StormPRO & SewerPRO. Twin-Walled Corrugated Polypropylene Pipe and Fittings System for Non-Pressure Applications LIGHT WEIGHT

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1 Twin-Walled Corrugated Polypropylene Pipe and Fittings System for Non-Pressure Applications LIGHT WEIGHT EASY TO HANDLE - COST EFFECTIVE TO INSTALL SIMPLE & EFFECTIVE JOINTS ADAPTS TO SOIL MOVEMENT DOMESTIC OR INDUSTRIAL APPLICATIONS USED IN AGGRESSIVE OR SALINE SOILS Quality ISO 9001 Lic 570

2 INTRODUCTION 1 WHY CHOOSE STORMPRO & SEWERPRO 2 PRODUCT RANGE 3 Pipe 3 Fittings 4 PRODUCT DATA 10 Pipe Dimensions 10 Dimensions & Effective Lengths 11 Joint Details 12 Chemical Resistance 12 Temperature 12 Weathering Resistance 12 Manufacture 13 Standards 13 Material Properties 13 DESIGN 14 Structural Design 14 Hydraulic Design 15 Choice of Roughness Coefficients 16 INSTALLATION 22 General 22 Flexible Pipes 22 Handling & Storage 22 Trench Dimensions 23 Minimum Cover Height 23 Jointing 24 Cutting of Pipes 25 Selection of Embedment Material 25 Placing & Compacting Embedment Material 26 Connection to Structures 26 Backfilling 26 Above Ground Installation 27 Stormwater Connections 28 Leakage Test 28 Cut Ins & Repairs 29 Limitation of Liability This product catalogue has been compiled by Pty Limited ( the Company ) to promote better understanding of the technical aspects of the Company s products to assist users in obtaining from them the best possible performance. The product catalogue is supplied subject to acknowledgement of the following conditions: 1 The product catalogue is protected by copyright and may not be copied or reproduced in any form or by any means in whole or in part without prior consent in writing by the Company. 2 Product specifications, usage data and advisory information may change from time to time with advances in research and field experience. The Company reserves the right to make such changes at any time without further notice. 3 Correct usage of the Company s products involves engineering judgements, which can not be properly made without full knowledge of all the conditions pertaining to each specific installation. The Company expressly disclaims all and any liability to any person whether supplied with this publication or not in respect of anything and all of the consequences of anything done or omitted to be done by any such person in reliance whether whole or part of the contents of this publication. 4 No offer to trade, nor any conditions of trading, are expressed or implied by the issue of content of this product catalogue. Nothing herein shall override the Company s Condition of Sale, which may be obtained from the Registered Office or any Sales Office of the Company. 5 This product catalogue is and shall remain the property of the Company, and shall be surrendered on demand to the Company. 6 Information supplied in this product catalogue does not override a job specification, where such conflict arises; consult the authority supervising the job. Copyright Pty Limited.

3 StormPRO & SewerPRO INTRODUCTION SewerPRO and StormPRO provide the sewer and stormwater markets with a modern pipe and fittings system for non-pressure applications. StormPRO and SewerPRO pipes are twin-wall, corrugated polypropylene pipes for non-pressure applications, manufactured in accordance with AS/NZS Utilising modern co-extrusion techniques, StormPRO and SewerPRO are manufactured with a smooth bore for optimum hydraulic performance and a corrugated outside wall for high stiffness to weight ratio. SewerPRO and StormPRO pipes combine the strength and toughness of advanced polypropylene materials with a structured wall design. SewerPRO provides a cost effective pipe for sewer applications with a full range of fittings to suit different designs and installations. SewerPRO pipe is a comprehensive solution for sewer needs. StormPRO has its own fittings specially designed for stormwater needs, providing a cost-effective system for drainage applications. StormPRO and SewerPRO can be installed in trafficable areas including under road pavements and non-trafficable areas. SewerPRO and StormPRO are sensitive to the environment, with their material efficient design reducing raw material usage, long life and recyclability at the end of life contributing to reduced environmental needs. SewerPRO and StormPRO are less likely to crack than rigid pipe, resulting in less leakage and consequential environmental issues. 1

4 Why Choose StormPRO & SewerPRO Corrugated Polypropylene Pipe System. A full system solution in sizes from DN150 to DN900. Can be used in aggressive or saline soils Sensitive to the environment Lower total installed cost Lightweight product easy to handle Light internal colour to facilitate video inspection Complete range of fittings Less heavy lifting equipment required Pipes easy to cut Ease of jointing Introducing the improved PRO2 joint Reduced jointing forces Enhanced joint performance under adverse soil movement and deflection conditions New rubber ring design Polypropylene (PP), Polyethylene (PE) and polyvinyl chloride () materials are used in PRO fittings. All fittings are SN8 minimum. offers a range of adaptors to connect to non PRO systems. Special fittings can also be provided you should contact. Note that fittings DN450 and larger are generally not stocked. Contact sales for price and availability. The new PRO2 joint is not compatible with the old joint or rubber rings. Make sure you only use fittings labelled PRO2 with PRO2 pipes to ensure dimensional compatibility and system performance. Note that systems may not be leak tight if PRO2 fittings are not used. PRO2 sockets should only be joined using PRO2 rubber rings StormPRO Fittings, Accessories & Tools also offers fittings, accessories and tools specifically designed for StormPRO applications. The PROgrommet is a quick and easy system to install 100mm and 150mm connections to StormPRO pipe. Optimum hydraulic performance Smooth inner skin for hydraulic flow The PROsaw has been specifically designed to accommodate the PRO rib height and for simple installation of the PROgrommet. Surface resistant to buildup 2

