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1' TOL057A 0000245 O L 5 - E " , -_

', 1 I Civil r

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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 GRP sewer rpnnvntion units.

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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

Products manufactured using ordinary Portlanu ~eiiieiii to BS 12

Products manufactured using a combination of OPC to BS 12 and pulverised fuel ash to BS 3892 Part 1 .

SRC 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.

H 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.

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

pipes.

w Actual bore sizes available on request

Nominal Maximum Maximum

Size of Pipe Allowable DKW Angular

Deflection DN

300 - 600

675 - 1200

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

1350 - 1800

a

a

a

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I Concrete Pipes Data I I I I I

I-WIIIIIIW Pipe Dimensions class n Peiivery uetai ' ig iest Loaas K N / ~ Size of I

Pipe External Diameter

DN J A J ~ ~ 'B' mm 'c' mm ID' mm kg

Effective. length Socket Barrel Th

- 300 2500 48; , 410 55

wu!

I I I I I I I - 25

25 3. 44

25 38 I 48

j8 25

25 50 53

48 53 67

52 I

58 6: 84

60 72 90

1 2500 ! 670 I 578 I 64 I 715 128/33 I 20 450

- -

575 I 2500 I 567 ' '.85 I 5F 1 510 I39/47 ' 20

~~

I 1 " 1 I

6% 525 2500 79:

600 2500 87(

675 2500 968

750 2500 1056

Y -

9q0 1080

13(

241 -

15 1(

91 114

0 138

975* I 2438 310 I 1145 85 - I970 I110/12 1 48 ~

%--+-E- /8 51 64

5 5/6 58 72

4550 4/5 63 79 96 120

5134 ' /4 69 87 10. - 558 /4 75 94 111

1 O!

120

150 I 150

- 1260

1440

1740 I 1680

95( 1800

98( 1920

22 153

1 ,?n

143 160 11600 1 2500 4 183

58 198 124 155 a -

'Spun pipe

Standard bends are available at

angles of 1 1 '/doand 22'/z0. Bends of

45O and 90' are available dependent

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 Bends and Junctions -._._._._._._._._._._._.

Junctions are provided with

DN 100, 150 and 225 Densleeve

clay branches to BS EN 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 microtunnelling pipes suitable for

installation by modem microtunnelling techniques.

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.

w lnterjack stations with integral ’cans’

are available for DN 900 and DN 975 pipes.

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.

7 Internal 1 External r H e c t i \ = T p p r o x i r n a t e

I a 7nn 3 AA E I 0 7 K I

Manhole 8t Soakaway Rings -.-._._._._._._._._.-.-.- m TO10578 000025Y 0 2 8

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

Thickn -t4vailable Depth of

Section in mm 'ind.stem I

Lifting Holes

2400

2700

900

1200

1350

1800

00

2400

2700

3000

4

A __.

6

6 -

8

9 - 4

4

Designed to replace engineering bricks

to seat a cast iron cover and frame.

4 Effective thickness is 67mm i.e. the

thickness of a standard brick course.

w Average compressive strength similar to

Class B engineering bricks.

w Standard access hole is 600mm

square.

w Overall diameter is 1065rnm.

w Each seating ring is reinforced and

weighs 73kg.

.. Cover slabs are heavy duty reinforced.

Supplied with standard 600mm or

675rnm square access hole to suit

chamber rings of DN 900 and above.

w Circular or non-standard access

openings can be made to special

order.

Cover Slabs Data

Cover Slabs & Reducing Slabs _._.-.-._._._._._._._._. W TOL0598 000025b 7 T O

0 - Reducing Slabs

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Reducing slabs are available to suit

chamber rings of DN 1200 and

above.

Reducing slabs are supplied with a

cast-in step iron and have an effective

thickness of 250mm

I Reducing Slabs Data ' Nominal

DiarFter 1 Diameter Overall 1 zT 7 umber 'A' mm

200 1350 + 1500 - 800

J Reinforced landing slabs are available

for use in deep manholes.

Landing slabs have an effective

thickness of 160mm for DN 1500 and 200rnrn for DN 1800 to 3000.

I Landing Slabs Pata

I N o m i n a l vera I meter Diameter

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

TO10578 0000257 837

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.

