Professional Documents
Culture Documents
Volume III
Sewer Networks
and Pump Stations
Published by :
Suruhanjaya
Perkhidmatan
Air Negara (SPAN)
Ministry of
Energy, Water
and Communication
Malaysia
Foreword by the
CEO of SPAN
M
unicipal wastewater treatment technology in Malaysia has evolved through several eras. In the
past, only basic facilities were used, e.g. overhang latrines, pit privy, bucket systems and pour
flush systems. Some improvement were observed when more modern system like septic tank and
Imhoff tank systems were introduced into the country some 40 years ago. The municipal
wastewater treatment in Malaysia sees a significant improvement in the last three decades since the introduction
of new technologies in the form of oxidation ponds, aerated lagoons, activated sludge system, package systems
and a variety of mechanical plants into the country. However, sewage still remains as one of the major pollutants
of our inland waterways. In the 1900s, the emergent of new treatment technologies were mainly driven by the
basic need to treat the sewage so as to control waterborne diseases. Today, the environmental regulations are
becoming stringent with the increasing awareness toward sustainable environmental management. Allowable
effluent discharge limits are becoming lower globally. Public are also more educated and more alert on the needs
to preserve the environment. Hence the evolution of municipal wastewater treatment technologies now are even
more revolutionary and more rapid in order to meet the stricter regulators’ requirements and to compete in the
increasing competitive market.
While the nation moves towards achieving the status of a developed country, sustainability of our environment,
in particularly the Malaysian rivers and streams must be strengthened. With this vision in mind, the Sewerage
Services Department published its first edition of the guidelines for sewerage industry titled “Design and
Installation of Sewerage Systems” in January 1995. The main purpose of these guidelines is to assist the
developer and his designer to plan and design systems acceptable to the regulatory authorities which, in
turn speeds up the approval processes. The Guidelines has clearly guided the nation sewerage industry towards
achieving an improved sewerage system in the country. Subsequently, the Department further improvised the
Guidelines in its second edition titled “Guidelines for Developers” which comprise five volumes covering
specific topics.
As a continuation to the efforts by the Sewerage Services Department, the National Water Services Commission
undertake to revise and improvement the Guidelines for Developers. The product of the revision is “Malaysian
Sewerage Industry Guidelines” which also comprise five volumes. These new revisions incorporated valuable
knowledge gained by various stakeholders over a decade since the implementation of the first Guidelines for
Developers and upkeep with the aim towards sustainable environmental management.
Volume 3 is specifically developed to provide a clear understanding of policies of the SPAN for the
provision, refurbishment or upgrading of sewer networks and pumps stations. This volume covers
planning, design, material selection, construction, installation and sewer testing requirements. The
implementation of these guidelines since 90’s has undoubtedly achieved some levels of consistency in the
design and construction of sewerage network nationwide. Finished sewerage networks quality has also
been elevated while the operation and maintenance of the plants have improved significantly in terms of
safety, health, operability and robustness. Whilst the adherence to these guidelines is necessary,
engineering discretion is also required, especially for large sewers and pumping station with special
situations. It is hoped that the publication of the third edition of this Volume further improve the municipal
wastewater treatment facilities in this country.
National Water Services Commission and Registered Certifying Agencies employees are
permitted to copy and use the information in this publication, for internal purposes only.
Section 1 Introduction
1.1 Purpose of This Volume 1
1.2 Who Should Use This Volume 1
1.3 Related Reference Material 1
Appendix B Tables
Table B1 : Classes of Rigid Pipe Required for Various Depth 127
The owner must comply with the requirements set out in this volume when
submitting an application for the approval of the Commission.
This volume generally does not cover internal plumbing systems within buildings.
However, some guidelines are provided on the provision of interceptors to protect
public sewers from the discharge of oil and grease from garage workshops, hotels,
restaurants, canteens or any premises that collect such matter.
MS 1228 shall take precedence over other foreign standards in the event when
there are discrepancies on the requirements.
a) Malaysian Standards
i. MS 28 Specification for test for water for making concrete
ii. MS 29 Specification for aggregates from natural sources for
concrete
iii. MS 144 Specification for cold reduced mild steel wire for
reinforcement of concrete
iv. MS 145 Specification for steel welded fabric for the reinforcement
of concrete.
v. MS 146 Specification for hot rolled steel bars for the reinforcement
of concrete.
vi. MS 522 Specification for Portland cement (ordinary and rapid
hardening)
vii. MS 523 Specification for concrete including ready mixed concrete
viii. MS 628 Specification for unplasticised PVC (uPVC) pipes for water
supply
Part 1 : Pipes
Part 2 : Joints and fittings for use with unplasticised PVC
pipes
ix. MS 672 Specification of rubber seals in water supply, drainage and
sewerage pipelines
x MS 740 Specification for hot-dip galvanized coatings on iron and
steel articles
xi. MS 822 Specification for sawn timber foundation piles
xii. MS 881 Specification for pre-cast concrete pipes and fittings for
drainage and sewerage
Part 1: Specification for pipes and fittings with flexible
joints and manholes
xiii. MS 922 Specification for concrete admixtures
Part 1 : Accelerating admixtures, retarding admixtures and
water-reducing admixtures
MS 923 Specification for joints and fittings for use with uPVC
pressure pipes [delete]
Part 3: Mechanical joints and fittings, principally of uPVC
[delete]
xiv. MS 979 Specification for unplasticizes sewerage pipes and fittings
Part 1: Pipes of diameter 100mm and 155mm
Part 2: Pipes of diameter 200mm and above
xv. MS 980 Specification for safety signs and colours : Colorimetric and
photometric properties of materials
xvi. MS 981 Specification for safety signs and colours : Colour and
design
xvii. MS 982 Specification for fire safety signs, notices and graphic symbol
xviii. MS 1037 Specification for sulphate-resisting Portland cement
xix. MS 1058 MS 1058 Specification for polyethylene (PE) piping
systems for water supply
Part 1 : General
Part 2 : Pipes
xx. MS 1061 Vitrified clay pipes and fittings and pipe joints for drains
and sewers
xxi. MS 1195 Code of practice for structural use of concrete
xxii. MS 1227 Specification for Portland pulverised fuel ash cement
xxiii. MS 1228 Code of Practice for Design and Installation of Sewerage
Systems
xxiv. MS 1347 Cathodic Protection : Part 1 Code of practice for land
applications
xxv. MS 1292 Specification for rubber seals – water stop for sealing joints
in concrete – Specification of materials
xxvi. MS 1389 Specification for Portland blastfurnace cement
b) British Standards
i. BS 65 Specification for vitrified clay pipes, fittings and
ducts, also flexible mechanical joints for use solely
with surface water pipes and fittings
ii. BS 915 Specification for high alumina cement. Metric unit.
iii. BS 3416 Specification for bitumen-based coatings for cold
application, suitable for use in contact with potable water
iv. BS 3692 ISO metric precision hexagon bolts, screws and nuts.
Specification.
v. BS 4147 Specification for bitumen based hot applied coating
materials for protecting iron and steel including suitable
primers where required
vi. BS 4164 Specification for coal-tar-based hot-applied coating
materials for protecting iron and steel including a suitable
primer
vii. BS 4248 Specification for Supersulfated cement
viii. BS 4515 Specification for welding of steel pipelines on land and
offshore.
ix. BS 5153 Specification for cast iron check valves for general purposes.
x. BS 5480 Specification for Glass Reinforced Plastic (GRP) pipes,
joints and fittings for use for water supply or sewerage
xi. BS 5911 Part 1 : Precast concrete pipes, fittings and ancillary
products. Specification for unreinforced and reinforced
concrete pipes (including jacking pipes) and fittings with
flexible joints (complementary to BS EN 1916)
xii. BS 5975 Code of practice for falsework.
xiii. BS 6076 Specification for polymeric film for use as a protectiv
sleeving for buried iron pipes and fittings (for site and factory
application)
xiv. BS 6105 Specification for corrosion resistant stainless steel fasteners.
[delete]
xv. BS 7123 Specification for metal arc welding of steel for concrete
reinforcement.
BS 7874 Method of test for microbiological deterioration of
elastomeric seals for joints in pipework and pipelines.
BS 8005 Sewerage [delete]
xvi. BS 8007 Code of practice for design of concrete structures for retaining
aqueous liquids
xvii. BS 8010- Code of practice for pipelines. Pipelines on land : design,
2.1 construction and installation. Ductile iron
xviii. BS 8666 Specification for scheduling, dimensioning, bending and
cutting of steel reinforcement for concrete.
xix. BS EN 124 Gully tops and manhole tops for vehicular and pedestrian
areas. Design requirements, type testing, marking, quality
control
BS EN 295 Specification for vitrified clay pipes and fittings with
flexible mechanical joints [delete]
Part 7: Requirements for vitrified clay pipes and joints for
pipe jacking [delete]
xx. BS EN Vitrified clay pipes and fittings and pipe joints for drains
295-1 and sewers. Requirements
xxi. BS EN Vitrified clay pipes and fittings and pipe joints for drains
295-7 and sewers. Requirements for vitrified clay pipes and joints
for pipe jacking
xxii. BS EN 545 Ductile iron pipes fittings and accessories and their joint for
water pipelines – requirements and test methods
xxiii. BS EN 598 Ductile iron pipes fittings and accessories and their joint for
sewerage applications – requirements and test methods.
xxiv. BS EN 681 Elastomeric seals. Materials requirement for pipe joint seals
used in water and drainage applications.
xxv. BS EN 682 Elastomeric seals. Materials requirement for pipe joint seals
used in pipes and fittings carrying gas hydrocarbons fluids.
xxvi. BS EN 752 Drain and sewer systems outside buildings
xxvii. BS EN Vacuum sewerage systems outside buildings
1091
xxviii. BS EN Specification for flake graphite cast iron
1561
xxix. BS EN Specification for spheroidal graphite or nodular graphite cast
1563 iron
xxx. BS EN Copper and copper alloys. Ingots and castings.
1982
xxxi. BS EN Hot rolled products of non-alloy structural steels.
10025
xxxii BS EN Seamless and welded steel tubes. Dimensions and masses
10220 per unit length.
xxxiii. BS EN Non-alloy steel tubes and fittings for the conveyance of
10224 aqueous liquids including water for human consumption.
Technical delivery conditions.
xxxiv. BS EN Bright steel products. Technical delivery conditions.
10277 Part 1 : General
Part 2 : Steels for general engineering purposes
d) German Standards
i. DIN Thermoplastic pipes and fittings with profiled outer and
16961 smooth inner surfaces
Part 1: Dimensions
Part 2: Technical delivery conditions
e) International Standards
i. ISO 1083 Spheroidal graphite cast irons - Classification
ii. ISO 3506 Mechanical properties of corrosion-resistant stainless-steel
fasteners
iii. ISO TR Underground installation of flexible glass-reinforced
10465 thermosetting resin (GRP) pipes
Part 1: Installation procedures
Part 3 : Installation parameters and application limits
The Commission will, from time to time, specify additional standards to be used in
the design and construction of sewerage works. These standards shall be referred
to as appropriate for the design and construction of sewer networks and network
pump stations.
All standards used in the design and construction of sewerage works shall be the
latest or the most updated. When any one of the above mentioned standards is
withdrawn or superseded, the latest or updated standards shall be referred to as
appropriate. This shall be the same for any applicable act, guideline, by-law, etc.
related to sewerage works endorsed by the government.
2.1 Sewers
2.1.1 Pipe Material Selection Factors
There is an extensive range of pipe materials available in Malaysia for use for
gravity, pressure and vacuum sewers. The materials and the standards which the
pipes are required to conform to are as follows:
d) Mild Steel
i) BS EN 10025
i) BS EN 10224
e) Stainless Steel
i) BS EN 10220
Marking of all pipes shall comply with available Malaysian or British Standards
where applicable. Additional requirements to those given in the above standards
may be specified from time to time by the Commission.
1) Gravity sewers
a) Rigid pipes b) Flexible pipes
i) VC i) GRP
ii) RC ii) Ductile Iron
iii) HDPE (Profile)
3) Vacuum sewers
i) ABS – for internal use
ii) HDPE (Solid) – for external use
There are specific requirements such as pipe class, joint type, linings etc. which the
above approved pipe materials must meet in order to suit the above applications.
Also, there are certain limitations for use of each pipe type. These requirements
and limitations are specified in the following sections.
From time to time, the Commission will publish sewer selection guides which will
provide more detailed direction on the selection and use of sewer materials.
For other pipe materials not listed above, their use will be given considerations in
special circumstances. However, only pipes and fittings from manufacturers and
suppliers approved by the Commission are permitted to be used for sewerage
applications.
1) Gravity Sewer
a) VC
i. Only size 150 mm or above shall be used
ii. The minimum size for public sewer shall be at least 225 mm
b) RC
i. Pipe protection linings are required
ii. Only sizes 600 mm or above are allowed in compliance to the
policy
iii. Flexible joints are recommended
c) GRP
i. Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade the
pipe
ii. Pipe shall not accept any industrial or other aggressive discharges
that may affect the pipe integrity
iii. Pipe shall be used only when no fittings are required
iv. Only sizes 600 mm or above are allowed
d) DI
i. The use is only allowed for applications needed high pipe strength
ii. Pipe protection linings and coatings are required
iii. Polyethylene sleeving is required for all buried applications
e) HDPE
i. Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade the
pipe
ii. Pipe shall not accept any industrial or other aggressive discharges
that may affect the pipe integrity.
iii. Only pipe with profile wall is permitted.
2) Force Mains
a) DI
i. Pipe shall not be used in unstable ground
ii. Pipe protection linings and coatings are required
iii. Polyethylene sleeving is required for all buried applications
iv. Flexible joints are recommended
b) GRP
i. Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade the
pipe
ii. Pipe shall not accept any industrial or other aggressive discharges
that may affect the pipe integrity.
iii. Fittings shall be made of ductile iron
iv. Only sizes 600 mm or above are allowed
c) ABS
i. Where VC or RC pipes are not suitable
ii. Only for nominated projects or as permitted by the relevant
authority
d) HDPE
i. Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade the
pipe
ii. Pipe shall not accept any industrial or other aggressive discharges
that may affect the pipe integrity.
e) Steel
i. Pipe is allowed only for sizes 700 mm or above
ii. Pipe protection linings and coatings are required
Vitrified clay pipe that has extra chemical resistance is suitable for sewerage
applications. This type of VC pipe may be used even under very corrosive sewage
environment. However, the potential for infiltration is great and must be minimised
by careful laying procedures on site.
Vitrified clay pipes are permitted for gravity sewers. The minimum permissible
size for public gravity sewer shall not be less than 225mm and service connection
shall not be less than 150mm.
VC pipes and fittings shall conform to the requirements of MS1061. Pipe strength
is classified by the crushing strength (FN) value tested in accordance with BS EN
295-3. The crushing strength for pipe with DN150 shall not be less than 22 kN/m.
The crushing strength of the pipe with size ≥ DN 225 is classified by class number.
All VC pipes and fittings shall be furnished with spigot-socket flexible joints and
rubber ring seals or polyurethane seals. Glazing of VC pipes and fittings are
preferred.
Common reinforced concrete pipes are not resistant to acidic corrosion which
occurs in certain septic sewage conditions. The cement used to manufacture
concrete pipe shall be factory produced by the cement manufacturer. Pipes can be
manufactured using Ordinary Portland Cement, Rapid Hardening Portland Cement,
Portland Blast Furnace Cement, Portland Pulverised Fuel Ash Cement and
Sulphate Resisting Portland Cement. All these types of cements are corrosion
resistance, except Ordinary Portland Cement and Rapid Hardening Portland
Cement. To improve the corrosion resistance, high alumina cement mortar lining,
PVC lining, PE lining and sacrificial lining have been used. Low heat and super-
sulphated cements have also been found in some tests to improve the corrosion
resistance. The inclusion of calcareous or limestone aggregate is another measure
found to improve corrosion resistance. To resist corrosion by neutral sulphates
occurring in aggressive soils and groundwater, RC pipes are sometimes
manufactured using sulphate resistance cement and where not available, portland
pulverised fuel ash cement or portland blastfurnace cement shall be used with the
approval from relevant authority.
RC pipes are permitted for gravity sewers of diameter DN600 and larger. Pipe shall
be of Standard Strength or higher as determined from structural design. RC pipes
below 1000mm in diameter linings shall consist of either 12mm thick high alumina
cement or 38mm thick (as appropriate) sacrificial concrete lining. For RC pipes
greater than 1000mm diameters either PVC or HDPE plastic lining or 38mm thick
sacrificial concrete lining shall be employed. Other linings may be used if approval
from the Commission is obtained. Concrete pipe junctions shall be fixed to the
main pipe by the pipe manufacturer and fabricated to clay pipe dimensions.
Flexible joints which utilise a rubber ring to join a rebated joint and a spigot to a
socket are commonly used and are recommended. Ogee joint (fixed joint) shall be
used in conjunction with concrete bedding haunching only. RC pipe when used for
pipe jacking purpose, shall be comply with BS 5911. The RC pipes also
incorporate rebated joints with joint elastomeric ring seals either integrated in the
unit or supplied separately.
DI pipe is permitted for force mains and internal pipings of pump stations. DI pipe
shall be used for gravity sewers only where it is needed to take the advantages of
the high strength of ductile iron, e.g. shallow cover sewers subjected to high live
load or sewers of above ground applications.
Pipes shall have flexible joints, i.e. spigot-socket rubber seal joints or mechanical
joints, except for pump station pipework and valve connections where flange joints
shall be used.
The finishing layer, which is normally bituminous product, shall cover the whole
surface of the applied coating and shall prevent defects such as the loss of
adhesion. In addition, the material of the finishing layer shall be compatible with
the coating.
Unless otherwise approved by the Commission, all fittings and accessories shall be
provided with external and internal epoxy coating.
Polyethylene sleeving shall be used for all the buried pipe and fittings.
Steel pipes will undergo corrosion when in contact with aggressive soil and sewage
and, thus, require an internal lining and an external coating. Pipe internal linings
normally include high alumina cement mortar, coal tar enamel, coal tar epoxy,
sulphate resistant cement lining, or bitumen. Pipe external coatings often include
coal tar enamel, bitumen enamel or asphalt enamel and glass fibre.
Steel pipes are permitted only for inverted siphons (depressed sewers) and internal
pump station pipework. For force main larger than 700 mm, steel pipe may be
used if the approval from the Commission is obtained.
The internal and external surfaces of the pipes and fittings shall be coated with
thermosetting (epoxy paint or powder or epoxy tar resin) or thermoplastic
(polyethylene or polyurethane) material. The type of external protection shall be
determined by the Qualified Person based on soil condition. Following the completion
of pipe jointing, exposed steel at the joints shall be protected from corrosion by
manually applied external tape wrap and internal cement mortar lining.
A spigot and socket joint welded both externally and internally shall be used for pipe
joints except for pump station pipework and valve connections where flange joints
shall be used. Mechanical joints are only permitted for cut pipe lengths, where
internal cement mortar lining at joints is not possible and where movement of the
pipeline is to be allowed for.
Since PE pipes are flexible, the design of the pipe/trench system is more critical
than for rigid pipe materials. Compared to rigid pipes, the stability of flexible
pipes relies more on the side support of the earth backfill around the pipe.
Consequently, in an urban environment, where the side support may be removed
during future adjacent construction of underground services, pipe failures could be
more frequent. Ground conditions which provide poor pipe side support are
unsuitable for flexible PE pipe.
