Ci/SfB

UDC
628.24

THE COMPLETE TECHNICAL DESIGN GUIDE

mpa British Precast Drainage Association

 Sir Joseph Bazalgette (1819 – 1891) As Chief Engineer of London’s Metropolitan Board
of Works his major achievement was the creation of a sewer network for central London.
Completed in 1858, it extended 82 miles, required 670,000m³ of concrete and is still in use today.
 ‘Sewerage’ is the entire system of pipes,
manholes, gullies and channels.

‘Sewage’ is the foul water effluent that flows

within a sewerage system.

A ‘Sewer’ is the pipeline, either for foul

or for surface water.
 FOREWORD
Precast concrete pipeline systems are the UK’s choice for drainage and sewer solutions. With the inherent
benefits of concrete in terms of cost, strength, inertia and durability, precast systems are the preferred choice
with a design life in excess of 100 years.

Concrete drainage units manufactured in accordance with BS EN 1916 and BS EN 1917 are suitable for slightly
aggressive chemical ground conditions. In the UK, some soils are more aggressive in nature. As a safeguard,
the provision of a concrete suitable for ACEC AC-4 conditions as described in Building Research Establishment
Special Digest 1 2005 is specified. The preferred method to achieve AC-4 for a 100 year intended working life
is the use of a DC-4 concrete with surface carbonation (i.e. precast concrete) without the need for additional
protective measures.

DC-4 concrete is adequate for the vast majority of discharges in normal conditions of use.
However, further consideration should be given to suitable additional protective measures in the
following cases:-

• where a sewer, drain or other component within the system is liable to carry
untreated or corrosive trade effluents

• a rising main discharge

• septic sewage

• inadequate ventilation.

• pipeline systems exposed to the highest level of aggressive conditions (AC-5 family).

In general, the type of surface protection will be specified by the construction designer and will be
provided by the site contractor rather than the manufacturer of the pipeline system. Appropriate
options are discussed in Section D6.4 of Special Digest 1, Concrete in Aggressive Ground.

CONTENTS
CONTENTS

1: SYSTEM DESIGN 06

1.1 Pipeline Hydraulic Design 06

1.2 Pipeline Structural Design  19

1.3 Manhole Design 32

1.4 Box Culvert Design  39

2: INSTALLATION- PIPES 49

2.1 Planning  49

2.2 Handling and Storage  49

2.3 Excavation and Laying  52

2.4 Jointing  54

2.5 Reinstatement  56

2.6 Testing  56

2.7 Jetting  58

3: INSTALLATION – JACKING PIPES 59

3.1 Introduction  59

3.2 Technique and Equipment  59

3.3 Advantages  59

3.4 Products  60

3.5 Further Information 60

4: INSTALLATION - MANHOLES 61

4.1 Planning  61

4.2 Handling and Storage  61

4.3 Construction  61

4.4 Jointing  62

4.5 Reinstatement  63

4.6 Testing 63

5: INSTALLATION - BOX CULVERTS  64

5.1 Planning 64

5.2 Delivery, handling and storage 65

5.3 Construction 66

5.4 References  67

6: REFERENCES AND FURTHER READING  68

 6 1: SYSTEM DESIGN

1: SYSTEM DESIGN
1.1 PIPELINE HYDRAULIC DESIGN
1.1.1 Pipeline Design
Background

There are two main categories of drainage:

1. Surface (or Storm) water systems which generally discharge untreated into rivers or water
courses. Surface water includes agricultural, roof or paved areas and highway drainage.

2. Foul water systems that feed into sewage treatment plants. Foul water can be from either
domestic or industrial sources.

Up to the early 20th century, the majority of drainage systems were ‘combined’, that is, the foul
and surface water fed into the same main sewer. More recent installations opted for separate
systems. To further complicate the situation there are partially separate systems where in times
of surface water flooding, provision is made for cross-linking of the two systems. Combined
systems are still sometimes used, although the government is insisting that they are phased
out and replaced by separate systems.

Even today, for some new installations, mis-connections between surface water and foul water
systems are a problem. The design of drainage should be integral to the design of a development
and follow an holistic approach, working from the whole to the part and not the other way round.

