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6. TESTING ............................................................................................................................... 11
6.1 Drainage and Sewer Pipework........................................................................................ 11
6.2 Water Test ...................................................................................................................... 11
6.3 Air Test ........................................................................................................................... 12
6.4 Manholes ........................................................................................................................ 12
6.5 Clear and Flush all Drains............................................................................................... 12
6.6 Test Programmes ........................................................................................................... 12
6.7 Records of Tests............................................................................................................. 12
7. DISPOSAL OF MATERIALS AND TEST FLUIDS .................................................................. 12

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1. SCOPE
The work covered by this Specification includes pipe bedding, laying and jointing of
concrete, ductile iron, GRP, plastic and carbon steel pipes, all materials used in the
construction of the underground drainage systems and surface water ditch systems.

The excavation of trenches for drainage and underground services is covered in

Specification for Earthworks, document no. 3280-45C2.

Contractor shall comply with all requirements and conditions set out in this
Specification.

2. REFERENCES
All materials and workmanship shall comply with the relevant sections of the latest
editions of the following Standards and Codes of Practice, unless otherwise specified
herein.

2.1 Project Specifications

3280-45C2 - Specification for Earthworks
3280-43C1 - Specification for Concrete Works
3280-83A4 - Coating and Wrapping of Buried Pipework

2.2 British Standards

BS EN 124 - Gullly tops and manhole tops for vehicular and pedestrian
areas – Design requirements, type testing, marking,
quality control

BS EN 545 - Ductile iron pipes, fittings, accessories and their joints for
water pipelines – Requirements and test methods

BS EN 598 - Ductile iron pipes, fittings, accessories and their joints for
sewerage applications – Requirements and test methods

BS EN 752 - Drain and sewer systems outside buildings

BS EN 771 - Specification for masonry units

Part 1 - Clay masonry units
Part 2 - Calcium silicate masonry units
Part 3 - Aggregate concrete masonry units (Dense and light-
weight aggregates)

BS EN 934 - Admixtures for concrete, mortar and grout.

Part 1 - Common requirements
Part 2 - Concrete admixtures - Definitions, requirements,
conformity, marking and labelling

BS EN 1401 - Plastic piping systems for non-pressure underground

drainage and sewerage.
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Part 1 - Unplasticized poly (vinyl chloride) (PVC-u). Specifications

for pipes, fittings and the system.

BS EN 1796 - Plastics piping systems for water supply with or without

pressure – Glass – reinforced thermosetting plastics
(GRP) based on unsaturated polyester resin

BS EN 1916 - Concrete pipes and fittings, unreinforced, steel fibre and

reinforced

BS EN 1917 - Concrete manholes and inspection chambers,

unreinforced, steel fibre and reinforced

BS 3506 - Specification for unplasticized PVC pipe for industrial

uses

BS 4962 - Specification for plastics pipes and fittings for use as

subsoil field drains

BS 5911 - Concrete pipes and ancillary concrete products

Part 1 - Specification for unreinforced and reinforced concrete
pipes (including jacking pipes) and fittings with flexible
joints
Part 3 - Specification for unreinforced and reinforced concrete
manholes and soak aways
Part 4 - Specification for unreinforced and reinforced concrete
inspection chambers
Part 5 - Specification for prestressed non-pressure pipe and
fittings with flexible joints
Part 6 - Specification for road gullies and gully cover slabs

BS 7159 - Code of practice for design and construction of glass-

reinforced plastics (GRP) piping systems for individual
plants or sites

BS EN 10224 - Non-alloy steel tubes and fittings for the conveyance of

water and other aqueous liquids - Technical delivery
conditions

BS EN 12620 - Aggregates for concrete

BS EN 13101 - Steps for underground man entry chambers –

Requirements, marking, testing and evaluation of
conformity

BS EN 13139 - Aggregates for mortar

BS EN 13253 - Geotextiles and geotextile-related products

characteristics required for use in erosion control works

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BS EN 13598 - Plastic piping systems for non-pressure underground

drainage and sewerage
Part 2 - Unplasticized poly(vinyl chloride) (PVC-U), polypropylene
(PP) and polyethylene (PE). Specifications for manholes
and inspection chambers in traffic area and deep
installations.