Solid wall HDPE pipes are suitable for buried pressure sewer and buried vacuum
sewer installations. Butt fusion joints shall be used for PE pipe. uPVC fittings are
not permitted for force mains. Solid wall pipe for pressure main application shall
be of minimum PE80-PB10. The use of specific strength shall depend on the depth
and nature of the soil as confirmed by the Qualified Person. Solid wall pipes for
vacuum sewer shall be minimum of PE80-PN8 and at least PN10 for heavy vehicle
loading.
A profiled wall pipe is a pipe with a plain inside surface and with a ribbed or
corrugated outside surface. The ribs or corrugations are normally either aligned
circumferentially or helically. These corrugated or ribbed profiles optimise the pipe
ring stiffness to weight ratio. The pipe can be designed with double-wall profile or
triple-wall profile.
There are two principal manufacturing methods for GRP pipes, centrifugal casting
and filament winding. The centrifugal casting GRP pipe incorporates silica sand in
the wall structure in addition to resin and chopped strand mat glass fibres. The
silica sand shall have a maximum particles size of 10 mm. The centrifugal casting
GRP pipe shall be according to AS 3751.
The filament winding GRP pipe does not normally incorporate sand, which permits
centrifugal casting GRP pipe to have a much thicker wall, and thus much higher
ring stiffness than the filament winding GRP pipe. The filament winding GRP pipe
uses continuous glass fibres wound helically about the pipe. The design of filament
winding GRP pipe shall be in accordance with BS 5480.
Centrifugal casting GRP pipe is available in sizes from 200 mm to 2,400 mm and
standard length of 6 m. The inner surface of the pipe is usually finished with a
resin rich lining which is resistance to attack by sulphuric acid that may result from
septic sewage. Centrifugal casting GRP pipe has a rubber sealing sleeve joint
which is supplied fitted to one end. So jointing is similar to a spigot-socket joint.
These pipes can also be supplied with flange joints, sleeve-locking joints and
sleeve recessed joints for special applications such as pipe jacking and pipeline
towing.
GRP pipe is classified as a flexible pipe. It requires sufficient side support to retain
its structural integrity in cross-section in the same way as uPVC and PE pipe. GRP
pipe has lower strain limits than uPVC and PE pipes since it is made of thermoset
resin, which is brittle compared to thermoplastic material. Due to its inherent
structure, GRP pipe has a much higher modulus of elasticity than uPVC and PE
pipe. Thus, it may have a much thinner wall than uPVC and PE pipes to achieve
equivalent ring stiffness. GRP pipe is generally available in higher stiffness than,
uPVC and PE pipe.
Approval for the use of GRP pipe shall be sought from the Director General for
each project intending its use. GRP pipes are permitted for gravity and pressure
sewers. For gravity sewers, GRP pipes are only permitted for sizes of 600mm
nominal diameter and larger where no fittings are required. The minimum pipe
stiffness shall be SN 5000 with the appropriate stiffness determined in accordance
with structural design to AS 2566. For pressure sewers, fittings must only be of
ductile iron meeting the coating, lining and other requirements.
ABS, like uPVC and PE, is resistant to corrosion in the most corrosive sewage
environment that could occur. ABS is used in a range of applications requiring
pressure pipe. Because of its excellent resistance to abrasion and UV degradation,
ABS has found use in industrial and mining applications and also in treatment
plants for sewage and water.
ABS pipes may be permitted for force mains under special circumstances which
require the benefits of such pipes. If used, the approval of the Commission is
required. ABS pipes may be permitted for use in buried forced mains and buried
interconnecting pipe-works within pump stations.
The sewerage system shall be suitably designed to carry all sewage flows including
sullage to the approved disposal point. Unauthorised connections of surface waters
or excessive infiltration to the sewerage system are not permitted.
Unless otherwise agreed by the Commission, all sewers shall be sited in public
road reserve so that access can be gained for maintenance purposes. Under special
circumstances where the sewer cannot be sited in public road reserve then
vehicular access of at least 3 m in width and road bearing capacity of not less than
5 tonne shall be provided.
Few principal considerations when selecting the diameter and gradient of a sewer
are:
a) Average Flow:
The volume of sewage that needs to be treated per day is based on an assumed
contribution per person of 225 litres. Another assumption is made as to the
contribution from various types of premises where the contribution from each
premise type is defined in terms of an equivalent population. The recommended
minimum population equivalent values are given in Table B.1.
b) Peak Flow:
The flow used to determine the diameter and gradient of the pipeline is the peak
flow. Peak flow is the most severe flow that could occur on any day when
considering daily flow fluctuations and infiltrations. The peak flow is derived from
the average flow by applying a peak factor for daily flow fluctuations. The peak
factor shall be estimated from the following formula:
c) Infiltration:
Infiltration is the amount of groundwater that enters sewers through damage in the
network such as cracked pipes, leaking joint seals, leaky manhole walls, etc. There
are many variables affecting infiltration such as quality of workmanship, joint
types, pipe materials, height of water table above pipeline, soil type, etc. The peak
factor above has included the contribution of infiltrations. The maximum allowable
infiltration rate shall be 50 litre / ( mm diameter.km of sewer length.day ).
The principal accumulants in sewers are slimes and sediments. The hydraulic
requirements for cleansing the sediments of sewer differ from those required for
cleansing the slimes of sewer.
a) Sediment Cleansing:
For the removal of sediments, the traditional design approach has been to set a
minimum velocity to be achieved at least once daily. Minimum velocity values at
full bore of 0.8 m/sec are commonly specified. However, it has been found that
larger pipe diameters require higher velocity to cleanse the sediment. This is
mainly due to higher sediment depths in large diameter pipes
b) Slime Cleansing:
The removal of slime depends on the stress needed to shear sections of slime from
each other or from the pipe wall. However, the shear stress required to remove
slimes is not a function of pipe diameter. The necessary shear stress depends on
the thickness of slime to be removed and the pipe material. The degree of removal
of slimes in any pipe material varies with the sewage velocity.
Removal of large portion of slimes requires high sewage velocities. It has been
found that 85% or more of the sulphide producing slimes are removed when the
grade of the sewer is 2.5 times of that for sediment cleansing. In many instances, it
may not be practical to design a sewer to achieve such velocities due to the
excessive cost of constructing such a deep and steep sewer. Although increasing
the velocity up to the critical velocity will increase the amount of slime being
sloughed off, the rate of sulphide production remains substantially unaffected by
the thinner slime layer. Therefore, the selection of steep gradient to achieve
velocities for full slime stripping is not a design requirement.
Except for very high velocities, slime will always be present, which will increase
the pipe roughness. Abrasion by sediments will also impart a permanent increase
in roughness. Pipeline roughness decreases as the velocity increases. However,
there is insufficient data to accurately determine the pipeline roughness for a wide
range of velocities or at small incremental changes in velocity. In addition, the
velocity of the sewage flow varies due to the factors such as daily fluctuations,
different type of catchment, different stage of catchment maturity, etc. Therefore, it
is not possible to select the pipe roughness with great accuracy.
Roughness, ks (mm)
Pipe Material
New Old
Vitrified Clay 0.06 1.5
Concrete: 0.15 3.0
Plastic 0.06 0.6
Old and new roughness values shall be used to determine the sewer cleansing and
maximum design velocities respectively.
Table 2.1b Normal Pipe Roughness for Force Mains for All Pipe
Materials
Unless special arrangements have been agreed for the structural protection of pipes,
the minimum depth of soil cover over the sewer shall be 1.2 m. Sewers are not to
be constructed under buildings.
The minimum size of public gravity sewers shall be 225 mm in diameter. The
minimum size of domestic connections to the public sewer shall be 150 mm in
diameter. The maximum design velocity at peak flow shall not be more than 4.0
m/s.
The design shall be based on the worst case scenario. The selection of the gravity
sewer diameter and gradient to cope with the peak flow shall be based on the
following equations:
where
V = velocity
S = hydraulic gradient (m/m)
ν = kinematic viscosity of water (m2 / sec)
D = internal diameter (m)
g = acceleration due to gravity (m/sec2)
ks = roughness coefficient (m)
Typical ks values for various types of sewer pipes are presented in Table 2.2 below:
2. Manning Equations
R 2 / 3 S1/ 2
V = n
where
V = velocity (m/sec)
S = hydraulic gradient
R = hydraulic radius
n = Manning coefficient
Typical n values for various types of sewer pipes are presented in Table 2.3 below:
Manning Coefficient, n
Material Good Condition Bad
Condition
Uncoated cast-iron 0.012 0.015
Coated cast iron 0.011 0.013
Ductile iron 0.012 0.015
Vitrified clay pipe 0.010 0.017
Concrete 0.012 0.016
where
V = velocity (m/sec)
S = hydraulic gradient
R = hydraulic radius
C = Hazen - Williams coefficient
Typical C values for various types of sewer pipes are presented in Table 2.4 below:
Colebrook-White Equation has been deemed to give the most accurate results.
However, the other equations, such as Hazen-Williams Equation and Manning
Equation are easier to use and may be used too. Various design charts and tables
have been developed elsewhere to aid the manual computations.
The minimum diameter of force mains (also known as rising mains) shall be 100
mm diameter. There shall be no reduction in force main diameter with distance
downstream.
All bends on force mains shall be securely anchored to resist lateral thrusts and
subsequent joint movements.
Air release valves and washouts shall be provided at appropriate locations along
the longitudinal profile.
For long and undulating force mains, hydraulic pressure transient analyses may be
required to ensure that the force main can cope with water hammer pressures.
Retention times in force mains must not exceed 2 hours without special precautions
to mitigate septicity.
All force main shall be designed to withstand at least 1.5 times the working
pressure. Approval from the Commission is required if any force main is to be
designed to withstand pressure less than the pressure stated above.
Where retention times in the force mains exceed two hours and where concrete
pipe are laid downstream of the force mains, an induct vent shall be provided at
manholes receiving pumping discharges.
Friction losses are normally calculated using either Darcy - Weisbach (Colebrook-
White) Equation or Hazen-Williams Equations. The forms of the equations are
different from the equations used to design gravity sewers. The equations are
listed below:
1. Darcy-Weisbach Equation
2
fLV
hf =
2 gD
where
hf = Friction loss
f = Coefficient of friction
V = Velocity in the pipe
g = Acceleration due to gravity
D = Equivalent diameter of the pipe
L = Length of pipe
The value of f is known to depend on the Reynolds number, Re, pipe roughness, ks,
and pipe diameter, D, through the Colebrook-White equation as follows:
1 = -2 log ks + 2.51
sqrt (f) 3.7D Re sqrt (f)
Re = VD
v
where v is the kinematic viscosity of the fluid, typically equal to 1 x 10-6 m2/s for
sewage.
The above equations together with the Moody Diagram are used to determine the
coefficient of friction, f.
2. Hazen-Williams Equation
1.85
⎛V ⎞ L
hf = 6.82 ⎜ ⎟
⎝ C⎠ D1.167
where
hf = Friction loss
C = Hazen-William Coefficient (refer to Table 2.4)
V = Velocity in the pipe
L = Length of pipe
D = Equivalent diameter of the pipe
Force mains shall be designed to handle the full range of flows from present
minimum to future peak.
The design velocity shall fall within the range of 0.8 to 3.0m/sec over the full range
of design flows.
The hydraulic resistance of force main fittings and bends shall be included in the
hydraulic design.
The design requirements of this Guidelines are the minimum requirements, and do
not constitute in themselves a comprehensive design guide sufficient to ensure a
correctly functioning system. Every system must be individually designed, based on
the design parameters of the system employed; where proprietary systems are
employed, it shall be designed in compliance with the requirements of system
manufacturers.
2.1.19.1 General
This Guidelines assumes that all sewage transportation modes have been identified, C
their respective feasibilities evaluated against technical, environmental, financial, o
economic and other relevant criteria over the design life of the asset and that n
vacuum sewage collection system has been confirmed as the best option. The c
Commission may request for net present value (NPV) calculations for all options
prior to approving construction of a vacuum sewage collection system.
Consideration shall be given to the use of the vacuum system in one or more of the
following circumstances:
b) Unit Processes
Typical unit processes for a vacuum sewage collection system is shown in typical
drawing in Appendix A. The unit processes shall comprise of, but not limited to, the
followings:-
i. Collection chamber for housing vacuum interface valve and also forming a
sump from which collected sewage is evacuated;
ii. A vacuum sewer network for the transport of sewage collected in the
collection chambers to a central vacuum station;
iii. A central vacuum station where the vacuum pressure is generated which
allows the sewage to be collected and forwarded to a receiving gravity
sewer manhole or a sewage treatment plant.
c) Description of System
The vacuum sewer discharges into the vacuum vessel at the vacuum station. The
vacuum is maintained, by vacuum pumps, at a predetermined level. The sewage is
generally pumped from the vacuum station by sewage discharge pumps.
ii ) Vacuum station
The vacuum station is similar to a conventional pumping station with the addition
of vacuum pumps and a closed vacuum vessel. Typical vacuum station is shown in
typical drawings in Appendix A. The level of the sewage in the vacuum vessel is
monitored by a level detection probe which activates the sewage discharge pumps.
If the sewage rises too high in the vessel then a high level detection probe stops and
locks out the vacuum pumps to prevent the flow of sewage into the vacuum pumps.
The vacuum in the vacuum vessel is maintained within the operational range by
pressure switches.
Since the vacuum system involves proprietary design and equipment, specialist
system designers shall be accountable to the performance of the entire vacuum K
system including both design and construction aspects. The specialist system P
designers shall also specify clearly the specific maintenance and operational K
requirements of the system. T
/
2.1.19.2 Collection Chamber
Collection chambers shall have sufficient capacity to store sewage discharged from
all connected properties for at least 6 hours in the event of a valve failure or similar
emergency, which is sufficient to cover the IWK’s emergency response time.
The overflow storage time shall be based on the ultimate sewage design flow that
will enter the collection chamber. The volume that can be used for emergency
storage shall be the volume contained in the collection chamber from the base of the
collection chamber up to the lowest ground level at any point served by the chamber
as well as the volume contained in the gravity lateral sewers entering the collection
chamber.
The chamber shall resist external forces and internal water pressure.
The collection sump requires a benching section that allows a scouring action from
the sewage as it enters the suction pipe, thereby rendering the sump self-cleansing.
The internal surfaces of the sump shall be both strong as well as resistant to
corrosive attacks from the collected sewage.
Where the interface valve is situated over the collection sump, a working platform
shall be provided for allowing maintenance engineers to stand on when carrying out
scheduled maintenance to the interface valve.
The sump shall be sufficiently vented to allow the intake of air without causing a
noise nuisance and to ensure that the operation of the vacuum system does not
unseal the water traps on the gravity drainage system.
The location of each collection chamber and the number of properties connected to
each collection chamber shall be specified in the Design Drawings / Calculations.
Sewage flow from the maximum number of existing or future properties that are K
proposed to be connected to a collection chamber shall be quantified, and the P
retention time of the collection chamber can be then established. The retention shall K
exceed 6 hrs. T
/
c) Maximum flows to collection chambers
The maximum sewer design flow to a single vacuum interface valve collection
chamber shall not exceed 0.25 lit/s. Where single point flows in excess of 0.25 lit/s
occur, multiple vacuum interface valves shall be installed. Typical multi-valve W
S
collection chamber is shown in typical drawings in Appendix A.
A
d) Breather pipes
Some vacuum interface valves inhale and exhale air during their operation. This is
accomplished through a screened air pipe known as a "breather".
While breather bells are generally mounted inside the collection chamber, it may be
necessary to mount them externally.
W
S
Each breather pipe shall be fitted inside the "breather bell" located at the top of the
collection chamber in an accessible location to allow their removal for maintenance
purposes.
a) General
The interface valve shall fail safe in the closed position and shall prevent backflows
from the crossover pipes to the collection sump. When the valve is open, the flow
path shall not be obstructed by the valve mechanism. The valve shall evacuate at
least the batch volume each time it cycles. Valves installed in the sump shall be
capable of operating when submerged provided that the breather pipe is not
submerged.
The valve shall be installed in the collection chamber using demountable, re-useable
“ No Hub” couplings suitable for vacuum service.
b) Level sensor
The valve shall be equipped with a sensor to determine the level of sewage in the
collection sump; this sensor shall be designed to be fouling resistant. Level sensor
pipes shall not be less than DN/ID 45.
The controller shall open the valve only if there is a minimum partial vacuum of
0.2bar below atmospheric available and shall maintain the valve fully open until at
least the batch volume has been evacuated. If the design provides for the
introduction of air after the sewage has been evacuated, the controller shall maintain
the valve open for a further period. The controller shall be adjustable so that a range
of air to sewage ratios can be obtained. Controllers installed in sumps shall be
capable of operating when submerged.
d) Explosion proof
Every interface unit, comprising the interface valve, controller and sensor shall be
expected to last in excess of 25 years. Manufacturers shall clearly specify scheduled
maintenance, thus allowing the operators to keep the interface units in tip-top
conditions at all times.
a) General
For a completely flat area, the length of a single sewer branch shall not be more
than 3km. However, the maximum limit of the pipe length would vary according to
the gradient achievable in that line. Specialist system designer shall provide a
detailed hydraulic calculation for the vacuum sewer network.
i. Minimise lift;
ii. Minimise length;
iii. Equalise flows on each vacuum main;
iv. Provide adequate access for operation and maintenance.
b) Sewer depth
Vacuum sewers, branch sewers and crossover pipe connections from the collection
chambers, shall have a minimum cover of 0.9 m to withstand the stresses arising
from traffic loads.
When sewers are not buried, they shall be protected from extremes of temperature,
ultra-violet radiation and possibility of vandalisms.
When sewers are suspended underside walkways or bridges, they shall be rigidly
supported so there is no visible sagging between supports. Supports shall withstand
all static and specified dynamic conditions of loading to which the piping and
associated equipment may be subjected. As a minimum, consideration shall be
given to the following conditions:
c) Sewer profiles
Pipeline profiles shall be self cleansing and prevent the accumulation of solids.
Typical pipeline profiles are shown in typical drawings in Appendix A. For
crossover pipes, the minimum distance between lifts shall be 1.5 m. Vacuum sewers
shall have a minimum gradient of 1 in 500. Where the ground has a gradient of 1 in
500 or more in the direction of flow, the vacuum sewer may be laid parallel to the
surface as shown in typical drawings in Appendix A.
i) Design tolerances
The chainage and invert levels of the pipeline(s) shall be determined to the
following levels of design accuracy and specified in the Design Drawings:
Crossover pipe shall initially fall away from the interface valve and shall connect
into the top sector of the vacuum sewer contained within the angle of ± 60° about
the vertical axis as shown in Standard Drawing – Figure Vac7.
v) Water-logging
The profile shall ameliorate water-logging at any change in gradient even when a
prolonged power failure occurs (both TNB supply and standby genset fail), and the
vacuum interface valves continue to operate and admit sewage until the vacuum
level reduced to the point when they will no longer open. When power is again
available, the system shall be capable of recovering to normal operation without
intervention by an operator.
i) Pipe size
The suction pipe DN/ID shall not be greater than the DN/ID of the interface valve.
The minimum diameter of crossover pipe shall be DN/ID 50 and shall be greater
than the DN/ID of the suction pipe. Vacuum sewer shall have a minimum diameter
of DN/ID 80.
PE pipes and fittings less than DN 160 shall be jointed using electrofusion fittings.
Pipes and fittings DN 160 and larger shall be jointed with electrofusion fittings or
butt fusion welding.
To act as a warning to an excavation possibly carried out at a later date, the use of a
marker tape laid 300mm on top of the pipe is recommended. This shall be a 150mm
wide polyethylene and printed with a descriptive warning of the pipework below.
e) Isolation valve
The isolation valve clear opening shall be not less than the DN/ID of the pipe, and
be capable of sustaining a vacuum pressure of -0.8 bar(g).