5 PRODUCT RANGE Pipe SewerPRO pipes are designed for sewerage applications and StormPRO used for stormwater applications. SewerPRO has a dark grey coloured corrugated outside surface and a smooth light grey interior. StormPRO has a black coloured corrugated outside surface and a smooth light grey interior. Each length of SewerPRO and StormPRO pipe is supplied with a rubber ring. SewerPRO and StormPRO pipe is available in standard rubber ring jointed spigot/socket configuration (Sp/So). SewerPRO comes in 3m nominal lengths and StormPRO comes in 6m nominal lengths. Please see below tables for Product Data. StormPRO Polypropylene Pipe Nominal 6m Length Nominal Diameter Product Description Comments StormPRO2 SN8 PP 6.02m StormPRO2 SN8 PP 5.99m StormPRO2 SN8 PP 5.94m StormPRO2 SN8 PP 5.93m StormPRO2 SN8 PP 5.95m StormPRO2 SN8 PP 5.89m StormPRO2 SN8 PP 5.85m StormPRO2 SN8 PP 5.92m Reduced Spigot StormPRO2 SN8 PP 5.91m Reduced Spigot Available in other lengths for projects Sufficient Lubricant is supplied with pipe. Additional Lubricant may be ordered if required. SewerPRO Polypropylene Pipe Nominal 3m Length Nominal Diameter Product Description Comments SewerPRO2 SN10 PP 2.95m SewerPRO2 SN10 PP 2.92m SewerPRO2 SN10 PP 2.87m SewerPRO2 SN10 PP 2.86m SewerPRO2 SN10 PP 2.86m SewerPRO2 SN10 PP 2.80m SewerPRO2 SN10 PP 2.76m SewerPRO2 SN10 PP 2.82m Reduced Spigot SewerPRO2 SN10 PP 2.81m Reduced Spigot Available in other lengths for projects PP PRO Shorts Note: Rubber Rings are normally supplied with all pipe and fittings PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP PRO MHole SP SN10 600mm PP 3

6 PRODUCT RANGE Fittings Rubber Rings Rubber rings are normally supplied with all pipes and fittings. Additional rubber rings may be ordered separately if required. DN Product Description Availability PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM PRO2 PP Ring EPDM Rubber Rings for use with Slip Couplings DN Product Description Availability PRO2 PP SlipCoup Ring EPDM PRO2 PP SlipCoup Ring EPDM and PE PRO Couplings Product Description Availability PRO Coupling SN PRO Coupling SN PRO Coupling SN PRO Coupling SN PRO Coupling RMPE Contact PRO Coupling RMPE Contact PRO Coupling RMPE Contact PE PRO Slip Couplings Product Description Availability PRO Slip Coupling SN PRO Slip Coupling SN PRO Slip Coupling SN PRO Slip Coupling SN PRO Slip Coupling RMPE Contact PRO Slip Coupling RMPE Contact PRO Slip Coupling RMPE Contact PRO Slip Coupling PE Contact PRO Slip Coupling PE Contact 4 Note: Rubber Rings are normally supplied with all pipe and fittings.

7 15 Degree PRO Bends Product Description Availability PRO Bend 15D SN8 FF Contact PRO Bend 15D SN8 FF Contact PRO Bend 15D SN8 FF Contact PRO Bend 15D SN8 FF Contact 22.5 Degree PRO Bends Product Description Availability PRO Bend 22.5D SN8 FF Contact PRO Bend 22.5D SN8 FF Contact PRO Bend 22.5D SN8 FF Contact PRO Bend 22.5D SN8 FF Contact M&F PP 30 Degree PRO Bends Product Description Availability PRO Bend 30D SN8 FF Contact PRO Bend 30D SN8 FF Contact PRO Bend 30D SN8 FF Contact PRO Bend 30D SN8 FF Contact PRO Bend 30D SN10 MF PP Contact PRO Bend 30D SN10 MF PP Contact F&F PP 45 Degree PRO Bends Product Description Availability PRO Bend 45D SN10 FF PP PRO Bend 45D SN8 FF PRO Bend 45D SN8 FF PRO Bend 45D SN8 FF PRO Bend 45D SN10 MF PP Contact PRO Bend 45D SN10 MF PP Contact PRO Bend 45D SN10 MF PP Contact PRO Bend 45D SN10 MF PP Contact PRO Bend 45D SN10 MF PP Contact M&F PP Note: Rubber Rings are normally supplied with all pipe and fittings. 5