BS 14364 - Plastic piping systems for drainage and sewerage with or

without pressure. Glass-reinforced thermosetting plastics
(GRP) based on unsaturated polyester resin (UP).
Specifications for pipes, fittings and joints

3. MATERIALS

3.1 Materials for Concrete

Unless otherwise specified, all materials employed in the production of concrete shall
comply with requirements of Specification for Concrete Works document no. 3280-
43C1.

3.2 Pipework
3.2.1 General

All pipework supplied by Contractor, for use in the works, shall be obtained from an
approved Manufacturer. Contractor shall forward to the Engineer, certificates from the
Manufacturer certifying that the pipes and fittings have been tested and comply with
the appropriate standard, before despatch.

3.2.2 Concrete pipes

Concrete pipes shall comply with the requirements of BS 5911 or BS 1916 and the
strength class shall be as indicated on the drawing.

3.2.3 Steel Pipes (Unlined)

Steel pipes for the use in the surface water, hydrocarbon and chemical drainage
system shall be in accordance with BS EN 10224. Buried pipework shall be provided
with an external corrosion protection system and where necessary be cathodically
protected.

3.2.4 Steel Pipes (Internally lined)

Lined steel pipes for the use in contaminated, uncontaminated, hydrocarbon and
surface water systems shall be in accordance with BS EN 10224. Buried pipework shall
be provided with an external corrosion protection system and where necessary be
cathodically protected.

The type of internal lining will be dependent on the wastewater properties, operating
temperature and shall be in accordance with BS EN 10224 annex D.

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3.2.5 Ductile Iron (Cement Lined)

Ductile iron pipes for contaminated and uncontaminated systems shall be in

accordance with BS EN 598 with an external coating consisting of a layer of metallic
zinc covered by a finishing layer of either epoxy or polyurethane. In very aggressive
ground conditions additional corrosion protection may be required subject to approval
of the Engineer.

3.2.6 Glass Fibre Reinforced (GRP)

GRP pipes for sewage, surface water and certain chemical effluents shall be in
accordance with BS EN 1796. The resin type, pipe properties and construction shall
be considered in relation to the wastewater being carried and the surface / ground
loading criteria employed.

3.2.7 Plastic (Unreinforced)

uPVC pipes for uncontaminated and sewage systems shall be in accordance with BS
EN 1401.

3.2.8 Pipe Joining Materials

The method of installation and materials used for jointing of the different pipe material
types above shall be in accordance with the relevant Manufacturer's recommendations
and instructions, and shall be suitable for the expected operating conditions,
temperature range, differential settlement and wastewater expected within the system.

3.2.9 External Corrosion Protection

Steel pipes and fittings shall be provided with external corrosion protection in
accordance with Specification for Coating and wrapping of buried pipe work document
no. 3280-83A4

Where necessary, other metallic pipework including cast iron and ductile iron may
require additional protection in addition to that supplied by the pipe manufacturer.

Plastic, concrete and other non-metallic pipework shall not be protected.

3.3 Pipe Bedding & Surround Materials

For ductile iron and concrete pipe the bedding & surround material shall comprise of a
well graded readily compacted broken stone, crushed rock or gravel. All granular
material shall be single sized or graded in accordance with BS EN 12620 category

Pipe bedding & surround for carbon steel, GRP and uPVC pipes shall comprise of
natural sand well graded and free from contamination and deleterious material.

3.4 Manholes, Catchbasins, Sumps and Pits

Manholes and catchbasins shall be constructed utilising precast concrete rings and
cover slabs which shall comply with the requirements of BS 5911.

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Alternatively manholes, catch basins, sumps and pits may be constructed from either
engineering brickwork or in-situ concrete. Reinforcement size, spacing and location
shall be indicated on the drawings.