Isolation valves shall be resilient seated gate valves with the body, bonnet, gate and
bridge fabricated from ductile or cast iron. The stem shall be stainless steel, and the
gate shall be encapsulated with EPDM. End connections to the valves shall be
flanged.
When isolation valves are buried, they shall have extension spindles and surface
boxes.
a) General
It is desirable to have the vacuum station located as centrally as possible within the
sewer network. This lends itself to a system with multi-branches hence giving
added operating and design flexibility. Ideally, the design capacity of a single-
vessel vacuum station shall not exceed a population equivalent of 8,000 persons. A
The floor level of the dry well shall be designed to suit the invert levels of the
incoming sewers, the vacuum vessel diameter and the dimensions of the selected
sewage discharge pumps.
The vacuum vessel, the sewage discharge pumps, valves and pipework associated
with the sewage discharge pumps and a small sump to collect washdown water shall
be located in the dry well.
The plant room shall contain the vacuum pumps, control panel, standby diesel
generator, vacuum pressure gauges, and moisture trap.
c) Vacuum vessel
Vacuum vessels shall be designed to meet the requirements of ASME Section VIII
Division 1 – 2004 Edition. The vessel shell shall be constructed from mild steel or
any other approved material.
Sewer inlets shall be provided with short radius elbows inside the vessel to direct
the sewage inflow away from the sewage discharge pump suction connections and
the vessel walls.
A vacuum vessel may have up to five (5). incoming vacuum sewers connected
directly to the vessel. No inlet pipes shall be connected below the system
emergency stop level. Sewage discharge pump suction connections shall be
provided at the invert of the vacuum vessel. The vacuum vessel shall be fitted with
an externally mounted sight glass which is suitable for operation in a vacuum and is
easily removed for cleaning without decommissioning the vessel.
The vacuum vessel shall be provided with a DN 600 access opening, and the cover
shall be provided with a lifting eye. Wherever possible, the opening is preferably
positioned on the top of the vessel in order to minimise the size of the structure
necessary to house the vessel, this conserves valuable resource, reduces the
footprint of the building, and thus allows adjacent residences to enjoy more buffer
spaces.
During the inspection or maintenance works, safe entry procedures shall be adhered
to, according to the Department of Occupational Safety and Health (DOSH) codes
of laws, by trained certificated operator, and that the vessel is decommissioned,
with the access opening removed and discharge pipeworks at the two (2) draw-off
points dismantled, and a forced air ventilation is applied.
It is important to ensure that the system would operate continuously in the face of
having the vacuum vessel temporarily out of service during an interval inspection. C
o
n
cl
u
d
32 Volume 3 Malaysian Sewerage
e
Industry Guidelines
Planning, Material and Design
The incoming sewage shall manually be bypassed to a mobile vacuum tanker via a
flexible ribbed pipe. The pipe is of an adequate length to reach the bypass valves
safely. Typical bypass valve arrangement is shown in typical drawings in Appendix
A.
d) Moisture trap
When mechanical vane vacuum pumps are selected, moisture trap shall be provided
for the vacuum pumps.
Baffles or moisture removing material shall be fitted inside each vessel to assist
with moisture removal.
e) Vacuum pumps
Vacuum pump capacity (Qvp) shall be rated. The selection of appropriate size of
vacuum pump is determined by the following four factors:-
i) Evacuation time
When the vacuum pumps, collection chamber and vacuum vessel have been sized,
system evacuation time for an operating range of – 0.55 bar(g) to –0.65 bar(g) shall
be calculated using:
⎡⎛ 2 ⎞ ⎤
⎢⎜ 3 ⎟Vvs + (Vvv − Vo ) + Vmt ⎥ × 60
⎝ ⎠
t=⎣ ⎦
Qvp
Where,
t = system evacuation time, minutes
Vvs = volume of vacuum sewers, m³
Vvv = volume of vacuum vessel, m³
Vo = operating volume of vacuum vessel, m³
Vmt = moisture trap volume (if fitted), m³
Qvp = vacuum pump capacity, m³/hr
The system evacuation time, which is defined as the time period between the
vacuum pump start and stop, shall be between 2 and 5 minutes.
ii) Selection of vacuum pumps
Vacuum pumps shall have sufficient capacity to serve the system. A minimum of
two vacuum pumps of equal capacity shall be installed such that one pump can be
removed for maintenance without loss of system capacity. Vacuum pumps, where
used, shall be suitable for both continuous operation and for a minimum of 6 starts
per hour.
ABS pipes and fittings shall be used for interconnecting pipework between the
vacuum pumps and the vacuum vessel within vacuum stations.
Two sewage discharge pumps of equal capacity are recommended for use in a
vacuum station. Each pump shall be sized to discharge sewage at a rate at least
equal to the calculated design peak flow for the vacuum system. Sewage discharge
pumps shall be capable of pumping unscreened sewage and suitable for immersed
operation in the event of the vacuum station dry well flooded. In normal operation
the dry well will not contain water.
Sewage discharge pumps shall be suitable for a minimum of 6 starts per hour.
Equalizing lines connecting the discharge side of the centrifugal sewage discharge
pumps to the vacuum vessel shall be installed if required to prevent cavitation or to
ensure that the pump inlet is always flooded.
Sewage discharge pumps shall be fitted with isolation valves to allow removal of
the pump without disrupting the system operation.
Discharge pipework for each pump shall be fitted with a non-return valve and a
resilient seated gate valve on the discharge side. Where the discharge pipework is
manifold, the final discharge pipe shall also be fitted with a non return valve. The
valves shall be able to be operated from the vacuum station floor.
g) Vacuum gauges
h) Fire-fighting system
Fire-fighting system using carbon dioxide at the genset / fuel room shall be
provided at every vacuum station in accordance with Bomba’s requirements.
i) Odour control
Effective odour control system shall be provided to treat air vents from a vacuum
station to prevent malodour impacts being imposed on downstream residential
areas.
Biofilters shall be used to remove the odours from the vacuum pump exhaust gases
containing toxic and odorous compounds by passing the gases through a natural
biologically active filter medium.
j) Noise control
Vacuum station shall be acoustically designed and fitted with noise control
measures, as required to control noise to levels that comply with local council’s
regulations.
Vacuum levels in the vacuum vessel shall be controlled by vacuum switches with
an operating range of 0 to -1 bar(g). Their purpose is to control the operation of the
vacuum pumps and to maintain the vacuum within the vessel inside the operating
range. A minimum of four vacuum switches shall be provided to operate the duty
and assist pumps, and to provide a high and a low vacuum alarms.
The level detection probes shall be mounted on the vacuum vessel. Their purpose is
to control the operation of the sewage discharge pumps and to maintain the sewage
within the vessel inside the operating range.
Probes shall be manufactured in one length without any screw joints along their
length. Any form of float switch, including magnetic and ultrasonic types shall not
be permitted.
The level control system shall respond to the following sewage levels in the vacuum
vessel:
The controls shall permit the selection of duty, duty assist (where provided) and
standby vacuum pumps and sewage discharge pumps and shall provide for the
automatic introduction of the standby units in the event of failure.
The electrical controls shall allow sequential operation of all pumps so that running
times are equalised. The standby pump shall automatically cut-in should the duty
pump fail.
Valve monitoring and station telemetry systems are optional, but, shall be
implemented for larger schemes comprising more than 50 interface valves.
The open and closed status of interface valves shall easily be detected by the use of
a remote control via infrared/radio signals. Alternatively, system suppliers may
install a signal cable to relay this information to a display panel within the vacuum
station. All monitoring components installed at the collection chambers shall be
robust and suitable for use in sewerage application.
Large schemes shall also include a telemetry section with volt-free contacts for each
condition/alarm of the station equipment as shown in Table 2.5
A back-up diesel generator shall be provided to adequately run the station in the
event of an electric power disruption. The generator shall be capable of providing
120% of power for at least one vacuum pump and one sewage discharge pump and
other necessary equipment.
Manual computations for the hydraulic design of a sewer network can be avoided
for many aspects using proprietary computer software or in-house computer
programs. However, there are many variations possible for the different aspects of
hydraulic design, i.e. flow contributions from different sources, quantity of
infiltration, quantity of inflow, sediment cleansing requirements, pipeline
roughness coefficients, etc. It is therefore necessary that the computer software or
programs adopt the hydraulic design requirements as detailed in this guideline.
Some proprietary softwares may not permit certain adaptations required to conform
to the hydraulic design requirements given in this guideline. As such, these
software would be unsuitable.
Inverted siphons are introduced along a gravity sewer line in order to pass under an
obstacle (e.g. railway line, stream, culvert, etc). An alternative to an inverted
siphon for bypassing obstacles is a pump station. But such an option may be
economically not viable. The profile of an inverted siphon encourages solids
settlement and accumulation and therefore they require more frequent cleaning.
They must be avoided as much as practicable.
Inverted siphon shall consist of at least two or more parallel pipelines (or barrels).
The minimum pipe size of a barrel shall be 225mm, and shall be provided with
necessary appurtenances for convenient flushing and maintenance. There will be an
inlet chamber designed to divide the flow among the pipes by allowing each pipe to
come into operation in succession and an outlet chamber designed to prevent
eddies from carrying solids and sediments back into the siphons.
Longer siphons shall be provided with hatch box with access for maintenance and
cleaning. These siphons shall have independent washout facilities.
The manholes shall have adequate clearance for rodding. In general sufficient head
shall be provided and pipe sizes selected to secure flow velocities of at least
0.9m/sec for average flow. The inlet and outlet shall be arranged so that the normal
flow is diverted to one barrel, and so that either may out of service for cleaning. Its
choice should be taken into consideration the operational and maintenance aspect
of siphons. The siphons shall not have sharp bends, either vertical or horizontal.
The horizontal leg of the siphon shall have a negative gradient of 8° to 10°, whilst
the rising leg shall be limited to 30° to 45° should space permitting. There shall be
no change in pipe diameter along the length of the barrel. Pipes and pipe joints
used for siphons shall be designed at the appropriate pressure rating.
The structural design of a buried sewer can be divided into the following two
categories:
a) rigid pipe
b) flexible pipe
All two structural designs shall take account of how the sewer is supported to
determine the loading which the sewer can safely withstand.
The structural design of a buried sewer normally considers only the structural
integrity of the pipe cross section. Although not as critical as the structural
integrity of the pipe cross section, the considerations for the ground conditions and
sewer installation practices that will affect the longitudinal structural integrity shall
not be omitted.
There are many design approaches for each of the two structural design categories.
However, there are only minor alterations among these different approaches. Some
design approaches tend to give a more favourable prediction of performance for a
particular pipe material than other approaches. The use of standard design
approaches given in this guideline will prevent the selection of a particular design
approach purely to favour one material over another. Also, the following
recommendations are only meant for general design aspects. Any design aspects
that are not covered by this guideline, the designer shall refer to BS EN 752 or any
other standards deemed appropriate by the Commission.
The failure of a rigid pipe normally occurs by pipe fracture. Thus, for structural
performance, the determination of the pipe ring crushing strength/load is required.
This strength is determined using a three point loading test as described in the
respective Malaysian standards for the above pipes. Both VC pipe and RC pipe
can be made to achieve different ring strengths as defined in the standards.
When a buried rigid pipe is supported, the load which the pipe can safely withstand
is higher than the load which caused failure in the three point loading test.
By varying the pipe ring strength and the pipe support, different load resistance can
be achieved.
The pipe support designs permitted by this guideline are limited to those in typical
beddings in Appendix A. They include the following:
It is important that the pipe bedding should be properly constructed to allow for the
flexibility at the pipe joints and to ensure uniform pipe supports. Point supports or
loads which may lead to pipe failure must be avoided.
The soil load to which a rigid pipe can be subjected to shall be determined from
Martson Load Theory. According to the theory, the soil load on a rigid pipe differs
from that on a flexible or semi flexible pipe. The load on a rigid pipe is a function
of trench width, backfill soil type and trench depth. In a narrow trench, trench wall
friction reduces the load applied by the soil backfill. Therefore, wide trench gives
a more conservative loading and shall be used to determine the load on rigid pipe.
Where vehicles will pass over the sewer and the sewer is laid with a cover depth of
less than 2.5 m, the sewer will be subjected to additional loads from such vehicles.
The Boussinesq theory should be used to determine the loads from vehicles in the
design.
The ultimate vehicle load to which the sewer will be subjected to shall be used for
structural design. Where the sewer may be subjected to construction traffic or may
have temporary shallow cover during installation, structural design must examine
such loading conditions to ensure the sewer can withstand such temporary vehicle
loadings.
Loads on buried rigid pipe for field conditions and for main roads can be found in
Simplified Tables of External Loads on Buried Pipelines published by the UK
Transport Research Laboratory.
i. PE pipe
ii. GRP pipe
iii. ABS pipe
iv. Steel pipe
Normally a standard long term allowable ring deflection is applied for all flexible
pipe. A 5% long term deflection limit has been the most commonly adopted limit
and shall be used except for steel pipe with cement mortar lining. For steel pipe
with cement lining, a 2% deflection limit shall be used. Where surface settlement
is critical, a lower allowable deflection limit may be adopted.
Similar to rigid pipe, the loading which a flexible pipe can withstand can be
increased when the pipe is supported. For flexible pipes, this external ring support
is more critical. Without it, a flexible pipe would fail under the loads applied by
usual soil cover for gravity sewers and under vehicle loads for shallow cover force
mains.
By varying the pipe ring stiffness and surrounding soil stiffness, different load
resistance can be achieved for flexible pipe. Flexible pipe must be completely
embedded in crushed rock, with the rock to be finished at 150 mm over the top of
the pipe. Crushed rock will give a uniform support around the pipe.
The soil load used for structural design for flexible pipe support shall be the prism
load or the weight of the column of soil directly above the pipe. Marston Load
Theory mentions that this column of soil is partly supported by friction provided by
adjacent soil. Therefore, this frictional support of soil column causes the load on
the flexible pipe to be less than the weight of soil directly above the pipe. This
frictional support may be lost with time and the design using prism load represents
a conservative design.
Where vehicles will pass over the sewer and the sewer is laid with a cover depth of
less than 2.5 m, the pipe will be subjected to additional loads from such vehicles.
The Boussinesq theory should be used to determine the loads from vehicles in the
design approach in this guideline.
The ultimate vehicle load to which the pipe will be subjected to shall be used for
structural design. Where the pipeline may be subjected to construction traffic or
have a temporary shallow cover during installations, structural design must
examine such loading conditions to ensure the pipeline can withstand such
temporary vehicle loadings.
For force mains with shallow cover, structural design of flexible pipe may not be
necessary. However, when the structural design of flexible pipe for such a force
main is undertaken, the re-rounding effect of internal pressure should be ignored to
allow for the worst case design, which occurs when the line is out of service.
2.2 Manhole
2.2.1 General
Pre-cast concrete manholes shall conform to MS881 and BS5911. Manholes shall
be constructed with pre-cast concrete sections surrounded by an in-situ concrete
surround. Protecting lining/coating shall be provided to prevent corrosion of the
concrete due to sulphide attack. Walls shall be either rendered with sulphate
resistant cement mortar at least 20mm thick or lined with PVC, HDPE or epoxy
coating. PVC or HDPE lining shall be at least 5mm thick. Continuity of the lining
shall be provided by means of welding or fusing each individual sheet to the next
prior to the concrete curing. The epoxy coating shall either be high build tar epoxy
system complying with AS 3750.2 and applied in two or more coats to give a total
dry film thickness of not less than 500µm; or high build micaceous iron oxide
pigmented epoxy system complying with As 3750.12 and applied in two or more
coats to give a total dry film thickness of not less than 250 µm. The benching shall
be protected with epoxy coating, high alumina cement mortar, or equivalence.
Only materials and application processes approved by the Commission may be
used.
Brick manholes shall not be used, due to the high risk of excessive infiltration.
Details of manhole types and construction are shown in Appendix A. Straight back
type taper top shall be used while reducing slabs type are acceptable as alternative.
Any other type of pre-fabricated manhole will require prior approval of the
Commission.
diameter. The top of the concrete support of the vent shall be built up above flood
level. Details of the induct vent are shown in Appendix A.
a) for pipe size equal to 225 mm or less, back-drop manhole shall be provided
when the difference in invert level is equal to 900 mm or more.
b) for pipe size more than 225 mm, back-drop manhole shall be provided
when the difference in invert level is equal to 1000 mm or more.
Unless otherwise agreed by the Commission, all manholes shall be sited in public
road reserve so that access can be gained for maintenance purposes. Manhole shall
be provided for the following locations:
i.the starting end of all gravity sewers, this may be replaced by a terminal layout
ii.every change in direction or alignment for sewers less than 600 mm in diameter
iii.every change in gradient
iv.every junction of two or more sewers
v.every change in size of sewer
Unless adequate modern cleaning equipment is used for the maintenance of the
sewer, the spacing between manholes shall not be more than 100 m for sewers less
than 1.0 m in diameter. For sewers with diameter larger than 1.0 meter, the spacing
between manholes shall not be more than 150 m.
Where site conditions prevent manhole construction on the existing public sewer, a
manhole shall be provided on the connection pipe as near to the public sewer as
possible.
The connections, details, and methods of manhole construction not covered in this
guidelines shall be in accordance with MS 1228. In addition, the current policies
of the Commission with respect to safety and operation shall be strictly followed.
To prevent the differential settling of the manhole and the connecting sewer from
breaking the sewer pipe, rotational flexibility in the sewer close to the manhole is
required. A single flexible joint placed immediately outside the entry to the
manhole is not sufficient to solve the differential settlement problem, unless graded
(governed by gradient permissible range) to connect directly to match invert level
of manhole channel, if unable to match invert level. A short length of “rocker pipe”
having a flexible joint at both ends shall be provided. A 600 mm length short
“rocker pipe” is sufficient to provide the rotational flexibility required for most
circumstances in small diameter pipelines (≤300 mm). For larger pipe, a 900mm
length short “rocker pipe” shall be provided. Refer to drawings in Appendix A.
xxi. Precast or cast in-situ concrete base of minimum grade 20 with 1 layer of
A6 BRC, 300 mm thick or to Qualified Person’s design shall be provided
under poor soil condition including piling, if necessary.
Manhole covers and frames shall comply with the specifications in this guideline
and BSEN124. Where the specifications in this guideline contradict the
specifications given in BSEN124, the specifications in this guideline shall take
precedence.
Manhole covers and frames shall be capable of bearing wheel loads of up to 400
kN and, as such, shall meet the test load requirements for Class D400 manhole
covers and frames given in BSEN124.
2.3.3 Material
The material for manhole covers and frames shall be of spheroidal or nodular
graphite iron (otherwise known as ductile iron) complying with the requirements
specified in BSEN1563 for Grade 500/7.
The production, quality and testing of spheroidal graphite cast iron shall comply
with ISO 1083.
The manhole covers shall be free of defects which might impair their fitness for
use.
The dimensions, marking and surface finish of manhole covers and frames shall
comply with the requirements given in Figure A.1 to A.4 in Appendix A.
2.3.5 Seating
When a random cover is placed in a random frame, the adjacent top surfaces of the
cover and frame shall have flushness of level within ± 1 mm.
The manholes covers shall be compatible with their seatings. These seatings shall
be manufactured in such a way to ensure stability and quietness in use.
2.3.6 Casting
All cast units shall be cleanly cast and free from air holes, sand holes, cold shuts
and chill. They shall be neatly dressed and carefully fettled. All castings shall be
free from voids, whether due to shrinkage, gas inclusions or other causes.
