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Stanton Bonna was formed in 1989 as a loint venture beiween the Concrete Division of

Stanton PlC and Bonna, the largest manufacturer of precast concrete products in Europe

The amalgamation has enabled Stanton Bonna and its customers to benefit from over 170

years combined experience in the production of high quality precast concrete products for the

sewerage and drainage markets

The centrally located complex at Stanton-byDale near Noitingham is ideally positioned to

serve UK customers quickly and efficiently and substantial investment has taken Stanton Bonna

to the forefront of concrete pipe and manhole manufacturing technology. The result is the

Vi-KingTM range renowned for the highest standards of vertically cast vibrated products.

Stanton Bonna's expertise in precast concrete products has resulted in diversification into the

power, rail and street lighting markets. The company has subsequently established market

leading positions for its concrete pressure pipe for power stations, twin block railway sleeper

for linht rnil systems, concrete street lighting columns nnrl G P sewer rpnnvntion units. R

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Utilising modern computerised manufacturing equipment, Vi-KingTM pipes uriu iriuiiholes are vertically cast in steel moulds with a semidry concrete mix which is compacted by sophisticated vibration patterns. The result is consistently high quality products with sharply defined joint profiles.

All Stanton Bonna's products are available to meet classes of sulfate attack as defined in
BRE Digest 363 1996 as detailed in the table below.

OPC OPCIPFA SRC

Products manufactured using ordinary Portlanu ~eiiieiii BS 12 to Products manufactured using a combination of OPC to BS 12 and pulverised fuel ash to BS 3892 Part 1 . Products manufactured using sulfate resisting Portland cement to

BS 4027.

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Stanton Bonna offer an extensive range of precast concrete flexible joint pipes from DN 300 to DN 1800 including bends,.junctions (see pages 8 and 9), rocker and butt pipes.

H Vi-KingTM pipes are vertically cast using vibration to


compact a semi-dry concrete mix into the mould. Spun pipes are centrifugally spun in a mould to produce a highly compacted product.

H Vi-KingTM pipes employ a unique Delta gasket which,


compared to a circular gasket, requires lower jointing forces and offers increased resistance to withdrawal after jointing.

Gaskets are manufactured in SBR or EPDM and comply with BS 2494, other types of joint gasket material (including nitrile compound) can be supplied on request.

Vi-KingTM pipes will not joint to any other cast or spun pipes.

Actual bore sizes available on request

Nominal Size of Pipe

Maximum Allowable Angular Deflection

Maximum

DKW

DN

300 - 600
675 - 1200

*As defined in BS 591 1 : Part I O U

1350 - 1800

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Concrete Pipes Data


I
Size o f Pipe

Pipe Dimensions class n


External Diameter Effective. length Socket J A J '' mm B ~ ~ Barrel Th mm ID' mm

Peiivery uetai

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wu!

ig iest Loaas K

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N / ~

DN
I

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,
I

kg

300 575 450


~~

2500

48; 567 670 79: 87( 968 1056 13( 241

I 2500 I
2500 2500 2500 2500 2500

'

410 '.85 578

55
5F

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1
1

510 I39/47 715 128/33


"

64

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20 25 25 25 3. 38 44

I 20
I

525 600 675 750

48

% 6

25 25 48 52 58 60 64 72 79 87 94 96 10.
111

j8 -Y

1080

9q0
85
1O! -

50 53

5 3 67
I

6: 72

84 90

1 5

1(

975*

I 2438

310

I 1145
1260 1440

I970 I110/12
~

%--+-E1740 95( 11600

1 48
51 58 63 69 75

91

114

/8 5 5/6

120 150 150 160

138 153

I 1680
1800 1920

4550 5134 558

'

4/5 /4 /4

120
1 ,?n
143

22

2500

98(

183 198

124
a

155
-

58

'Spun pipe

Standard bends are available at angles of 1 1 '/doand 22'/z0. Bends of

45O and 9 ' are available dependent 0


on diameter (see table below). Bends having nonstandard angles up

to 900can be manufactured on request


dependent upon diameter. Bends are of polygonal construction (cut and stuck from two or three pipe pieces). Dimensions and leg lengths available on request.

Bends are not designed as load bearing structures and should be encased in Q suitably designed in-situ concrete surround.

TO10598 0000252 255

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Bends and Junctions

Junctions are provided with

DN 100, 150 and 225 Densleeve

N clay branches to BS E

295

or with

concrete socket or spigot branches for DN 300 and above. Branches are fitted to full length pipes using cementitious or resin mortars.

Full dimension details of junctions


and backdrop junctions are available on request.