3.5 Manhole Covers and Catchbasin Gratings

Covers and gratings shall comply in all respects with the requirements of BS 124 and
shall be of the type, class and material indicated on the drawings or manhole schedule.
Catchbasin grating and frames may either be a manufactured item or site fabricated.
Proposed design and free flow area shall be submitted for approval prior to ordering or
fabrication.

3.6 Engineering Brickwork

Clay engineering bricks shall be Class B and comply with the requirements of BS EN
771-1. Bricks shall be bedded and jointed with 3:1 sand/cement mortar.

3.7 Waterstops
Waterstops installed in concrete structures shall be a proprietary PVC or rubber
material to provide a permanent liquid-tight seal. The type of waterstop shall be
selected in consultation with the manufacturer.

Pipes cast into or passing through drainage structures shall have a hydrophilic
waterstop bonded to the external face of the pipe located at the midpoint of the wall or
slab.

3.8 Sand for Mortar

Sand for mortar shall comprise a natural sand or crushed natural stone or a
combination thereof with naturally occurring sand, hard, clean and free of adherent
coatings. It shall comply in all aspects with BS EN 13139.

3.9 Mortar Plasticisers

Mortar plasticisers shall be at the discretion of the Engineer. All such plasticisers shall
comply with BS EN 934 and shall be used in strict accordance with the Manufacturer's
instructions.

3.10 Membranes
Geotextiles utilised for erosion control shall be in accordance with BS EN 13253.

Membranes used for secondary linings to effluents collection or treatment sumps,

retention ponds or manholes shall be resistant to the wastewater properties and
ground conditions.

3.11 Keys
Contractor shall provide and hand over to the Client at completion of the works, two
sets of lifting/locking keys to suit each specific pattern of installed manhole
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cover/grating.

4. HANDLING AND STORAGE OF MATERIALS

4.1 General
All materials shall be stored in such a manner as to protect them from deterioration and
contamination from whatever source.

4.2 Material for concrete

All materials used in the production of concrete shall be handled and stored in the
manner described in Specification for Concrete Works document no. 3280-43C1.

4.3 Pipework
All pipes and fittings shall be thoroughly inspected on delivery and again before being
placed in position. Throughout the operations of delivery, handling, storing and
transporting on or about the site, Contractor shall use such methods, plant and
equipment as will prevent damage to the pipes and to any coating. Impacts shall be
avoided. Ropes, cables and hooks shall not be used during handling. Instead, wide
straps shall be used and shall be of a length suited to the diameter of the pipes.

During storage, the pipes shall not be placed directly on the ground and shall not be
stored one on top of another. They shall be placed on wide timber bearers with
suitable interplacing of a protective material.

Coated and wrapped carbon steel, uPVC and PE pipework shall be protected from the
direct rays of the sun. To avoid damage to linings or pipes and fittings special care and
attention shall be taken when lifting, moving and placing pipe on site.

5. WORKMANSHIP

5.1 Trench Excavation

Excavation for underground pipework shall be carried out in accordance with
Specification for Earthworks document no. 3280-43C2.

5.2 Bedding
A bed of selected bedding material as specified in Clause 3.3 and shall be laid and
compacted to 100mm minimum thickness over the full width of the trench, where the
bed thickness is measured from the bottom of pipe to the trench bottom. The minimum
bed thickness shall be increased to 150mm in rock or hard soil conditions. The bed
shall be scooped out locally at pipe sockets where socketed pipes are used. The bed
thickness under sockets shall not be less than 50mm.

Alternative bedding types shall be considered where required by specific site

conditions.

Pipes shall be adjusted to line and level within tolerances specified in the design to
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ensure that pipe barrels rest uniformly on the bedding along their whole length. Where
sidefill is required, further selected backfill material shall be laid and compacted
uniformly by hand halfway up each side of the pipe.

5.3 Pipe laying

Before installation and prior to lowering into the trench the pipe shall be inspected for
defects. Any pipe or fitting found to be defective before or after laying shall be
replaced at no addition cost.