All surfaces of manhole covers and frames shall be supplied coated with either a:
Immediately prior to coating, surfaces shall be clean, dry and free of rust. The
coating shall be free of bare patches or lack of adhesion. The mean thickness shall
be no less than 70 µm and the local thickness shall be no less than 50 µm.
2.3.8 Water-tightness
No visible leakage shall occur between the manhole cover and its seating in the
frame when tested in accordance with Appendix E of AS 3996.
Manhole covers shall be provided with locking device and hinge to prevent rocking
due to traffic and to provide a theft proof design.
a) Locking Devices
Locking devices shall be either bolts and nuts or a mechanism with a special key
design. The mechanism shall be able to be integrated with the covers and can also
be used as a lifting device. All the mechanism for locking device shall be of
stainless steel in accordance with BS EN ISO 3506. Bolts and nuts for locking
devices shall be hexagonally headed, complying with BS3692.
b) Hinge
All manhole covers shall be hinged. The hinge shall be designed such that, when
in the open position, they shall be secured by a positive mechanical retainer to
prevent accidental closure of the covers. The opening angle of hinged covers shall
be at least 100o to the horizontal. If hinge bolt is used for coupling separate
sections of covers and frames, it shall be of stainless steel in accordance with BS
EN ISO 3506.
Manhole covers and frames shall be certified as complying with the requirements
of this specification. The product testing for certification purposes shall be
undertaken by SIRIM QAS, IKRAM QA services or other third party certification
body. The approval of the product shall be from the Commission.
The quality control of the certified manhole covers and frames shall meet the
requirements given in Clause 10 of BSEN 124. However, the final inspection and
tests and the frequency of tests/inspection shall not be as shown in Table A3 of
BSEN 124. Instead, the specifications as shown in Table 2.7 below must be
followed. All final inspection and test documents shall be retained for at least 5
years.
iii. Drainage of dry wells and valve pits shall be provided. Drainage lines shall
be equipped with back flow protection to ensure that the chamber is not
flooded.
iv. Wherever possible, the wet well shall not be housed within a building
structure with insufficient ventilation.
v. Where separate valve pits are used, then the connecting pipes shall
incorporate at least two flexible joints to allow for differential settlement.
vi. The designer shall ensure that his/her designs comply with all relevant
legislation, standards, guidelines and requirements, and its latest
amendments.
vii. Access and appropriate parking shall be provided at all times for emergency
vehicles, maintenance vehicles and ancillary equipment.
viii. Adequate protection against lightning shall be provided
In order to minimise the nuisance of odours from pumping stations, buffer zone
shall be provided at all sides. The zone shall be at least 20 m from the pumping
station fence to the nearest habitable building fence. The presence of a pumping
station in any development may draw negative visual impacts. To minimise the
visual impact of surface structures of the pumping station, landscaping shall be
provided. Landscaping shall comprise of trees that are non-shedding to minimise
maintenance. The buffer requirements are shown in Appendix A.
Under conditions where there exists the potential of odour nuisance to the nearest
habitable building property line within residential and commercial development
despite having the minimum buffer zone, such odour shall be minimised to the
lowest possible level and in compliance with the EQA.
i. Pipe work shall be of ductile iron with approved internal lining. Other
approved material by the Commission may be used.
ii. External surface of pipe work in chambers and wells shall be epoxy coated.
iii. Buried ductile iron pipe shall have polyethylene sleeving.
iv. Pipe work shall be adequately supported
v. Flanges shall be located at least 150 mm away from structures.
vi. Dismantling joints such as bends shall be provided.
vii. Pumping thrust shall be resisted using pipe supports
viii. All internal pipework within the pump station shall have flanged joints
unless the pipe selected has special jointing requirements.
ix. Flexible couplings should be used where they will facilitate dismantling and
accommodate vibration.
i. The size of dry well depends primarily on the number and type of pumps
selected and on the piping arrangement.
ii. The requirement of pump installation is to provide at least 1.0m from each
of the outboard pumps to the nearest side wall and at least 1.2m between
each pump discharge casing.
iii. Sufficient room is required between pumps to move the pump off its base
with sufficient clearance left in between the suction and discharge piping
for site repairs, inspection or removal from the pit to the surface for repairs.
iv. Consideration should be given to the installation of monorails, lifting eyes
in the ceiling and A-frames for the attachment of portable hoist cranes and
other devices.
v. Provision should also be made for drainage of the dry well to the wet well.
i. Ventilation shall be provided for all hazardous zones of the pump station.
ii. Covered pits shall have mechanical ventilation.
iii. Separate ventilation shall be provided for wet wells and dry wells.
i. the potential for odour generation, its impact and treatment, shall be
considered in all aspects of design
ii. isolate odorous gasses from general ventilation exhausts by containing
identified odour generating sources with a separate local exhaust system
iii. containment of the odour sources shall be by installing lightweight and
corrosion resistant covers/enclosures designed for practical operation and
maintenance works
iv. the local exhaust odorous air shall be conveyed through well designed and
balanced ductworks by a centrifugal fan to an effective odour treatment
equipment
i. Centrifugal
ii. Screw
iii. Screw Centrifugal
Pumps are to be equipped with an auto restart mechanism to allow for automatic
pump restart after power supply has resumed from a power failure. Pumps shall be
equipped with protection accessory, e.g. thermal sensor, leakage sensor, etc. Dry
well mounted pumps shall be equipped with auxiliary services such as cooling and
gland seal water supply.
Guide rail, lifting device and other wet well fittings must be fabricated of stainless
steel, that is corrosion resistant. The use of hot dip galvanised iron is not
recommended.
Pre-fabricated pump stations are acceptable for small installations of PE less than
or equal to 2,000.
2.4.12.1 General
i. All valves shall be anti-clockwise opening.
ii. All valves shall be suitable for use with wastewater and shall be designed to
prevent retention of solids.
iii. All valves shall be identified by durable name plate. Direction of flow shall
be stamped on the valve body.
iv. Bodies and cover for all valves shall be made of ductile iron to BS EN
1563: 1997. Special protective surfaces finishing by short blasting and
finished externally with epoxy corrosion resistant coating shall be provided.
vii. In the absence of check valve, the reverse rotation of the pump shall not
exceed 150% of the rated speed or limit set by the manufacturer.
viii. Tapping (12 mm BSP) shall be located upstream and downstream of check
valves.
i. Either floats, electrodes or ultrasonic level controls may be used for start-
stop level of pumps. Those level controls with environmental friendly
features are recommended.
ii. Ultrasonic level control is recommended due to its clog-free nature.
iii. Non-mercury type floats are recommended.
iv. Hollow tube electrodes are not acceptable.
v. Level controls shall be placed where they are not affected by the turbulence
of incoming flow and where they can be safely removed.
vi. When floats are used, cable hanger shall be installed.
i. System curves
ii. Pump curves
iii. Operating point of pumps with respect to flow and total dynamic head
(TDH)
iv. Operating characteristics such as efficiency, horsepower, motor rating and
NPSH
i. All pumping station design shall give consideration to all potential hazard
and operability of design.
ii. HAZOP study may need to be conducted for pumping station design to
identify the hazards and operability issues.
iii. The need for HAZOP study shall comply with requirements stipulated the
Volume II.
Table 2.8 Recommended Design Parameters for Pump Stations (continue on next page)
Design Parameters
Description Unit PE ≤1,000 1,000 < PE ≤ 5,000
Design Parameters
Description Unit 5,000 < PE ≤ 20,000 PE > 20,000
Type of station wet well or dry well up to 10,000 PE wet well and dry well
10,000 PE above – wet well and dry well
2.5 Interceptors
All development schemes including individual premises that involve any sewerage
works are vetted by the Director General. As part of this vetting, a check is made
on the means of protecting public sewers from the discharge of prohibited matters
such as oil, grease, petrochemicals, fats and solid food wastes. These matters can
lead to congealment, constriction and blockage of sewers and pipelines and can
also present hazards for sewer operations and maintenance. Therefore, suitable
interceptors must be provided on the sewerage systems of garage workshops,
engineering workshops, canteens or any premises that collect such matters. The
design specfication may be acquired from the Director General for such a system.
Oil interceptors shall be provided in drain lines from areas such as garages, parking
zones, service stations, machine shops and industrial plants where oil sediments
and other volatile liquids are generated.
Oil interceptors shall be designed in such a way that pollutants that are lighter than
water liquid are trapped in a chamber and are prevented from being discharged to
the public sewer. The chamber shall be normally fitted with a device to trap
sediments and heavy particles that settle to the bottom. The removal of these
sediments is required periodically.
Intercepted oils shall be capable of being drained off for storage from suitable draw
off points on a continuous operational basis.
Grease traps shall be provided in drain lines from areas such as restaurants,
canteens, food processing and animal product or feeds factories, where grease and
fat are likely to present in wash down waters or sullage.
Grease traps shall be designed in such a way that solidified grease and fats are
trapped in a chamber prior to discharge and may be skimmed off by means of a
perforated strainer or bucket.
The trap shall be sized adequately to contain the volume of liquid to be discharged
from the drain line and the accumulated grease.
2.6.1 Concrete
2.6.2 Cement
3.1 Introduction
The correct installation of sewer systems is critical to the efficient and effective
sewer system operation. Poor construction practice causes defects in the sewer at
joints, along pipe barrels, at manholes, transition points (e.g. pipe to manhole), etc.
Adequate site supervision and certification by consultants, with reference to
approved design drawings, are therefore also required.
The various construction and installation aspects of sewer system can be divided
into:
h) The delivered pipes and fittings shall be checked against the design
drawings and the delivery docket to ensure the pipe and fittings delivered
are of the strength, stiffness, pressure class, length, joint type, diameter,
fitting type, etc. specified.
i) The delivery truck shall be positioned on a flat ground or in such a way
that pipes and fittings would not fall off the truck when unsecuring the
fastenings.
j) Pipes and fittings shall not be pushed off the delivery truck and shall not
be allowed to drop to the ground.
k) When pipes are delivered in crates, the crates shall be removed intact,
wherever possible.
l) Pipes and fittings shall be lifted from the delivery truck using approved
slings. Plastic covered wire mesh slings, hemp rope slings and chain
slings without rubber sleeving are not suitable. For plastic pipes or pipes
with external coating, webbed synthetic slings shall be used.
m) Alternatively, pipes and fittings can be removed from the delivery truck by
rolling a pipe at a time down the wooden runners. The pipe rolling shall
be simultaneously controlled by ropes.
n) Uncrated light thermoplastic pipes shall be lifted manually and carefully
off the truck and shall not be dragged across the truck bed, edges or other
hard and sharp surfaces. This is to avoid the scoring of plastic pipe.
k) The slings or chains used for lifting the load shall be secured to the load in
the right manner to ensure the load does not slip or tilt excessively.
l) All other safe lifting procedures not covered above shall be adopted.
m) The lifting and moving of all the steel pipes and any pipes that contain
internal linings shall follow the manufacturer instructions.
a) The pipe and fittings storage area shall be away from traffic and shall not
obstruct any property access or pedestrian route.
b) The pipe and fittings storage area shall be at a location that allows lifting
machinery to position easily and safely for lifting pipes and fittings.
c) Pipes shall be stacked on a flat and level firm ground or the base of the
pipe stack shall be made level using additional solid timbers under base
bearers.
d) There shall be no rocks, tree roots, etc. under the pipe stack, which may
cause point load.
e) The sockets shall be alternated to different ends for each pipe stack layer.
The sockets shall be protruded out of the stack.
f) The base timber bearers shall be sound and without protrusions. The cross
section of each timber shall be at least 75 mm by 75 mm. The base bearers
shall provide support near the pipe ends, but placed behind sockets. The
placement of base bears shall not be more than 1.5 m apart.
g) VC, RC, DI, Steel and GRP pipe layers shall be separated using timber
spacers of at least 50 mm wide and 50 mm thick. These spacers shall not
be placed more than 1.5 m apart. These spacers will prevent pipes in each
layer from touching pipes in the next layer.
h) For VC and RC pipes that are not crated, the pipes shall not be stacked
more than 3 pipes high. The pipe stacks shall be wedged to prevent them
from rolling off the stack.
i) Thermoplastic pipes (PE and ABS) shall be stacked in such a way to
prevent them from being twisted or bowed.
j) Thermoplastic pipes shall be either stacked in a pyramid with no more than
1 m high or in a square with vertical side supports for more than 2 pipes
high.
k) Plastic pipe and fittings shall be kept under a cover that prevents direct
exposure to sun light.
l) Plastic pipe and fittings shall not be covered with plastic sheeting.
m) Plastic pipe and fittings shall be stored away from oils, greases, solvents
and other aggressive chemicals.
n) Plastic pipe shall be stored away from sources of heat such as engine
exhausts.
o) Care shall be taken to prevent scoring and scratching of plastic pipe and
fittings.
p) Joint lubricants, rubber rings and other jointing materials shall be stored in
a secured area that cannot be accessed by the public.
q) Any safe pipe stacking procedure not covered above, but recommended by
the manufacturer, shall be adopted.
r) The rubber rings that are not delivered fitted to the pipe socket or sleeve
shall be stored away from direct sunlight or continual artificial light. Also,
the rubber rings shall be stored in a cool area that is away from oils,
greases or other petroleum products.
s) When rubber rings are delivered fitted to a pipe socket or sleeve, the pipe
ends with the rubber ring shall be shielded from sunlight using a hessian
cloth.
t) Rubber rings shall be retained in the original sealed packaging until they
are required.
a) Pipes, fittings (including coatings and linings) and rubber rings shall be
inspected for damage on delivery, immediately before laying and after
laying.
b) Damaged pipe and fittings shall be identified and marked with an indelible
marking of “Damaged” in a clearly distinguishable colour.
c) Damaged rubber rings shall be cut through completely to prevent
inadvertent use.
d) Damaged pipe, fittings, and rubber rings shall be set aside and separated
from the undamaged components.
e) Pipes or fittings shall only be repaired if they can be restored back to a
satisfactory state. Approval for repair shall be sought from the
Commission before the repair.
f) Pipes or fittings that are damaged and are in a repairable state shall be
repaired according to the manufacturers instructions.
g) Damaged pipe and fittings that are not permitted to be repaired shall be
removed from the site as soon as possible.
h) PE and ABS pipes with damage in the barrel, shall have the damaged
section and at least 100 mm either side of the damage cut from the barrel.
i) Repaired pipes and fittings shall be used only after the approval for reuse
from the Commission is granted.
a) The required line of the sewer and manhole locations shall be set out using
accepted surveying practices.
b) Manhole locations shall be pegged and the line of the excavation between
manholes shall be maintained straight using one or more of pegs, chalk lines
laser beam lines and string line.
c) Changes to the line, grade or level due to unforeseen obstructions or
proximity to services shall be approved by the Commission prior to making
the actual changes.
d) The trench shall be excavated precisely along the marked alignment to
ensure the sewer will be in the centre of the trench.
e) The trench shall be excavated to a depth so that the sewer can achieve the
specified level and grade when the specified bedding depth is used.
f) Over-excavation of the trench depth shall be avoided.
v) Changes to the line, grade or level of the sewer shall be properly recorded
for incorporation in the as-constructed drawings. All as-constructed
drawings, irrespective of whether there are changes to the original design
drawings, shall be certified by consultants and shall include sufficient
details, including as-built sewer invert levels. These drawings shall be
submitted to the Director General.
w) Excavation shall not proceed too far ahead of pipe laying to avoid damages
from flooding or spoil.
x) Excavation shall not proceed too far ahead of the required trench support
placing to avoid trench wall from collapsing.
y) Excavation shall comply with the relevant Occupational Safety and Health
Act (OSHA) requirements for safety.
a) The bore shall be on the line, level and grade and of sufficient diameter to
allow pipes to be inserted without over-stressing the joints or damaging the
pipes.
a) Only approved materials are allowed to be used for pipe embedment. They
shall be in accordance to the approved longitudinal and cross-sectional
sewer profile drawings, which shall also provide details of the designed
bedding types.
b) The bedding material shall be placed as soon as possible after the base of
the trench is prepared and excess water has been removed.
c) Granular bedding shall be placed, compacted and graded so that it offers
continuous support to the sewer. The compacting, where required, shall
achieve a uniform density.
d) A small hole shall be left in granular bedding for each socket, jointing
sleeve, flange, etc. that may project into the bedding. The holes shall be of
size that is just sufficient for projections to be clear of bedding. Long and
large holes that may undermine the pipe barrel support are not allowed.
e) A recess shall be made in the bedding to permit the withdrawal of the sling
without disturbing the remaining bedding.
f) Where the bedding is disturbed, the pipe shall be raised again to repair the
bedding.
g) Pegs or other temporary aids to levelling shall be removed before pipe
laying.
a) Before lowering the pipes into the trench, pipes shall be placed next to the
trench away from the trench edge. The pipes shall be placed on the opposite
side of the spoil beside the trench with their sockets facing upstream.
Where required, the pipes shall be blocked or chocked to prevent any
rolling.
b) Pipes and fittings (including linings, sheathings and protective paintworks)
shall be checked for damage before and after laying in the trench.
c) VC pipes shall be carefully tapped at mid length and either end with a
wooden mallet or, otherwise, a metal bar. This is to detect a clear ring that
indicates soundness. This is best undertaken while each pipe is lifted in free
air with a lifting sling.
d) Pipe and fittings shall not be dropped into the trench. Instead, pipes shall be
lowered into the trench using approved slings.
e) Pipes shall be laid from the downstream end towards the upstream end.
f) The laying of pipes shall proceed carefully to ensure the line, level and
grade are within the specified tolerances.
g) Pipes shall not be dropped or impacted forcefully into the bedding to obtain
the specified level or grade.
h) Concrete pipes with elliptical reinforcement shall be laid with the load line
on the vertical axis at the top or bottom position.
i) Holes made in granular bedding for projections of sockets, flanges, etc. shall
be lightly filled where necessary without pushing the pipe/fitting off line,
level or grade.
j) Bedding shall be checked to ensure continuous support along the pipe
barrel. Further bedding material shall be placed to an even height and
uniformly compacted across the trench to ensure the full support of the pipe
haunch.
k) Pipes that are laid on concrete, grout, cement stabilised bedding or
connected to a concrete structure shall consist of a flexible joint at the
upstream end immediately outside such a zone.
l) Pipe level, grade and alignment shall be sighted using sight rails and boning
rod or laser and target. They shall be in accordance to the approved
longitudinal and cross-sectional sewer profile drawings, which shall be
submitted for approval before work at site is allowed to begin.
m) The invert level of each pipe laid shall be checked during laying and
immediately after laying completion, and with reference to the approved
drawings.
n) Boning rods shall have a foot to rest on the pipe invert with a vertical spirit
level attached and shall not be more than 45 m apart.
o) The pipe interior shall be cleaned after laying and kept clean and free of
water.
p) The pipe ends shall be sealed with a tightly fitting plug immediately after
laying, cleaning of the pipe interior and at the end of the day after laying.
q) The branch arm of the oblique branch junction fitting, if installed, shall be
laid in such a way that it is at approximately 45° off horizontal level.
r) Junction fittings shall be properly supported using well compacted crushed
rock (or, where required, concrete). The coverage of the support shall be
across to the trench wall and into the junction trench.
s) Branch connections shall be sealed with an approved plug where
connections are to be made at a later time.
t) Any pipe laid that is out of alignment either vertically or horizontally or
shows undue settlement shall be taken up and re-laid correctly.
u) Photographs shall be taken during pipe laying and after sewer pipe laying
for all lengths of pipes and manholes.
a) Jacking method of pipe laying shall be employed only when the conditions
or the requirements of the responsible authorities require such a method.
b) The pipes used for jacking shall be able to withstand the laterally induced
jacking stresses without damage.
c) The setting out of the guide rails for the pipe and the actual jacking
operation shall maintain a high accuracy level of line and grade.
d) The direction and grade for jacked sewer shall not deviate from the designed
alignment for more than 100 mm for every 100 meters of sewer.
e) All the joints used for connecting the jacked pipes shall be watertight and
durable.
a) Only VC, HDPE, ABS and DI pipes are permitted to be cut in the field.