8 PP 88 Degree PRO Bends Product Description Availability PRO Bend 88D SN10 FF PP PRO Bend 88D SN8 FF PRO Bend 88D SN8 FF PRO Bend 88D SN8 FF PRO Bend 88D SN10 MF PP Contact PRO Bend 88D SN10 MF PP Contact PRO Bend 88D SN10 MF PP Contact PRO Bend 88D SN10 MF PP Contact PRO Bend 88D SN10 MF PP Contact M&F PP PP 45 Degree PRO Junctions Product Description Availability PRO Jun 45D SN10 FF PP x x150 PRO Jun 45D SN8 FF PRO Jun 45D SN8 FF x x150 PRO Jun 45D SN8 FF x x225 PRO Jun 45D SN8 FF PRO Jun 45D SN8 FF x x150 PRO Jun 45D SN8 FF x x225 PRO Jun 45D SN8 FF x x300 PRO Jun 45D SN8 FF PRO Jun 45D SN8 FF PRO Jun 45D SN10 MF PP Contact x x375 PRO Jun 45D SN10 MF PP Contact PRO Jun 45D SN10 MF PP Contact PRO Jun 45D SN10 MF PP Contact PRO Jun 45D SN10 MF PP Contact PRO Jun 45D SN10 MF PP Contact M&F PP 45 Degree PRO Junction Adaptor to DWV x x100 PROJun45D SN8 FF SWJ x PROJun45D SN8FF RRJ 6 Note: Rubber Rings are normally supplied with all pipe and fittings.

9 PP 88 Degree PRO Junctions Product Description Availability PRO Jun 88D SN10 FF PP x x150 PRO Jun 88D SN8 FF PRO Jun 88D SN8 FF x x150 PRO Jun 88D SN8 FF x x225 PRO Jun 88D SN8 FF PRO Jun 88D SN8 FF x x150 PRO Jun 88D SN8 FF x x225 PRO Jun 88D SN8 FF x x300 PRO Jun 88D SN8 FF PRO Jun 88D SN8 FF x x375 PRO Jun 88D SN10 MF PP Contact PRO Jun 88D SN10 MF PP Contact PRO Jun 88D SN10 MF PP Contact PRO Jun 88D SN10 MF PP Contact PRO Jun 88D SN10 MF PP Contact PRO Jun 88D SN10 MF PP Contact M&F PP PP M&F PP PRO Tees PRO Tee SN10 FF PP x x150 PRO Tee SN8 FF PRO Tee SN8 FF x x150 PRO Tee SN8 FF x x225 PRO Tee SN8 FF PRO Tee SN8 FF x x150 PRO Tee SN8 FF x x225 PRO Tee SN8 FF x x300 PRO Tee SN8 FF PRO Tee SN8 FF x x150 PRO Tee SN10 MF PP Contact x x225 PRO Tee SN10 MF PP Contact x x300 PRO Tee SN10 MF PP Contact x x375 PRO Tee SN10 MF PP Contact PRO Tee SN10 MF PP Contact PRO Tee SN10 MF PP Contact PRO Tee SN10 MF PP Contact PRO Tee SN10 MF PP Contact PRO Tee SN10 MF PP Contact PP PRO Inspection Tees x PRO InspTee SN10 FF PP x x150 PRO InspTee SN8 FF x x150 PRO InspTee SN8 FF x x150 PRO InspTee SN8 FF Note: Rubber Rings are normally supplied with all pipe and fittings. 7

10 PRO Level Invert Tapers x x150 PRO LITaper SN8 FF x x150 PRO LITaper SN8 FF x x225 PRO LITaper SN8 FF x x225 PRO LITaper SN8 FF x PRO LITaper SN8 FF PP and PE PRO Push On Caps PRO Push on Cap PP PRO Push on Cap PP PRO Push on Cap PRO Push on Cap PRO Push on Cap RMPE Contact PRO Push on Cap RMPE Contact PRO Push on Cap RMPE Contact PRO Adaptor Couplings - PRO to DWV SWJ PRO Coupling SN8 SWJ PRO Coupling SN8 SWJ PRO Coupling SN8 SWJ PRO Coupling SN8 SWJ PRO Adaptor Couplings - PRO to DWV RRJ PRO Coupling SN8 RRJ PRO Coupling SN8 RRJ PRO Coupling SN8 RRJ PRO Coupling SN8 RRJ PRO Adaptor Couplings - PRO to Ultra Rib PRO Coupling URib SN PRO Coupling URib SN PRO Coupling URib SN PRO Coupling URib SN8 PRO Adaptor Couplings - PRO Spigot to DWV SWJ Socket (DWV socket has thread for access cap) x x100 PRO LIT M-DWV F no cap 8 Note: Rubber Rings are normally supplied with all pipe and fittings.

