Denlok

NAYLOR
DENLOK
EMAIL: [email protected] WEB: WWW.NAYLOR.CO.UK

DENLOK
Vitrified Clay Jacking Pipes
Product Manual and Specification Data

December 2007

Index of Contents

Introduction - Pipelines of the Future The Need for Trenchless Technology Development of Trenchless Technology Applications for New Installations Product Process Product Specification Product Data Delivery and Site Handling Product Features Technical Data For Further Information

2 2 3 5 6 7 8 9 9 10 12

Pipelines of the Future

For a company with its origins in clay pipes it is natural that Naylor Drainage Limited is in the forefront of product development and innovation. With over 100 years of constant production of pipes and fittings throughout the development of waterborne sewerage systems with their associated improvements, the Naylor company has developed a product that is a core requirement for the trenchless construction industry. With worldwide operational activities, Naylor Drainage has become the world's leading international supplier of specialist pipes for trenchless technology and many prestigious projects have been supplied throughout the companys UK home base as well as many continents overseas. Reputation for product reliability and customer service is part of the Naylor tradition. The companys trenchless technology product - Denlok - is a speciallydeveloped vitrified clay pipe system to meet the requirements of pipe installation by trenchless construction methods which include: Microtunnelling Guided Auger Boring Pipe Bursting Pipe Eating Slip Lining The Naylor approach to its development of products for the trenchless construction industry has resulted in new manufacturing equipment and production techniques. These progressive steps have led to reductions in specialist product costs and these savings have been passed onto the customer to enable the use of a firstclass product at affordable prices.

The Need for Trenchless Technology

Water and sewerage infrastructures have represented a significant asset investment on the part of most municipal organisations and water authorities for well over 100 years. The distribution networks for utility services have been located underground in pipes that are laid, repaired or replaced by trenching from the surface. In cities and urban areas, these distribution networks are located underneath roads. This often makes access difficult, particularly in areas congested with traffic and buildings. When pipeline infrastructures are not well maintained then inefficiencies arise. For example, in water distribution systems, leakages occur and water shortages are possible. However, in sewerage systems, cracked and damaged pipes can cause wastewater seepage, leading to contamination of groundwater. These problems often give rise to related health and environmental impacts. The oldest underground utility services are usually found close to the surface. Services installed later are most often found below or interwoven with the initial installations. Construction and repair carried out from the surface inevitably disrupts traffic, business and other services. This disruption has a negative impact on the local environment in terms of air quality, noise and other pollution, as well as on local vegetation and buildings. This in turn diminishes the quality of life for local residents. Trenchless technologies, which minimise the requirements for surface excavation, can significantly reduce the environmental impacts of underground utility service installation, maintenance and repair. By minimising surface disruption, traffic congestion is significantly reduced.

CAIRO, EGYPT

The Development of Trenchless Technology Systems

Until recently, city administrators and planners believed that the use of construction techniques involving surface trenching was the only option for the construction and repair of utility services. It was assumed that existing services were in good condition unless there was evidence to the contrary. In reality, gradual deterioration went unnoticed and failures occurred without warning, in many cases requiring an urgent response. Over the last 25 years, it became apparent that little was known about existing utility services. Installation drawings, where they existed, gave little information on pipe capacity or materials used. Furthermore, the condition of the pipe linings was unknown, leakage and infiltration were unmeasured and related health issues were often not addressed. Trenchless technology projects require careful consideration of the existing condition of the underground pipes and ground conditions in order to select the most appropriate technique. The technology and approach must be determined and the surface work must be conducted using an existing access or by digging access pits. The determination of the technique, location of the access pits and the route for a new pipe requires an initial survey. This is often viewed as an additional expense in comparison to open cut techniques. However, the cost of the initial survey stage of a trenchless project is usually offset by a shorter time on site. Trenchless technologies present a number of unique advantages. With new installations, engineers can install pipe in the most favourable stratum, irrespective of depth. For gravity sewers, significant savings can be realised by retaining gravity flow and avoiding pumping stations. For trenchless projects, experience has shown that there is little relationship between cost and depth. For work on existing services, the access points already provided could be used and work can be planned to reduce disruption.

