finalised by the Developer. The details of relevant easements are to be shown on the design drawings. All tie dimensions to manholes and dead ends are to be shown in metres and parts thereof and are to be taken from corners of buildings, lots or other similar permanent marks. Ties to fence posts, trees and other impermanent or temporary structures are not permitted. Manhole and junction types (based on drawings SD 33 and SD 38) are to be noted on the design drawings.
14.3.2
Work as Executed Drawings Work as executed drawings are required to be submitted to the Engineer by the Developer after completion of the works. Refer Clause 2.32. The work as executed drawings will show, but not be limited to, the following details: a Minimum of two ties to manholes in relation to lot boundaries or other permanent marks; Minimum of two ties to dead end lines in relation to lot boundaries or other permanent marks; The reduced level of manhole and dead end and sideline inverts and the downstream side of manhole surround.
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April 1999
The finished surface level above the sewer mains, where the proposed surface deviates from the constructed ie where lots are terraced. Information on the sewer junction for each lot serviced covering:i ii iii iv distance from the centre of the downstream manhole depth from finished surface level to the invert of the junction shown "D..." except where a riser is in place where it shall be to the top of the riser. length of projection shown "P....". the height of riser from invert of main shown "R...." where applicable.
Refer Drawing SD 71A for examples. f The distance between manhole centres and lengths of dead ends and sidelines. The pipe sizes, class and type of material used, and the work as executed pipe grade. Extent of concrete encasing.
Measurements for "e", "g" and part of "c" will need to be taken at construction stage to ensure accuracy for inclusion in the Works as Executed Drawings. All work as executed drawings are to be certified by a Registered Surveyor. 14.4 14.4.1 SEWER DESIGN Locations Generally Sewer mains are to be constructed and laid in the locations shown on the approved engineering plans. Where sewer mains have been approved to be constructed in the footpath area parallel to property boundaries they are to be laid within the sewer allocation zone as shown on Drawing SD 26A "Location of Public Utilities". Sewer mains (gravity) are to be located as follows: a b c d 1.0m from rear boundary to centerline of pipe. 1.5m from rear boundary to centreline of pipe when located parallel to interallotment drainage. 1.0m from side boundary to centreline of pipe. 1.0 to 4.0m from front boundary to centreline of pipe.
Where significant vegetation is to be retained within or adjacent to the above alignments, variations to the above alignments may be required. Vegetation protection requirements of Chapter 3 shall apply. 14.4.2 Datum All levels shown on the drawings are to be to Australian Height Datum. The locations and reduced levels of the benchmarks and origin of levels used for the design are to be detailed on the drawings.
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Permanent, substantial and easily accessible bench marks are to be provided by the Developer and their location and level are to be clearly shown on the drawings. 14.4.3 Gravity Mains a All gravity sewers and rising mains are to be designed in accordance with the current Public Works Department of NSW, Manual of Practice "Sewer Design" unless otherwise amended in this specification. Design flows for sewers in industrial areas, mobile home/caravan parks and other non-residential areas are to be obtained from the Engineer prior to the commencement of the design. Council requirements supersede the Public Works Department requirements in this regard. Unless otherwise directed by the Engineer all sidelines, risers and connection points are to be 150mm nominal size.
14.4.4
Sewer Manholes a Position of Spacing of Manholes Maximum permitted spacings are set out hereunder: Sewer Size (mm) 150 - 300 375 - 900 Maximum Spacing (m) 90 120
Manholes shall not be located within 5 metres of each other unless otherwise approved by the Engineer. b Manhole Design Drawing SD 33 details the range of drops for varying pipe diameters and pipeline deflections through manholes. Refer Drawing SD 46 for manhole benching details. c Manhole Alignment Manholes shall not be located on property boundaries or fence lines. Manholes shall be located at least 1 metre clear of all structures, boundaries or fence lines, for maintenance purposes unless otherwise specifically approved by the Engineer. Manholes and junctions shall be located to avoid conflict with existing/future accesses and driveways where possible.
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April 1999
Lampholes Lampholes in accordance with Drawing No. SD44 shall only be constructed with the approval of the Engineer. The use of lampholes is not supported
14.4.5
Dead End Lines and Dead End Treatments a Distance Maximum length of a dead end line shall be 37 metres. b Depths and Access of Dead End Lines Access to dead end lines between 1.0 and 1.5 metres deep is to be provided in accordance with Drawing SD 32. Dead ends deeper than 1.5 metres shall be accessed with a manhole. Dead ends less than 1.0m deep to be a capped junction laid on its side, similar to the "type A" junction on Drawing SD 38.
14.4.6
Provision to Service Future Development Where the development is located downstream of potential future development areas, the sewer is to be designed to accommodate loadings from these areas. The Engineer should be contacted initially to ascertain this requirement. The sewer is to be constructed up to the extremities of the next stage of development and terminate with a manhole. Pipe stubs are to be provided at the end manhole for the connection of future upstream works. The direction of the pipe stubs shall be to suit the future upstream layout if known or as directed by the Engineer.
14.4.7
Depth of Servicing Points The depth to invert for all sewer drainage connection points is to be where possible a maximum of 1800mm below finished ground level, however, in all cases will be at sufficient depth to service at least 80% of the lot being served. In special cases the Engineer may vary these requirements. Areas of lots that cannot be serviced are to be hatched on the engineering and work as executed plans.
14.4.8
Cover Requirements - Gravity Sewers and Rising Mains The minimum depth of cover to be provided for gravitation sewers and rising mains as measured from the finished ground level to the top of the pipe barrel shall be as follows:
Location of Pipe 1 Areas not subject to vehicular loading: 2 Areas potentially subject to vehicular loading: Gravitation Sewers All Pipes 600mm 750mm Rising Mains UPVC 600mm 750mm Other 600mm 600mm
Refer to Clause 14.4.7 and 14.5.1.
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Lesser covers may be permitted subject to the approval of the Engineer where the pipes are laid in ductile iron or where special protection of the pipelines such as concrete encasing has been specified or directed by the Engineer. 14.4.9 Connection Requirements for Torrens Title Subdivision of Dual Occupancies When a dual occupancy development is subdivided under the Torrens Title System, a separate junction shall be provided for each lot . If a dwelling is required to be serviced through an adjoining lot the house service line is to be placed as near as practical to the boundary and contained within an easement. The minimum easement width is to be 1.5 metres unless there is provision for it to be placed within a right of carriageway, or there is no alternative location other than between the boundary and an existing dwelling set back from the boundary of less than 1.5 metres in which case a minimum easement width of 0.9 metres will be accepted. The easement is to be created by the Developer in favour of the lot benefited. The ownership and maintenance of the service line shall be the responsibility of the owner of the lot benefited. An inspection opening (I/O) is to be provided as close as possible to the Council junction (nominally 300mm). This point will be the boundary of the Council maintained main and the private house service line. House service lines 30 metres long or less shall be laid in 100mm nominal size pipe. For lengths in excess of 30 metres a 150mm nominal size pipe shall be laid. Concrete encasing shall be required in accordance with Drawing SD 37B if the service line is located within the zone of influence of the footings of the existing adjacent dwellings, or proposed future dwellings. 14.4.10 Lot Connections (Junctions) Sidelines and Appurtenances a All junctions, bends and fittings for gravity pipelines are to be laid to the details in Drawings SD 33 and SD 38 as applicable. Junctions shall be inserted along pipelines in locations shown on the approved drawings. Sewer drainage connection points (junctions) for each lot are to be located a minimum of 300mm inside the lot and located generally at the lowest corner of the lot being served. Where the lot is a battle axe type configuration and the sewer main is located at the front of the battle axe handle the connection point will be located, where practical, at least 300mm inside the boundary of the "handle" and clear of any proposed access way. The Developers attention is also drawn to Clause 14.4.4(c).
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Where the sewer main is located within the footpath and the proposed lot is to be serviced via a right of way or easement for services the connection point shall be provided a minimum of 300mm into the right of way/easement in accordance with Clause 14.4.10(c). If a battle axe handle or right of way is to service more than one lot, extension of Council's main may be required to service each individual lot. Backfill around risers to the top of the socket or coupling on the highest branch of the riser is to be sand or other approved non-cohesive, free-draining material with its grading conforming to Clause 14.10.2. The sand is to be placed and compacted by flooding with compactive effort for the full width of the trench and for a minimum distance of 500mm both upstream and downstream of the riser centreline. Risers are to be fully supported during backfilling and compaction. Sand placed around risers will be contained by bulkheads conforming to Clause 14.4.12. Refer Drawing SD 38. Backfilling of the trench will proceed progressively as the riser is constructed. Junctions for risers shall be encased in concrete in accordance with Drawing SD 38. In all cases encasement shall not interfere with flexible joints and the joints shall be kept clean of mortar.