This method of construction meets the

requirements of Building Regulations 1992

Building Standards [Scotland) Regulations

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.

Slabs are 1 OOmm thick and weigh

approximately 80kg.

1994, DOE Working 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)

1989, Water Services Association Civil

Engineering Specification for the Water

Industry (4th edition) 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.

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m TOL0578 0000258 773 m Manhole Construction -.-.-.-.-.-.-.-.-.-._._.

Manhole Construction I 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

b) as a manhole base section

c) immediately above a landing slab

Sections of 1 .Om and 0.5m depth may

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

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

0.25, 0.50, 1 .OO

d) immediately above a reducing slab a as a shaft section.

0.50, 1 .OO

0.25,0.75

Reducing slab

0.50, 1.00

0.50, 1.00

- Shaft sections (m)

Chamber sections (m)

0.25,0.50

0.75, 1 .OO I I

landing Slab

0.25,0.50, 1 .OO

0.50, 0.75, 1 .OO

In-situ base

- Chamber sections (m)

Volume 1 of Tables for the hydraulic design

of pipes, sewers and channels: 6th

Edition.

Sewers for adoption 4th Edition.

(WRC/WSA).

Civil engineering specification for the

water industry. 4th Edition. (WRC/WSA).

A guide to design loadings for buried rigid

pipes. (TRRL/HMSO 1983).

Simplified tables of external loads on

buried pipelines. (TRRL/HMSO 1986).

BRE Digest 363. Sulfate and acid

resistance of concrete in the ground.

(BRE 1996).

Water Industry Specifications 4484 1 . Imported granular and selected asdug

bedding and side fill materials for buried

pipelines.

Water Industry Specification 4-1 241 . Precast concrete pipes - unreinforced and

reinforced, with flexible joints.

Manual of Contract Documents for

Highway Works. (Department of Transport

HMSO).

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.

H The pipe laying contractor should take

all precautions required by statutory

regulations, or any dictated by actual

circumstances, to ensure the safety of I

the public and the pipe layers when

handling pipes, digging trenches,

jointing pipes and backfilling.

W TO10578 0000259 bOT W ~-

British Standards

BS EN I S 0 9002: 1994. Model for

quality assurance in production, installation

and servicing.

BS 591 1 : Precast concrete pipes, fittings

and ancillary products.

BS 1 2: 1996. Specification for Portland

cement.

BS 1247 Part 1 : 1990. Specification for

galvanised ferrous or stainless steel

manhole steps.

BS 4027: 1996. Specification for sulfate

resisting Portland cement.

BS 4482: 1985. Specification for cold

reduced steel wire for the reinforcement of

concrete.

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.

BS 8010: Part 2. Pipelines on land:

design, construction and installation.

BS 830 1 : 1985. Code of practice for

building drainage.

1 :r --

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Soft areas, local hard spots or boulders

in the bed should be dug out and the

level restored using well-tamped

granular material.

H Disturbance of wet finegrain soils such

as clay, silts and fine sands in the

trench bottom should be avoided.

, I , 1 . .. :

H Drainage of the pipe trench or the

provision of a blanket of coarse

granular material confined within a

trench mat may be needed.

Product Health & Safety Data TO10598 00002b0 3 2 1

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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.

2. Physical and Chemical characteristics.

0 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.

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 @

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

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.

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.

Handling

w 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 13501 800 Vi-KingTM pipes.

H Use of correct off-loading equipment on

site is essential to ensure a safe

operation and avoid damage to pipes.

w A properly designed "C" beam or

broad banded canvas/fabric slings

with a central lift should be used.

w Pipes should not be lifted by chains

passed through the bore.

w Pipes should not be dropped or

subjected to impact.

w Gaskets should be stored without ties

and protected from sunlight, oil, grease

and heat.

w Pipes should be stacked neatly on level

ground on wooden chocks up to the

height stated in the table below.

DN Max. Number of Layers

no0 - 375

450 - 6 0 ~

675 - 975 2 -

,Le\,, 0 7 K

Laying and hinting

w Before jointing, each pipe should be

examined for damage and the jointing

surfaces and gasket thoroughly

cleaned.

w The Vi-KingTM pipe incorporates a

flexible rolling gasket joint which uses

the unique Delta shaped gasket.

w 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.

w The gasket must be positioned on the

spigot and against the locating step

with the white line facing away from

the spigot (see illustration].