Installation Options
The two installation options currently available for access to underground utility services are Open Cut and Trenchless. For access by open cut there are four stages: Excavation of the trench, removal of spoil and temporary support of other services. Laying and jointing the product pipe. Refilling the trench and compacting the selected spoil or filling material. Restoring above ground infrastructure. All four stages are characterised by the amount of physical work to be undertaken. Typically, 50 times the amount of spoil to be occupied by the product pipe has to be moved once during excavation and again in refilling. Much of the work in all four stages is labour intensive, involving different skills that require co-ordination between several companies and authorities. A large project can extend over a long period and be very disruptive in social, economic and environmental terms. Access using trenchless techniques also requires surface work, but not on the scale needed for an open cut approach.

CLAY TUNNEL PIPE

Site assessment
Whichever construction technique is used to install underground service utilities, the project is greatly improved by an understanding of the existing services and the ground in which they are to be installed before work commences. This is particularly important for trenchless projects, where the project design is based on a site investigation report. In open cut projects, the trench itself is often the investigation and the plan usually involves solving problems as they occur. Advances in the design and use of CCTV have considerably reduced the cost of surveying water and sewage networks, and information on conditions below the water level can be obtained by the use of ground penetrating radar. A traditional rule for most underground projects is that cost usually rises in direct relationship to the depth of work below the surface. As a result, the first consideration has been to make any new installation as shallow as practical, and any access to an existing service as short and direct as possible.

For new projects, the nature of the ground and depth of the water table can influence the chosen technology and process to be used. By using trenchless technologies, project designers can take advantage of the most favourable ground conditions, irrespective of depth, allowing for the installation of new services in areas where open cut methods were previously impossible. The ability to install pipe at great depths can help to simplify designs by allowing longer pipe runs with shallow gradients, thus avoiding the need for pumping stations and sumps. This facilitates pipe installation below already congested underground areas close to the surface in towns and cities.

Financial Considerations
In addition to environmental and social factors, financial comparisons can be made between trenchless technologies and traditional open cut methods. However, these comparisons are often difficult because there are no universal cost comparison methods. While technically the best solution depends upon the ground conditions and the location of the water table, in practice the financial boundaries of a project and the degree of acceptable financial risk generally play a more significant role in the decisionmaking process. The question also arises, cost to whom? The client is responsible for the direct costs of the contract and possibly for any compensation for the loss of amenity or trade by local residents and businesses. This often means that the costs are borne by local citizens and future generations. Furthermore, certain government financial policies can distort the real costs of installing, maintaining and repairing utility services. This can lead to the misconception that open cut is cheaper, when in fact a full accounting of the environmental and social costs may indicate otherwise. The direct costs of both the trenchless and open cut methods in the terms of materials, time and equipment can be established relatively easily. Indirect costs such as reinstatement of the surface, long-term repairs to roads and buildings due to delayed settlement, useful life of the service after work and a degree of risk for unplanned or additional emergency work that may arise

during the project can often exceed direct costs. An advantage of trenchless methods is that there are generally less indirect costs because surface access is less disruptive, projects are shorter and hence the social and environmental costs are considerably reduced.

Strategic Considerations
Open cut construction work disrupts roads, buildings and other infrastructure. The duration of these disruptions is a major source of frustration for local residents, business and the general public. This has resulted in growing opposition to construction work in general, including concern for the natural environment, as well as an increase in claims for compensation. Health and safety of workers, equipment operators and the public is well recognised and has led to the introduction of legislation requiring the use of safe working practices. In the case of underground utilities, the closer workers and operators are to mechanical and electrical equipment, to moving traffic, or the more they have to work in confined spaces the greater the risk of accidents. With trenchless projects, surface excavation is confined to relatively small entry and exit pits or shafts, and it is often possible to locate these away from hazardous areas and road traffic. In comparison to the use of open cut methods, trenchless projects are characterised by minimal surface disruption over a much shorter period of time. For a well-managed trenchless project, the public may not be aware that major construction work is actually going on below them.