11 PRO Adaptor Couplings - PRO Spigot to DWV SWJ Socket PRO Access Coup DWV F +cap PRO Adaptor Couplings - PRO to DWV Spigot SP-PRO SOC SN8 Adap SP-PRO SOC SN8 Adap SP-PRO SOC SN8 Adap SP-PRO SOC SN8 Adap Stormwater Applications Only Stormwater 90 PRO Elbows PRO Elbow 90D SN8 FF PRO Elbow 90D SN8 FF PRO Elbow 90D SN8 FF 45 Degree Stormwater Junctions x x150 PRO Jun 45D SN10 MF PP Contact x x225 PRO Jun 45D SN10 MF PP Contact x x300 PRO Jun 45D SN10 MF PP Contact PE 88 Degree Stormwater Junctions x x150 PRO Jun 88D SN10 MF PP Contact x x225 PRO Jun 88D SN10 MF PP Contact x x300 PRO Jun 88D SN10 MF PP Contact PE (For use with StormPRO Only) PROgrommet / / PROgrommet / / PROgrommet /450/ /450/ PROgrommet /450/ /450/ PROgrommet /750/ /750/ PROgrommet PROsaw Diameter PRO Saw Diameter PRO Saw Note: Rubber Rings are normally supplied with all pipe and fittings. 9

12 PRODUCT DATA Pipe dimensions A schematic of the wall profile is shown in Figure A and significant dimensions are given in Table 1. FIGURE A - WALL PROFILE Table 1 StormPRO & SewerPRO Pipe Dimensions Nom Diameter Mean Pipe Outside Diameter Mean Pipe Internal Diameter Profile Pitch Minimum Profile Thickness Inner Wall Thickness (e) Approx. Pipe Mass StormPRO (kg/length) Approx. Pipe Mass SewerPRO (kg/length) Number of Pipes per Crate or

13 Dimensions & effective lengths StormPRO and SewerPRO are available in spigot/socket configuration (Sp/So) in 6m and 3m nominal lengths respectively. The effective length of pipes is the overall length minus the insertion depth into the socket. The effective lengths of Storm- PRO and SewerPRO given below in Table 2: Table 2 - StormPRO and SewerPRO Pipe Effective Length StormPRO Nominal Diameter Length (Sp/So) 6m Nominal Effective Length (m) SewerPRO Length (Sp/So) Effective Length (m) NB NOMINAL OVERALL LENGTHS ARE LONGER THAN EFFECTIVE LENGTH DUE TO SOCKET LENGTH 11

14 Joint details StormPRO and SewerPRO pipes have a simple and effective rubber ring joint system which is easy to assemble, leak-tight and protects against tree root intrusion. The rubber ring is located on the spigot in the last trough between the corrugations. Figure B shows the joint in cross section. For sizes DN150 to DN600, the pipe can be cut to length as required anywhere along the barrel and the same jointing system used. The spigot ends on pipe sizes DN750 and DN900 are geometrically different to the main pipe barrel. Where these pipe sizes need to be cut to length, couplings must be used for jointing. This system is suitable for occasional use but is not recommended for routine jointing. If many shorter pipe lengths are required, contact to discuss an alternative solution. No chamfer is required. PRO fittings are manufactured from, PP or PE, depending on size and configuration. These plastics materials have been proven in sewer applications for over 50 years and have excellent resistance to any substances found in normal sewage effluent. Pollution control measures mean that these plastics materials can be safely used in any sewerage network, including areas accepting industrial discharges. Users should check local authority requirements. Polypropylene is generally not recommended for aromatic and halogenated hydrocarbons. For more details or to check resistance to specific chemicals, refer to the Chemical Resistance Guide (VIN067) on our website. PRO2 is a new jointing system designed for easier installation and leak tight joint performance. The PRO2 joint design uses a new redesigned rubber ring Nominal to match new socket geometry. Ensure that only PRO2 rubber rings are used with PRO2 sockets. PRO2 sockets can be identified by a label on the socket and PRO2 rubber rings can be identified by PRO2 marking on the ring. Temperature 3m Nominal StormPRO and SewerPRO pipes have high temperature resistance. Continuous service temperatures of up to 60 C and short term applications of up to 90 C will not adversely affect the performance. RUBBER RING IN LAST PIPE SOCKET LEADING IN FLARE OF SOCKET MOUTH LEADING EDGE OF PIPE SPIGOT WITNESS MARK (WHITE LINE AROUND CIRCUMFERENCE) Chemical resistance Weathering resistance StormPRO and SewerPRO polypropylene pipes are resistant to corrosion by aggressive soils and substances typically found in sewage effluent, including most industrial discharges. Therefore, the question of chemical resistance is likely to arise only if the pipes are used in unusual circumstances. StormPRO and SewerPRO pipes are manufactured from compounds containing additives which ensure their resistance to ultraviolet light and weathering during handling and storage. 12 Chemical resistance is affected by concentration, temperature, period of contact and stress. Polypropylene is resistant to weak inorganic acids, organic acids, alcohols, ammonia and oxidising salts and has limited resistance to aliphatic hydrocarbons, esters, ketones and ethers.