However prior approval from the Director General is required should the
HDPE helically wound profile wall pipe needs to be cut in the field. All
pipes shall be cut in accordance to approved methods.
b) Rough edges and burrs shall be removed from inside and outside of HDPE
and ABS pipe with a rasp or file.
c) Pipes shall be cut in a neat and skilful manner by workers experienced in
pipe cutting.
d) Pipes shall be cut perpendicularly to the pipe axis.
e) Any damage to the cement lining of DI pipe shall be repaired to the
satisfaction of the Commission.
a) Selected excavated material shall be placed above the specified pipe support
until 300 mm above the sewer. They shall be in accordance to the approved
longitudinal and cross-sectional sewer profile drawings, which also give the
bedding details and the types of fill material.
b) Trench support shall be progressively removed as the backfill is placed.
c) There shall be at least 300 mm of cover over the sewer before light
mechanical compaction can commence.
d) There shall be at least 1000 mm of cover over the sewer before heavy
mechanical compaction can commence.
e) For plastic pipe, a metallic marker tape shall be laid along the line of the
sewer at approximately 500 mm below the surface level.
a) Joint components (i.e. spigots and sockets or sleeves and rubber seals) shall
be checked for damage after delivery, before and after usage.
b) Every part of the rubber ring shall be bent by hand to detect cracks.
c) VC pipe sockets shall be gently tapped with a wooden mallet or, otherwise,
a metal bar to detect a clear ring that indicates soundness.
d) Steel sleeve collars used for jacking pipe shall be checked for damage to the
coating.
e) Pipe jointing surfaces and rubber seals shall be wiped clean immediately
before jointing using a clean cloth.
f) The rubber ring shall be placed correctly around the pipe joint.
g) The rubber ring shall not be twisted in any way prior to jointing and shall be
seated in the correct position.
h) For skid type of joints (i.e. the sealing ring remains stationary and does not
roll into place), the spigot shall be lubricated with an approved lubricant.
i) The pipe to be jointed shall be aligned with the laid sewer before pushing in
the joint.
j) The pipe to be laid shall be orientated so that the offset inside the pipe at the
joint is minimise at the invert.
k) The pipe that is already laid and to be connected to another pipe shall be
restrained to prevent its pipe joints being further stressed and to prevent the
laid pipe from being pushed off grade or alignment.
l) Pipe joints shall be connected using a bar and block (crow bar and a block
of wood to protect the pipe end) or a pipe puller.
m) A machine bucket shall only be used to connect a pipe joint where approval
is given by the Commission. This method shall only be used for large
diameter pipes (larger than 600 diameter pipe) where the jointing
compression force makes it impossible to use a bar and block or pipe puller.
A timber shall be placed across the pipe end to protect the pipe from
damage. Pressure shall be applied by the bucket gently while the insertion
shall be carefully monitored and directed by a person next to the joint.
n) No excessive force shall be applied to make the joint.
o) After pushing the spigot into the socket, the seal shall be checked to ensure
the seal is correctly located and the spigot is properly inserted. No
contaminants are allowed between jointing surfaces. The joint or pipe shall
not have damage from jointing.
p) Any allowable deflections at joints shall only be made after the pipe jointing
is made.
q) Where a pipe is to be deflected at a joint, the deflection shall not exceed the
allowable limit for the specific type of joint.
a) The socket and spigot shall be checked for damage before and after jointing.
b) Damaged spigot ends shall be cut from the pipe with 100 mm clearance to
the damage. The spigot end shall be cut perpendicularly to the pipe and any
burrs shall be removed.
c) The spigot shall be inserted up to the witness mark.
d) If a witness mark is not already on the pipe, the mark shall be made to
ensure that the spigot is inserted to the appropriate length.
e) Witness marks drawn on site shall be made with a soft pencil or felt pen
marker that would not score or scratch the pipe.
f) The witness mark shall be of the depth of the socket and shall be measured
from the pipe end.
g) A dry fit of the joint shall be made before the jointing.
h) Jointing surfaces shall be wiped clean and dried with a clean cloth.
i) Jointing surfaces shall be primed using an approved priming solution. The
priming shall be applied with a clean cloth or swab freshly dipped in the
fluid immediately before jointing.
j) A thin and even coat of solvent cement shall be applied to the socket and the
spigot, which should then be inserted up to the witness mark.
k) The jointing surfaces shall not be contaminated with water, dirt, etc.
l) The jointing shall be made immediately after the application of solvent
cement.
m) After the spigot is pushed firmly into the socket, the joint shall be hold in
the same position for at least 30 seconds without moving.
n) The jointed pipes shall not be moved for at least 5 minutes after jointing.
The jointed pipes shall be handled with extreme care for at least another
hour.
o) Joints shall be left to dry for at least 24 hours before pressure testing.
p) Containers of solvent cement and primer shall be kept tightly sealed when
not in use.
q) Solvent cement and priming fluid are highly flammable. Therefore, the
solutions shall be stored in a cool place away from any source of spark or
fire.
a) Flanges, particularly flange faces and rubber seal shall be checked for
damage before and after jointing.
b) Appropriate metal backing plates shall be used on plastic flanged pipe.
c) Screwed-on flanges shall have the screw thread sealed with a compound
suitable for sewers.
d) Flanged ends shall be correctly aligned before jointing.
e) A steel bar or similar object shall not be used as a lever through the flange
holes to bring the bolt holes into line prior to bolting.
f) The rubber seal between flanges shall be made of an approved compound
and shall meet the specified requirements.
g) The flange faces and the rubber seal shall be wiped clean with a cloth
immediately before jointing.
h) Bolts shall be tightened evenly and gradually in rotation.
i) Bolts and nuts shall be tightened with a torque trench set at an appropriate
torque.
j) Plastic flanges shall not be distorted before or after jointing.
k) After pressure testing, metal flanges shall be reprimed and painted with two
coats of bituminous based coating in accordance with BS 4147 for below
ground protection.
a) The welded joint shall use a socket-spigot joint with taper sleeve wherever
possible.
b) Welding surfaces shall be cleaned to a bright metallic finish before welding.
c) Welders shall be qualified in accordance with the requirements of British
Standard BS 4515 Specification for welding of steel pipelines on land and
offshore.
d) Welding procedures shall be tested, qualified and approved in accordance
with BS 4515.
e) Welds shall be inspected and tested in accordance with BS 4515.
f) After welding, exposed external surfaces shall be cleaned by sand blasting
or wire brushing. The dry surfaces shall be wrapped in an approved manner
with an approved wrapping tape to provide corrosion resistance.
a) The pipes to be joined shall be of the same grade of polyethylene and of the
same wall thickness.
b) The butt welding machine shall be of an approved type and shall be fit for
use.
c) The welding machine shall be sheltered from wind and rain during the
welding process.
d) A practice weld shall be performed and discarded to check the operational
effectiveness of the machine.
e) The pipe ends shall be trimmed square.
f) The ends to be jointed shall be kept free of dirt, grease and moisture after
trimming.
g) The heating plate shall be brought into contact with the pipe ends only after
it is at the correct temperature.
h) The pipe ends shall be held against the heating plate for the specified time
appropriate for that pipe size.
i) Immediately after the removal of the heating plate (no longer than 15
seconds after heating), the pipe ends shall be pressed together with an
appropriate pressure for a specified time appropriate for that pipe size.
j) The joint shall be maintained clamped and pressurised in the machine for a
suitable period of cooling time (approx. 10 minutes minimum).
k) After removed from the machine, the joint shall not be stressed until it has
completely cooled (approx. 10 minutes minimum).
l) The weld shall not be artificially cooled with cold air or water.
m) The external bead shall carefully be removed. The joint zone shall be
thoroughly checked.
n) A pipe end that has undergone a complete heating cycle but not joined shall
not be reheated. The unjoined pipe end shall be cut off to at least 250 mm
from the end.
a) The thrust block shall be extended to approximately 180° around the fitting.
b) The thrust block shall not cover a flexible joint.
c) The thrust block shall be constructed equally around the centreline of the
fitting.
d) The thrust block shall bear firmly against a recess at the side of the trench.
e) The trench face which the thrust block bears against shall be freshly cut and
undisturbed.
a) A bulkhead to prevent soil erosion shall be used where the gradient of the
sewer is steeper than 1 in 40.
b) A restraint to prevent sewer slippage shall be used where the gradient of the
sewer is steeper than 1 in 6.
c) The restraint or bulkhead shall be placed at the downstream side of the
socket.
d) Concrete bulkheads shall be keyed into the base and sides of the trench by at
least 100 mm.
e) A weep hole with the upstream end covered with a geotextile filter shall be
provided through a bulkhead immediately above pipe invert to allow
drainage of groundwater.
a) The embedment material type and its grading shall take considerations of
the sewer type or length.
b) Reference shall be made to the approved longitudinal and cross-sectional
drawings of the sewers showing the bedding types, which shall be designed
based on supporting soil reports.
c) Embedment material shall not be contaminated with other soils.
d) Embedment material shall be brought up evenly in layers on each side of the
pipe.
e) Each embedment layer shall be placed to a depth that permits the
compaction equipment to achieve the specified density.
f) The pipe shall not be pushed off alignment, level or grade while placing the
embedment.
g) Where the embedment requires tamping, tamping equipment shall not come
into contact with the pipe.
h) Temporary trench wall support shall be lifted when the embedment is
compacted.
i) While placing the embedment for the pipe haunches, unnecessarily voided
areas shall be avoided.
j) At least 300 mm of cover shall be placed over the pipe before light
mechanical compaction, such as a hand operated whacker, can commence.
a) The ‘rocker’ pipe connecting sewers to manholes shall have sufficient cast
insitu concrete surround and extended concrete base as shown in typical
manholes drawings in Appendix A.
3.7 Reinstatement
a) All structures, services, fences, drains, gardens, improved surfaces, etc.
disturbed by the construction shall be restored within 7 days after
backfilling. The restored conditions shall be as similar as possible to their
original condition. Also, the condition shall be to the satisfaction of the
Commission, other responsible authorities and property owners.
b) Where a structure or service is affected by construction, the trench fill shall
be compacted to the equivalent of that under a pavement.
c) Within 7 days after backfilling, fill over unimproved surfaces shall be
placed to a height that will make the filled surface level and the adjacent
undisturbed surfaces closely matching after settlement. All contours shall
be similar to the original condition.
d) Unimproved surfaces shall be levelled and settled to as near as possible to
their original condition in 30 to 40 days after backfill.
e) Road pavements and access ways shall be temporarily restored to a safe
condition, immediately after completion of backfilling. Then, the
pavements shall be permanently restored to as similar as possible to their
original condition within a time frame specified by the responsible
authority.
a) The owner must seek the approval of the Director General for any
connections that involve physical work to an existing public sewer. The
initial notification must be made on the appropriate form.
b) Once approved, the owner may make the connection only if his contractor is
licensed by the Commission for this category of work.
c) The type and location of connections shall be determined by the
Commission. The type of connection could be a connection to a manhole or
a connection to a sewer through junction or saddle fittings.
d) The cost of the work in making the connection shall be borne by the owner,
regardless of whether the work is undertaken by his licensed contractor or a
licensed contractor employed by Services Licensee.
e) The connection must be correctly made by the licensed contractor under the
supervision of an authorised inspection person.
f) When the connection is ready for inspection, the owner must notify the
Commission on the appropriate form. At the same time, he must give a
copy of the notice to the authorised inspection person who will make
arrangements for the inspection.
g) The connection must be completely watertight to prevent infiltration. Any
evidence of infiltration in the connection pipe shall be referred to the Local
Authority who may withhold issuing the Certificate of Fitness.
h) For a development which contains several connections from individual
premises to the proposed public sewers within the development, the
connections may be deemed covered by the original technical proposals.
These individual connections will be inspected as part of the routine
inspection by the authorised inspection person.
i) The inspection by the authorised inspection person for the connections to
existing public sewers shall be subjected to a standard inspection fee.
j) The design and installations shall incorporate the considerations of health
and safety
k) The difference between each premise platform level and the nearest public
sewer invert level shall not be less than 1.2 metres to avoid flooding of
premises.
Where an existing public sewer is circular and is of diameter DN 450 or less, any
connection to that sewer may be made using a Y junction fitting.
Where the location of future connections are known, Y Junction fittings and the
accompanying junction connection pipework may be installed at the time of the
public sewer construction.
Saddle connections may only be permitted where the existing sewer is at least two
pipe sizes greater than the proposed connection pipe. Only saddles specifically
designed for the type and size of the sewer to be connected to shall be used. Also,
the saddle used shall be approved by the Commission.
The saddle must be purpose-made by off-site manufacture except when the existing
pipe size is 900 mm in diameter or greater, which other forms of connection are
preferred.
The saddles for concrete or vitrified clay sewers shall be bedded on cement mortar
(mix 3:1) with a depth not less than 40 mm below the base of the saddle. A
flexible joint shall be provided between the saddle and the remaining connection
pipe.
The hole prepared for the saddle connection on the existing sewer shall not have
any rough edges that might cause blockage. The location of the hole on the pipe
shall be at a 45° to 60° angle to the horizontal. The hole shall be made at the
middle of the pipe to avoid damages or excessive loading to the existing sewer pipe
joints. The existing pipe may require extra strengthening by additional concrete
surround to withstand the extra load from the connection pipe and fittings.
The connection pipe must not protrude into the existing sewer.
Any debris falling into the existing sewer during the connection shall be removed.
Manholes may be constructed on the public sewer for private sewer connections
where:
Where site conditions prevent manhole construction on the existing public sewer,
the manhole may be provided on the connection pipe as near to the public sewer as
possible.
4.1 General
Sewers and ancillary works shall be tested and inspected for water-tightness to
prevent infiltration and exfiltration and to ensure the pipe are laid correctly
according to the designed straightness and grade. The testing of the sewers and
ancillary works before backfill will facilitate the replacement of any identified
faulty pipes and joints. The testing of the sewers and ancillary works after backfill
will reveal the leakages caused by the displacement of joints and subsequent
damage. The testing shall be supervised by consultants and their testing certificates
issued by the consultants shall be submitted to the Commission before final
approval.
I) Before Backfill
a) Gravity Sewer:
i. Exfiltration Test (Either low pressure air or water tests)
ii. Check for straightness, obstruction and grade
b) Force Main:
i. Exfiltration Test (When required)
ii. High pressure water test
iii. High pressure leakage test (Following high pressure water test)
iv. Check for straightness, obstruction and grade
For pipe or part that is made of material that will deteriorate under the sun, the
exposed parts of the pipe shall be shielded from direct exposure to the sun during
testing.
The concrete used for supporting the pipe or resisting thrust shall be cured for at
least seven days prior to testing.
a) Gravity Sewer:
i) Exfiltration Test (Either low pressure air or water tests)
ii) Infiltration Test (when required)
iii) CCTV Test (when required)
Before and after any test, the sewer pipeline to be tested shall be clean, which shall
be flushed clean when necessary. Any leaks or defects identified from any test
shall be located and repaired. After testing has been completed, the cleaned sewer
shall be plugged at open ends to prevent dirt or soil from getting into the sewer.
An exfiltration test, which can be either a low pressure air test or a water test shall
be performed on the sewer before any concrete pipe encasement or backfill. After
backfilling, an exfiltration test is required again on the sewer laid. In addition, an
infiltration test shall be conducted if:
When infiltration has been confirmed by the infiltration test, light and mirror
method or CCTV may be used to isolate the locations of leaks. If a CCTV
inspection is conducted, a video and written record of the CCTV inspection shall
be provided to the Commission no later than 7 days after the inspection.
For gravity sewers, the sewer length to be tested shall be the length between
manholes or proposed manhole locations. The test length for water test may be
shorter where the gradient is so steep as to cause too high a head at the downstream
end. The pressure head on the sewer being tested shall not be less than 2 m above
pipe crown at the upstream end and shall not be more than 7 m above pipe crown at
the downstream end.
When desired, the air and water tests may be undertaken on shorter lengths of the
laid sewer before backfill. This is to prevent any faulty joint to go unnoticed until
it is revealed by a test on the complete length, which will be more costly and time
consuming to rectify the defects. Testing of shorter lengths may also be necessary
where it is required to backfill the sewer to surface level quickly. This early
backfill may be encountered when there is wet weather, traffic crossings or site
safety requirements.
In every stage of the works, frequent tests of straightness and obstruction shall be
conducted, when required, to ensure there is no line obstruction and the
straightness or grade is correct.
As in gravity sewers, the force mains should be checked to ensure the straightness
is correct and to ensure no obstruction in the force mains. Also, force main is
required to be tested for its mechanical stability through the high pressure water
test. Its water-tightness shall be tested through high pressure exfiltration test.
Before conducting these high pressure tests, the sewer support and thrust block
shall be allowed to develop the sufficient strength. In addition, cautions shall be
taken when dealing with high pressure.
For the high pressure water test, the test length will depend on:
a) the length which can be isolated effectively, i.e. suitable anchorage for
temporary end closures
b) the time permitted to leave the trench open without backfill taking
considerations of weather, safety, traffic etc.
c) the location of permanent anchorages
d) the maximum volume of water available to fill the pipeline
e) the requirement to have the pressure at the highest point not less than 0.8
times the pressure at the lowest point
After taking the above considerations, initially a maximum of 300 m length of pipe
shall be laid and tested to verify that pipe laying practices are to an acceptable
standard. The maximum lengths for subsequent tests may be progressively
increased, as determined by the authorised inspection person, but shall not exceed
1500 m.
Connections between sewer and manholes shall be constructed with extended cast-
in-site concrete base and surround over the top of the rocker pipe in accordance to
the standard drawing attached.
A visual inspection is required on all the external and internal sections of each
manhole before backfill. Particular attention shall be given to:
Low pressure air test is one of the two sewer exfiltration tests recommended for
sewer testing. The air test is quicker to conduct than the water test. Furthermore,
no large quantity of water needed to be disposed of after the test. This test provides
a quick mean for checking any damage pipe or joints. Sometimes the test is
conducted on a short length to prevent damage pipe or joints from passing without
noticed until the final sewer test, which could be more costly and time consuming
to rectify. However, these tests on the shorter length should not replace the final
test.
a) Seal the open ends, including sideline ends, using approved plugs. Strut the
plugs to prevent movement. Provide temporary bracing where necessary to
prevent pipeline movement during testing.
(One of the end plugs will require a connection point to permit injection of
air.)
b) Connect a hand or motorised pump to the pressure injection line at the end
plug. Pressurise the test length at a slow and constant rate.
c) Use dial pressure gauges to measure pressure. Apply an air pressure of:
i. 30 kPa for vitrified clay and reinforced concrete pipelines
ii. 50 kPa for all other pipelines
(Two gauges in series shall be used so that the accuracy of one gauge can
be confirmed by the other. The dial gauges shall be able to be read to an
accuracy of ± 0.1 kPa.)
d) Wait five minutes for air pressure to stabilise due to temperature absorption
into pipe wall and other effects. Adjust the pressure to the required test
pressure during this period.
e) Check for leaks at plugs and test apparatus. Release the air pressure where
leakage occurs. Make necessary repairs and adjustments of apparatus to
prevent leakages. Repressurise the sewer pipeline in accordance with the
preceding steps again.
f) Start the test and record the pressure loss for the test duration after the final
gauge adjustment to the test pressure. Conduct the test for the test duration
given in Table 4.1.
g) Pass the test if the pressure loss over the test duration does not exceed:
I) Before Backfill
a) Readjust the pipe pressure to the specified test pressure and examine for
leakage by pouring a solution of soft soap and water over the exposed joints
if the test fail.
b) Repair leaks and repeat testing where leaks are found at joints.
c) Where leaks are not found at joints, move the plug, the one that is not used
to exert air pressure, along the pipeline to isolate lengths with leakage.