Where the main sewer trench has battered or terraced sides, sidelines from risers will be laid in 600mm long pipe lengths to the point where undisturbed foundation in the trench exists. During testing, plugs (disced couplings or caps) on sidelines and the top of risers are to be restrained against movement by suitable anchorages. Anchorages should be removed after testing. Any sideline longer than 5 metres shall be provided with a slope junction at the upstream end. The property will be connected through the branch of the junction. The Developers attention is also drawn to Clause 14.4.9. Multiple connections may be permitted through a single junction on a sewer as follows: i More than one junction may be provided on risers to serve adjacent properties. Each sideline is considered separate from the other. Two connections may be made to one sideline. Where a sideline off a sideline has been used the combined total length of sidelines will not exceed 15 metres.
ii
Marking of Junctions and Sidelines The position of each riser, junction or end of a sideline shall be clearly marked by the Developer on completion of backfilling. The marking may be made by one of the following methods.
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Where the position of a riser, junction or the end of a sideline is at a substantial permanent boundary fence or structure located on the boundary, a neatly stencilled letter "J", 50mm high is to be painted thereon using an approved durable paint of a distinct colour. An underground identification tape as specified below shall finish flush with the existing ground surface as close to the boundary fence or structure as possible. Elsewhere or as an alternative to the above, a hardwood peg, 50 x 25 x 450 long will be driven into the ground at that position, and left 150mm above the finished surface level. The peg will be painted white with a letter "J" marked in black on its side. The peg will be connected to an underground identification tape as specified hereafter.
ii
The identification tape will be tied to the junction or end of sideline and held in a vertical position during backfilling. The top end of the tape will be spiked by the junction peg immediately upon completion of backfilling, or left flush and visible at ground level where no peg is provided. A further warning ribbon is required 300mm above the connection point and at 90 degrees thereto in accordance with Drawing SD 38. The identification tape shall be polyethylene tape with the inscription "Caution - buried sewer line", printed in heavy black letters every 200mm. 14.4.11 Trench Stops a Where a gravity sewer or rising main is laid on bedding in accordance with Clause 14.10.2 in trenches of permeable material at a grade of two and one half percent or steeper, trench stops are to be provided in accordance with Drawing SD 37C and as follows. No trench stops are required where non-cohesive granular bedding and surround material in accordance with clause 14.10.3 is used. i At the socket side of the joint nearest to the position of a trench stop required in accordance with the formula below. The bags are to be placed to give close contact with the pipe and to fill the entire space between the excavated recess and the pipe. Bags will not be placed onto sand bedding. The distance between trench stops will be determined by the following formula: D = 30 , whereby G D = Distance between stops in metres, G = Grade of pipe expressed in percentum.
ii
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Where a gravity sewer or rising main is laid on bedding in accordance with Clause 14.10.2 in trenches of rock or other impermeable material (ie stiff clay), at a grade of one and one half percent or steeper, trench stops as specified in Clause 14.4.11(a) will be installed at intervals determined by the formula: D = 20 G
14.4.12 Concrete Bulkheads Where a gravitation sewer or rising main is installed at a grade of ten percent or steeper concrete bulkheads of Grade 20 concrete 150mm minimum thickness will be constructed as follows and as indicated on Drawing SD 37C. Where concrete bedding or encasement to a pipeline is required as specified herein, the 150mm thick bulkhead will be cast integral with the concrete bedding or encasing as applicable. The bulkhead is to extend to 300mm below finished surface. Refer Drawing SD 37C. The distance between concrete bulkheads will be determined by the following formula: For gravity sewers D = 100 G D = 450 , whereby G
For pressures mains
D = Distance between bulkheads in metres, G = Grade of pipe expressed in percentum. 14.4.13 Steep Pipelines a All gravitation sewers laid on grades of 15 percent to 50 percent shall be bedded on Grade 20 concrete. Such concrete bedding is to have a thickness of at least 75mm below the underside of the barrel and socket of the pipe and shall extend to a level above the invert of the pipe of one quarter of the external diameter of the pipe or 150mm minimum thickness, whichever is greater and a width across the trench not less than the minimum width specified in Clause 14.8.2. (Refer Drawing SD 37C) All gravitation pipelines and rising mains laid on grades steeper than 50 percent are to be encased in concrete as specified in Clause 14.4.15 and Drawing SD 37C.
14.4.14 Thrust and Anchor Blocks for Rising Mains Thrust blocks shall be provided at valves and bends (both horizontal and vertical) or any other point where unbalanced forces resulting from internal pressures will occur.
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The Developer is to provide permanent thrust blocks of concrete conforming with Clause 14.15.4 a) ii) such that the thrust blocks bear against sound undisturbed material normal to the direction of thrust. Should the insitu material be unsound it shall be removed and replaced with approved compacted material. The bearing area shall be not less than that specified on the approved engineering drawings or the manufacturers specifications. The Developer shall provide permanent concrete anchor blocks complete with all necessary straps or reinforcement of a volume not less than that specified on the approved engineering drawings or to the manufacturers specifications. All thrust and anchor blocks will be designed by the Developer's Consultant and submitted to the Engineer for approval. 14.4.15 Sewer Protection i Concrete Encasing a Non Reinforced Where gravity sewers or rising mains (excluding those in ductile iron) have less cover than that specified in Clause 14.4.8 and in situations where approved, the pipe shall be encased in concrete. Such concrete shall conform with Clause 14.15.4 (a) (ii) and shall have the following minimum dimensions: a For trenches in other than rock: 150mm under, on both sides and on top of the pipe barrel. For trenches in rock: 100mm under the pipe barrel, 150mm on top of the pipe barrel and for the full width of trench excavated.
Reinforced Reinforced concrete(or the alternative steel fibre reinforced concrete "Fibrecrete") encasement of a pipeline may be required due to the possibility of a permanent structure being built near or over the line in the future. Where concrete encasement is specified the work is to be carried out in accordance with Drawing SD 37C. Where a sewer will be located within the zone of influence of an existing structure, the structure shall be underpinned in accordance with a certified design by a structural engineer prior to excavation. Generally gravity sewers adjacent to side boundaries in narrow lots or next to narrow lots will require reinforced concrete encasing.
Alternatives Notwithstanding Clauses 14.4.15 (a) and 14.4.15 (b) alternative pipe materials not requiring protection such as ductile iron may be permitted.
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It should be noted that only one class and type of pipe is permitted between manholes. ii Concrete Cradles Where stormwater pipes or similar structures are located above sewer mains that may impose additional loads concrete cradles in accordance with Drawing SD 66A shall be provided. 14.4.16 Under Boring of Existing Council Roads All Council roads shall be under bored unless otherwise approved. Where the provision of sewer mains requires the crossing of existing Council roads by under boring the following requirements shall be met: a Construction shall be by means of thrust boring, pipejacking or other nonsurface disruptive construction. The Developer is to supply all materials and plant for the work. The encasing pipe is to be steel or reinforced concrete complying with the respective requirements of (i) and (ii) below. i Steel encasing pipe is to be fabricated from steel having a specified minimum yield strength of 230 MPa and will have a minimum wall thickness of 8mm for inside diameter less than 450mm or 12mm for encasing pipes of larger inside diameter up to 800mm; Reinforced concrete encasing pipes are to be rebate jointed complying with AS 4058. The minimum class of pipe will be Class 4;
b c
ii
The inside diameter of the encasing pipe is to be at least 100mm greater than the largest outside diameter of the sewer main as measured at the joint or coupling to allow installation of the line to its design grade and line within the specified tolerances; Subject to compliance with tolerance for line, grade and level as outlined in Clauses 14.13.2 and 14.13.7, the sewer main may be located anywhere within the encasing pipe. The Developer shall provide approved pipe support cradles to support the sewer main to the required grade. The first and last cradle is to be within 1000mm from each end of the encasing pipe; After installation and pressure testing in accordance with Clause 14.16 the Developer will fill the annular space between the sewer main and encasing pipe completely with a grout mix complying with Clause 14.4.16(h). All precautions are to be taken to ensure that there is no movement of the sewer main from its line and grade during grouting. The sewer main shall be filled with water prior to grouting; Grout to be used for the sealing of the annular space is to be a mixture of cement, sand (1:12) and water, plus an admixture if specified.