DUNSTABLE, UK

Trenchless Technology Applications for new installations

PIPES BEING LOADED FOR DESPATCH

The trenchless sector is continually being refined and developed. Improvements cover both large and small diameters, longer drives, greater accuracy, faster and curve driving, different soil conditions and the ability to work deeper into water tables. There are many variants of Pipe jacking, during which the product pipe is forced into the ground by hydraulic cylinders mounted horizontal in a launch shaft. The run is completed when the pipe string reaches an exit shaft. Both shafts are used later as service access points.

The various systems for new installations can be broadly categorised into: Pipe Jacking in which the spoil and water is removed by pumping as slurry. Guided Auger Boring where the spoil is removed by an auger through a steel casing. Specially designed pipes are then hydraulically jacked in by the machine. Pipe Bursting where the existing pipeline is forced into the pipeline bedding by the means of an expanding hydraulic cone controlled from the surface. The new pipe pushes the expanding head through the pipeline which is being replaced. Pipe Eating where the existing pipe line is ground using a cutting head and the fragments of the pipeline are removed by augers through the new incoming pipe. Slip Lining where pipes are winched through an existing pipe system and the voids between new system and old system are filled with grout.

DN700 SLIPLINING, CARDIFF

Production Process
1
Locally-quarried raw materials are accurately blended before being ground to a fine form to enable subsequent extrusion.

Clay raw material is mixed with water to give plasticity for extrusion. High-pressure extrusion ensures that a strong dense pipe body is produced. Close attention to drying to remove moisture is undertaken prior to firing under accurate temperature control.

Use of special highly-insulated kilns is employed for attaining accurate firing. Smaller diameters fired in continuous production tunnel kilns.

The special qualities of vitrification of the pipe body are attained at a firing temperature in excess of 1050C.

After the firing and subsequent grading processes the pipe ends are accurately machined with computercontrolled diamond profile cutters. Accurate production of parallel ends is also achieved.

Intermediate inspection takes place as well as pipe ends being pressure tested to ensure integrity of pipe material. The joint components are then applied and materials are packed for shipment.

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Certification

Product Specification
Component Specification
All Denlok pipes and assemblies are manufactured in accordance with BS EN295-7 Requirements for vitrified clay pipes and joints for pipe jacking.

Denlok pipes and joint assemblies are manufactured in accordance with BS EN12889: 2000 Trenchless construction and testing of drains and sewers. Joint components fully comply with the requirements set out in the BS EN295-7 together with the following joint material components standards: BS EN295-10 Performance Requirements.

Joint Component Standards

Sleeve - manufactured from stainless steel complying with: BS EN10088-1 Stainless steel - Part 1: Technical delivery conditions for bars, wire rod and forgings. BS EN10088-2 Stainless steel - Part 2: Technical delivery conditions for sheet, plate and strip for general purposes. EN1008.2 Ti 1.457 stainless steel is used as standard or customers own specification.

Sealing components - manufactured from elastomers complying with: BS EN681-1:1966 ISO 3302: 1990 Elastomeric seal material requirements for pipe joint seals used in water and drainage applications. Rubber - Dimensional tolerances for use with products. EPDM rubber is used as standard or customers own specification.

Joint packing rings - manufactured from either EPDM for use with the NC type joint or wooden particle boards for use with the NS type joint all complying with: Pr EN312: Part 1: Pr EN312: Part 4: Particle boards - Requirements. Particle boards - Requirements for load bearing boards for use in dry conditions. Particle boards - Requirements for load bearing boards for use in wet conditions. Rubber - Dimensional tolerances for use with products.

Pr EN312: Part 5:

ISO 3302: 1990

Quality Assurance
Naylor Drainage manufactures its products under the control of an approved Quality Assurance System complying with the requirements of BS EN9002. Naylor Drainage Ltd is a Registered Firm of Assessed Capability (BSI Certificate No. FM1420).