Uncover pipe barrels in the isolated lengths where leakage in pipe barrels is
suspected. Replace leaking pipe lengths and repeat testing.
d) Conduct low pressure water testing to verify that the air test was not
erroneous where the test length fails the air test but no source of leakage
can be identified.
a) Move the plug up from the other end along the sewer pipeline to isolate the
lengths that fail the air test.
d) Conduct water testing to check that the air test was not erroneous when
failed lengths could not be isolated using the air test.
e) Use CCTV, when required or available, to identify the leakage if the fail
section can not be isolated by the air test or water test.
The low pressure water test is commonly used for checking the water-tightness of
the joints and the integrity of the sewer pipes. Unlike the high pressure water test,
this test can not be used to check the mechanical strength of the sewer pipe.
Compared with low pressure air test, this test requires more time to set up the test.
Also, the water used for the test require disposal in an appropriate manner.
However, this test will show the location of the leaks more clearly than the low
pressure air test.
4.6.2 Procedure
a) Seal the open ends, including sideline ends, using approved plugs. Strut the
plugs to prevent movement. Provide temporary bracing where necessary to
prevent sewer movement during testing.
b) Establish appropriate arrangements involving a standpipe to apply the water
head at the upstream end.
(Acceptable arrangements include:
i. temporarily fitting a 90° bend to the upstream end, which should then
be connected with a vertical riser of straight pipe to used as a
standpipe
ii. sealing the upstream end with a plug which has a connection point for
a hose, which can be connected to a tube acting as a standpipe)
d) Fill in water from the upstream end. Ensure water head is not less than 2 m
above pipe crown at the upstream end and not greater than 7 m above pipe
crown at the downstream end. Shorten the test length if the sewer gradient
is so steep as to cause these water head requirements not to be met.
e) Fill the sewer slowly to the required head and bleed air from behind the
upstream plugs.
(Air may be released by slightly loosening the plug and pushing in a piece
of wire between the seal and the pipe.)
f) Maintain the water head for two hours. Top up the water as required.
g) Check for leakage at the plugs and the test apparatus during the pressurising
period and the constant pressure holding period. Release the water pressure
if leakage occurs. Make the necessary repairs and adjustments before
repressurising again.
h) Commence the test immediately after the last adjustment of water head in
the preceding two hours period.
i) Add water to maintain the starting water head every 5 minutes during the
test period of 30 minutes. Record the total amount of water required for
readjustment.
j) Pass the water test if:
i. the loss of water does not exceed 1 litre per hour per linear metre per
metre internal diameter for vitrified clay and reinforced concrete
pipes,
ii. there is no loss of water for pipe other than vitrified clay and
reinforced concrete pipe,
iii. these is no visible leakage at the joints for all pipe types.
I) Before Backfill:
a) Readjust the internal water head to the specified test head if the test section
fails the water test. Examine visually for leakage at the external surface of
joints.
b) Uncover pipe barrels and inspect for leakage if leakage is not evident at
joints. Drain the water and move the downstream plug towards upstream,
where necessary, to isolate pipe lengths that fail the water test.
c) Repair or replace pipes before repeating the low pressure water test until the
sewer passes the test.
a) Isolate pipe lengths that fail the water test by moving the downstream plug
towards the upstream end in sections when the test sewer fails the water
test. Alternatively, conduct a CCTV inspection, where required, to identify
the source of leakage if the source of leakage can not be isolated.
b) Exhume failed pipe lengths and replace.
c) Repeat test until the sewer pipeline passes the test.
High pressure water test is normally used for testing the pressure sewers and pipe
works within the pump station. The main aims of the test are to ensure the
mechanical stability of the pipe and joints to withstand the working pressure. Since
the test is conducted under high pressure, the anchorage of the sewer is more
critical than the low pressure tests. Preferably, the test should be conducted before
backfill. During the test, the test pumps should not be subjected to hydrostatic
pressure.
4.7.2 Procedure
a) Seal the sewer pipeline ends using “test-end” units consisting of short
lengths of pipe permanently fitted with caps or valves. Connected the “test-
end” units to the test pipe section using a standard coupling, which permits
easy removal of “test-end” units after testing.
(The “test-end” units should have a valve with pressure gauge to allow
filling of the test length with water or for venting air. The gauge shall be a
conventional circular gauge not less than 200 mm diameter and shall be
able to read to an accuracy of ± 0.01 Mpa.)
b) For sewer on level grade, fit tees along the test length, where necessary, to
ensure all the air can escape. Fit air valves to such tees. Remove air valves
and blank off tees after the test is applied.
c) Fit the test pressure gauge at the lowest end of the test length.
(This prevents the test pressure from exceeding the permitted maximum
pressure in the test length.)
d) Place pre-constructed temporary thrust blocks behind the test end units to
brace against thrust from the test pressures.
(No temporary bracing is permitted along the sewer pipeline. All specified
thrust blocks must be constructed and left to cure before testing.)
e) Fill the test length slowly with water through the valve at the lowest test-
end unit.
(The water shall be of fair quality and free from sediment. A firm foam
swab placed ahead of the water column will improve the expulsion of air.)
f) Set all valves at high spots to vent air.
g) Close the air vents after thorough venting of all air.
h) Fill the test length with water. Leave the filled test length undisturbed for
24 hours prior to testing to allow for absorption of water into the pipes and
/or jointing materials.
i) Wipe the exposed fittings and joints clean and dry and check for leakage
and other irregularities during this preparatory period. Check also the test
pipe for any appreciable movement and disturbance of anchorages. Drain
the water and repair any damage found. Repeat the water filling again to
start the test.
j) Pump more water into the test length to raise the pressure. Raise the
pressure slowly in increments of 1 bars, with pauses of one minute between
each increment until achieving the lower of:
i. the maximum rated pressure of the pipes laid, or
ii. 1.5 times the design operating pressure of the pipeline (includes surge
allowance)
k) Stop the test immediately should any appreciable drop in pressure be noted
during one of these pauses. Determine the cause of the pressure drop.
Drain the test length where repairs are required. Start the test again after
repairing.
l) Pass the pressure test if there is no reduction from the test pressure in the
next 10 minutes after the test pressure is achieved. Do not reduce the
pressure since the high pressure leakage test should be conducted
immediately next.
High pressure leakage test normally follows the high pressure water test
immediately. This is to avoid any unnecessary pressurising and water filling, which
could take time and is costly. The purpose of this test is to ensure the pipe and
joint will remain intact under the pressure environment.
4.8.2 Procedure
a) Conduct the test immediately after the high pressure water test. Maintain
the following test pressures (whichever is lower) for 24 hours by pumping
in make-up water if necessary:
i. the maximum rated pressure of the pipes laid, or
ii. 1.5 times the design operating pressure of the pipeline (includes surge
allowance)
b) Measure the amount of make-up water pumped into the pipe to maintain the
test pressure.
c) Pass the test if the measured amount of make-up water does not exceed 0.1
litre per millimetre of pipe diameter per kilometre of pipe per day for each 3
bars of pressure applied.
d) Reset the test pressure and check all visible joints to locate leakage when
the test length fails the test.
a) Visual inspection
b) Insertion of mandrel
c) CCTV inspection
It should be noted that the visual inspection is only for checking a short length.
Sufficient light shall be provided when carrying out the inspection. For checking a
long sewer, insertion of a mandrel should be adopted.
The first three methods will provide a more exact assurance for both the grade and
straightness of sewers, which shall be used whenever possible. The latter two
methods will provide a rough ideas on whether the sewers are laid graded or
straight, which should be used only for a quick check.
a. Solid state colours CCTV camera with pan & rotate features, together with
a lighting unit, automatic date/ metre age.
b. A self powered tractor or crawler on which the camera is conveyed along a
pipeline under inspection in a stable manner.
c. Calibration chart for various sizes of sewer for the camera used.
d. Test device for the CCTV camera using 'Marconi Resolution Chart No.1' or
its derivative to demonstrate satisfactory performance of the camera.
e. Test device for the monitor and video recorder to establish the effectiveness
and accuracy of the 'on-site' monitor and video recorder.
f. The control unit comprises the camera unit, crawler control and
screenwriter. This console can be mounted permanently in a vehicle or use
as portable system.
g. A video recorder for recording high quality video images.
h. A means of producing still images from the monitor screen.
Software standardisation using databank software that can produce report, based on
WRc format.
a) For the diameter pipe greater than 600mm, it shall have zooming
capabilities.
The following areas area identified as the minimum coverage for CCTV inspection.
A 100% CCTV inspection shall be conducted for sewers laid in the ground with
high risk of failure and having the following characteristics:
a) Initial CCTV testing & inspection shall be conducted for a minimum 10%
random selection of sewers including all manholes and lateral property
connections in accordance with standard procedure.
a) Stage 1- All projects are to start with stage 1 inspection where 10 % (by
length) of sewer network and property connections involved, shall be
randomly selected and CCTV inspected.
b) Stage 2 - Should any Grade 3,4 or 5 conditions as defined in the Manual for
Sewer Condition Classification approve by the Commission, found in Stage
1 inspection, the CCTV inspection shall proceed to Stage 2 inspection.
Stage 2 inspections shall include another 40% of the sewer network to be
randomly selected for CCTV inspection.
c) Stage 3- Should any Grade 3,4 or 5 conditions as defined in the Manual for
Sewer condition classification approve by the Commission, found in Stage
2 inspection, the CCTV inspection shall proceed to Stage 3 where all the
remaining network shall be CCTV inspected.
a) All construction works have been completed and tested by the supervising
qualified person.
b) Sewer networks have been cleared of debris and are ready for inspection.
c) A CCTV Inspection Contractor licensed with the Commission has been
appointed to carry out the inspection.
a) The list of sewer segments and house connections selected for CCTV
inspection shall be recorded and the parties witnessing the selection process
shall duly sign the record.
a) The CCTV inspection shall be carried out 7 days after notice issued by the
Commission.
b) Inspection shall be carried out in within 24 hours after random selection has
been completed.
c) Once started, CCTV inspection for a project shall be carried out without
any break. Should for any reason a break/delay of more than 24 hours
become necessary, the random selection process shall be repeated to select
the remaining sewer segments for the inspection. Reasons for the
break/delay shall be recorded.
d) Representative from the Commission or authorized person, consultant
representative and contractor responsible for the construction of the sewer
shall be present at the onset of CCTV inspection at each project site.
a) At the start of the CCTV recording, the following details must be recorded:
i. Date and starting time of inspection.
ii. Project name and location
iii. Names and designation of persons involved (i.e representative of the
Commission or authorized person, consultant & contractor and
CCTV contractor).
b) At the beginning of each CCTV recording for every segment of sewer shall
be marked with their respective code number with chainage together with
the date, start and end times of the recording.
c) After the CCTV inspection and recording have been completed for a
project, a copy of recorded CCTV shall be handover to the Commission or
authorized person immediately. Report on the CCTV inspection together
with the recording and recommendations shall be prepared by the CCTV
contractor and submitted to the relevant the Commission branch office or
the appointed agency not more than 7 days after the date of inspection. The
format of reporting shall follow the standard that had been given (Appendix
C). The copy of the tape (or other recording media used to store the record)
containing the CCTV inspection records shall be submitted to the
Commission Branch office or the appointed agency together with a
certificate duly signed by the qualified person responsible for the CCTV
inspection declaring the authenticity of the recording submitted and that the
CCTV inspection has been done in accordance with the procedure stated in
this guideline.
a) For Grade 1 and Grade 2, the developer shall rectify and make good to all
the defects in 30 days. These rectification works shall be witnessed by the
parties concerned and agreed together that the works had been completed.
The Commission or the authorised person may instruct CCTV inspection to
be carried out again. Under these grade classifications, the letter of
recommendation for CFO will be released by the Commission or the
authorised agency.
b) For Grade 3, 4 or 5 classifications, the developer shall change, replace,
relay or reconstruct the rejected works. Further CCTV inspection shall be
carried out before acceptance. The letter of support for CFO will be
released upon acceptance.
c) In the events of any blockages, damages, seepages and etc to the sewer
networks during the defects liability period, JPP may require the developer
to carry out further CCTV inspection to determine the cause and extent of
the problems that arises. CCTV inspection shall be carried out immediately
within 24 hours.
Grade 1
Occurances without damage and no cracks of pipe but only acceptable displacement on
joint where no visual infiltration can be observe: e.g.
Grade 2
Examples: Joint displaced large; badly torched intakes; minor deformation of plastic
pipes (<5%); minor erosions; infiltration seeping; Cracks – joint, circumference,
longitudinal; Debis, silt – 15%; Encrustation light.
Grade 3
Examples: Infiltration dripping. (OMD); Open joint; untorched intakes; cracks; minor
drainage obstructions such as calcide build ups; protruding laterals; minor damages to
pipe wall; individual root penetrations; corroded pipe wall; flexible pipe deformation
(>5%); Lining defect.
Grade 4
Grade 5
Examples: collapsed or collapsed eminent; major deformation; deeply rooted pipe; any
drainage obstructions; pipe loses water or danger of backwater in basements etc
Infiltration test is normally conducted after backfill and after the groundwater level
has stabilised. The procedures are as follows:
4.11.2 Procedure
a) Plug the inlets at all upstream open ends, after the groundwater level has
stabilised following backfilling.
b) Measure any infiltration from the sewer to the manhole or within manhole
itself.
c) Conduct the measurement of infiltration for at least 24 hours.
d) Pass the infiltration test if the infiltration does not exceed 1 litre per hour
per metre diameter per meter of pipe run.
a) Conduct a light and mirror test to identify the location of the infiltration if
the pipe is small and short.
b) Move an inflated rubber plug toward downstream end to isolate lengths of
leakage. Repeat the test procedure after each plug relocation
c) Conduct a CCTV inspection if the location of the infiltration can not be
identified by the light and mirror test or moving the inflated rubber plug.
d) Exhume and repair the fail section of the pipe.
The test should be carried out only after the structures have achieved sufficient
strength to withstand the test pressure. Where possible, the test shall be carried out
before backfilled or concrete surrounded.
For manhole less than 1.5 m in depth, the manhole shall be filled with clean water
to the bottom of cover. For manhole more than 1.5 m in depth, the water head for
the test shall not be less than 1.5 m or the mean groundwater level, whichever is
larger. For any other ancillary structure, the water shall be filled to the top of the
structure unless otherwise specified by the authorised inspection person.
The procedures for testing the manhole are listed below. For other ancillary
structures, the procedures can still be adopted. However, the height which the
water level should be tested shall follow the instruction from the authorised
inspection person.
4.12.2 Procedures
APPENDIX A
Figure A.3 : Standard Precast Concrete Manholes (Shallow, 2.5 to 5 metres, and > 5
metres depth): Add standard drawing for large diameter manhole with RC
chamber. Page 107.
Figure A.4 : Standard Precast Concrete Manholes (Shallow, 2.5 to 5 metres, and > 5
metres depth): Add standard drawing for large diameter manhole with RC
chamber. Page 108.
Figure A.5 : Standard Deep Precast Concrete Manhole: Remove or reposition landing
for clear passage from manhole top, as landing may obstruct operations
activity (eg. jetting hose).Page 109.
Figure A.5 : Standard Precast Concrete Manholes (Shallow, 2.5 to 5 metres, and > 5
metres depth): Add standard drawing for large diameter manhole with RC
chamber. Page 109.
Figure A.6 : Standard External Drop Junction: Present susceptible to blockage.
Improve construction details to minimise blockage Page 110.
a. Outlet for 90 deg bend pipe, to raise to min. 300 mm above crown
of sewer pipe.
b. Size of drop pipe min. 300 mm dia.
Figure A.13 : Typical Induct Vent Detail: Delete this figure, as not applicable. Page 117.
Figure A.14 : Typical Details of a Wet Well Submersible Pump Station: Review, include
also typical details not using the circular wet well type (which is now not
common). Page 118.
Figure A.18 : Buffer Zone for Pump Station with and without Super Structure: Buffer
zone for fence to fence, add note “where located in high risk areas,
brickwall fencing may be specified for safety”. Page 122.
Figure A.19 : Buffer Zone for Pump Station with and without Super Structure: Buffer
zone for fence to fence, add note “where located in high risk areas,
brickwall fencing may be specified for safety”. Page 123.
Note: Other figures added are distributed as hard copies for incorporation in the documents.
OTHER COMMENTS
25 50.5
HINGE DEVICE BOLT HOLES
5
RUANG TERKURUNG
20
DILARANG MASUK
20
50.5
SEE DETAIL `2'
SEE DETAIL `1'
60°
840
652
MODEL NO. AND THE
MARKING "BSEN 124 MANUFACTURER'S NAME AND
CLASS D400 " PLACE OF MANUFACTURE
10
EMBOSSED LOGO(SEE DETAIL `X')
DANGER
25
5
5
CONFINED SPACE
20
SERIAL NO.
DO NOT ENTER
20
91
LOCKING AND
LIFTING DEVICE
PLAN
TYPICAL DETAILS OF HEAVY DUTY D.I. MANHOLE DETAIL `2' & '3' : EMBOSSED DESIGN
COVER AND FRAME
665
655
652
9
100
60
55 55 65 55
55
600
20
250
140
840
20 20 20
55
TYPICAL SECTION OF HEAVY DUTY D.I. MANHOLE 290
(SECTION Y-Y)
22
ALL CORNERS TO BE ROUNDED OFF
NOTES:
6
22
3
SECTION Z-Z
100
20
20
120 120
SECTION Y - Y
SECTION X - X
TYPICAL HINGE
TYPICAL LOCKING DEVICE
20
20
120
120
SECTION Y - Y SECTION Y - Y
COVER HINGE OPEN AT 90° COVER HINGE OPEN AT MINIMUM 100°
SECTION Z - Z
1:12
1:12
1:12
FALL
FALL
FALL
INLET ET
OUTL
FA
L
1:1 L
2
OUTLET INLET OUTLET INLET
1:12
1:12
1:12
FALL
FALL
FALL
2
PRECAST REINFORCED
CONCRETE RING WITH
150 THK. MIN.
CONCRETE SURROUND
MANHOLE OPENING MANHOLE OPENING
OUTLET
OF MANHOLE TYPE A OF MANHOLE TYPE B OF MANHOLE TYPE D
(FIRST MANHOLE) MIN 1200 (CHANGE OF DIRECTION)
(STRAIGHT THROUGH)
Volume 3
INLET
HALF ROUND
V.C. CHANNEL MANHOLE OPENING
PRECAST REINFORCED PRECAST REINFORCED PRECAST REINFORCED PRECAST REINFORCED HALF ROUND
CONCRETE RING WITH CONCRETE RING WITH CONCRETE RING WITH CONCRETE RING WITH V.C. CHANNEL
150 THK. MIN. 150 THK. MIN. 150 THK. MIN. 150 THK. MIN.
CONCRETE SURROUND CONCRETE SURROUND CONCRETE SURROUND CONCRETE SURROUND
SEWER PIPE SEWER PIPE SEWER PIPE SEWER PIPE SEWER PIPE
(DIA. VARIES) (DIA. VARIES) (DIA. VARIES) FA (DIA. VARIES) (DIA. VARIES)
1:12
1:12
FALL
FALL
LL LL
1:1 FA
2 2
1:1
1:12
FALL
OUTLET INLET INLET INLET INLET OUTLET
INLET INLET
FA FA
LL 1:1 LL LL LL
FA
FA 2 1:1 LL LL
FA 2 2 2
FA 2 1:1
1:12
FALL
MANHOLE OPENING
MIN 1200
OUTLET
OUTLET
SECTIONAL PLAN VIEW SECTIONAL PLAN VIEW SECTIONAL PLAN VIEW NOTE :
OF MANHOLE TYPE E OF MANHOLE TYPE F OF MANHOLE TYPE G 1. ALL DIMENSIONS ARE IN MILLIMETRES UNLESS OTHERWISE STATED
(MULTIPLE INCOMING) (TWO INCOMING SEWER) (THREE INCOMING SEWER) 2. DIAMETER OF PIPE INSIDE MANHOLE BASE TO BE OF EQUAL SIZE
OR LARGER THAN THE INCOMING PIPE DIAMETER.