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These materials are to be mixed to a consistency which satisfies the Engineer, so as to completely fill all voids within the annular space between the sewer main and the encasing pipe. 14.4.17 Pipe Crossings - RTA or SRA Property Not withstanding the above, where the provision of sewer mains requires non surface disruptive crossings of RTA or SRA property the requirements of those authorities shall be sought by the Developer and complied with. 14.4.18 Steel Sleeve Encasing Under Trees Refer Drawing SD64 for details of service encasing under trees. 14.5 SEWER GRAVITY MAINS Changes in pipe size, class and type is not permitted within a section of main between manholes and the higher class pipe shall be used for that section as required. 14.5.1 General Requirements - Residential/Commercial Reticulation Where developments are residential and/or commercial all sewer gravity mains (except gravity lines between the collection manhole and sewer pump station) of size less than 375mm nominal diameter shall be UPVC conforming to AS 1260. For pipe sizes of 375mm nominal diameter and greater the Developer's attention is directed to Clause 14.5.3. UPVC pipes shall be Class SH where pipework is laid at depths less than or equal to 3.0 metres. Class SEH pipework shall be used at depths greater than 3.0 metres. In this regard, all depths are from the ultimate finished ground level to the invert of the pipeline. 14.5.2 General Requirements - Industrial Reticulation Notwithstanding this Clause and subject to the approval of the Engineer gravity mains servicing light industrial developments may be UPVC in accordance with Clause 14.5.1 subject to assessment on a case by case basis and approval by the Engineer. Where developments are intended to contain a substantial industrial component all sewage mains (except gravity lines between the collection manhole and sewer pump station), shall be constructed using Class Z Vitrified Clay pipes and fittings conforming to the requirements of AS 1741. Developers wishing to propose alternate pipe materials shall provide information as specified within Clause 14.6.7. 14.5.3 General Requirements - Trunk Mains For gravity pipe sizes 375mm nominal diameter and larger the Developer shall submit a proposal for pipe supply for approval by the Engineer. In this regard the Developers attention is also drawn to Clause 14.5.2 outlining particular information required for industrial developments.
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April 1999
14.6
SUPPLY OF PIPES, FITTINGS AND MATERIALS GENERALLY The Developer shall supply and deliver all pipes, pipe fittings and any other materials required to construct the work as detailed on the approved drawings and in accordance with Clauses 14.5 and 14.16.
14.6.1
Quality Assurance a In regard to the manufacture of products included under Clauses 14.5, 14.6.3 to 14.6.8, 14.7, 14.11, 14.12, 14.13.6 and 14.15 the Manufacturer shall have implemented a Quality Control/Assurance System to ensure that all testing and manufacturing equipment, manufacturing processes, hardware, materials and workmanship meet the requirements of this specification or the relevant Australian standard. Except where otherwise specified, the Quality Control/Assurance System will meet the minimum requirements of AS/NZS ISO 9002-1994 (Quality Systems for Production and Installation). Prior to the use of any product on site, the Developer will provide the Engineer with a Certificate of Compliance from the manufacturer stating that all products supplied and which are included under Clause 14.6.1 have been manufactured in accordance with AS/NZS ISO 9002-1994 (or the applicable quality Standard) and comply with all specification requirements and relevant standards. Where the Manufacturer of any of the products listed involves a number of Manufacturers, a certificate from the Head Manufacturer or Supplier will be accepted subject to the Head Manufacturer establishing Quality Procedures for the product supplied from other Manufacturers and verifying such quality in accordance with the required standard. Certificate of Compliance The Certificate of Compliance required in clause 14.6.1(c) is to include the following:i ii iii iv the Developers name or reference number; the name of the manufacturer; the plant where the items were fabricated; the signature of the manufacturer's Quality Assurance Officer at the plant and the signature of the Developer's representative on site, confirming compliance of items with the contract conditions including mine subsidence requirements.
Any items which are delivered without a certificate will be rejected.
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The acceptance by the Engineer of items or goods supplied by the Developer based upon the Certificate of Compliance shall not constitute approval of any items or other matters nor shall it prejudice any right or claims by the Engineer to later reject items or materials found not to comply with the requirements of this specification. 14.6.2 Mine Subsidence Where pipelines are subject to ground movements due to mine subsidence, flexible joints must comply with the following requirements: When a joint is assembled so that adjacent pipes are co-axial and the end of the spigot is located at the bottom of the socket or coupling, the spigot should be capable of being withdrawn without impairing the water tightness of the joint a minimum distance M as follows: a For spigot and socket pipes of steel, ductile iron, cast iron, vitrified clay and concrete: M min = 3SL + OD b For spigot and socket pipes of UPVC: M min = 3SL + OD + [1.5 t T]L
o -5/o (Note: For t = 8.1 x 10 C and T = 22 C o (ie +/- 11 C), the value of 1.5 t T is 0.0027)
For pipes with couplings: M min = 1.5 SL + 0.5 OD Where: S = design ground strain.* L = length of pipe in mm. O = permitted angular deflection at joint in radians. D = inside diameter of socket or coupling in mm.
When determining the effective depth of a socket, or the length of a coupling or collar, required to accommodate the relevant movement M, any chamfer at the spigot end is to be taken into consideration. design ground strain is to be obtained by the Developer from the Mines Subsidence Board for the work area. Refer Clause 14.2. A full circle witness mark or groove is to be provided on each spigot. The centre line of such mark or groove is to be at a distance W from the spigot end as follows: a For spigot and socket pipes of steel, ductile iron, cast iron, vitrified clay and concrete: W = depth of socket - SL
*Actual
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April 1999
For spigot and socket pipes of UPVC: W = depth of socket - (SL + [0.5 t T]L)
o -5 o (Note: For t = 8.1 x 10 / C and T = 22 C o (ie. +/- 11 C) the value of 0.5 t T is 0.0009)
For pipes with couplings: W = 0.5 (length of coupling - SL)
14.6.3
Jointing Systems All flexible joints for pipes and fittings shall be manufactured to produce a watertight joint with rubber rings or other means having a similar degree of flexibility. Rubber rings will conform to the requirements of AS 1646 - 1987. All fittings shall be socket ended unless otherwise specified. Where other types of flexible joints are proposed full details are to be provided to the Engineer for consideration. Refer Clause 14.6.7. For developments not within proclaimed mine subsidence areas standard proprietary jointing systems may be used. For development within proclaimed mine subsidence areas joint systems shall be in accordance with Clauses 14.2 and 14.6.2. In accordance with Clause 14.6.1 the manufacturer is to state on the Certificate of Compliance that the pipe jointing system supplied will meet all mine subsidence requirements detailed in Clause 14.6.2. Any pipes, fittings and accessories used in the work incorporating a non-approved jointing system shall be rejected.
14.6.4
Slope Riley Fittings Where slope riley fittings are used they are to be supplied as a one (1) unit fitting. If circumstances are such that the Developer temporarily cannot supply SRJ as a one (1) unit fitting, approval may be given by the Engineer to accepting SRJ's made up of a slope junction and a bend.
14.6.5
Manhole Couplings UPVC pipe couplings to be built into manholes shall be at least 300mm long and have either: a One end as a standard socket suitable for flexible jointing and the other end plain; or One end as a standard spigot suitable for flexible jointing and the other end plain.
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The plain ends of both couplings are to be treated on the external surface in such a manner that full adhesion will be achieved between that surface and the concrete in which the coupling is embedded to ensure an adequately sound joint preventing the passage of fluids. The surface will be treated as follows: i ii iii iv 14.6.6 Cleaned with approved cleaning fluid. Coated with "solvent weld cement". Dipped in clean sand. Treatment will be at least 150 mm long.
Witness Marks A full circle witness mark is to be provided on each spigot at all pipes supplied by the pipe manufacturer. The actual mark will take into account allowances required for mine subsidence in accordance with Clause 14.6.2. The Developer is to lay the pipes such that the centreline of the witness mark or groove, or at least one point thereof, is in the plane of the face of the socket and such that no portion of the centreline is inside the socket. The permissible deflection as recommended by the manufacturer applies in all cases except where the requirements of the specification take precedence. Any pipes cut to length will have their witness mark reinstated at the position recommended by the manufacturer prior to jointing.
14.6.7
Alternative Pipe Material and Fittings Where the approved drawings indicate pipelines or fittings constructed of alternative material, these are to have performance ratings equivalent to or better than materials specified in Clauses 14.5.1, 14.5.2 and 14.5.3 and will comply with all other requirements of this specification. Where alternative pipe materials and fittings are offered full technical details shall be submitted to the Engineer for consideration and shall include:i ii iii iv v Technical specification. Statement of warranty from the manufacturer disclosing suitability of pipe material and/or fittings for intended used. Details of previous usage in similar situations. Copies of approval/authorisation of use and any specific requirements of other sewer authorities. The current and projected availability of materials and fittings required for maintenance or connection works and their cost comparisons to currently used materials.
Alternative pipes and fittings materials are not to be used without the prior written approval of the Engineer. 14.6.8 Handling and Storage The method of loading and storage of all pipes and fittings shall be in accordance with the manufacturer's recommendations.
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April 1999
14.7 14.7.1
SEWAGE RISING MAINS Pressure Pipe Unless otherwise approved all sewage rising mains will be constructed using minimum class 9 rubber ring jointed UPVC pressure pipes complying with the requirements of AS/NZS 1477-1996- PVC Pipes and Fittings for Pressure Applications - Series 1. The minimum nominal size of all sewerage pressure mains shall be 80mm. Pipelines used for crossing of roadways shall be minimum Class 12 rubber ring jointed UPVC pressure pipe complying with AS 1477-1996- Series 1. All pipes supplied shall conform, where appropriate, to requirements of Clauses 14.2 and 14.6.2.