15 Manufacture Standards StormPRO and SewerPRO pipes incorporate the latest manufacturing technology using continuous polypropylene dual extrusion combined with a vacuum controlled corrugating process. The twinwall structure consists of simultaneously extruded smooth inner wall and corrugated outer wall. At the valley of each corrugation, where the inner and outer walls meet, the two surfaces are fused together for the full circumference of the pipe. StormPRO and SewerPRO pipes are manufactured in accordance with AS/NZS 5065: Polyethylene and Polypropylene pipes and fittings for drainage and sewerage applications, complying with the dimensional requirements of Type B pipes - ID series. AS/NZS 5065 classifies pipes according to their minimum ring-bending stiffness in short term laboratory tests. This is a measure of the ability of a pipe to resist deformation due to an external load. Stiffness classes are identified by an SN number where a higher number indicates greater resistance to deflection. SewerPRO pipes are classified as SN10 with a minimum stiffness of 10,000 N/m.m. StormPRO pipes are classified as SN8 with a minimum stiffness of 8000 N/m.m. Material properties Table 3 - Typical Material Properties of StormPRO and SewerPRO Property Value Standard Polypropylene (PP) pipe compound block copolymer Density 900kg/m³ ISO 1183 Flexural modulus 1700MPa ISO 178 Creep ratio (2 years) 3 ISO 9967 Pipe ring bending stiffness StormPRO 8,000N/m.m AS/NZS Pipe ring bending stiffness SewerPRO 10,000N/m.m AS/NZS Coefficient of thermal expansion 15 x 10-5 / C ISO Tensile stress at yield (50mm/min) 31 MPa ISO Tensile strain at yield (50mm/min) 8% ISO Poisson's ratio 0.45 ISO Charpy impact strength - notched (+23) 50kJ/m² (-20) 5 kj/m² ISO Shore D hardness 60 ISO 868 Melt flow rate 0.3g/10min ISO 1133 Melting point C 13

16 DESIGN Structural design Under general gravity drainage and sewer pipe laying conditions, detailed calculations predicting pipe performance are not necessary. Following an extensive study of installed pipe performance, The European Plastic Pipe and Fitting Association (TEPPFA) concluded that final deflection of pipes was controlled by the settlement of the soil after installation. Where installation was controlled, or self-compacting granular material were used, pipe deflections were consistently low regardless of installation depth and traffic or other loads. In the graph below: "Well" compacted refers to bedding material placed and compacted around the pipe to a minimum 94% dry density ratio, in layers of maximum 300 mm thickness, to a minimum depth over the pipe of 150mm; and "Moderate compaction refers to bedding material placed and compacted around the pipe to 87% to 94% dry density ratio, in layers of maximum 500mm thickness, to a minimum depth over the pipe of 150mm Where SewerPRO or StormPRO pipes are to be installed in normal conditions at depths up to 6m such that the depth to diameter ratio is at least 2, design calculations are not required. Simply following the recommended installation procedures will ensure that deflections are controlled. This is particularly true for installations under roadways, where the level of compaction required to prevent subsidence of the pavement also provides a highly supportive structural environment for the pipe. For unusual conditions, or depths greater than 6 metres, design calculations may be performed in accordance with AS/NZS The structural design aspects of buried flexible pipes to be considered are vertical deflection, ring bending strain and buckling. The following typical values in Table 4 may be used in pipe design. The graph shows deflection after immediately installation. Final pipe deflection after soil settlement are expected to be 1% higher for well compacted granular soil, 2% for moderately compacted granular soil and 3-4% where no compaction has taken place. Table 4 - Typical Structural Design Properties of StormPRO and SewerPRO Property Symbol Value Short Term Stiffness - StormPRO S DI 8000 N/m/m Short Term Stiffness - SewerPRO S DI N/m/m Allowable Long Term Deflection 7.5% Allowable Long Term Ring Bending Strain ɛball 4% Long Term Stiffness - StormPRO S DL N/m/m Long Term Stiffness - SewerPRO S DL N/m/m 14

17 Hydraulic design StormPRO and SewerPRO pipes are normally sized to accommodate maximum design discharge when flowing full. The discharge rates in Tables 5 through 9 on Pages 19 to 23 for StormPRO and SewerPRO pipes flowing full are based on the Colebrook-White formula which is recognised by engineers throughout the world as the most accurate basis for hydraulic design over a wide range of flow conditions. The Colebrook-White formula expresses velocity as: In addition to friction losses in the pipeline, a pressure drop will occur due to energy loss at any change in the direction of flow or pipeline cross section. In long pipelines, these form losses are usually small in comparison to friction losses. However, they may be considerable in pipelines with many fittings or in short pipes such as in culvert applications, where entry and exit losses may dominate. For more information on form losses, consult the Flow Charts (VIN015 and VIN039) Where: V = Velocity (m/s) H/L = Pipe Gradient, i.e. friction head loss / pipe length (m/m) D i k v = Internal Diameter (m) = Colebrook-White roughness coefficient (m) = kinematic viscosity of water (m 2 /s) 1 x 10-6 m 2 /s for water at 20 C g = acceleration due to gravity (9.8m/s 2 ) And Q = VA Where: Q = flow rate (m 3 /s) A = Internal area (m 2) 15