Third Party Assurance

Denlok is Third Party Certified by BSI Quality Assurance under Licence No 20173. CE07 in accordance with Directive 93/68/EC.

CE Conformity
Naylor Drainage Vitrified Clay Pipe conforms to European Standard: EN 295-10.

Product Data

DN150 NC

Naylor Denlok NC Range DN150

Comprising of a vitrified clay jacking pipe with EPDM seals and an injection moulded polypropylene sleeve and integral thrust ring.

Naylor Micro-Duct Range from DN150 to DN300

Microtunnelling pipes developed for NoDig installation of ducting for high voltage electrical cables and fibre optics.

Naylor Denlok NC range from DN200 to DN300

Vitrified clay jacking pipes with 316 Ti stainless steel coupling fitted with integral EPDM seal and thrust ring component. (This joint system is especially beneficial for smaller diameter jacking pipes as the joint system can accommodate better storage extremes).

Naylor DenChem range from DN150 to DN300

For pipelines needing to operate at high temperatures - up to 150C - the Denlok DenChem range is ideally suitable. Special ceramic pipes capable of withstanding higher temperatures can now be offered for microtunnelling. Applications within the chemical, pharmaceutical, food and dairy processing as well as brewing industries can be accommodated. High temperature chemical effluents resulting from process or cleaning operations can be handled with confidence.

Naylor Denlok NS range from DN400 to DN1200

Vitrified clay jacking pipes with 316 Ti stainless steel sleeves, EPDM seals to achieve min. 2 bar internal/external pressure with factory fitted particle board thrust ring.

Naylor Revit range from DN400 to DN600

Vitrified clay jacking pipes designed for installation by either the 3 pass guided auger boring or pipe bursting.

Delivery and Site Handling

Pipes are despatched in unit packs that are made up using timber spacer boards and frameworks to ensure that there is no pipe-to-pipe contact. Unit packs can be handled by forklift to facilitate offloading and site storage. If packs are to be offloaded using lifting slings then advice of this method of handling must be notified to us for loading purposes. Close attention to packing for transportation and overseas shipment is part of the Naylor delivery service. It is a major recommendation that all unit packs must be kept assembled with all protection intact until the pipe is ready for use. All Denlok pipes and elastomer components are resistant to heat, ozone and ultra violet light.

Product Features and Benefits

Major advantages of Denlok Vitrified Clay Jacking Pipes are: Denlok is covered by and fully certified to EN295, the international standard for clay jacking pipes. High-axial strength for jacking force assurance. High crushing strength for load bearing capabilities. Smooth wall surface with very minimal frictional resistance. Excellent chemical resistance, Denlok handles domestic, industrial and chemical effluents. Accurately machined pipe ends for easy load transference of jacking force. EPDM elastomer sealing components and particle board thrust rings factory fitted. Particle board components tested as best material for load transference. Wide range of diameters available. Worldwide international project-supply references. International Technical and Commercial support.

Naylor Denlok NC range of jacking pipes

Jacking Strengths
1. F1 = permissible jacking force for manual recorded safety factors 2/2 (for standard dimensioning) 2. F2 = permissible jacking force for automatic and control, recorded safety factors 2/1.6)

Denlok NC Jacking Pipe DN150

Vitrified clay jacking pipe with polypropylene sleeve coupling and moulded-in EPDM rubber seals

Pipe Dimensions
Nominal Size DN mm 150 Internal Diameter d1 mm 1493.0 External Pipe End Diameter Width d2 mm 2083.0 d3 mm 521.0 Pipe End Diameter d4 0.5 mm 186 Effective Length L 0.5 mm 996

Sleeve Dimensions
External Diameter c1 1.0 mm 200 Width c2 1.0 mm 100 Pressure Transfer Ring Width c3 mm 5

Jacking Strength
Manual Steering F1 (2) sf=2.0 kN 183 Automatic Steering F2 (3) sf=1.6 kN 228 Approx Weight

kg/m 45

Denlok NC Jacking Pipe DN200 - DN300

Vitrified clay jacking pipe with stainless steel sleeve coupling and integral EPDM elastomer sleeve moulding