14.7.2
Pipe Fittings Pipe fittings for use with pipes supplied under 14.7.1 shall be manufactured from Ductile Iron in accordance with AS2280-1988. All fittings will be socket ended and unless otherwise specified will be internally and externally coated with an approved nylon coating system typically "Rilsan Nylon 11" as detailed in Appendix C, to Sydney Water standard and further detailed in Clause 13.5.5 as applicable. Where fittings cannot be supplied that meet this coating requirement full details of the alternative external / internal system shall be submitted prior to use for the consideration of the Engineer. All fittings supplied shall conform where appropriate to requirements of Clauses 14.2 and 14.6.2.
14.7.3
Alternate Pipe and Fitting Materials Notwithstanding Clauses 14.7.1 and 14.7.2, alternative pipeline and fitting materials may be offered but shall not be used without the prior written approval of the Engineer. Alternatives shall have performance ratings equivalent to or better than items covered by Clauses 14.7.1 and 14.7.2 and shall comply with Clause 14.6.7 and all other aspects of this specification where applicable. All alternative pipes and fittings supplied shall conform to the requirements of Clause 14.2 and 14.6.2.
14.7.4
Joints Pipes and fittings for pressure pipelines shall be manufactured for jointing to produce a watertight joint with rubber rings or other means having a similar degree of flexibility. Rubber rings will conform to the requirements of AS1646-1987. Where other types of flexible joints are proposed full details in accordance with clause 14.6.7 are to be provided to the Engineer for consideration.
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All joints shall conform where appropriate to requirements of Clauses 14.2 and 14.6.2. 14.7.5 Witness Marks Witness marks for pressure pipes shall be in accordance with Clause 14.6.6. 14.7.6 Handling and Storage The method of loading and storage of all pipes and fittings is to be in accordance with the manufacturers recommendation. 14.7.7 Rising Main Fittings a Stop valves shall be inserted where shown on the approved engineering plans. Stop valves are to be fixed plumb and square to the centre line and at a depth to provide clearance of between 150mm (minimum) to 300mm (maximum) from the top of the valve spindle to the top of the surface box lid as shown on Drawing No SD 41C. All valve boxes are to be "proud" of the general footpath finished level by 25mm. A minimum 300mm width strip of couch turf is to surround the finished box construction unless otherwise approved. The Developer's/Contractor's attention is drawn to the fact that some stop valves installed in accordance with this Clause will require the pipeline to be installed at a greater depth than that specified in Clause 14.4.8. b All stop valves will be provided with a cast-iron cover box and a concrete surface box all conforming to the requirements of this clause and Drawing SD 41C. Surface blocks are to be reinforced Grade 20 concrete with 20mm coarse aggregate and is to be a maximum of 570mm in diameter or 570mm square as detailed on Drawing SD 41C. The surface finish of the concrete blocks is to be smooth and dense. Blocks are to be properly cured prior to placement. c Protective boxes for stop valves are to be constructed around the fitting stems and are to consist of interlocking concrete blocks conforming to Drawing SD 41C. The walls are to provide a firm and even support for the concrete surface block. Air release valves, scours and other fittings, will be inserted where shown on the approved drawings. The Developer will supply all materials and labour necessary to complete these installations. The Developers attention is drawn to Drawing SD 36A - Air Release Valve Installation.
The orientation of the incoming rising main/s shall be located to direct flows towards the outgoing gravity main to minimise turbulence.
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April 1999
14.7.8
Connection to Discharge Manholes Connection to the discharge manhole shall be in accordance with the approved plans and Drawing SD 72.
14.7.9
Main and Fittings - Marker Posts and Plates Aluminium marking plates bearing the letters 'SV" for stop valves, "AV" for air valves, "SCOUR" for scour locations and "SRM" at changes of direction and at such chainages that the location of the main is marked at least once each 100 metres, will be provided as specified below. Where a valve or fitting is at too great a distance from any existing wall, fence, post or other permanent feature to which a marking plate could be conveniently fixed, the Developer will provide marker posts conforming to Drawing SD 40A. Posts will be placed adjacent to property boundaries. Notice plates shall be cast into the posts. The distance to the fitting in metres, to an accuracy of 100mm, shall be permanently die-stamped or painted in black exterior enamel on the marking plate with numbers 25mm high. Where soft ground is encountered, the post is to be driven into the ground to a minimum depth of 600mm. Extreme caution should be exercised due to the possibility of other underground services being present.
14.8 14.8.1
EARTHWORKS General All excavations will be to the lines and grades shown on the approved drawings and in accordance with the requirements of this clause. Where earthworks requirements outlined in this Clause conflict with the pipe manufacturers recommendation the requirements of the manufacturer shall apply.
14.8.2
Trench Width For all gravitation sewers or UPVC rising mains:a Minimum Width The minimum clear width of trench (inside internal faces of timbering or travelling box, if used) to a height of 150mm above the top of the pipe will be the nominal size of the pipeline plus 250mm. b Maximum Width The maximum width of trench from the trench base to a height of 150mm above the top of the pipe will be the outside diameter of pipe barrel plus 400mm. However, in timbered or travelling box excavated trenches, the width of trench when measured to the outside of the support used may be increased to a maximum of 580mm plus the outside diameter of the pipe barrel.
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Extra Width Excavation Where the width of trench below a level of 150mm above the top of the pipe is greater than the maximum width specified above, from any cause whatsoever before or after laying of the pipe, the Developer is to remove all disturbed material from the trench. The Engineer may then direct one or more of the following: i Bedding and laying, as specified in Clauses 14.10 and 14.13 for the same pipe; Installation of a heavier class of pipe; Filling the space between the pipe and the undisturbed ground on both sides of the pipe and to a height of 300mm above the top of the pipe with sand or granular material of the type approved for pipe bedding as specified in Clause 14.10. Such sand or granular material is to be compacted in layers not greater than 150mm thick. Bedding of the pipe and concrete cradle extending a minimum of 100mm on each side of the outside diameter of the pipe, a minimum of 100mm under the barrel and to a level above the bottom of the pipe of one quarter of the external diameter of the pipe.
ii iii
iv
Backfilling and compaction for the remainder of the trench will be in accordance with Clause 14.14. 14.8.3 Excavation Depth For all gravitation and pressure pipelines, excavation is to be carried out to a depth of not less than 75mm below the underside of the pipe barrel and socket or coupling in the case of earth foundations and 100mm below the underside of the pipe barrel and socket or coupling in the case or rock foundations. 14.8.4 Provision for Soft Ground a Extra Depth Excavation Where, in the case of poor ground conditions extra depth excavation in order to obtain a firm trench bottom is required. The excavated area will be re-filled to the level required for bedding of the pipe with an approved free-draining non-cohesive material such as sand, fine crushed rock, or granular material (blue metal), placed in layers 150mm thick and compacted by approved means to achieve an adequately sound foundation. Notwithstanding the above, where excavation in a trench has been carried out to a level deeper than the level required for the bedding of the pipe, the Developer is to remove all disturbed material from the bottom of the trench and supply, place and compact, an approved material to refill the over-excavated portion to the required level to achieve an adequately sound foundation.
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April 1999
In addition to the requirements of Clause 14.8.4(a) where the foundation level of structures or trenches is spongy or boggy and over excavation and the use of non-cohesive backfill alone is considered to provide insufficient support, the Engineer may direct the Developer to carry out the following works: 1 Supply and place clean ballast of not less than 75mm size in layers and compact by ramming into the boggy ground until an approved firm foundation is obtained at the level required for the bedding layer. The Developer is to remove and dispose of any surplus material displaced by placing of ballast as directed. AND/OR 2 Supply and place "Terra Firma" Grade 1000, separation membrane or approved equivalent across the full trench width extending up each side of the trench to a level a minimum of 450mm above the top of the pipe. AND/OR 3 Supply and place non-cohesive material encapsulated in "Terra Firma" Grade 1000, separation membrane or approved equivalent to form a pillow in the trench bottom as follows: Cut the stabilising fabric to the following dimensions: Length - as required. Width - 3 x (width of trench as excavated) plus 500mm. When laying the stabilising fabric membrane the Contractor will proceed as follows: i Over-excavate to a depth of at least 300mm below the invert level or additional as required. Centrally place the stabilising fabric along the trench and backfill with non-cohesive material to a minimum depth of 200mm or to 100mm less than the over excavation depth across the trench onto the fabric; and Form a pillow of the non-cohesive material with the stabilising fabric ensuring at least one trench width overlaps at the top surface of the so-formed pillow and providing overlaps of 500mm between each section of fabric laid on the trench along the pipe route. The overlay will be stitched to the preceding section in accordance with manufacturers requirements.
ii
iii
Where the Developer has been directed to carry out the work described in (ii) and/or (iii) above without the use of any other foundation stabilisation method and if the material is boggy and cannot adequately support the geofabric material, the Developer will initially prepare the foundation material by the use of clean granular material or ballast placed in accordance with Clauses 14.8.4(a) and 14.8.4.(b) as applicable.