18 Choice of roughness coefficients AS Design charts for water supply and sewerage - recommends k values in the range to 0.015mm for clean, concentrically jointed thermoplastics pipes and AS National plumbing and drainage, Part 3 Stormwater drainage - specifies 0.015mm for design of plastics stormwater pipe drains for normal conditions. However, it is important to note that factors such as slime growth and accumulation of debris can affect the selection of roughness coefficient in some circumstances. In addition, local utilities may have preferred values for design of their systems. For flow under alternative conditions contact or use the Friction Loss in Uniform Fluid Flow (FLUFF) software. For partial flow, consult Figure C for adjustment factors DEPTH TO DIAMETER RATIO d D DISCHARGE 0.4 VELOCITY HYDRAULIC RATIOS V PART AND Q PART V FULL Q FULL FIGURE C n VARIABLE DEPTH n CONSTANT 16

19 TABLE 5 Full Discharges and Velocities DN150 DN225 Gradient H/L Velocity/ Discharge k Di DN 150 DN Di /10 1/20 1/30 1/40 1/50 1/60 1/70 1/80 1/90 1/100 1/120 1/140 1/160 1/180 1/200 1/250 1/300 1/400 1/500 m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s

20 TABLE 6 Full Discharges and Velocities DN300 DN375 Gradient H/L Velocity/ Discharge k Di DN 300 DN 375 Di /10 1/20 1/30 1/40 1/50 1/60 1/70 1/80 1/90 1/100 1/120 1/140 1/160 1/180 1/200 1/250 1/300 1/400 1/500 m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s

21 TABLE 7 Full Discharges and Velocities DN450 DN525 Gradient H/L Velocity/ Discharge k Di DN 450 DN 525 Di /10 1/20 1/30 1/40 1/50 1/60 1/70 1/80 1/90 1/100 1/120 1/140 1/160 1/180 1/200 1/250 1/300 1/400 1/500 m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s

22 TABLE 8 Full Discharges and Velocities DN600 DN750 Gradient H/L Velocity/ Discharge k Di DN 600 DN 750 Di /10 1/20 1/30 1/40 1/50 1/60 1/70 1/80 1/90 1/100 1/120 1/140 1/160 1/180 1/200 1/250 1/300 1/400 1/500 m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s

23 TABLE 9 Full Discharges and Velocities DN900 Gradient H/L Velocity/ Discharge k Di DN /10 1/20 1/30 1/40 1/50 1/60 1/70 1/80 1/90 1/100 1/120 1/140 1/160 1/180 1/200 1/250 1/300 1/400 1/500 m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s m/s L/s

24 INSTALLATION General StormPRO and SewerPRO pipes are twin-wall, corrugated polypropylene pipes for non-pressure applications, and can be installed in non-trafficable and trafficable areas, including under road pavements. This guide is intended to provide general information for the safe installation of StormPRO and SewerPRO pipes. For more detailed information refer to AS/NZS 'Buried flexible pipelines: Part 2, Installation'. When designed and installed correctly, StormPRO and SewerPRO systems will provide continuous service in excess of 50 years. pavements is well established throughout the world and in Australia. As flexible pipes transfer load through deflection, loading outside design parameters leads mostly to deformation without structural damage. Overloading results in cracking of rigid pipes. Flexible pipes provide a substantial insurance for operational conditions outside design parameters. Handling & storage Flexible pipes StormPRO and SewerPRO are flexible pipes. This means that as vertical loads are applied, the pipe will deflect and take advantage of horizontal soil pressure to provide additional support. After initial compaction and settlement, applied vertical loads have very little effect on deflection. Rigid pipes, such as steel reinforced concrete pipes do not deflect, and are designed to carry all applied vertical loads caused by soil and traffic. The surrounding soil provides little or no horizontal support to a rigid pipe. Notwithstanding this, proper placement and compaction of bedding material around rigid pipes is critical in minimising the load on the pipe. Flexible pipes have some ability to deform without structural damage and provide designers and installers with a wide range of advantages. The structural action and design methodology of flexible pipes is well understood. Their use in all buried applications and particularly under road Being manufactured from tough polypropylene, StormPRO and SewerPRO pipes are robust and are suitable for use in most site conditions. The pipes are relatively light weight and can generally be manhandled. Care should always be taken when pipes are loaded, unloaded, stacked or distributed on sites. When pipes are lifted mechanically, web or rope slings should be used. Pipes should not be allowed to overhang by more than 1 metre. Transport should not have sharp projections which could cause damage to pipes. Pipes should not be dragged along the ground as this can damage the pipe, causing difficulty with jointing and testing. StormPRO and SewerPRO pipes should be stacked on flat firm ground, which has been cleared of debris. Pipes should be laid flat on transverse bearers at least 75mm wide at maximum 1.5m centres. Pipe sockets should be supported so that the ends are free from loading, with sockets in each layer opposite to the previous layer. Different sizes are best stacked separately. If this is not practical, then stack with the largest pipes at the base. Framed crates must be stored timber on timber and may go up three crates but should not exceed 3m in height. If pipes are to be nested for long periods, stacks should not exceed 2m in height. Rubber rings should be stored away from direct sunlight or weathering. Rubber rings should never be placed on the ends of pipes which are being stored. 22