Pipe Dimensions
Nominal Size DN mm 200 225 250 300 Internal Diameter d1 mm 2003.0 2254.0 2534.0 3055.0 External Pipe End Diameter Width d2 mm 2713.0 2934.0 3574.0 4125.0 d3 mm 53 53 53 53 Pipe End Diameter d4 0.5 mm 246 272 332 388 Effective Length L 0.5 mm 996 996 996 996

Sleeve Dimensions
External Diameter c1 1.0 mm 266.5 291.7 351.4 409.5 Width c2 1.0 mm 107 107 107 107 Pressure Transfer Ring Width c3 mm 6 6 6 6

Jacking Strength
Manual Steering F1 (2) sf=2.0 kN 350 358 815 938 Automatic Steering F2 (3) sf=1.6 kN 438 447 1019 1172 Approx Weight

kg/m 60 80 100 120

Pipes up to and including DN300 are generally supplied in 1.0m lengths DN300 are available in 2.0m lengths Other lengths available as special requirements

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Naylor Denlok NS range of jacking pipes

Jacking Strengths
1. F1 = permissible jacking force for manual recorded safety factors 2/2 (for standard dimensioning) 2. F2 = permissible jacking force for automatic and control, recorded safety factors 2/1.6)

Denlok NS Jacking Pipe DN400 - DN1200

Vitrified clay jacking pipe with stainless steel sleeve, EPDM elastomer seals and factory fitted packing ring

Pipe Dimensions
Nominal Size DN mm 400 450 500 525 600 700 800 900 1000 1100 1200 Internal Diameter d1 mm 4065.0 4505.0 5045.0 5245.0 6097.0 7209.0 7909.0 8909.0 9919.0 External Diameter Pipe End d2 mm 5525.0 5855.0 6395.0 6605.0 7587.0 8559.0 9509.0 10809.0 11939.0 d3 0.5 mm 526.5 564.0 612.5 633.0 730.5 824.0 921.0 1051.0 1164.0 1276.0 1393.0 Effective Length L 0.5 mm
984 1984 984 1984 984 1984 984 1984 984 1984 984 1984 984 1984 984 1984 984 1984 984 1984 984 1984

Sleeve Dimensions
Internal Diameter c1 1.0 mm 541.0 578.0 626.0 646.5 744.0 837.0 935.5 1065.5 1178.5 1209.5 1407.5 Width c2 0.5 mm 115 115 115 115 115 125 125 125 125 125 125 Pressure Transfer Ring Thickness Width t mm 2 2 2 2 2 3 3 3 3 3 3 p 0.5 mm 18 18 18 18 18 18 18 18 18 18 18

Jacking Strength
Manual Steering F1 (2) sf=2.0 kN 1575 1625 1700 1780 2260 2500 3077 4350 5210 6237 7527 Automatic Steering F2 (3) sf=1.6 kN 1969 2031 2125 2225 2825 3126 3846 5437 6512 7797 9408 Approx Weight

kg/m 240 250 260 280 338 430 508 680 800 967 1170

108512.0 130712.0 118312.0 143012.0

Revit NS Pipe DN400 - DN500

Vitrified clay jacking pipe with stainless steel sleeve, EPDM elastomer seals and factory fitted packing ring

d4

Pipe Dimensions
Nominal Size DN mm
400 450 500

Sleeve Dimensions
Pipe End Diameter d4 mm
468.5 534.5 586.5

Jacking Strength
Maximum Working Jacking Load kN
650 745 815

Internal Diameter d1 mm
4005.0 4505.0 5005.0

External Diameter d2 mm
4825.0 5485.0 6105.0

Internal Diameter c1 mm
475 541 593

Approx Weight

kg/m
149 202 232

All information correct at time of print.

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NAYLOR
DENLOK

Further Information
Information on other Naylor Group Products may be obtained by faxing this form back to Liz Hudston on 01226 794415

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Naylor Industries plc - more than 100 years production and supply to the Construction Industry

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DENLOK
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