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14.8.5
Dewatering Trenches will be kept free of water after excavation and during construction of the sewers by means of internal or external dewatering or other approved ground stabilising techniques. Dewatering shall be carried out in accordance with Clause A.10.1. Any auxiliary excavation carried out in or adjacent to the trench excavation for that purpose will be backfilled and compacted with approved homogeneous material in accordance with this specification. Where sub-drains have been used, this may include backfilling with grout consisting of not less than one part of cement to ten parts of sand when batched by volume.
14.8.6
Support of Excavations Where required the Developer will adequately support all trenches and excavations as the works proceed. All trench support systems will conform to the requirements of the current Construction Safety Act and Occupational Health and Safety Act. When withdrawing any supports, the Developer is to ensure against slips or falls by means of intermediate shoring. Backfilling and compaction is to be performed simultaneously with the withdrawal of supports. Timber shoring may be required to be left in place where its removal may endanger structures in the vicinity of the excavation.
14.9
EROSION AND SEDIMENT CONTROL In the event of any trenching being left open for an extended period of time of longer than one week, the Developer shall provide erosion control measures to ensure minimal soil disturbance and material loss off the site. These measures are to be provided as outlined in Appendix A - Control of Erosion and Sedimentation. Additional control measures may be necessary as detailed below. Such measures shall be as directed. a Provision of trench stops every 30 metres along a trench with provision for overtopping to be directed to the kerb. Placement and maintenance of blue metal bags along kerb and gutter at maximum 30 metre spacings. Placement and maintenance of blue metal bags around downstream drainage pits. Construction of diversion banks to divert the uphill catchment water from entering the trench.
14.10
PIPE BEDDING
14.10.1 General When excavation of a trench has been completed, the Developer is to provide bedding for the pipe in accordance with the following requirements. Where the manufacturers bedding requirements exceed those outlined below the requirements of the manufacturer shall apply.
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April 1999
14.10.2 Sand Bedding For all sewer gravity and rising mains the material to be used for pipe bedding (underlay a minimum of 75mm below the pipe barrel and socket for earth foundations and 100mm for rock foundations), side support and overlay to a minimum depth of 150mm above the top of the pipe shall be sand or other approved non-cohesive free draining material, either crushed natural or blended, and its grading is to fall within the following limits:
Sieve Size Aperture Width (AS 152) 9.5mm 6.7mm 425um 150um Equivalent B.S. Sieve Size (BS 410) 3/8 inch 1/4 inch No 36 No 100 Percentage Passing
100 90 - 100 40 - 90 0 - 10
The material is to be adequately compacted under, around and to a minimum of 150mm above the top of the pipe and is to extend for the full width of the excavated trench. Sand bedding shall be used in all cases, except where the provisions of Clause 14.10.3 prevail. 14.10.3 Granular Bedding Non-cohesive granular bedding and surround shall be used in saturated ground or in impermeable material such as rock and clay. The material used for pipe bedding, side support and overlay (to a depth of 150mm over the top of the pipe) shall be graded aggregate, either crushed rock or gravel, with grading to fall within the following limits:
Sieve Size Aperture Width (AS 152) 19.0mm 16.0mm 13.2mm 8.0mm 4.75mm Equivalent B.S. Sieve Size (BS 410) 3/4 inch 5/8 inch 1/2 inch 5/16 inch No 4 Percentage Passing
100 50 - 80 30 - 65 15 - 50 0 - 10
The material is to be adequately compacted under, around and to a minimum of 150mm above the top of the pipe and is to extend for the full width of the excavated trench. Where such graded aggregate is being used, the installation of trench stops will not be required.
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14.11
MANHOLES (ACCESS CHAMBERS)
14.11.1 Cast Insitu Manholes General Cast insitu manholes shall comply with Drawings SD 33 and SD46. Mechanical vibrators shall be used for the compaction of all concrete used to construct manholes. All concrete used for cast insitu manholes shall conform to the requirements of Clause 14.15. Construction of manholes shall be carried out progressively as pipeline construction proceeds. Each manhole shall be constructed to finished surface level and the excavation backfilled seven (7) working days after the backfilling of the first-constructed pipeline which enters that manhole. Backfilling and compaction shall be in accordance with Clause 14.14 and shall be brought up in equal levels around the manhole. All disturbed areas around the manhole will be topsoiled and couch turfed unless otherwise approved to a minimum width of 600mm. External formwork shall be used for manholes unless otherwise approved and all external formwork is to be removed prior to backfilling. Manholes trenches shall not be backfill less than four (4) days or more if required to ensure adequate strength is achieved and structural damage does not occur. Manholes that exhibit structural damage will not be accepted. Notwithstanding the above no backfilling will take place prior to the inspection. 14.11.2 Concrete Covers and Surrounds Concrete manhole covers and surrounds shall either be light or heavy duty as shown on the approved plans and conform to the requirements of Drawing SD 31. Heavy duty manhole covers and surrounds will be required in areas that will or probably will be trafficked irrespective of details on the approved plans except as required in Clause 14.11.3. Manhole covers and surrounds are to be manufactured by an approved concrete products manufacturer. Covers and surrounds will not be warped or twisted. Surfaces will be finished such that there are no abrupt irregularities and gradual irregularities will not exceed 3mm. Unformed surfaces shall be finished by approved methods to produce a surface that is dense, uniform and free from blemishes. All exposed edges are to have a minimum 4mm radius. Tolerances for the dimensions on the COVER will be - 3mm, + 1 mm. Tolerances for the dimensions on the SURROUND will be - 3mm, + 3mm. Concrete manhole covers are to be seated on a layer of "Compriband" or similar approved material, having cross-section dimensions of 25 x 25mm.
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April 1999
14.11.3 Cast Iron Covers and Surrounds In particular situations cast iron manhole covers and surrounds are required in lieu of concrete covers and surrounds. These situations are as follows:a b c where manholes are located in stormwater flow paths; where manholes are located below the 100 year flood level; or where the Engineer directs.
Where shown on the approved engineering drawings or where directed by the Engineer, the Developer shall supply and install a "Gatic" type or approved equivalent cast iron cover and surround with concrete infill in accordance with the manufacturer's requirements. Cast iron manhole covers will be either: a Light duty "Gatic" type L185 or approved equivalent for use in areas not subject to vehicular loading; or Heavy duty "Gatic" type H191 or approved equivalent for use in areas subject to, or potentially subject to vehicular loading.
All "Gatic" or approved equivalent manhole covers are to be supplied complete with plastic insert seals for the lifting holes. "Gatic" or approved equivalent covers for use in cast insitu manholes shall be cast integrally with the manhole at the time of construction. Where this method is not possible, and for pre-cast manholes the covers will be set to the correct level and installed using circular formwork. The formwork is to provide a minimum of 200mm wide by 200mm thick concrete surround for the cover. The surround will be cast around the cover and the section of the manhole using structural grade concrete conforming to Clause 14.15 to permanently secure the surround to the top section of the manhole. In all cases concrete shall fully encase the flanges and the top section of the manholes. 14.11.4 Precast Manholes General Approved factory manufactured precast manholes may be used in lieu of cast insitu manholes. Precast manholes shall be manufactured, supplied and installed in accordance with Drawing SD 45A and this clause. a Wall Thickness The walls of approved unreinforced precast concrete manholes shall be a minimum thickness of 90mm. The use of reinforced precast concrete components will not be permitted.
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Step Iron Installation Step irons for use in precast manholes are to be fixed in position using an epoxy mortar grout, CIBA, GEIGY, LC273 or approved equivalent in accordance with Drawing SD 34. Cement mortar will not be permitted. Step irons will conform to the requirements of Clause 14.12.
Concrete Specification Concrete for use in precast manhole components shall conform where appropriate to Clause 14.15 and further as follows: a b Minimum batched cement content per cubic metre of concrete will be 400kg. Maximum water/cement ratio will not exceed 0.45 (by mass).
Workmanship and Finish Workmanship and finish for all components shall comply with the requirements of AS 4058-1992 and the type of finish shall be as shown on Drawing SD 45A and further as follows: i Precast manhole components that exhibit cracks exceeding 0.1mm in width shall be rejected. All components will be free of porous, segregated or honeycombed concrete. Except where specified, any surface irregularities shall not exceed 3mm in depth. Hand finishing of concrete which has only just taken its initial set will be permitted, provided no cracking or other deterioration of the concrete occurs as a result. However, no bagging or rendering of components is permitted. iii The depth of any single air void will not exceed the following values: 1 2 10mm for external surfaces of unreinforced components; 3mm for internal surfaces (including joint surfaces) of all components. For the purpose of this document, joint ends of components will be deemed to be internal surfaces.
ii
iv
Surface irregularities (excluding those detailed in ii) above) will not exceed 3mm in depth. Step irons will not be displaced from their specified position by more than 5mm. Any precast manhole component, whether delivered or installed, that does not meet these requirements shall be rejected and removed from site at the full cost of the Developer.