General

The capacity of sewers are selected to meet the design criteria for the hydraulic and environmental
performance of the system. Pipes must be selected to:-
• transport the required design flows
• limit sediment build up
• reduce risk of blockage
• allow effective maintenance

Design considerations
In the design of a surface water or foul water sewer, similar criteria must be considered:-
• average and peak flows and their duration gradient
• the position of the sewer within the network and whether flooding can be tolerated
• the cover depth of the sewer
• any topographical or structural feature (such as a valley, building or embankment)
• surface characteristics (road, field or paved area)
• access to the sewer for maintenance (frequency, size, spacing and depth of manholes)

The basis for design is that flows in sewers are turbulent. Two formulae are recommended for
calculating turbulent flows in sewers: Manning and Colebrook-White.

Pipe headlosses

When using recommended hydraulic pipeline roughness values, it is necessary to establish

whether allowance has been made for local headlosses. The hydraulic pipeline roughness (Ks)
or the Manning flow coefficient (K) should allow for headlosses due to pipe material, taking into
account other factors including the internal profile of the pipe in its in-service state and biofilms
that grow on the pipe surface below water level. The effect of the biofilm can be more significant
than any difference in the roughness of the material without the biofilm. A single value regardless
of pipe material is therefore often used.

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 1: SYSTEM DESIGN 7

The Manning formula

For both circular and non-circular cross-sections whether running full or partially full,
the velocity of flow is given by the formula
V=KRh 2/3 i 1/2
Where:
V = mean fluid velocity (m/s)
K = Manning flow coefficient
Rh = hydraulic radius
i = bed slope
= A/P
= flow cross sectional area
wetted perimeter

The Colebrook-White formula

The general formula for flow in a circular pipe is:

1 = - 2log10 Ks + 2.51
√λ 3.71 Re√λ

Where:
λ = Darcy friction coefficient, 64/Re
Ks = a linear measure of effective roughness (m)
Re = Reynolds number, V D where V = mean fluid velocity (m/s)
ℵ D = hydraulic diameter of pipe (m)
ℵ = Kinematic viscosity (1.31 x 10-6m2/sec) = μ/ρ (m/s) where
μ = dynamic viscosity (Ns/m2 or kg/ms)
ρ = density of the fluid (kg/m3)

In engineering terms, the expression for transitional pipe flow may be written:

V = -2√ (2gDi) log10 Ks + 2.51ℵ

3.71 D√(2gDi)

g = gravitational acceleration (9.81 m/sec 2)
i = hydraulic gradient; invert and water surface slope in uniform flow in open channel.
The depth of flow in the sewer will affect the hydraulic efficiency and Chart A1 gives the proportional
velocity and discharge in part-full circular sections.

For design purposes, ‘Sewers for Adoption’ recommends Ks values of 0.6mm for surface (storm) water and
1.5mm for foul water sewers irrespective of pipe material. The charts (A2 and A3) relate to these values.

For the full range of Ks values see

• Tables for the Hydraulic Design of Pipes, Sewers and Channels (8th edition). HR Wallingford, DIH
Barr, 2006, Thomas Telford
• Charts for the hydraulic design of channels and pipes. Hydraulics Research Station Sixth Edition 1990.

For further detailed information on system design see European Standard EN 16933-2 which
supersedes EN 752 on aspects of hydraulic design for drains and sewer systems.

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 8 1: SYSTEM DESIGN

This section is generally based on the guidance and recommendations within Sewers for
Adoption and BS EN16933-2:2017 Drain and sewer systems outside buildings. Design.
Hydraulic design.

1.1.2 Hydraulic design of surface water sewers

Surface water runoff from impermeable surfaces, such as roads and car parks must first pass
through an interface between the impermeable surface and the drain or sewer system. To
minimise the impact of sewer flooding, the flow at this interface must be considered and its
capacity to accommodate the flow passing through it.

For smaller schemes, a simple approach is recommended where sewers are usually designed
to run full, without surcharge, for relatively frequent design rainfall events on the basis that
this will generally provide protection against sewer flooding from more severe rainfall events.
Rainfall intensity and duration figures applicable to the area should be used.

For larger schemes, where damage or public health risks are significant, the level of sewer
flooding protection should be directly assessed. A sewer flow simulation model based on the
Wallingford Procedure should be used to check the level of flood protection against the sewer
flooding design criteria and the design adjusted where the required sewer flooding protection
is not achieved.