Pipe laying should commence at the downstream end of the system. Immediately
following the excavation of the trench, the pipe shall be laid and jointed in accordance
with the Manufacturer's recommendations and as detailed on the drawings. Joints shall
be undamaged and clean. Brick or other hard blocks, etc shall not be placed under the
pipes for temporary support.

Cutting of pipe shall be carried out with manufacturer’s recommended tools and
procedures. Damage to internal and external coatings and or linings shall be repaired
in accordance with manufacturer’s instructions.

The full length of each section of pipe shall rest solidly upon the pipe bed. A pipe that
has the gradient or joint disturbed after laying shall be taken up and relaid. Pipes shall
not be laid when trench conditions are unsuitable for the work. When work is not in
progress open ends of pipes, fittings and valves shall be securely closed so that no
water, sand or other substance will enter the pipes or fittings. Pipe ends left for future
connection shall be valved, plugged or capped.

Each length of pipe shall be laid in a dead straight line both in the horizontal and
vertical planes, the levels and/or gradients shown on the drawings being rigidly
adhered to, unless otherwise approved by the Engineer. Permanent adjustments to line
and/or level shall not be achieved by local packing. As the work progresses the interior
of the pipe shall be cleared of all superfluous materials. As soon as possible after the
joint is made, sufficient backfill material shall be placed along the pipe to prevent pipe
movement of line or grade and the invert level checked.

5.4 Trench Backfill

Bedding & surround material shall be laid in 100mm layers and hand compacted to a
level 150mm above top of pipe followed by selected backfill material placed and
compacted in 150mm layers. On completion of backfilling, surface finish shall be
installed / reinstated as indicated on drawings. Any trench sheeting should be
withdrawn as the work proceeds. Mechanical compactors shall not be used until there
is at least 450mm hand compacted cover over the crown of the pipes.

Where necessary, temporary bridges or additional surface protection shall be provided

over trenches to carry construction traffic and prevent damage to pipework after
backfilling.

5.5 Manholes etc.

Manholes, valve chambers, catchbasins, pump chambers etc., shall be constructed at
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locations indicated on the drawings and in accordance with the details shown.

Bases to manholes etc shall be cast in concrete and be 150mm minimum thickness.
The minimum size of the base shall be equal to the external dimensions of the
manhole chamber.

Concrete manholes shall be constructed with precast concrete sections complying with
the relevant requirements of BS 5911 or BS 1917 with ogee or similar approved joints.
A chamber ring with openings for the drain inlets and outlets shall be set vertically in
the manhole base, and subsequent sections added, as required, and set vertically, to
build the manhole up to surface level.

Care shall be taken to locate step irons in succeeding precast units vertically above
step irons in proceeding units.

All spun concrete manhole sections shall be supplied with mastic fillets at the joints to
provide watertight seals.

Bed the top pre-cast concrete section dry pending completion of surrounding levels.
Replace or adjust as necessary to give accurate and even final levels.

Flexible joints shall be provided on all rigid pipes projecting through manhole walls
positioned minimum 150mm from external face of walls where connected to drain runs
jointed with flexible joints.

5.6 Bedding Manhole cover Frames

Manhole cover frames shall be bedded as shown in the detail drawings.

All frames shall be solidly bedded so that the manhole cover is even with the
surrounding finished surface. Any installed cover or frame not level or that allows
rocking of the cover, shall be made level or replaced at Contractor's expenses.

5.7 Temporary Manhole Covers

Partly constructed manholes shall be provided with timber or metal temporary covers.
Building debris being allowed to accumulate in chambers shall require the associated
pipe runs to be rodded out at Contractor's expense.

5.8 Sealing Open Pipe Ends

All pipe open ends and terminations for later connections of pipes shall be securely
sealed, plugged or capped during progress of the works to prevent entry of foreign
matter. Plastic, shaped hardwood, metal plugs or drain plugs shall be used. Screwed-
up paper or cloth pushed into pipe ends will not be acceptable and shall not be used.