Junctions are not designed

as load bearing structures


and should be encased in a suitably designed in-situ concrete surround.

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Stanton Bonna offer a range of microtunnellingpipes suitable for installation by modem microtunnellingtechniques.
The joint incorporates the well proven steel collar and elastomeric sealing gasket to ensure a watertight joint. Mild steel collars are provided with a paint coating. Pipes with stainless steel collars can be supplied on request. Pipes are manufactured to produce accurate joint surfaces with square faces and a strong high density concrete with a smooth surface finish to assist in reducing jacking forces.

Full technical details including pipe


dimensions, packing details and allowable jacking loads are available on request. The diameter range is being extended to suit market requirements and enquiries are welcomed for diameters/lengths not detailed.

lnterjack stations with integral cans are available for DN 900 and DN

975 pipes.

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Internal

External r H e c t i \ = T p p r o x i r n a t e

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3 AA

TO10578 000025Y 0 2 8

Manhole 8t Soakaway Rings

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Vi-KingTM chamber rings are manufactured with tongue and groove joints designed to accommodate cement mortar or 'Tokstrip' flexible jointing compound (see page 14). Shaft and chamber sections for all diameters are supplied with galvanised malleable iron steps to BS 1247 as required. ladders can be supplied on request. Chamber rings can alternatively be supplied with single or double plastic encapsulated mild steel steps which conform to BS 1247 and Water Industry Specification 4-330 1

-t4vailable

Depth o f Section in mm

Lifting
Thickn
Holes

'ind.stem

2400

2700

900

1200
1350

4 __.
A

1800

6 6
8 4 4

00

2400
2700

3000

Designed to replace engineering bricks


to seat a cast iron cover and frame.

4 Effective thickness is 67mm i.e. the


thickness o a standard brick course. f

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Average compressive strength similar to Class B engineering bricks. Standard access hole is 600mm square.

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Overall diameter is 1065rnm. Each seating ring is reinforced and weighs 73kg.

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Cover slabs are heavy duty reinforced. Supplied with standard 600mm or 675rnm square access hole to suit chamber rings o DN 900 and above. f Circular or non-standard access

openings can be made to special order.

Cover Slabs Data

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Cover Slabs & Reducing

Slabs _._.-.-._._._._._._._._.

Reducing Slabs
Reducing slabs are available to suit

f chamber rings o DN 1200 and


above. Reducing slabs are supplied with a cast-in step iron and have an effective thickness of 250mm

Reducing Slabs Data

'

Nominal DiarFter umber

0
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200
1350 1500

Diameter Overall

zT 7

'A' mm

800

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Reinforced landing slabs are available

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I N o m i n a l I meter

for use in deep manholes. Landing slabs have an effective thickness of 160mm for DN 1500 and 200rnrn for DN 1800 to 3000.

Landing Slabs Pata


vera Diameter

TO10578 0000257 837

Vi-KingTM manholes are designed and manufactured to provide accurate joint profiles with a high quality finish and when used in conjunction with 'Tokstrip' flexible jointing compound, will enable the contractor to construct watertight manholes quickly, without the need for concrete surround. 'Tokstrip' is approved for such applications by the Department of the Environment and the Ministry of Agriculture Fisheries and Food and

the use of 'Tokstrip' with precast concrete units is strongly urged on engineers in the Reports of the Working Party on the Construction and Design of Underground Pipe Sewers so that the high costs of insitu concrete surrounds can be avoided.

1994, DOEWorking Pariy on Sewers and


Water Mains Report 1975 and is specifically endorsed by laxton's General Specification

1996, Scottish Association of Directors of


Water and Sewerage Services and DOE Northern Ireland Standard Specification for Water and Sewerage Schemes (3rd edition)

This method of construction meets the


requirements of Building Regulations 1992 Building Standards [Scotland) Regulations

1989, Water Services Association Civil


Engineering Specification for the Water Industry (4thedition) 1993, BS 8005 (Sewerage) 1987 and BS 8301 [Building Drainage) 1985. The use of the Vi-KingTM precast concrete products with 'Tokstrip' flexible jointing compound also meets the requiremenk of Water Authorities Association specification Sewers for Adoption (4th edition) 1995.

1990, DTp Specification for Highway Works

Kiternarked gullies made to

BS 591 1 :

Part 230 are available and can be supplied with adaptors for connection to clay or plastic pipes. Gully cover slabs are available with a

DN 450 or DN 375 access.

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Slabs are 1 OOmm thick and weigh approximately 80kg.