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April 1999
Jointing Compound Jointing compound shall be "Bostic 5322" or approved equivalent comprising, a butyl rubber sealing compound and will have an internal thread to prevent elongation or distortion.
Manhole Base The manhole base will be placed insitu using a concrete mix as specified in Clause 14.15 and compacted using an approved vibrating method and further as follows: i Where the lowest component of the chamber section is entirely above the pipes embedded in the base, there will be a minimum of 30mm of insitu placed concrete between the barrel of the largest pipe or coupling in the base and the bottom edge of that component. Where the concrete in the lowest component is being cut-away to accommodate the various pipes in the base, the cut-away section will be such that there will be a minimum clear space of 30mm between the top of any pipe barrel or coupling and the concrete in the cut-away section of the lower component, when the latter is resting on the concrete in the base; The lowest component will be of the shortest possible length without step irons which will be suitable in accordance with the approved design of each manhole. Any joints between the base, pipes or adjacent manhole components shall not permit the ingress of water or any other foreign matter
ii
iii
Spacer Rings A maximum of 2 "Spacer Rings" ("Make-up Rings") may be used between cone sections and surrounds to make up height differentials of less than 350mm.
Backfill Backfill for all precast manholes shall be of a non-cohesive granular material placed and compacted evenly around each manhole to a level of 300mm above the top of the highest incoming pipe for the full width of the excavation in accordance with Clause 14.10. The remaining backfill will be placed and compacted to the finished surface level in accordance with Clause 14.14.
Concrete Covers and Surrounds The Developers attention is drawn to Clause 14.11.2 outlining requirements.
Cast Iron Covers and Surrounds The Developers attention is drawn to Clause 14.11.3 outlining requirements.
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14.12
STEP IRONS
14.12.1 Specification Step irons shall be installed in all manholes deeper than 1.2 metres. Step irons shall be in accordance with and embedded in concrete as detailed in Drawing SD 34. Step irons will be fixed in formwork prior to placing of concrete for cast insitu works. 14.12.2 Alternative Types Step irons not conforming to Clause 14.12.1 may be considered for approval subject to prior submission to the Engineer for assessment. 14.12.3 Location Step irons are to be located over the outlet pipe of the manhole. 14.13 LAY AND JOINTING
14.13.1 General Requirements Pipes shall be laid and jointed in accordance with the manufacturer's instructions and the provisions of this specification. Where the manufacturers pipe laying requirement exceed those outlined in this specification the requirements of the manufacturer shall apply. Before being laid all pipes, fittings, valves, etc, are to be cleaned. The Developer is to suspend each or any pipe in a sling to enable inspection by the Engineer if required. The laying of pipelines shall commence at the downstream end of the line and progress upstream unless otherwise approved. The Developer shall install temporary plugs of an approved type in manholes, upstream ends of incomplete sections and where house connections have been made or other location necessary to prevent drainage, silt and debris entering the sewers. Any temporary supports are to be removed prior to completion of backfilling. The Developer will take all necessary precautions to prevent flotation of pipes during laying, backfilling and initial testing. 14.13.2 Pipe Grading and Alignment All pipelines will be laid on the grade and alignment as shown on the approved drawings within the specified tolerances, otherwise the requirements of Clause 2.33 shall apply. Flexibly jointed pipelines for rising mains with gradual changes in alignment or grade are to be laid with the joint being deflected after it has been made. The manufacturer's recommendations in respect of maximum deflection for each joint are to be complied with.
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Unless otherwise approved, pipes for rising mains are to be laid on continuously rising grades from scour valve to air release valve, notwithstanding any minor irregularities in the ground surface. Deflections of pipe joints within mine subsidence areas are to be reduced or the sockets adjusted so the sum of the deflection and the effective socket depth based on the design ground strain does not exceed the tolerance specified herein. 14.13.3 Jointing Details The lubricant specified by the manufacturer is to be applied in making the joint. When the joint is made, the witness mark will at no point be more than 1mm from the end of the socket. Solvent cement jointing of UPVC fittings (refer Clause 14.6.3) will only be permitted when specified or approved by the Engineer. Where pipes are to be cut in the field, a witness mark (pencil or similar) will be made on the pipe at the length from the end of the pipe specified by the manufacturer. Scoring of pipes is not permitted. Where spigots and sockets are not made by the same manufacturer, reference will be made to the socket manufacturer for the correct marking depth and suitability of the spigot dimensions and the socket manufacturers gasket requirement. 14.13.4 Rubber Ring Installation For pipes with roll-on roller ring joints, spigots and sockets will be clean and dry before making the joint. After making the joint a feeler gauge will be used to check that the rubber ring has rolled in evenly, and if not, the pipe will be withdrawn and the joint re-made. 14.13.5 Cutting of Pipes Pipes may be cut as required to the manufacturers specification to suit closing lengths, to remove damaged parts or to remove sockets. 14.13.6 Polyethylene Wrapping of Pipelines and Fittings - Ductile Iron All ductile iron pipes and fittings shall be wrapped in polyethylene sleeving in accordance with the manufacturers specifications typically "Century Plus" or approved equivalent. Any damage done to the polyethylene tubing before, during or after backfilling of the trench or to existing service wrappings will be made good by the Developer at no cost to Council. Should the protective wrapping of any existing pipeline or fitting be disturbed or damaged by the Contractor it shall be rectified by the Contractor under Council supervision at no cost to Council.
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14.13.7 Tolerances Pipelines Gravity pipelines shall be installed within the following tolerances:a b Horizontal deviation from design alignment: 30mm Vertical deviation from design invert level: i ii c For pipeline grades up to and including 1%: 15mm For pipeline grades steeper than 1%: 30mm
Angular deviation at any flexible joint: Up to 50% of the manufacturers maximum recommended deflection. Refer clauses 14.6.3. No pipe to have backfall (negative grade). No horizontal section to be more than one pipe length long.
d e
Notwithstanding the above vertical construction tolerances; no sewer is to be laid below the grade recommended by the Public Works Department for the design loadings or below their minimum self cleansing grade where design loadings do not apply. Pressure pipelines shall be installed within the following tolerances:a b c Horizontal deviation from design alignment: Vertical deviation from design invert level: 50mm 30mm
Angular deviation at any flexible joint: Up to 50% of the manufacturers maximum recommended deflection. Refer clause 14.13.2. All pipes in a length between design low and high points are to have continuously rising grade towards the high point. Locate air valves off roadways and driveways unless otherwise approved. Install valves, scours, tees, bends and other fittings and structures within 300mm of the design location along the main.
14.13.8 Structures and Pipelines at Manholes a Manhole covers and surrounds shall be finished flush with the surface in roadways, footpaths and paved surfaces. Elsewhere manhole covers and surrounds shall be finished 25mm (10mm) above the ground to allow for 600mm couch turf surround unless otherwise approved and to prevent the entry of surface water.
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Pipelines are to be connected to manholes or other structures in accordance with the following: A 300mm long pipe stub extending approximately 150mm from the face of the structure connecting to a 600mm long pipe so that two flexible joints are provided (refer Drawing SD 33). Where flexible joints cannot be made with cut pipes the Developer is to provide the second joint within 300mm of the position shown on the drawings. For the purpose of this clause pipes and fittings encased in concrete shall be considered as structures.
The positions of manholes shown on the approved drawings may be subject to alteration by the Engineer immediately prior to construction. They may be varied to suit changes, such as erection of structures, growth of flora and installation of services. Once the final position of a manhole has been determined, construction tolerances will as follows: i Permitted tolerances for manhole positions in plan location shall be no more than 100mm from the design or determined manhole centre. The adjusted vertical and horizontal alignment of affected pipelines shall meet the requirements of Clause 14.13.7 and 14.4.8.
ii
Lampholes are generally not permitted, however, with the prior approval of the Engineer shall be provided in accordance with Drawing SD 44. The Developer's attention is drawn to Clause 14.1.4 in regard to work constructed outside tolerance.
14.14
BACKFILLING AND COMPACTION
14.14.1 General a When laying and jointing of a pipeline has been completed and before backfilling is commenced, (refer Clause 14.3.2(e)) an inspection by the Engineer shall be undertaken. Backfill down to within 150mm of the pipe surround is to be selected backfill free of large stones, rocks or hard nodules and if suitable may be taken from the excavated material. The backfill material is to be compacted for the full trench depth as specified below. Where insufficient approved excavated material is available the Developer shall import approved select backfill material. Surplus material not suitable for backfilling shall be removed and disposed of in an approved manner.