Where storage is provided to control surface water discharges, the designer should demonstrate that:

• the system upstream, including inlets, has sufficient capacity to accommodate the flows to storage

• an overland flood exceedance route is provided that will deliver sufficient capacity

Large (“oversized”) pipes may be used as part of a Sustainable urban Drainage System (SuDS)
- see section 1.1.6. In these situations the pipe is sized to accommodate a calculated volume
of surface water to store and attenuate flow at the discharge point. For “on-line” attenuation
systems a low-flow channel is usually provided within the invert to encourage self-cleansing. If
oversized pipes are used off-line from the sewer, self-cleansing velocities are not expected and
effective silt removal must be provided upstream of the storage.

1.1.3 Hydraulic design of foul water sewers

For drains and sewers serving small populations, the capacity of the pipe is often established
by the minimum pipe size specified by the relevant authority.

In gravity drains and sewers, the ratio between the peak flow and the average dry weather flow
reduces as the flow moves downstream.

The peak design flow rate for dwellings may be based on:

• BS EN16933-2:2017 and calculated in accordance with BS EN12056-2:2000 Gravity drainage

systems inside buildings Part 2: Sanitary pipework, layout and calculation - System II.

Or

• 4000 litres per dwelling per day (0.05 litres per second per dwelling). This is not a daily average
water usage and represents the peak flow rate from a number of appliances. Reducing daily
water usage does not necessarily reduce the peak flow rate.

Unless specifically directed by the client, the choice of method is at the discretion of the designer.

For self-cleansing properties, the foul sewer must flow at a minimum of 0.75 m/sec at one third
of the design flow, the main governing factors being the pipe diameter, the gradient and the
volume of effluent (the larger the pipe and the flatter the gradient, the greater amount of effluent
will be required to achieve self-cleansing velocity).

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 1: SYSTEM DESIGN 9

If there is only a small flow, it is unwise to select too large a pipe “to allow for possible development”
as this may lead to settling out of solids, long retention periods, blockages and build-up of
septicity. A limited period of surcharge and backing up of a sewer is generally preferable to a
consistently low velocity and its attendant problems.

It should be noted that the following hydraulic design charts are for reference only
to help demonstrate a basic hydraulic design process. Users should acquire the full
HR Wallingford publication if they wish to carry out their own design projects. Pipe
networks, with interconnecting branches, manholes and changes in pipe size, direction
and gradients are far more complex design challenges and would normally require
computer modeling software.

Chart A1. Relative Velocity and Discharge in a Circular Pipe for any Depth of Flow.

1.0

0.9

0.8

0.7
Proportional Depth of Flow

0.6
R GE
HA
SC
L DI
0.5 NA
RTIO
O PO
0.4 PR

0.3
CITY
LO
L VE
0.2 NA
R TIO
O PO
PR
0.1

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

Proportional Velocity and Discharge in Pipes Flowing Part Full

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 10 1: SYSTEM DESIGN

1.1.4 Hydraulic Flow Charts

1.1.2
Chart A2

Ks = 0.6 mm (Storm water sewers)

Hydraulic Flow based on Colebrook-White Pipes flowing FULL.

Roughness Factor, Ks = 0.6 mm.
Water Temperature 15ºC

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 1: SYSTEM DESIGN 11

Chart A3

Ks = 1.5mm (Foul sewers)

Hydraulic Flow based on Colebrook-White Pipes flowing FULL.

Roughness Factor, Ks = 1.5mm
Water Temperature 15º C

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 12 1: SYSTEM DESIGN

1.1.3 Worked examples

1.1.5
1) Design of surface (storm) water sewer
Total length of pipeline = 2300m. Total fall to outlet = 15m. Design discharge = 0.3m3/s
Determine required pipe size for: a) Pipe flowing full b) Pipe flowing quarter full

Ks for storm water sewer = 0.6mm

Hydraulic gradient = δy/δx
= 15m/2300m
= 0.0065
= 1:153
Example 1a) Pipe flowing full
Step 1: read off discharge = 03.m3/sec on y-axis and project a line
horizontally across the chart
Step 2: read off hydraulic gradient = 1:153 on x-axis and project a line
vertically across the chart
Step 3: at intersection of Steps 1 and 2 project a line parallel to sloping
line for pipe (internal/nominal) diameter lines.
The required pipe size is between DN450 and DN525.
DN450 is insufficient capacity so select DN525.