TOL0578 0000258 773

Manhole Construction

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Manhole Construction
The in-situ base must be levelled to provide a vertical manhole chamber. Install chambers and shaft sections vertically and in the correct sequence to ensure proper positioning of the steps [see notes below). Sections of 0.75m depth should only be used:a) as a single section manhole be used in any combination (but not immediately above a reducing slab). Sections of 0.25m depth should only be used:a) as the manhole top section

Sections of 1 .Om and 0.5m depth may

b) immediately below a landing slab


c) immediately above a reducing slab as a shaft section

d)

two sections together at any position.


Seating ring Cover slab

b)

as a manhole base section

c) immediately above a landing slab

d)

immediately above a reducing slab as a shaft section.

0.25, 0.50, 1.OO

- Shaft
0.50, .OO 1

sections (m)

0.25,0.75
Reducing slab

0.50, 1.00

0.50, 1.00

Chamber sections (m)

0.25,0.50

0.75, .OO 1
landing Slab

0.25,0.50,.OO 1

- Chamber
0.50, 0.75, .OO 1

sections (m)

In-situ base

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Volume 1 of Tables for the hydraulic design of pipes, sewers and channels: 6th Edition. Sewers for adoption 4th Edition.

British Standards
B E I S 0 9002: 1994. Model for S N quality assurance in production, installation and servicing.

(WRC/WSA).
Civil engineering specification for the water industry. 4th Edition. (WRC/WSA).

BS 591 1 : Precast concrete pipes, fittings


and ancillary products.

BS 1 2: 1996. Specification for Portland


cement.
I

A guide to design loadings for buried rigid


pipes. (TRRL/HMSO 1983). Simplified tables of external loads on buried pipelines. (TRRL/HMSO 1986).

BS 1247 Part 1 : 1990. Specification for


galvanised ferrous or stainless steel manhole steps.

BS 4027: 1996. Specification for sulfate


resisting Portland cement.

BRE Digest 363. Sulfate and acid


resistance of concrete in the ground.

BS 4482: 1985. Specification for cold


reduced steel wire for the reinforcement of concrete.

(BRE 1996).
Water Industry Specifications 4484 1 . Imported granular and selected asdug bedding and side fill materials for buried pipelines. Water Industry Specification 4-1241 . Precast concrete pipes - unreinforced and reinforced, with flexible joints. Manual of Contract Documents for Highway Works. (Departmentof Transport

BS 882: 1992. Specification for


aggregates from natural sources for concrete.

BS 2494: 1990. Specification for


elastomeric seclls for joints in pipework and pipelines.

BS 8005: Part 1 : 1987. Guide to new


sewerage construction.

HMSO).

BS 8010: Part 2. Pipelines on land:


design, construction and installation.

BS 830 1 : 1985. Code of practice for


building drainage.

01
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H Trench design and preparation has an


important bearing on the strength of the pipeline and it should be constructed fully in accordance with the contract specification and drawings.

Soft areas, local hard spots or boulders


in the bed should be dug out and the level restored using well-tamped granular material.
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H Disturbance of wet finegrain soils such


as clay, silts and fine sands in the trench bottom should be avoided.

H The pipe laying contractor should take


all precautions required by statutory regulations, or any dictated by actual circumstances, to ensure the safety of the public and the pipe layers when handling pipes, digging trenches, jointing pipes and backfilling.
I

H Drainage of the pipe trench or the


provision of a blanket of coarse granular material confined within a trench mat may be needed.

TO10598 00002b0 3 2 1

Product Health & Safety Data

0
1. P d u c t s
Precast concrete drainage units manufactured to various parts of BS 59 1 1 . Pipes and fittings for domestic and industrial sewerage, highway and agricultural drainage. Pipes for installation in trench (or by jacking) together with manholes, soakaways, slabs and road gullies. Protective gloves should be worn when handling products. Eye protection and respiratory masks to the relevant British Standards must be worn when cutting or drilling products. Care should be taken to chock pipes securely to prevent movement, particularly if products are stacked. risk of impact damage. Such dust if containing quartz and if inhaled in excessive quantities over extended periods can constitute a long-term health hazard. Products are generally cylindrical and can roll on uneven or inclined surfaces.

4. Precauiions

2. Physical and Chemical


characteristics.

Concrete unreinforced or reinforced with steel bars, mesh or steel cylinder. Concrete manufactured by the compaction of coarse and fine aggregates, cementitious material and water which subsequently undergo a curing process. Elastomeric sealing gaskets and cast iron steps.

5. Transport and Disposal


The transportation of these products is not subject to hazardous substance conveyance regulations and vehicle labelling is not required. The haulier is responsible for ensuring loads are secure to prevent movement in transit. Precast concrete products are inert, but should be disposed of in accordance with local legal requirements. Rubber gaskets are inflammable and if burned will give off toxic fumes.