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Trenches subject to vehicular traffic shall have all backfill material fully compacted in layers not more than 150mm thick to 100% of standard maximum dry density AS 1289 for cohesive materials and 65% density index determined in accordance with AS 1289 for non-cohesive material to the subgrade level of the road or the finished surface level as directed. Backfill from the subgrade level to the road surface level is to be an approved road base material to a minimum depth of 300mm or the approved design pavement. Compaction of the backfill material will be by mechanical means unless the backfill material is suitable for compaction by flooding with compactive effort. Flooding of cohesive materials will not be permitted. Prior to backfilling and compaction of trenches subject to vehicular traffic, trenchstops as detailed on Drawing SD 37C are to be constructed across the full width of the excavated trench directly behind the kerb, or where no kerb exists, behind the road shoulder, to contain the compacted material.
Within lots in housing developments, or in areas other than under roadways, the backfill will be compacted as specified above to 95% of the standard maximum dry density in accordance with AS1289. Where compaction is ordered and the trench has been externally dewatered, the dewatering equipment is to be kept operating until the compaction of the trench has been completed. Water discharge from external dewatering equipment may be used for compaction by flooding with compactive effort where such backfill material is of a non-cohesive nature. Backfilling and compaction will be carried out without damaging the pipe or its external coating or producing any movement of the pipe. Any subsidence or scouring of the trench backfill during the specified maintenance period will be rectified by the Developer at no cost to Council. Testing will generally be in accordance with the requirements of Clause 8.5.5 for road crossings (trafficable areas) and where considered necessary elsewhere.
14.14.2 Restoration All restoration works shall be carried out in accordance with the requirements of Clause 6.19 and 10.6.4 in the case of concrete footpath crossing restoration works. 14.14.3 Maintenance All restored surfaces are to be maintained by the Developer until the expiry of the Maintenance Period (refer Clause 2.34) applicable to those surfaces. The additional requirements of Clause 2.35 shall also apply. 14.15 CONCRETE
14.15.1 General Concrete shall meet the criteria specified in Clauses 14.15 and 14.11 for manholes.
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14.15.2 Finish The finish to concrete surfaces will be as follows: a i Use: For all surfaces that are in contact with sewage or sewage sludge including the inside surfaces of manholes, pump stations, wet wells, valve pits and all external visual surfaces. Criteria: No abrupt irregularities will be permitted and gradual irregularities will not exceed 6mm. Tie rod holes are to be filled with stiff cement mortar and mortar fins removed.
ii
Unless otherwise approved by the Engineer, formed surfaces will be thoroughly wetted and ground with a carborundum stone until all form marks have been removed and the whole surface made uniform in texture and colour by approved finishing methods. Unformed surfaces are to be finished by approved methods and equipment (steel or wooden trowels as applicable) to produce a surface that is dense, uniform and free from blemishes. Joints and edges will be tooled. b i ii Use: All other surfaces not specified in Clause 14.15.2(a)(i). Criteria: Abrupt irregularities are not to exceed 6mm and gradual irregularities will not exceed 12mm. Tie rod holes are be filled with stiff cement mortar and mortar fins removed.
Unformed surfaces are to be wooden floated to produce a surface that is free from screed marks and is uniform in texture. Joints and edges are to be tooled. 14.15.3 Cement Cement used in all concrete work specified in Clause 14.15.2a(i) must be sulphate resistant (SR formerly Type D). The Developer shall supply to the Engineer written evidence that concrete supplied incorporates sulphate resistant cement where applicable. 14.15.4 Concrete Criteria a Concrete will conform to the following criteria: i Pipe encasing (reinforced), and manhole concrete; 1 2 nominal maximum aggregate size will be 20mm; the characteristic compressive strength at 28 days will not be less than 20mpa; Slump shall not exceed 100mm.
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ii
Backfill concrete encasing (un-reinforced), concrete bulkheads, concrete bedding, concrete encasement to risers and thrust blocks: 1 2 nominal maximum aggregate size will be 25mm; the characteristic compressive strength at 28 days will not be less than 20 MPa; Slump shall not exceed 100mm.
3 b
The applications for the different grades of concrete will be as shown on the approved engineering drawings or as specified in Clause 14.15.4(a). No admixture shall be used in the manufacture of ready mixed concrete for the work unless previously approved by the Engineer. Each load delivered to the site is to be accompanied by a Despatch Slip stating the time at which the concrete was batched and further as follows: i ii iii iv v The size of the load in cubic metres; The compressive strength; The total cement content of the load in kilograms (kg); The amount of free water batched in litres (L); The slump at time of batching in millimetres (mm).
e 14.16
No additional water is to be added.
TESTING OF GRAVITY SEWERS
14.16.1 General All sewers and manholes shall be subject to an initial test, with sewers being tested prior to the commencement of backfilling except as allowed under Clause 14.16.2(b). An acceptance test will then be carried out before acceptance of the works by the Engineer and not earlier than one month after completion of construction of all sewers and manholes and initial testing in that section of main. Should the sewer mains or manholes fail any test, defects will be located and repaired and the test repeated. The process of testing, detection and repair of defects and retesting will continue until a satisfactory test is obtained. All lines will be clear and free from soil, slurry, liquids and other foreign substances at the time of initial and acceptance testing and when handed over to the Engineer. Clearance of affected lines shall be the responsibility of the Developer. 14.16.2 Initial Test of Gravitation Sewers a The initial testing of gravitation sewers will be made with compressed air in accordance with the relevant requirements and method of testing specified in Clause 14.16.5. Before the initial test is performed, all pipelaying on the section will be completed and backfill will be compacted to the level of the centre of the pipe barrel.
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The initial test may be carried out before risers and/or sidelines are constructed so that the main line can be backfilled. However, a further initial test shall be carried out on the risers and sidelines as soon as they are completed. Where construction of pipelines in other than full lengths between manholes is permitted, each length of pipeline will be initially tested before backfilling together with the downstream portion of the manhole length under construction except as detailed in Clause 14.16.2(b). Any fault detected will be rectified and a satisfactory test obtained before the remainder of backfill is placed. b When a trench support system is used which requires leapfrogging and thus progressive backfilling, the Developer may elect to carry out initial testing following backfilling, subject to the following conditions: i The initial test must be carried out at the completion of each manhole length, or the end of a day's work on any incomplete length, whichever is the sooner. If the initial test fails, the Contractor must immediately locate the cause and carry out all necessary repairs satisfactorily and repeat the initial test. This procedure will be repeated until testing is successful.
ii
14.16.3 Initial Test of Manholes Each completed manhole must be initially tested for leakage within seven days of backfilling. The initial test will be carried out with the manhole cover surround fitted but prior to any rendering of channels and benches. The test will be made by plugging all pipe openings in the walls and by filling the manhole with water to the lowest point on the top of the manhole cover surround. The plugs will be positioned in the pipes as near as practicable to the internal face of the manhole. After allowing an interval for absorption, the manhole will be refilled and the loss of water during the following 30 minutes measured. The test on the manhole will be considered satisfactory provided the water lost is less than 3mm depth in the top section of the manhole for each 1m depth of manhole. The depth of manhole is to be taken from the bottom of the manhole cover recess in the cover surround to the invert of the outlet pipe from the manhole. The plug of the outlet will be fitted with a suitable release for emptying the manhole on satisfactory completion of the test. 14.16.4 Acceptance Test of Gravitation Sewers and Manholes The acceptance test on all components in the section of the system will be made in the same manner as the initial test except where the provisions of Clause 14.16.7 prevail. Hydrostatic testing in accordance with Clause 14.16.6 may be permitted except where the provisions of 14.16.7 prevail in lieu of compressed air testing.