Example
1(b):
2.14m3/s

Example
1(a):
0.3m3/s

1:153

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 1: SYSTEM DESIGN 13

(a) PIPE FLOWING QUARTER FULL:

1.0

0.9

0.8
Example 2
0.75
0.7
Proportional Depth of Flow

0.6 E
A RG
S CH
L DI
0.5 NA
IO
O RT
OP
0.4 PR

0.3
Y
Example 1(b)
OCIT
0.25 EL
LV
0.2 NA
TIO
OR
OP
PR
0.1

0
0.14 0.92 1.13
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

Proportional Velocity and Discharge in Pipes Flowing Part Full

Example 1b) Pipe flowing quarter full

Step 1: read off 0.25 (a quarter) on the proportional depth of flow y-axis and project a
line horizontally to intersect with the proportional discharge curve
Step 2: at the intersection of Step 1, project a line vertically down to the x-axis
Step 3: read off proportional discharge = 0.14
Step 4: equivalent full pipe flow is 0.3m3/sec /0.14 = 2.14m3/sec
Step 5: from the chart on page 10, project a line horizontally from discharge =
2.14m3/sec on y-axis
Step 6: project a line vertically from hydraulic gradient = 1:153 to intersect with Step 5
Step 7: project line parallel to sloping line for pipe (internal/nominal) diameter lines.

The required pipe size is between DN975 and DN1050. DN975 is insufficient capacity so
select DN1050

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 14 1: SYSTEM DESIGN

2) Design of foul water sewer

Housing Scheme =180 houses. Total length of pipeline =1650 m. Total fall = 3.6m
Sewers for Adoption - 4 m3/ dwelling / day. Assume half flow over 6 hours and 6 x average flow as design maximum.

=1 4(m3 / dwelling/day) x 180 dwellings x6 (av.Flow) = 0.1m3 /sec

2 6 (hours) x 60 x 60

Ks for foul sewer = 1.5mm

Assume pipeline runs ¾ full and self-cleansing velocity = 0.75m/sec

From Proportional Flow Chart on page 11

Step 1: proportional discharge = 0.75 (3/4 full)
Step 2: discharge factor = 0.92
Step 3: equivalent full pipe flow is 0.1m3/sec / 0.92 = 0.11m3/sec
Step 4: pipe flowing full velocity = 0.75/1.13 = 0.66m/sec

On this chart
Step 5: project horizontal line from y-axis at discharge = 0.11m3/sec
Step 6: project parallel sloping line at velocity = 0.66m/sec
Step 7: Intersection of Step 5 and 6 is between DN450 and DN525.
DN450 is insufficient capacity so select DN525

0.66m/s

Example 2:
0.11m3/s

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 1: SYSTEM DESIGN 15

1.1.6 Sustainable Urban Drainage Systems (SuDS)

BPDA Proprietary Sustainable Drainage Systems and Components

The use of sustainable drainage systems, known as SuDS, and best management practices
should be an integral part of any development’s surface water management strategy. This should
provide a basis for replicating the response of a catchment and its surfaces by mimicking,
to some extent, the behaviour of surface water on the developed site as if it had remained
undeveloped. Modern sustainable drainage systems should aim to offer improvements to
existing surface water runoff, negating any increased risk of flooding by using methods for
managing surface water by focusing on three key elements:

• Controlling surface water quantity (reducing off-site low rates)

• Improving surface water quality
• Providing added amenity value to the development

The successful implementation of a sustainable drainage scheme should consider a combination

of natural and proprietary techniques, complemented by traditional drainage methods, where
appropriate.

It is essential that planners, designers, installers and operators of SuDS systems take into account
the importance of whole life maintenance and the use of suitable components that deliver
authentic sustainable drainage performance and longevity.

Management Train

The SuDS philosophy is underpinned by the water “Management Train”.

The Management Train applies SuDS techniques in series and is based on:

• Prevention; good housekeeping measures within the development

• Source control; runoff managed as close as possible to where it originates as rain

• Sub-catchments; division into small areas with different drainage characteristics

and land use

- Site Control; dealing with runoff within or local to the development

- Regional Control; e.g. SuDS features within amenity space before final outfall

The Management Train can be divided into the following processes:

• Collection • Treatment • Re-use

• Infiltration • Attenuation • Conveyance

BDPA Sustainable Drainage Solutions

BDPA members offer a wide variety of proprietary SuDS components and systems suitable for
use within a sustainable drainage system.