Appendix A
Page 99
STANDARD MANHOLE D.I FRAME STANDARD MANHOLE D.I FRAME
STANDARD MANHOLE D.I FRAME AND COVER TO DETAILS AND COVER TO DETAILS
AND COVER TO DETAILS
Page 100
FILL WITH 1:3 CEMENT FILL WITH 1:3 CEMENT MORTAR MIX
MORTAR MIX
FILL WITH 1:3 CEMENT
Appendix A
MORTAR MIX PRECAST R.C MAKE UP RINGS AS REQUIRED PRECAST R.C MAKE UP RINGS AS REQUIRED
350 (MAX.)
350 (MAX.)
PRECAST R.C MAKE UP RINGS AS REQUIRED TO MATCH TOP OF MANHOLE COVER TO TO MATCH TOP OF MANHOLE COVER TO
350 (MAX.)
TO MATCH TOP OF MANHOLE COVER TO FINISHED SURFACE LEVEL FINISHED SURFACE LEVEL
FINISHED SURFACE LEVEL 600 600
600 PRECAST RC COVER SLAB WITH PRECAST RC COVER SLAB WITH
PRECAST RC COVER SLAB WITH UNDERSIDE PAINTED WITH 2 LAYERS OF UNDERSIDE PAINTED WITH 2 LAYERS OF
UNDERSIDE PAINTED WITH 2 LAYERS OF COAL EPOXY (100 THK. MIN.) COAL EPOXY (100 THK. MIN.)
COAL EPOXY (100 THK. MIN.)
PRECAST R.C CHAMBER RING WITH 20 PRECAST R.C CHAMBER RING WITH 20
MIN. INTERNAL LINING OF HIGH ALUMINA MIN. INTERNAL LINING OF HIGH ALUMINA
CEMENT MORTAR CEMENT MORTAR
PRECAST R.C CHAMBER RING WITH 20
MIN. INTERNAL LINING OF HIGH ALUMINA
CEMENT MORTAR
600 (MAX.)
DIRECTION OF MAIN FLOW
Volume 3
50 THK. CEMENTITIOUS
50 THK. CEMENTITIOUS
BLINDING
BLINDING
SECTION A-A SECTION B-B SECTION A-A (FREE DROP < 600)
(GROUND LEVEL TO INVERT LEVEL OF PIPE 1.2 < D < 2.5 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 1.2 < D < 2.5 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 1.2 < D < 2.5 METRES)
NOTES:
PLAN VIEW
Industry Guidelines
Malaysian Sewerage
STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS
STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS
FILL WITH 1:3 CEMENT
MORTAR MIX
FILL WITH 1:3 CEMENT PRECAST R.C MAKE UP RINGS AS REQUIRED
350 (MAX.)
MORTAR MIX TO MATCH TOP OF MANHOLE COVER TO
PRECAST R.C MAKE UP RINGS AS REQUIRED FINISHED SURFACE LEVEL
350 (MAX.)
TO MATCH TOP OF MANHOLE COVER TO 600
FINISHED SURFACE LEVEL
PRECAST RC COVER SLAB WITH
600 UNDERSIDE PAINTED WITH 2 LAYERS OF
PRECAST RC COVER SLAB WITH COAL EPOXY (100 µm THK. MIN.)
UNDERSIDE PAINTED WITH 2 LAYERS OF
COAL EPOXY (100 THK. MIN.)
Volume 3
50 THK. CEMENTITIOUS T12-150 B/WAY MIN. 400 GRADE 20/20 T12-150 B/WAY
BLINDING CONC. BASE
MIN. 400 GRADE 20/20
50 THK. CEMENTITIOUS CONC. BASE
BLINDING
SECTION A-A (BACKDROP > 600) SECTION B-B (BACK DROP > 600)
(GROUND LEVEL TO INVERT LEVEL OF PIPE 1.2 < D < 2.5 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 1.2 < D < 2.5 METRES)
A
375 125
Ø6
00
1/2Ø+100
B B
375 125
DETAIL 'A'
NOTES:
PLAN VIEW
FOR PILING.
Appendix A
Page 101
STANDARD MANHOLE D.I FRAME
Page 102
STANDARD MANHOLE D.I FRAME STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS AND COVER TO DETAILS AND COVER TO DETAILS
FILL WITH 1:3 CEMENT MORTAR MIX FILL WITH 1:3 CEMENT MORTAR MIX
Appendix A
350(MAX.)
PRECAST R.C MAKE UP RINGS AS REQUIRED TO
350 (MAX.)
350(MAX.)
PRECAST R.C MAKE UP RINGS AS REQUIRED
MATCH TOP OF MANHOLE COVER TO FINISHED MATCH TOP OF MANHOLE COVER TO FINISHED
TO MATCH TOP OF MANHOLE COVER TO
SURFACE LEVEL SURFACE LEVEL
600 600 FINISHED SURFACE LEVEL 600
PRECAST R.C. TAPER TOP PAINTED INTERNALLY PRECAST R.C. TAPER TOP PAINTED INTERNALLY
PRECAST R.C TAPER TOP PAINTED INTERNALLY
WITH 2 LAYERS OF COAL TAR EPOXY WITH 2 LAYERS OF COAL TAR EPOXY
WITH 2 LAYERS OF COAL TAR EPOXY
PRECAST R.C. CHAMBER RING WITH 20 MIN. PRECAST R.C. CHAMBER RING WITH 20 MIN.
INTERNAL LINING OF HIGH ALUMINA CEMENT INTERNAL LINING OF HIGH ALUMINA CEMENT
MORTAR MORTAR
CONCRETE BENCHING (20 HIGH CONCRETE BENCHING CONCRETE BENCHING (20 HIGH
ALUMINA CEMENT RENDERING) (20 HIGH ALUMINA ALUMINA CEMENT RENDERING)
CEMENT RENDERING)
1:12 1:12
1:12 1:12
600 (MAX.)
SHAPED TO DIRECT FLOW IN
DIRECTION OF MAIN FLOW
FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20 FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20
FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20
ALUMINA CEMENT MORTAR WHERE CHANGE CONC. BASE CONC. BASE
ALUMINA CEMENT MORTAR WHERE CHANGE CONC. BASE ALUMINA CEMENT MORTAR WHERE CHANGE
IN DIRECTION OR DIAMETER OCCURS IN DIRECTION OR DIAMATER OCCURS IN DIRECTION OR DIAMETER OCCURS
THROUGH MANHOLE OR THERE ARE 2 OR 3 THROUGH MANHOLE OR THERE ARE 2 OR 3 THROUGH MANHOLE OR THERE ARE 2 OR 3
INCOMING SEWERS INCOMING SEWERS INCOMING SEWERS
T12-150 B/WAY T12-150 B/WAY
50 THK. CEMENTITIOUS T12-150 B/WAY 50 THK. CEMENTITIOUS
50 THK. CEMENTITIOUS
BLINDING BLINDING
Volume 3
BLINDING
B 00
Ø6 B
(Ground Level to Invert of Pipe 2.5m ≤ Depth < 5m)
NOTES:
PLAN VIEW
Industry Guidelines
Malaysian Sewerage
STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS
350 (MAX.)
AND COVER TO DETAILS
PRECAST R.C MAKE UP RINGS AS REQUIRED
TO MATCH TOP OF MANHOLE COVER TO
FILL WITH 1:3 CEMENT
600 FINISHED SURFACE LEVEL
MORTAR MIX
350 (MAX.)
PRECAST R.C MAKE UP RINGS AS REQUIRED
TO MATCH TOP OF MANHOLE COVER TO
600 FINISHED SURFACE LEVEL
FORM CHANNEL USING 40 THICK HIGH FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20
ALUMINA CEMENT MORTAR WHERE CHANGE MIN. 400 GRADE 20/20 ALUMINA CEMENT MORTAR WHERE CHANGE CONC. BASE
IN DIRECTION OR DIAMATER OCCURS CONC. BASE IN DIRECTION OR DIAMETER OCCURS
THROUGH MANHOLE OR THERE ARE 2 OR 3 THROUGH MANHOLE OR THERE ARE 2 OR 3
INCOMING SEWERS INCOMING SEWERS
Volume 3
T12-150 B/WAY T12-150 B/WAY
50 THK. CEMENTITIOUS
BLINDING 50 THK. CEMENTITIOUS BLINDING
SECTION A-A (BACKDROP > 600) SECTION B-B (BACK DROP > 600)
(GROUND LEVEL TO INVERT LEVEL OF PIPE 2.5 < D < 5 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 2.5 < D < 5 METRES)
A
375 125
Ø6
00
1/2Ø+100
B B
375 125
(Ground Level to Invert of Pipe 2.5m ≤ Depth < 5m)
DETAIL 'A'
NOTES:
Page 103
STANDARD MANHOLE D.I FRAME STANDARD MANHOLE D.I FRAME STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS AND COVER TO DETAILS AND COVER TO DETAILS
Page 104
FILL WITH 1:3 CEMENT MORTAR MIX FILL WITH 1:3 CEMENT MORTAR MIX
FILL WITH 1:3 CEMENT
MORTAR MIX
PRECAST R.C MAKE UP RINGS AS REQUIRED TO
350(MAX.)
PRECAST R.C MAKE UP RINGS AS REQUIRED TO
350 (MAX.)
350(MAX.)
Appendix A
PRECAST R.C. TAPER TOP PAINTED INTERNALLY PRECAST R.C. TAPER TOP PAINTED INTERNALLY
PRECAST R.C TAPER TOP PAINTED INTERNALLY
WITH 2 LAYERS OF COAL TAR EPOXY WITH 2 LAYERS OF COAL TAR EPOXY
WITH 2 LAYERS OF COAL TAR EPOXY
PRECAST R.C. CHAMBER RING WITH 20 MIN. PRECAST R.C. CHAMBER RING WITH 20 MIN.
INTERNAL LINING OF HIGH ALUMINA CEMENT INTERNAL LINING OF HIGH ALUMINA CEMENT
MORTAR MORTAR
CONCRETE BENCHING (20 HIGH CONCRETE BENCHING CONCRETE BENCHING (20 HIGH
ALUMINA CEMENT RENDERING) (20 HIGH ALUMINA ALUMINA CEMENT RENDERING)
CEMENT RENDERING)
1:12
1:12 1:12 1:12
600 (MAX.)
SHAPED TO DIRECT FLOW IN
DIRECTION OF MAIN FLOW
FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20 FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20
FORM CHANNEL USING 40 THICK HIGH MIN. 400 GRADE 20/20
ALUMINA CEMENT MORTAR WHERE CHANGE CONC. BASE CONC. BASE
ALUMINA CEMENT MORTAR WHERE CHANGE CONC. BASE ALUMINA CEMENT MORTAR WHERE CHANGE
IN DIRECTION OR DIAMETER OCCURS IN DIRECTION OR DIAMATER OCCURS IN DIRECTION OR DIAMETER OCCURS
THROUGH MANHOLE OR THERE ARE 2 OR 3 THROUGH MANHOLE OR THERE ARE 2 OR 3 THROUGH MANHOLE OR THERE ARE 2 OR 3
INCOMING SEWERS INCOMING SEWERS INCOMING SEWERS
T12-150 B/WAY T12-150 B/WAY
50 THK. CEMENTITIOUS T12-150 B/WAY 50 THK. CEMENTITIOUS
50 THK. CEMENTITIOUS
BLINDING BLINDING
BLINDING
Volume 3
SECTION A-A SECTION B-B SECTION A-A (FREE DROP < 600)
(GROUND LEVEL TO INVERT LEVEL OF PIPE 5 < D < 9 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 5 < D < 9 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 5 < D < 9 METRES)
B Ø B
60
0
NOTES:
FOR PILING.
PLAN VIEW
Industry Guidelines
Malaysian Sewerage
STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS
STANDARD MANHOLE D.I FRAME
AND COVER TO DETAILS FILL WITH 1:3 CEMENT
MORTAR MIX
350 (MAX.)
FILL WITH 1:3 CEMENT PRECAST R.C MAKE UP RINGS AS REQUIRED
MORTAR MIX TO MATCH TOP OF MANHOLE COVER TO
FINISHED SURFACE LEVEL
350 (MAX.)
PRECAST R.C MAKE UP RINGS AS REQUIRED 600
TO MATCH TOP OF MANHOLE COVER TO
600 FINISHED SURFACE LEVEL
Volume 3
BLINDING T12-150 B/WAY
50 THK. CEMENTITIOUS BLINDING
SECTION A-A (BACKDROP > 600) SECTION B-B (BACKDROP > 600)
(GROUND LEVEL TO INVERT LEVEL OF PIPE 5 < D < 9 METRES) (GROUND LEVEL TO INVERT LEVEL OF PIPE 5 < D < 9 METRES)
375 125
Ø6
BOLTS WITH GUNMETAL NUTS 12 DIA. GALVANISED RAGBOLTS WITH
00
AND WASHERS GUNMETAL NUT AND WASHERS
B B
(Ground Level to Invert of Pipe 5m ≤ Depth ≤ 9m)
1/2Ø+100
375 125
DETAIL 'A'
A NOTES:
Page 105
GRD. LEV.
T W A W T
150mm CONC.
Page 106
675mm DIA.
SURROUND
OPENING
WITH D
GRATING 1200mm DIA.
ACCESS
Appendix A
T
CHAMBER WITH
GRADE 20/20 12mm HIGH
W
150mm CONC. E E
SURROUND CONC. ALUMINA LINING
SURROND BRANCH
SEWER FOOT HOLES
AT 300mm
MANHOLE TO BE
B B C/C
1:12
IDENTICAL TO
FALL
STANDARD
PRECAST
MANHOLE
A
675 DIA.
C OPENING C
GRADE 30
CONCRETE
WITH 12mm
DEPTH VARIES
150mm
MIN. 150
INVERT INTERNAL HA
W
MAIN SEWER CHAMBER
LEVEL LINING
12mm HA LINING
T
TO CHANNEL
PLASTIC BENCHING
PLASTIC WALLS AND TOP
SAFETY SAFETY
CHAIN SLAB
CHAIN
1800 MIN.
PLAN 6mm DIA. HEAVY STANDARD
MOULDED GMS (REFER TO LENGTH OF
CHANNEL DETAIL `A') PIPEWORK TO
SECTION A-A BRANCH
SEWER BE SET IN
MANHOLE
BRANCH
SEWER
D (V
D
ARIE
S)
3/4 D
INTERNAL
SECTIONAL PLAN C-C TYPE WIDTH, INTERNAL CHANNEL INTERNAL CHANNEL
`A' (mm) STRAIGHT THROUGH BENDS N.E. 22.5 N.E.
TO BENDS N.E. 22.5 90
SECTION D-D
Volume 3
GRD. LEV.
150mm CONC.
SURROUND
1200mm DIA.
ACCESS
CHAMBER WITH
150
12mm HIGH
ALUMINA LINING
150
COVER PLATE
A A
12mm HA LINING
MASS CONC.
MAIN 500 500 WALL
SEWER
6mm DIA. HEAVY
BRANCH GMS
SEWER
300
300
CONC.
CHAMBER
DIA
.O 30 APPROVED
6mm DIA. HEAVY STAINLESS
FM
AIN
GMS HEXAGON STEEL CHAIN
50
SE
W S) BOLT
ER IE 6mm DIA.
AR
(V STAINLESS
STEEL BOLT
AND NUT
20
GRADE 20/20
CONC. INVERT LEVEL INVERT LEVEL
SURROND
TO SUIT
38
50
50mm THK.
CONC. SCREED
Figure A9 : Typical Details of Large Diameter Manhole (LDM) Type
Industry Guidelines
Malaysian Sewerage
Appendix A
Induct Vent
Centreline of manhole
150 Min.
Column Support
Notes :
1. All dimmensions are in millimetres.
2. Diameter of induct vent shall be approximately 1/2
of the forcemain but shall not exceed 300mm.
Page 108
ONE LENGTH OF PIPE LIMIT OF WORKS FOR SEWER LINE ONE LENGTH OF PIPE
Appendix A
CL
45°
MAIN SEWER PIPE
150 Ø PIPE
150 Ø PIPE
R
STANDARD WYE
OR TEE
150
CL
PLAN
PLAN
TRENCH WIDTH
PLAN
VARIES
TWO 45° BENDS
Volume 3
300 MIN.
300 MIN.
SLOPE 1%
W
O
FL
1% MIN. GRADE TO MANHOLE
150 Ø PIPE STANDARD WYE OR MAIN SEWER PIPE WITHIN PROPERTY BOUNDARY
WITHIN PROPERTY BOUNDARY
TEE OR SADDLE
VARIES
150 Ø PIPE
SECTION R - R
FLOW
FLOW T
C
MAIN SEWER PIPE
A
45° BEND 150 THK. GRADE 25
CONCRETE SURROUND
W
O CONCRETE GRADE 20/20
FL
D
SADDLE T C A D L S R R1
MORTAR CONCRETE
MASS CONCRETE (10 THICKNESS) HUNCH
150x375 259 217 150 67 310 193 224 188
(GRADE 15) SECTION VIEW
225x375 353 308 225 80 310 284 224 188
MAXIMUM 2000
MAIN SEWER PIPE LATERAL SERVICE CONNECTION
300x375 447 389 300 82 318 355 224 188
REFER TO DETAIL `A'
150x300 259 217 150 67 255 193 178 151
L
SEWER
150x225 259 217 150 67 225 193 142 113
NOTES:
SECTION VIEW 1. SADDLE CONNECTIONS ONLY PERMITTED WHERE EXISTING SEWER IS THIS END OF PIPE MAIN SEWER PIPE
TO BE FLUSHED WITH
OF GREATER DIAMETER THAN THE PROPOSED CONNECTION PIPE.
INSIDE SURFACE OF
DEEP CUT LATERAL SERVICE CONNECTION S
2. ENSURE CONNECTION IS DONE ONLY ON THE TOP HALF OF THE EXISTING SEWER
EXISTING PIPE. THE HOLE SHALL BE MADE AT THE MIDDLE OF THE
EXISTING PIPE AT 45° TO 60° ANGLE TO THE HORIZONTAL. NOTES:-
SADDLE
Industry Guidelines
Malaysian Sewerage
A B C D
B B B B
A
A
A
A
C
TRENCH
TRENCH WIDTH
TR
EN
WIDTH
CH
C C
WID
TH
C TR
A B EN
CH
W
ID
TH
C
D
1 1
DETAILS OF THRUST BLOCK FOR BEND 11 4 OR 222 DETAILS OF THRUST BLOCK FOR BEND 45 DETAILS OF THRUST BLOCK FOR BEND 90 DETAILS OF THRUST BLOCK FOR TEE
DI
DI
D
DIA
DIA
A.