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Any pipeline or manhole where in the opinion of the Engineer is faulty will be rejected irrespective of test results. 14.16.5 Testing with Compressed Air a Equipment All necessary equipment is to be supplied by the Developer and maintained in good working order. Pressure gauges are to be tested daily by static water column. At least one spare gauge per test rig is to be kept on the job at all times. Compressed air is to be supplied by a compressor of the rotary vane type 3 capable of supplying at least 1m /minute at 35kPa. The air is to be fed through a pressure reducing valve capable of reducing pressure from that supplied to 28kPa +4kPa. The air is then to pass through an airtight line fitted with a 150mm Bourdon type pressure gauge reading from 0 to 50kPa, a pressure relief valve that may be set to blow off at 28kPa +4kPa and a gate valve to the pipeline to be tested. b Method of Carrying Out Test The method of setting up and carrying out the test will be as follows: i Insert a blank plug at one end and a disc with air-hose connection at the other end of the line. Care must be taken to ensure that the force due to pressure on the disc is not taken by pipe joints, but is taken by struts bearing on the disc or on the end pipe in the line. Couple the test equipment to the line under test and compressor or air line. Slowly increase the air pressure in the line from 0 to 28kPa (over one minute approximately). Hold air pressure at 28kPa for three minutes to stabilise temperature. Close gate valve to shut off air supply to test equipment. Measure the time it takes for the pressure to drop from 25kPa to 18kPa. If this time is less than that permitted in 14.16.5(c) or if the line cannot be pressurised to 28kPa, then the test is unsatisfactory and the pipeline should be checked for leaks. If leaks are detected they will be repaired by approved methods. Re-test as abovementioned until the time taken for the pressure to drop is greater than that shown in 14.16.5(c).
ii
iii
iv v vi
vii viii
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April 1999
Allowable Pressure Drop Times The time taken for the pressure to drop from 25kPa to 18kPa will be greater than: 100mm pipe - 1 minute 150mm pipe - 2 minutes 225mm pipe - 4 minutes 300mm pipe - 6 minutes 375mm pipe - 8 minutes 400mm pipe - 9 minutes 450mm pipe - 11 minutes 525mm pipe - 14 minutes 600mm pipe - 17 minutes Vitrified clay pipes, in particular, suffer from excessive air permeability under dry summer conditions. When this occurs pipes must be thoroughly saturated with water before testing or alternatively a hydrostatic test applied. In any case, where the specified allowable pressure drop time cannot be attained and there are no visible leaks, a hydrostatic test is to be applied in accordance with Clause 14.16.6.
14.16.6 Hydrostatic Testing The hydrostatic test will be carried out by connecting to the pipeline or part pipeline, a pipe or hose terminating in a 150mm diameter container not less than 100mm deep. All other open ends of the pipeline will be plugged. The pipeline under test, and the pipe or hose with container, will be filled with water until the free surface of the water is level with the top of the container, suspended in accordance with the following requirements: The test container will be suspended at a level such that the test head applied to the pipeline is as follows: a i For initial test when no sidelines or risers are constructed - a minimum head of 2 metres above the pipe invert at the upstream end of the line under test, or For initial test where sidelines and/or risers are constructed - a minimum head of 2 metres above the highest invert in the line under test, including its risers and sidelines.
ii
For acceptance test, a minimum head of 2 metres above the highest invert in the line under test, including its risers and sidelines, or above the free standing level of groundwater in the vicinity whichever is the higher. Where appropriate the free standing level of groundwater will be determined by the Developer at his own expense by a method acceptable to the Engineer. After allowing a minimum of 2 minutes for absorption, any fall of the free water surface is to be made good by adding extra water to the container. The volume loss during ten minutes thereafter will be measured.
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The pipeline will be regarded as satisfactory if there are no visible leaks, and if the volume loss does not exceed 4.4 ml per standard test length of the pipeline under test including sidelines and/or risers in the nominated interval (ten minutes). A standard test length in metres is defined as 1370m divided by the effective diameter of the pipeline in millimetres. a Where the pipeline under test is all of the same size, the effective diameter will be the nominal size of the pipeline. Where the pipeline under test has sidelines and/or risers of smaller nominal size than the main sewer line, then the effective diameter will be calculated as follows: Effective diameter = (L1 D1 + L2 D2 + ............ Ln Dn) / (L1 + L2 + ............ + Ln) where Ln is length (m) of sewer of nominal size Dn (mm) in section under test. 14.16.7 Visual Inspection and Measurement of Infiltration Whenever, in the case of acceptance testing, the pipeline is subjected to a significant head of groundwater (ie. 1500mm or more above the sewer main provided that groundwater is at least 150mm above any sideline included in the test) and with the approval of the Engineer, the tests previously prescribed may be dispensed with in favour of visual inspection and measurement of infiltration. In such circumstances, the Developer will provide full details of the method by which the infiltration is to be measured, to the Engineer. If approval of an inspection and infiltration test for the purposes of acceptance is permitted. The rate of infiltration will be measured over 2 hours and shall not exceed the allowable rate determined from the following:Allowable rate (L/hr) = 6.5 x 10-4 (L1 D1 H1 + L2 D2 H2 +.....+ Ln Dn Hn) where Ln is length in (m) and Hn average head (m) of groundwater above invert level of sewer of nominal size Dn (mm) in section under test. The head of groundwater shall be determined by the Developer at his own expense by a method acceptable to the Engineer. 14.17 TESTING OF RISING MAINS
14.17.1 General Rising mains shall be pressure tested in accordance with this sub-clause in order to detect excessive leakage and defects in the pipeline including joints, thrust and anchor blocks.
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14.17.2 Method of Carrying Out Test Pipelines will be tested in sections as soon as practicable after each section has been laid, jointed and backfilled, provided that: i If so specified or if the Developer so desires, or if required by the Manufacturer some or all of the pipe joints may be left uncovered until the whole of the section has been successfully pressure tested; and The pressure testing will not commence earlier than seven days after the last concrete thrust or anchor block in the section has been cast.
ii
For the purpose of this sub-clause a section will be defined as a length of pipeline which can be effectively isolated for testing by means of stop valves for example. Unless otherwise approved, pressure testing will not be carried out during wet weather. During pressure testing, all field joints which have not been backfilled will be clean, dry and accessible for inspection. During the pressure testing of a pipeline each stop valve will sustain at least once, the full test pressure on one side of the valve in closed position with no pressure on the other side for a minimum of 15 minutes. Before testing a pipeline section shall be satisfactorily cleaned and filled slowly with water, taking care that all air is expelled. Purging of air from rising mains is to be facilitated by opening air valves. In order to achieve conditions as stable as possible for testing, the section is to be pressurised to 75% of the specified test pressure and held for a period of not less than 12 hours prior to the commencement of the pressure testing. The hydrostatic test pressure which will be applied to each section of the pipeline shall be such that at each point of the section the test head will be equal to or greater than the design head specified (including water hammer allowance) as shown on the approved engineering drawings, but shall not exceed the design head by more than 20 per cent. The test pressure for the purpose of testing the pressure main (and fittings) will be in kilopascals. Raise the pressure to the specified test pressure as long as required while the whole of the section is inspected, and in any case, not less than 4 hours. For the purpose of determining the actual leakage losses, the quantity of water added in order to maintain the pressure during the period of testing shall be carefully measured and recorded. 14.17.3 Allowable Leakage Tolerances The pressure testing of a section will be considered to be satisfactory if:a there is no failure of any thrust or anchor block, pipe, fitting, valve, joint or any other pipeline component; and there is no visable leakage; and
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the average measured leakage rate during the last 4 hours of pressure testing does not exceed the following maximum loss rate: Allowable loss rate (L/hr) = Where: D = L = H = 1.4 x 10-7 x D x L x H
pipe diameter (mm) pipeline length (m) average test head (m) on section under test
14.17.4 Repair of Leaks Any failure, defect, visable leakage and/or excessive leakage rate, which is detected during the pressure testing is to be rectified by approved means by the Developer at no cost to Council. The Developer shall remove and replace all such defects from the main under test by the use of gibault joints conforming to the requirements of this specification or other approved repair methods that provides equivalent joint movement and deflection as the original jointing system. In making good the pipeline no more than two (2) gibault joints or approved alternative fittings shall be permitted in any 250 metre section of pipeline under test. 14.18 COUNCIL ACCEPTANCE Acceptance of gravity mains, rising mains and all auxiliary works will be subject to the successful completion of all required testing and any necessary repairs carried out to the satisfaction of the Engineer. Such acceptance does not absolve the Developer/Contractor of their responsibilities regarding the works for the duration of the Maintenance Period. Refer Clauses 2.34 and 2.35. 14.19 14.9.1 MISCELLANEOUS Treatment of Redundant Sewer Systems Approval from the Engineer is required prior to any such works commencing. Redundant sewers shall be either; i totally removed and all disturbed areas backfilled, compacted and restored in accordance with the requirements of this specification, or have the contents drained and disposed of in an approved manner. The ends of such mains shall be adequately capped with mass concrete.
ii
Manholes shall have the top section/s removed to a height equivalent to the lowest chamber and then be filled with mass concrete. All disturbed areas shall be reinstated as in (i) above. The prefered treatment of redundant sewers that will probably have some form of building development over the same location will be as in (i) above.
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All associated fittings, marker posts/plates etc shall be removed and disposed of in an approved manner. Reinstatement of disturbed areas shall be as in (i) above. Where required, it shall be the Developers responsibility to obtain all necessary permits to enter and carry out the necessary works. Where easements for rising mains or private services exist they shall be extinguished in accordance with standard procedures current at the time at no cost to Council. The extent of mains and structures made redundant shall be shown on the works as executed drawings for submission to the Engineer.
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Chapter 14 - Sewerage Design & Construction Table of Contents

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Chapter 14 - Sewerage Design & Construction Table of Contents

SEWERAGE DESIGN AND CONSTRUCTION