H The spun pipe joint is a selfaligning

flexible roll ring joint incorporating an

'0 ring gasket.

w The spun pipe gasket must be

positioned on the end of the spigot

w During jointing the pipe should be

supported at its point of balance and

positioned clear of the trench bottom.

Care must be taken not to displace the

gasket as the spigot is entered into the

socket .

w Lubricants must not be used.

w Before pushing the joint home, ensure

pipe ends are square with each other

to allow even gasket roll.

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.

1

I Jointed spun pipe cross section I

Loc-King lifting & Jointing Systei -.-.-.-.-.-.-.-.-.-.-.-.-

The Loc-King lifting and jointing system when used in conjunction with %KingTM pipes DN 1350 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

To engage a lifting eye with a lifting

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

To disengage a lifting eye, slacken the

chain set and rotate the eye tail away

from the pipe surface until the eye can

be lifted off the anchor head.

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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

butt pipes require jointing by traditional

methods. Rocker and butt pipes may be

lifted using the single cast in anchor.

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".

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.

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.

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Manhole Ring & Slab Handling -.-.-.-.-.-.-.-.-.-._._.

Manhole Ring & Slab Handling /

Deliveries are usually in 24 tonne Lifting holes are 40mm diu for

DN 900-1 500 chamber rings,

45mm for DN 1 800.2 100 rings and

50mm for DN 2400-3000 rings.

loads. The receiver is responsible for

all off loading.

w Chamber rings must not be lifted by attaching lifting equipment to steps. 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 should be lifted with

suitable lifting equipment for example

chains and quick release lifting eyes

which are available on request.

O F -

= 2100- -

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

up on suitable timber bearers at stack

heights not exceeding those detailed

below.

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 .

Allow a further 5 minutes to elapse

without pumping, the water head

should not drop below 75mm water

Sewers up to DN 750 should be

subjected to air or water tests which

accord with BS 8005 Part 1 . For

sewers above DN 750 special

equipment may be required however

a visual inspection is normally

considered sufficient.

w Where the pipeline is below the

water table the air test is not effective

and an infiltration test should be

used.

H The pipeline should be air tested at

least after every third or fourth pipe

laid, prior to backfilling.

w To air test, seal the pipeline at each

end and any junctions with

inflatable test stoppers. Attach

a U tube (manometer] and pressurise

to slightly above 1 OOmm water

gauge.

Allow 5 minutes for air temperature

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.

gauge.

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.

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Stockist network

Manholes and gullies are stocked

countrywide by merchants to support

local demand. Pipes are also stocked

by certain stockists at nominated

locations.

Technical support

Technical advice can be provided by

qualified staff either on site or from head

office.

Sales support

Rapid response quotations can be

provided by experienced sales staff.

Special products

Specials can be manufactured to

customers designs.

Loc-King system

Lifting and jointing equipment can be

supplied for DN 1 350 - 1800 Vi-KingTM

pipes (see pages 19/20).

The following literature for concrete drainage products is

also available on request by e-mail, fax or telephone.

Concrete Drainage Products Selector

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.

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

provided.

Jointing compound

'Tokstrip' can be supplied to suit all

manholes (see page 14).

Plastic encapsulated steps

Double width plastic encapsulated steps

(rungs) can be supplied loose or fitted to

manhole rings (see page 1 1 ) .

Manhole scheduling

Manholes can be scheduled and

numbered to customers requirements

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;

Maximum allowable.iacking loads

and jointing instructions for

microtunnelling pipes. a

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TOL0578 00002b7 78b

Tel: 01 15 944 1448

Fax: 0115 944 1466

E-mail: sales@stanton-bonna.co.uk

OFFICE HOURS 8.30am - 5.00pm

Member of the Concrete Pipe Association

Member of the Pipe Jacking Association

Stanton Bonna Concrete ttd littlewell Lane Stanton by Dale II keston Derbyshire DE7 4QW

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Ref CDP 05/97