These are listed in the following table indicating their functions within the Management Train.
For specific product information please consult our members.

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 16 1: SYSTEM DESIGN

Attenuatte
Infiltrate

Convey
Re-Use
Collect
SuDS Component

Treat
Rigid pipeline system with flexible joints for
conveyance of stormwater and storage /
attenuation, available with optional dry weather
Circular pipe • • • flow channel and side entry manhole access.
Perforated version enables stormwater to
percolate into the ground.

Elliptical pipeline system for conveyance

of stormwater and storage/attenuation with
Elliptical
pipe • • minimal cover requirement, available with
dry weather flow channel and side or top
entry manholes.

“Egg-shaped” pipeline system with integral

dry flow channel. Higher velocity at low flow
Ovoid pipe • • depths compared to circular pipe providing
reduced risk of siltation.

Modular
Modular tank systems using precast base,
Tank • floor and roof panels
Systems

Off-site, watertight solution pre-benched and

Manhole • • configured to required inlet/outlet orientation.

Multi
Purpose Precast box, base and cover slab in a range
Chamber • of sizes and loading categories.
System

Perforated chamber which may be open

void (providing storage) or contain filter
Soakaway • • • medium (providing treatment) to facilitate
percolation of stormwater into the ground.

Flow Off-site solution with pre-installed flow control

Control • • device such as penstock, non-return valve,
weir wall, orifice plate, vortex flow regulator.
Chamber

Designed to receive storm water runoff

Road Gully • • • • from paved surfaces and first-line gravity
separation of silt.

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 1: SYSTEM DESIGN 17

Attenuate
Infiltrate

Convey
Re-Use
Collect
SuDS Component

Treat
High Enhanced capacity road gully for first line
Capacity • • • • separation of silt and surface water runoff from
surfaces prone to flooding.
Road Gully

Gully pre-fitted with filter for removal

Filter Gully • • of oils and silt.

Hydro-
dynamic Chamber for silt capture, litter and
Vortex • • • some oils.
Separator

A variety of pre-configured chambers

Treatment
Chamber • • • for removal of foreign objects and pollutants
such as litter, oil, grease, silt & heavy metals.

For the gravity separation of debris and

Catch Pit • • • silt to prevent it passing downstream.

Filter catch Catch pit pre-fitted with filter for removal

Pit • • • of oils and silt

Inlets and outlets, available with flap

valves and grills, connecting swales,
Headwall • ponds, detention basins, etc. to
underground pipes.

Cascade
Unit • To protect embankments from erosion.

High Integrated gasket joint and excellent flow

Capacity • • characteristics for surface runoff and below
ground applications.
Slot Drain

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 18 1: SYSTEM DESIGN

Attenuate
Infiltrate

Convey
Re-Use
Collect
SuDS Component

Treat
Perforated
For shallow and deep channel
Drainage • • applications.
Trough

Range of sizes. Available with optional dry

Box Culvert • • weather flow channel.

Rainwater
Domestic and commercial rainwater
Harvesting • • harvesting systems
Tank

Rainwater
Rainwater harvesting pre-tank for leaf and
Filter • • • grit removal.
Chamber

Grey Water
Domestic and commercial grey water
Recycling • • recycling systems
Tank

SuDS References

Information sources to help plan, design and implement sustainable drainage:

1. The community for sustainable drainage. www.susdrain.org
2. CIRIA. The SuDS Manual C753. www.ciria.org
3. Association of SuDS Authorities (ASA). Guidance on SuDS standards:
https://www.suds-authority.org.uk/wp-content/uploads/2018/12/non-statutory-technical-standards-guidance.pdf
4. CIRIA. Site Handbook for the Construction of SuDS C698. www.ciria.org
5. BS 8582:2013 Code of practice for surface water management for development sites.
6. CIRIA. Designing for Exceedance in Urban Drainage Good Practice C635. www.ciria.org
7. CIRIA. Sustainable Drainage Systems. Hydraulic, Structural and Water Quality Advice C609. www.ciria.org
8. CIRIA. Infiltration Drainage – Manual of Good Practice R156. www.ciria.org
9. CIRIA. Control of Pollution from Highway Drainage Discharge R142.  www.ciria.org
10. British Hydrological Society. Sources of Hydrological Data. http://www.hydrology.org.uk/Data_sources.php
11. WRc. Sewers for Adoption. www.wrcplc.co.uk
12. Local Government Association. Flownet Knowledge Hub. A group for all those interested or involved in flood risk and
water management. https://knowledgehub.local.gov.uk/group/flownet
13. National Standards for sustainable drainage systems. Designing, constructing, operating and maintaining drainage for
surface runoff. www.defra.gov.uk
14. For information on SuDS legislation, questions on government policy and to register to receive updates.
email [email protected]