A.
D
D
D
.O
.O
F
OF
F
OF
PI
PI
PI
PIP
PE
E
PE
PE
CONC. TO BE CAST CONC. TO BE CAST CONC. TO BE CAST CONC. TO BE CAST
CONC. GRADE 20/20 AGAINST ORIGINAL CONC. GRADE 20/20 AGAINST ORIGINAL CONC. GRADE 20/20 AGAINST ORIGINAL CONC. GRADE 20/20 AGAINST ORIGINAL
SOIL SURFACE SOIL SURFACE SOIL SURFACE SOIL SURFACE
Volume 3
300 PIPE TRENCH WIDTH SIDE OF TRENCH
G
B B
GROUND LEVEL
300
15
0
E E F F
ADDITIONAL
300
TRENCH WIDTH
TRENCH WIDTH
IN
.1
00
m0
m
GRADE 25/20
CONCRETE
DETAIL OF THRUST BLOCK FOR VERTICAL BEND DETAIL OF ANCHOR BLOCK FOR VERTICAL BEND SECTION G - G
(ACTING UPWARD)
50mm THK. GRADE 15 /20
CONCRETE BLINDING
G
GROUND LEVEL GROUND LEVEL
NOTES :
ELEVATION
CONC.
GRADE 20/20 ANCHOR BLOCK
1. ALL DIMENSIONS ARE IN MILLIMETRES UNLESS OTHERWISE STATED.
150
C
12.5 % EVERY 2ND. PIPE
6. TEST PRESSURE FOR THRUST BLOCKS IS BASED ON 50mm HEAD OF
Figure A 12 : Typical Details of Concrete Thrust and Anchor Block
WATER.
150
20 % EVERY PIPE
B
7. DIMENSIONS OF THRUST BLOCKS TO BE INCREASED IF ACTUAL
B 2
CONC. BEARING PRESSURE IS FOUND TO BE LESS THAN 50 KN/M .
GRADE 20/20
8. DIMENSION `A' OF THRUST BLOCK TO BE ADJUSTED BY THE E.R. IF
NECESSARY TO SUIT TRENCH WIDTH.
Appendix A
Page 109
SECTION E - E SECTION F - F
B D
Page 110
500 Ø 500 Ø
Appendix A
750 Ø 750 Ø
350 Ø 350 Ø
A A C C
400 Ø 400 Ø
2000
750 Ø SLIDE GATE GUIDE (TYPICAL) SLIDE GATE GUIDE (TYPICAL) 750 Ø
500 Ø
500 Ø
Volume 3
350 Ø 350 Ø
SECTION A - A SECTION C - C
400
INVERT ELEVATION
232
375
OF 750 INLET
375
INVERT ELEVATION
250
232
OF 750 INLET
125
NOTES:
Industry Guidelines
Malaysian Sewerage
FORCE MAIN (FORCE MAIN ABOVE
GROUND TO BE PAINTED GREY) 45° BEND
ANCHOR BLOCK ANCHOR BLOCK
TO SUIT FLANGE JOINTS TO SUIT
FLEXIBLE COUPLING
A A
FILL WITH CEMENT MORTAR 1:3 HEAVY DUTY DUCTILE IRON COVER
AND FRAME (FRAME BEDDED ON
PLAN CEMENT MORTAR)
FLANGE ADAPTOR HEAVY DUTY PRECAST RC
COVER SLAB WITH 2 LAYERS
Ø150 SCOUR VALVE
OF COAL TAR EPOXY ON
UNDERSIDE
DETAIL `A'
APPROVED TEE
AIR VALVE
BELL MOUTH 300Ø SEWER PIPE
SLUICE VALVE 200Ø D.I.
SPIGOT
SOCKET
JOINT
Volume 3
FLANGE JOINTS 45° BEND FLEXIBLE COUPLING CAST INSITU CHAMBER 45° ANGLE 2 LAYER OF BRC A7
20 THK. RENDERING
BASE GRADE 20 IN 1:2 HIGH ALUMINA CHAMBER
ANCHOR BLOCK ANCHOR BLOCK CEMENT & SAND
TO SUIT TO SUIT 1000x1000x12 THK. UNBREAKABLE M.S. WITH SLOPE 1:12
CHEQUER PLANT STIFFENED BRACED WITH
STEEL FRAME COMPLETE WITH KEY AND
Washout Valve
NOTES:
3 NOS. Ø50
HOLES
1. ALL PRECAST MANHOLE COMPONENTS JOINTS
Ø50 AIR VALVE
SHALL BE FILLED WITH 1:3 CEMENT MORTAR.
300 THK. CONCRETE GRADE
20 BASE 2. ORIENTATION OF MANHOLE POSITION ACCESS
Ø50 SLUICE VALVE
COVERS AND CENTERLINE OF SEWERS SHALL BE
WELDED TO D.I. 300 THK. CONCRETE GRADE 100 THK. CAREFULLY
Ø50 D.I. EXTENSION PIECE TO SUIT 20 SUPPORT COMPACTED 20 MAX.
DETERMINED ON SITE.
PLATE ON FLANGED
END OF THE TEE AGGREGATE
3. ALL DIMENSIONS ARE IN MILLIMETRES UNLESS
OTHERWISE STATED.
DETAIL `A'
Figure A14 : Typical Details of Receiving Manhole, Force Main and
Page 111
Appendix A
Figure A15 : Precast Concrete Chamber (Type A ) and Details of Air Valve
and Scour Valve Chamber
300
150
225
75
900
150 150
75
225
150
75 MIN.
150
50 50 380 50 50
150 380 150
150
50
50
430
430
150
50
50
900 (NTS)
630
250
430
580
75
100
MIN. GRADE 20/20 CONCRETE
150 300 MIN SURROUND 150 MIN
GRADE 20/20 SELECTED
O.D + 300
CONCRETE BACKFILL COMPACTED BACKFILL
0.50 O.D.
SEWER PIPE
0.25 O.D. SEWER PIPE SEWER PIPE
0.50D
WITH 100 MIN.
20 AGGREGATE 20 AGGREGATE 0.25 O.D.
150 0.25 O.D. WITH 100 MIN. WITH 100 MIN.
O.D + 300
O.D + 300 0.D + 300
300 MIN
COMPACTED SELECTED
BACKFILL MATERIAL
BACKFILL WITH SAND
(HAND HELD COMPACTOR)
SEWER PIPE
300mm MIN.
0.25 O.D. SEWER PIPE
GRADE 20/20 CONCRETE INITIAL
0.25 O.D. WITH 100 MIN. BACK FILL 32mm Ø 2
CONCRETE GRADE 25 N/mm
PIPE EMBEDMENT SPRING LINE ONE LAYER OF A8 (BRC)
0.D + 300 (CRUSHER RUN)
150 THICK SAND
HAUNCHING SEWER PIPE
CONCRETE CRADLE
BEDDING 150 to 300mm (20mm Ø) "X' NO. OF 70 Ø BAKAU PILE (REFER TABLE `A')
70 Ø BAKAU PILE AT 300 C/C ALONG PIPE BAKAU
PILES SHALL BE DRIVEN TO SET OR 10m DEPTH
(2 x 5m LONG) WHICHEVER ACHIEVED FIRST
CRUSHER RUN BEDDING
FOR FLEXIBLE PIPES SEWER PIPE LAYING
ON UNSUITABLE SOIL
NOTES:
TABLE 2
TABLE 1
MAXIMUM TRENCH WIDTH
OVERFLOW CHAMBER
A 12
CONC. THRUST BLOCK.
GATE VALVE.
13 11
14 10
15 9
INCOMING SEWER
16 8
AIR EXTRACTOR FAN CHECK VALVE. EXTRACTOR FAN
G.I CHAIN GUARD 17 7
18 6
PENSTOCK R.C STAIRCASE TO ENGR'S DETAIL.
19 5
GRATING COVER 3 LAYER CONC. CONC. THRUST BLOCK. 20 4
PLAN VIEW
DOOR
SCREENINGS COLLECTION BIN
PENSTOCK BRICKWALL C/W
CEMENT PLASTER ON BOTH SIDES
WINDOW
HANDRAIL CHEQUER PLATE
3 LAYER CONC. VENTILATION
BLOCK
HANDRAIL
WET WELL
DRY WELL
PERFORATED SLAB
CAT LADDER
OPENINGS
ALARM
CHECK VALVE 2nd. STANDBY PUMP START
1st. STANDBY PUMP START
INCOMING SEWER 2nd. DUTY PUMP START
(FLOAT SWITCH) GATE VALVE 1st.. DUTY PUMP START
ALL PUMP STOP
STOP LOG
SUMP BWL
SECTION VIEW
CONC. APRON
COLLECTION BIN
CLEAR SPACING
S.STEEL MANUAL OVERFLOW
FINE SCREEN CHAMBER INFLUENT PUMP
A PRIMARY SCREEN A
GRATING COVER
EXPLOSION PROOF
17 18 19 20 21 22 23 SPOT LIGHT
PUMP SUMP
CHECK VALVE
S.STEEL HANDRAIL FLEXIBLE COUPLING
STEPS
PENSTOCK GATE VALVE
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DELIVERY PIPE
PLAN VIEW
LIFTING I-BEAM C/W
CARRIER
MECH. COARSE SCREEN
HANDRAIL
CHAIN GUARD
CHECK VALVE
CLEAR SPACING PENSTOCK
MANUAL FINE SCREEN FLEXIBLE COUPLING
GATE VALVE
OVERFLOW DELIVERY PIPE
PIPE DISCHARGE
TO DRAIN NON-EXPLOSION SPOT LIGHT
DELIVERY PIPE
OVERFLOW GUIDERAIL
S.S PERFORATED
CHAMBER TROUGH PUMP SUMP LIFTING CHAIN
PRIMARY SCREEN
CHAMBER
CONC. SLAB
R.C WALL TO
IL ENGR'S DETAIL
STOP
SECTION A-A
Typical Section
1. 20m buffer zone shall be provided from the external edge of the P.S super-structure
fence/boundary
to the nearest habitable building fence/boundary as required by building by-laws. The
buffer zone
shall be sufficient to allow for pump station access and working area .
3. Where the pump station is located in sensitive areas, additional buffer zone may be
specified for the purpose of beutification.
Vent
Vent
H
Properties Properties
P.S P.S
Fence Fence
Fence Fence
G
20m
(Mi ) 5m 5m 20m
Buffer ( ) ( )
Buffer
Access Access
and and
Beutifician Beutificatio
Sectional Plan
Note
1. 20m Buff er zone shall be prov ided f rom the perimeter (f ence/boundary ) of the pump station
to the nearest habitable building f ence/boundary as required by building by -laws. The buffer zone
shall be sufficient to allow f or pump station access and working area.
2. Non-habitable buildings may be located within the buffer zone but shall not obstruct operation,
maintenance and access.
3. H is the height of the v ent pipe which shall be at least higher than roof eav es lev el for buildings up
to 2 storey s high. The v ent cowl shall be at least 20m away f orm the nearest building windo w.
4. Where the pump station is located in sensitiv e areas, additional buff er zone may be specif ied f or the purpose
beutification.
BUILDING (WOODEN OR
DN 375 R.C.P DN 375 R.C.P
PROPOSED MANHOLE AND
SEWER IN PLAN
1:80 1:72
DIRECTION OF
BUILDING
SEW ER
(MASONRY)
GATE
POND
PON
PAVED
RAIL
ROAD
CULVER EXIST ING MANHOLE AND SEWER IN
PLAN
BRIDGE
T ELEPHONE
POLE
LIGHT SIDE
T ELEPHONE CONDUIT
P OLE SIDE
T (GENERALLY 1.5m DEEP)
PROPERT Y, LOT OR RESERVE
PROVISION FOR BACKDROP FOR
SEWER CONNECT ION
SEPT IC PROVISION FOR T -JOINT FOR
T ANK SEWER CONNECT ION
ST BOREHOL
Abbreviations
A.C.P. ASBESTOS CEMENT N.T.S. NOT TO
C.I. CAST O.D. OUTSIDE
CH. CHAINAG R.C. REINFORCED
CL. CLASS R.C.P REINFORCED CONCRETE
CONC. CONCRET RET. RETICULATION
CRS CENTRE RT RIGHT
D.I. DUCTILE S SLOPE
DIA.(ø) DIAMETE STREAM OR
SG.
D.M.H. DROP SHT. SHEET
DN. NOMINAL SPEC SPECIFICATI O
DRG. DRAWIN STD. STANDAR
EXIST. EXISTIN
SCW. STANDARD CUT-OUT
GD. GROUND
STEEL
STL.
GR. GRADE
STA. STATIO
H.A. HIGH
HORIZONTA TYP. TYPICA
HORZ VARIE
INSIDE VAR.
I.D. VERTICA
INVER VERT.
INV. VITRIFIED CLAY
V.C.P
JLN. JALAN HDPE HIGH DENSITY
KG. KAMPUN
LRG. LORON
LT LEFT
MAX. MAXIMU
M.H. MANHOL
MIN. MINIMU
MOD. MODIFIE
NO. NUMBE
Project-Information
Project Name : Project Number : Contact : Date :
Client :
Contact :
Position :
Road :
Town :
State :
Telephone :
Fax :
Mobile :
E- Mail :
Site :
Contact :
Position :
Road :
Town :
State :
Telephone :
Fax :
Mobile :
E-Mail :
Contractor :
Contact :
Position :
Road :
Town :
State :
Telephone :
Fax :
Mobile :
E-Mail :
Contractor :
Inspection Report
Date: Job nr: Weather Operator Section Number PLR:
Purpose: Size/Shape:
Use: Material:
Catchment: Lining:
Category:
Comment:
Location details:
Slope Position Code Observation Counter Photo Grade
MH
No.
Inspection Photos
Town : Road : Date : Section Nmber : PLR :
From MH : To MH :
N.B : When more than one defect is recorded at the same chainage, the most severe defect is counted.
From MH : To MH :
Item Position
Start MH Finish MH Code Description Grade
No. (M)
Appendix C 6 Modules
Section 5 - Structural Defect Coding (Module 6A)
C CRACK 5.1 F FRACTURE 5.7 B BROKEN 5.14 H HOLE 5.16 D DEFORMED 5.18 X COLLAPSE 5.22 J JOINT 5.25
CL Longitudinal 5.2 FL Longitudinal 5.7 BSV Soil Visible Beyond 5.14 HSV Soil Visible Beyond 5.16 DV Deformed Vertically 5.18 JO Joint Offset (Displaced) 5.25
CC Circumferential 5.2 FC Circumferential 5.7 Defect Defect (brick) XP Pipe Collapse 5.22 JS Joint Separated (Open) 5.25
CM Multiple 5.2 FM Multiple 5.7 BVV Vold Visible Beyond 5.14 HSV Vold Visible Beyond 5.16 DH Deformed 5.18 XB Brick Collapse 5.22 JA Joint Angular 5.25
CS Spiral 5.2 FS Spiral 5.7 Defect Defect Horizontally (brick)
S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE DAMAGE 5.30
DAMAGE DAMAGE DAMAGE DAMAGE DAMAGE DAMAGE
SRI Roughness 5.30 SAV Aggregate Visible 5.30 SAP Aggregate 5.30 SAM Aggregate 5.30 SRV Reinforcement 5.30 SRP Reinforcement 5.30 SAP Aggregate Projecting 5.30
Increased SAVM Mechanical 5.31 Projecting Missing Visible Projecting
SRIM Mechanical 5.31 SAVC Chemical Attack 5.31 SAPM Mechanical 5.31 SAMM Mechanical 5.31 SRVM Mechanical 5.31 SRPM Mechanical 5.31 SAPM Mechanical 5.31
SRIC Chemical Attack 5.31 SAVZ Not Evident 5.32 SAPC Chemical Attack 5.31 SAMC Chemical Attack 5.31 SRVC Chemical Attack 5.31 SRPC Chemical Attack 5.31 SAPC Chemical Attack 5.31
SRIZ Not Evident 5.32 SAPZ Not Evident 5.32 SAMZ Not Evident 5.32 SRVZ Not Evident 5.32 SRPZ Not Evident 5.32 SAPZ Not Evident 5.32
S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 S SURFACE 5.30 LF LINING FAILURE 5.44 LF LINING FAILURE 5.44 WF WELD FAILURE 5.56
DAMAGE DAMAGE DAMAGE DAMAGE (continue)
SMV Missing Wall 5.31 SSS Surface Spalling 5.31 SZ Other 5.31 LFD Detached Lining 5.44 LFOC Overcut Service 5.44 WFL Longitudinal 5.56
SMWM Mechanical 5.31 SSSM Mechanical 5.31 SZM Mechanical 5.31 SCP Corrosion 5.31 LFDE Defective End 5.44 LFUC Undercut Service 5.44 WFG Circumferental 5.56
SMWC Chemical Attack 5.31 SSSC Chemical Attack 5.31 SZC Chemical Attack 5.31 (metal pipe) 5.31 LFB Blistered Lining 5.44 LFBK Buokled Lining 5.44 WFM Multiple 5.56
SMWZ Not Evident 5.32 SSSZ Not Evident 5.32 SZZ Not Evident 5.32 LFCS Service Cut Shifted 5.44 LFW Wrinkled Lining 5.44 WFS Spiral 5.56
LFAC Abandoned 5.44
Connection LFZ Other 5.44 WFZ Unidentified 5.56
D DEPOSIT 6.1 D DEPOSIT (continue) D DEPOSIT (continue) 6.1 R ROOTS 6.7 R ROOTS (continue) 6.7 R ROOTS (continue) 6.7 R ROOTS (continue)
DA Attached 6.1 DS Settled 6.1 DN Ingress 6.1 RF Fine 6.7 RT Tap 6.7 RM Medium 6.7 RB Ball
DAE Encrustation 6.2 DSF Fine 6.2 DNF Fine Material 6.3 RFB Barrel 6.7 RTB Barrel 6.7 RMB Barrel 6.7 RBB Barrel
DAGS Grease 6.2 DSG Gravel 6.2 (silt & sand) RFL Lateral 6.7 RTL Lateral 6.7 RML Lateral 6.7 RBL Lateral
DAR Ragging 6.2 DSC Hard/Compacted 6.2 DNGV Gravel 6.3 RFC Connection 6.7 RTC Connection 6.7 RMC Connection 6.7 RBC Connection
DAZ Other 6.2 DSZ Other 6.2 DNZ Other 6.3
T TAP 7.1 T TAP (continue) 7.1 T TAP (continue) 7.10 IS INTRUDING 7.8 IS INTRUDING 7.8 L LINE 7.11 L LINE
TF Factory Made 7.1 TB Break in/Hammer 7.2 TS Saddle 7.2 SEAL MATERIAL SEAL MATERIAL (of sewer) (of sewer)
(junction) (connection) 7.2 (connection) 7.2 ISSR Sealing Ring 7.8 ISGT Grout 7.8 (continue)
TFA Active 7.2 TBI Intruding 7.2 TSI Intruding 7.2 ISSRH Hanging 7.8 ISZ Other 7.8 LL Left 7.11 LRU Right & Up
TFC Capped 7.2 TBA Active 7.2 TSA Active 7.2 ISSRB Broken 7.8 LLLU Left & Up 7.11 LRD Right & Down
TFD Defective 7.2 TBC Capped 7.2 TSC Capped 7.2 LLD Left & Down 7.11 LU Up
TFL Leaking 7.2 TBD Defective 7.2 TSD Defective 7.2 LR Left & Right 7.11 LD Down
TFL Leaking 7.2 TSL Leaking 7.2