3. Main Hazards
The principal hazards associated with these products concern handling and cutting. Concrete has a hard textured finish which may cause abrasions to the hands when handled. Excessive handling can also cause skin irritation and dermatitis. The cutting and drilling of concrete will create fine dust and can also project particles at high velocity with consequent

Handling

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Pipes should not be lifted by chains passed through the bore. Pipes should not be dropped or subjected to impact. Gaskets should be stored without ties and protected from sunlight, oil, grease and heat.

Deliveries are usually in 24 tonne loads. The receiver is responsible for all off loading. See pages 19 and 20 for details of the toc-King lifting and jointing system for DN 13501800 Vi-KingTM pipes.

H Use of correct off-loading equipment on


site is essential to ensure a safe operation and avoid damage to pipes.

Pipes should be stacked neatly on level ground on wooden chocks up to the height stated in the table below.

w A properly designed "C" beam or


broad banded canvas/fabric slings with a central lift should be used.

DN

Max. Number of Layers

no0 - 375

450 - 6 0 ~
-

675 - 975
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Laying and hinting

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The spun pipe gasket must be positioned on the end of the spigot During jointing the pipe should be supported at its point o balance and f positioned clear of the trench bottom. Care must be taken not to displace the gasket as the spigot is entered into the socket.

Before jointing, each pipe should be examined for damage and the jointing surfaces and gasket thoroughly cleaned.

The Vi-KingTM pipe incorporates a flexible rolling gasket joint which uses the unique Delta shaped gasket.

Care must be taken to ensure the Delta gasket is positioned on the spigot end without twists. The flat face of the Delta gasket is marked with a white line.

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Lubricants must not be used. Before pushing the joint home, ensure pipe ends are square with each other to allow even gasket roll.

The gasket must be positioned on the spigot and against the locating step with the white line facing away from the spigot (see illustration].

1 All necessary jointing tackle can be


supplied by Stanton Bonna at a nominal charge which is credited on return of the tackle. Alternative methods of joint assembly may be used, provided the spigot entry is steady and controlled to line and level.

I Jointedspun pipe cross section

H The spun pipe joint is a selfaligning


flexible roll ring joint incorporating an

' 0 ring gasket.

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Loc-King lifting & Jointing Systei

The Loc-King lifting and jointing


system when used in conjunction with %KingTM pipes DN1350 and above offers these major advantages:

Safe Handling
The Loc-King lifting eyes engage securely and provide a horizontal lift every time. Once engaged, the lifting eyes cannot disengage under load.

Speed Off loading, site handling and pipe


jointing with Loc-King is much faster than with traditional tackle and no weight balancing is required.

Cost Effective
Compared to traditional methods, the speed, safety and pipe laying efficiency of the Loc-King system generates savings in time, plant and labour.

1 The Chain Set .


The Loc-King system comprises lifting anchors cast into the pipe wall and a special three legged chain set (Fig. 1 J with lifting eyes which connect to the anchors for lifting and jointing operations.

2 Engoging the eye .


T engage a lifting eye with a lifting o

anchor simply place the eye opening over the anchor head and rotate the eye tail until it touches the pipe surface.

Correct engagement of the lifting eyes is essential prior to any lifting or jointing operation and the spare lifting eye should be secured to a shortening clutch to avoid accidental damage or injury.

3 Disengaging the eye .


T disengage a lifting eye, slacken the o chain set and rotate the eye tail away from the pipe surface until the eye can be lifted off the anchor head.

4 lifring and Handling


Position the crane's top guide pulley centrally between the lifting anchors and engage chain A with the socket end anchor, B with the spigot end anchor and secure C to its shortening clutch (Fig.4). During lifting the included angle between chains must not exceed 60".

General Advice
Pipes must be handled, stored and installed by persons trained in safe practices for these tasks. Chain sets are supplied having been tested in accordance with the Construction (lifting Operations) Regulations 1961. Users should have a current test certificate and certificate of examination as appropriate and should check equipment daily for obvious damage before use. If equipment is subjected to excessive shock load or abuse it should be taken out of use, reexamined and tested. Vi-KingTM junctions, bends, rocker and

5 Jointing
Lift the pipe, lower it into the trench and
enter the pipe spigot into the socket of the last laid pipe. Disengage chain A and secure to its shortening clutch. Position the crane's top guide pulley over the socket of the last laid pipe and engage chain C with the spigot end anchor (Fig.5). Take up any chain slack and continue lifting slowly to joint the pipes. Adjust the pipe to line and level and check for the recommended joint gap. Disengage the lifting eyes and repeat the lifting and jointing operations as necessary to complete the pipeline.

butt pipes require jointing by traditional


methods. Rocker and butt pipes may be lifted using the single cast in anchor.