25 Trench dimensions Minimum Cover Height Preparation The trench should not be excavated too far in advance of pipe laying and should be backfilled as soon as possible. Typical minimum covers heights are given in Table 10. Minimum Trench Width The trench width should be as narrow as is practicable, but wide enough to allow adequate compaction of the haunch zone. Pipes in Parallel Where pipes are laid in parallel, the minimum spacings between pipelines are given in Table 11 below. Table 10- Minimum depth of cover over pipe Loading Condition Not subject to vehicular loading Land zoned for agricultural use Subject to vehicular loading- (a) no carriageway (b) sealed carriageways (c) unsealed carriageways Pipelines in embankments or subject to construction equipment loads Minimum Cover (m) Table 11 - Minimum spacings between parallel pipelines Nominal Diameter Minimum Spacing The trench should be excavated deep enough to allow for the specified grade, the required depth of underlay and the minimum cover. 23

26 INSTALLATION Jointing Installation must follow the diagrams below: (referring to Steps 2 & 3) The following procedure is recommended when joining StormPRO and SewerPRO rubber ring jointed pipes: Step 1 Thoroughly clean and dry inside of pipe socket making sure it is free of dirt or any foreign matter. Step 2 Fit the PRO2 rubber ring in the last trough of the spigot. ENSURE THE UNDERSIDE OF THE RING AND THE TROUGH IS CLEAN AND FREE OF LUBRICANT. Step 3 Ensure rubber ring is evenly fitted by running fingers around the full circumference of the pipe. Step 4 Apply jointing lubricant to the inside of the socket and lead in. ENSURE FULL COVERAGE. Step 5 Insert the leading edge of the spigot into the receiving socket. It is essential that pipes are in a straight line before attempting to make the joint. Step 6 Do not apply jointing force directly to the socket. Insert a short piece of pipe in the socket. The short piece can be an off-cut, 50mm longer than the socket, and can be re-used. Step 7 Apply even jointing force. Subject to pipe diameter and local conditions, use a crowbar to push on a timber block on the end of the short pipe. Step 8 Push home the pipe until the spigot end comes into contact with the inner wall of the socket. NOTE: The pipe may be deflected at the joint after jointing has been completed. Any deflection should be limited to a maximum of 3º. 24

27 Cutting of pipes StormPRO and SewerPRO pipes may be cut anywhere along their length as required. The cut should be made in the valley between the corrugations at right angles to the axis of the pipe using a suitable saw. A chamfer is not required. Selection of embedment material Embedment material for StormPRO and SewerPRO pipes should preferably be granular, free-flowing material. This type of embedment material requires less compactive effort to provide support for the pipe and minimise soil settlement. The most common embedment material is 5-7mm crushed rock. A typical grading is shown in Table 15 below. Table 12 - Typical 5-7mm crushed rock grading Sieve % Passing by Mass Where sand is more readily available, a typical sand grading is shown in Table 16 below. Table 13 - Typical sand grading Sieve % Passing by Mass For further information, refer to AS/NZS

28 Placing & compacting embedment material Connection to structures The bedding material should be placed and graded to invert level, and compacted as required (refer to Structural Design on Page 17). In conditions where the trench bottom is wet, soft or irregular, it may be necessary to first stabilise, fill and level, and compact the base. Place and compact material in the pipe bedding zone to minimum depth of 75mm beneath the pipe. StormPRO and SewerPRO pipes may generally be connected to rigid structures without the use of short rocker pipes. StormPRO and SewerPRO pipes have sufficient flexibility and strain tolerance to accommodate differential settlement at the interface. The figure below shows a typical entry or exit to a concrete structure. In order to ensure uniform support along the pipe barrel, a small indentation should be excavated in the pipe bedding zone to accommodate the pipe sockets. The pipe side support material should be placed evenly on both sides of the pipeline and compacted such that relative compaction is consistent with design. Side support material should be worked under the sides of the pipe to minimise voids and provide maximum pipe haunching, taking care to minimise distortion of the pipe and maintain alignment and grade. The pipe overlay material should be levelled and compacted in layers, to a minimum height of 150mm above the crown of the pipe, or as specified. (OPTIONAL FOR StormPRO) Where short rocker pipes are specified, either in 300mm or 600mm lengths, these should be installed as shown below. The most cost effective method is to cut pipe off-cuts to length on site, and join with plain couplings. Note that sanded shorts are not required as the corrugated pipe provides an adequate keying action into the concrete. Backfilling Backfill should be placed on the pipe overlay and compacted as specified but generally not in layers in excess of 300mm. Complete the backfilling operation to finished surface level. 26