Building debris being allowed to accumulate in drains shall require rodding and clearing
out at Contractor's expense.

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6. TESTING

6.1 Drainage and Sewer Pipework

All drainage and sewer pipework shall be inspected and leak tested by Contractor in
the presence of the Engineer before haunching of the pipe and prior to backfilling and
again on completion before Contractor hands over the system. The initial visual
inspection shall include check of line and level, joints, damage or deformations and
linings / coatings.

The leak test shall comprise of either a water test in accordance with clause 6.2 or an
air test in accordance with Clause 6.3 of this Specification. Sections between manholes
shall be tested separately unless otherwise specified. All the necessary apparatus and
attendance for the test shall be provided by Contractor.

Pipework failing to satisfy the requirements of the water test shall be taken up, re-laid
and re-jointed as necessary and again tested to establish watertightness; at no extra
cost.

The drainage system shall not be deemed to have failed by means of an air test. A
water test should be carried out prior to the rejection of the system.

6.2 Water Test

Testing of sewers shall be as follows:-

- The section of the drain to be tested shall be suitability stoppered or

plugged at the end of connections. The test section shall then be filled with
water up to the ground level of either the downstream or upstream
manhole, as appropriate, but with a maximum pressure of 50 kPa and a
minimum pressure of 10 kPa measured at the top of the pipe. Steeply
graded drains shall be tested in stages where the above maximum
pressure would be exceeded if the whole section were tested at once.

- Unless otherwise agreed by the Engineer the test shall commence one
hour after filling the test section, at which time the water level in the feed
pipe shall be made up to produce the required test head. The test shall be
continued for sufficient time to allow the Engineer to inspect the pipeline
and satisfy himself regarding its watertightness and in any case for not less
than one hour.

- The pressure shall be maintained within 1 kPa of the test pressure by

topping up with water. The total amount of water added during the test shall
be measured and recorded with the head of water at the required test
pressure.

- The test requirement is satisfied if the amount of water added is not greater
than:

For clean un-contaminated systems:

a) 0.15 l/m2 during 30 min for pipelines;
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b) 0.20 l/m2 during 30 min for pipelines including manholes

Note. m2 refers to the wetted internal surface.

For Hydrocarbon or contaminated drainage systems no detectable loss

during the test shall be allowed, unless otherwise agreed with the Engineer

6.3 Air Test

The section of the drain to be tested shall be suitably stoppered or plugged. A
manometer shall be connected to one of the plugs and air pressure source shall be
applied to another plug. Pressure shall be applied either by mouth or with a hand
pump to achieve 100mm water gauge. The test apparatus should be left for a
minimum of five minutes.

The system is deemed to have passed the test if there is no fall in the head of water
during the test period.

6.4 Manholes
Each manhole shall be tested for watertightness in the presence of the Engineer by
filling with water to a level not exceeding 1.2m above the pipe soffit level or to ground
level. Contractor shall be responsible for locating, making good any leakages and the
work will be accepted as satisfactory only when a visual inspection for watertightness
reveals no leaks or external damp patches. This test is to be carried out prior to the
placing of the backfill material.

6.5 Clear and Flush all Drains

At completion of the works Contractor shall clear out and flush all drains, manholes etc
with clean water, rodding through drains where necessary to ensure clearance of
debris and leave the system in clean working order with all traps sealed with water.

6.6 Test Programmes

Contractor shall submit to the Engineer, for his prior approval, a testing programme for
all underground drainage and sewerage systems.

6.7 Records of Tests

Contractor shall keep a complete record of all tests carried out after installation and
shall supply the Engineer with a copy of the records as the testing proceeds and at the
end of the Contract, or as otherwise requested by the Engineer. Contractor shall
submit for approval a test record sheet and his proposal for an underground drainage
and sewerage Construction Records Dossier.

7. DISPOSAL OF MATERIALS AND TEST FLUIDS

Contractor shall leave all parts of the site in a clean, tidy and sound condition.
Contractor shall dispose of all materials and test fluids in accordance with local
regulations.

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