Anchor Recesses
Before backfilling, clean and make good anchor recesses flush to the pipe barrel surface with epoxy or polyester resin or a 1 :3 cement sand mortar proportioned by mass.

Manhole Ring & Slab Handling

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Manhole Ring & Slab Handling


/

Deliveries are usually in 24 tonne loads. The receiver is responsible for all off loading.

Lifting holes are 40mm diu for

Chamber rings should be stored vertically to prevent them from rolling or toppling. Slabs are manufactured with three lifting eyes and should be lifted level using suitable three legged chains. Slabs should be stored flat, right side

DN 900-1500 chamber rings, 45mm for DN 1 800.2 100 rings and


50mm for DN 2400-3000 rings.
Chains should be attached to lifting eyes on the inside of chamber rings and the chain angle should not exceed 45" to the vertical.

Chamber rings must not be lifted by attaching lifting equipment to steps. Chamber rings should be lifted with suitable lifting equipment for example chains and quick release lifting eyes which are available on request.

up on suitable timber bearers at stack


heights not exceeding those detailed below.

O F -

2100-

Quick release lifting eyes and chains are available to enable rapid handling and jointing of Vi-KingTM manhole chamber rings.

All lifting equipment is supplied


having been tested in accordance with the Construction (Lifting Operations) Regulations 1 96 1 .

Sewers up to DN 750 should be subjected to air or water tests which accord with BS 8005 Part

T air test, seal the pipeline at each o end and any junctions with

Allow a further

5 minutes to elapse

without pumping, the water head should not drop below 75mm water gauge.

1 . For

inflatable test stoppers. Attach


a U tube (manometer]and pressurise to slightly above 1 OOmm water gauge. Allow

sewers above DN 750 special equipment may be required however a visual inspection is normally considered sufficient.

If the water head drops more than


25mm investigate the possible causes, for example air temperature change, dryness of the pipe wall, faulty stoppers or test equipment. A solution of soap and water may be used to assist in the detection of leaks.

5 minutes for air temperature

Where the pipeline is below the water table the air test is not effective and an infiltration test should be used.

stabilisation and adjust the pressure back to 1 OOmm water gauge. The air test is temperature sensitive and a

1 "C change in air temperature will


result in a change of approximately 38mm in the water gauge.

H The pipeline should be air tested at


least after every third or fourth pipe laid, prior to backfilling.

Stockist network
Manholes and gullies are stocked countrywide by merchants to support local demand. Pipes are also stocked by certain stockists at nominated locations.

Lifting equipment
lifting chains, eye bolts and fabric slings can be supplied for safe product handling.

Crane off load


Crane off loading facilities can be

Technical support
Technical advice can be provided by qualified staff either on site or from head office.

provided.

Jointing compound
'Tokstrip' can be supplied to suit all manholes (see page 14).

Sales support Plastic encapsulated steps


Rapid response quotations can be provided by experienced sales staff. Double width plastic encapsulated steps (rungs)can be supplied loose or fitted to manhole rings (see page 1 1).

t J

Special products
Specials can be manufactured to customers designs.

Manhole scheduling
Manholes can be scheduled and

Loc-King system
Lifting and jointing equipment can be supplied for D N 1 350 - 1800 Vi-KingTM pipes (see pages 19/20).

numbered to customers requirements

The following literature for concrete drainage products is also available on request by e-mail, fax or telephone. Concrete Drainage Products Selector

Technical literature
Background and technical literature by the Concrete Pipe Association and the Pipe Jacking Association. Technical Data Sheets on: Bends and junctions for flexible joint pipes; Sulfate resistance of concrete products to BRE Digest 363; Site installation procedure for plastic encapsulated double steps;

A wall chart for site and office use.


lac-King User Guide

A five point user guide for site use


Site Information
An information sheet sent to all sites.

Maximum allowable.iacking loads and jointing instructions for microtunnelling pipes.

I TU10578 U0002bb BLfT

TOL0578 0 0 0 0 2 b 7 78b

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Tel:
Fax:

01 15 944 1448
0115 944 1466

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E-mail: sales@stanton-bonna.co.uk
OFFICE HOURS 8.30am

- 5.00pm

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Member of the Concrete Pipe Association

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(P
Member of the Pipe Jacking Association

Stanton Bonna Concrete littlewell Lane Stanton by Dale IIkeston Derbyshire

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DE7 4QW

Ref CDP 05/97