29 Above ground installation For above-ground applications Storm- PRO must be adequately supported in order to prevent sagging and excessive distortion. Clamp, saddle, angle, spring or other standard types of supports and hangers may be used where necessary. Pipe hangers should not be over-tightened. StormPRO should be supported at regular intervals as detailed below, always with one support located directly behind the socket. These support spacings are based on StormPRO carrying water at 20ºC. Note that where temperatures in excess of 20ºC are likely, the support spacing should be reduced. Table 14 - Minimum Horizontal Support Spacing Nominal Diameter Minimum Horizontal Support Spacing (m) The supports should provide a bearing surface of 120º under the base of the pipes and should be at least two corrugations wide. The pipes should be protected from damage at the supports with the provision of a membrane of PE, or rubber. 27

30 Stormwater connections Leakage test The PROgrommet range of stormwater service connections provide 100mm and 150mm diameter connections to StormPRO pipe up to 900mm nominal diameter. The following procedure is recommended when installing the PROgrommet : 1. Drill hole in StormPRO pipe using the PROsaw. Hole centre must be located in the valley between corrugations. 2. Inspect marking on PROgrommet to ensure the correct size for selected StormPRO pipe 3. Present PROgrommet to hole with PROgrommet flange to the inside and locating wings to the outside of the StormPRO pipe 4. Squash the PROgrommet by hand whereby the two locating wings align in the centre 5. With the flattened PROgrommet, form a C shape and offer it to the prepared hole 6. Position locating wings in the valley of the StormPRO pipe profile 7. Apply Lubricant to the inside diameter of the PROgrommet 8. Cut lead-in chamfer on pipe which is to be offered to PROgrommet 9. Mark a line on pipe showing the required insertion depth 10. Apply Lubricant to outside diameter of pipe 11. Insert prepared pipe to pre-marked insertion depth Leakage testing is carried out to identify installation faults and sources of infiltration and exfiltration in pipelines which are required to be water tight such as sewerage systems. Leakage testing is generally not required for stormwater drains. AS/NZS specifies detailed procedures for leakage testing using hydrostatic testing, air or vacuum testing or infiltration testing of non pressure pipelines. These methods are summarised as below. Notwithstanding this, leakage testing should be carried out in accordance with local authority requirements. Method 1: Hydrostatic Test Fill the pipeline with water and pressurise to not less than 20kPa at the highest point of the section being tested, but not greater than 60kPa at the lowest point of the test section. Maintain the test pressure for at least two hours by adding measured volumes of water if required. Each joint should be carefully examined visually for leaks, and any defects should be repaired. The pipeline section is deemed satisfactory if the make-up volume is less that 0.5L per hour per metre length per metre diameter. After any repairs, the pipeline should be re-tested. Method 2: Air Test Introduce air slowly by suitable means until a pressure of 25kPa is obtained. Maintain for a period of at least 3 minutes. If no leaks are observed after 3 minutes, shut off the air supply. If the pressure of air contained in the pipes under test does not fall below 18kPa within the time period specified in Table 18 below, the pipeline shall be considered satisfactory. If, however, the pressure is not maintained within the specified limits, reintroduce the air and examine the pipeline for leaks by pouring a concentrated solution of soft soap and water over the joints and fittings. Identify and repair any leaks. After any repairs, the pipeline should be re-tested. 28

31 Cut Ins & repairs Method 3: Vacuum Test Apply a vacuum until a negative pressure of 25kPa is obtained. Maintain for a period of at least 3 minutes. If no leaks are observed after 3 minutes, isolate the test section from the vacuum pump. Monitor the pressure for the time specified in Table 17. If the vacuum does not drop below 18kPa within the specified time period, the pipeline shall be considered satisfactory. Where the pipeline section fails the test, re-apply the vacuum and examine the pipeline for leaks. Identify and repair any leaks. After any repairs, the pipeline should be re-tested. Method 4: Infiltration Test Where there is a free standing water table at a height of at least 1.5m above the test section, an infiltration test can be carried out. Observe the pipe for 24 hours. Where infiltration is detected, the leak should be identified and repaired. Table 15 - Minimum Time Intervals for 7kPa Pressure Change in Air and Vacuum Test Cut-Ins To cut into an existing buried StormPRO or SewerPRO pipeline and install a socketed junction or other socketed fitting, the following procedure should be adopted: 1. Expose the existing pipe and cut out a length equal to the effective length of the fitting, plus approximately 600mm. 2. Connect 300mm long short pipes to the junction sockets and fit rubber rings to the spigot ends of the short pipes. 3. Fit slip couplings to the cut ends of the existing pipe and install junction. Repairs When selecting the required repair method, it is necessary to differentiate between minor and more extensive damage. Minor or localised damage should be limited to small holes in the pipe. In these situations, bolt tensioned wrap-around stainless steel repair fittings can be used. It is important to note that this type of fitting has no positive stop and must only be tightened in accordance with the manufacturers torque settings. Damage caused by excavation or other machinery will inevitably affect the structural integrity of the pipe and should be cut out and replaced using slip couplings. Test length (metres) DN Minimum Test Duration (minutes)

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