CONTENTS
 1: SYSTEM DESIGN 19

1.2 PIPELINE STRUCTURAL DESIGN

1.2.1 Design Principles
The forces acting on a cross section of pipeline arise from three main sources:

A) Weight of overlying fill, including any local surcharge.

B) Soil pressures transmitted to the pipe from surface loads, i.e. traffic and other transient loads.

C) Supporting reaction below the pipe.

The weight of water within the pipe is only significant for larger diameter pipes.

A: Weight of overlying fill

There are four main conditions in which pipes are installed:

a) “Narrow” trench.

b) “Wide” trench, or on the surface of ground over which an embankment is then built (positive
projection condition).

c) Narrow trench over which an embankment is then built (negative projection condition).

d) Tunnel, heading or by jacking.

The load Wc imposed by the backfill on a pipe in a “narrow” trench can be found from Marston’s
formula from which the Tables have been compiled in Section 1.2.5.

These Tables are only applicable to rigid pipes laid in “Narrow” trench conditions.

Note: The revision of BS9295:2020 has placed more emphasis on wide trench conditions. If
designers have sufficient control over the installation stage, the load-reducing effect of a narrow
trench can be incorporated into the design. It is recommended a maximum trench width is stated
on all designs. Narrow trench designs generally produce a more economic design and have been
standard design procedure for many years without any adverse issues. In all other cases where
the above cannot be complied with, the design should be based on the more conservative wide
trench model.

B: Traffic and other transient loads

Measurements have shown that on large civil engineering works pipes may well be subjected
to their highest loads during construction. Here, three categories of traffic loading are considered
and rigid pipes should normally be designed to withstand the most onerous likely to occur.

If during construction it is clear that excessive site traffic loading will occur, the design should
be checked accordingly or special crossing places must be designated.

a) Main road loading is intended to apply to all main traffic routes and to roads liable to
be used for the temporary diversion of heavy traffic.

As a guide it may be assumed that such roads carry at least 200 commercial vehicles
per day in each direction. The design principals given in BS 9295:2020 ‘Guide to the
structural design of pipelines’ have been assumed.

b) Field loading applies to fields, gardens and lightly trafficked access tracks. This loading
is also considered to be adequate to cater for occasional heaps or stacks of materials
on the ground surface. Massive heaps or stacks likely to produce a more severe loading
should be treated as a special design.

In assessing the loading category, regard should be paid to the possible future upgrading of a
road. Pipes under verges should normally be treated as though under the road, with the
possible exception of motorways and trunk roads and should take account of any planned road

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 20 1: SYSTEM DESIGN

improvement. For non-public roads such as industrial estate roads or roads within works, an
assessment should be made of the heaviest vehicle likely to use the road, and one of the above
three loading conditions selected as appropriate.

C: Supporting reaction below the pipe

British Standards for concrete pipes give maximum crushing loads for each diameter and
strength class of pipe. Loads are applied in a 3 edged loading test described in BS EN 1916 and
BS 5911-1. The pipe must not collapse under the maximum load specified.

Proof test loads are also specified. Reinforced pipes must not crack by more than a specified
amount under the proof load. The only proof load test for unreinforced pipes is the maximum load.

Pipes of a small diameter (Less than DN 300) may fail as a beam. BS EN 1916 and BS 5911-1
include suitable values of bending moment resistance.

Pipe bedding

This term is used to describe the complete arc of material within the trench, or in the case of
Class “C” or Class “D” beddings, a special preparation of the trench bottom. For further information,
see Section 1.2.4 “Pipe Bedding”.

Bedding factor

In the standard test on pipes the vertical loading and supporting reactions are line loads and
any trench situation in the field is unlikely to produce such an onerous loading condition. The
strength of the pipe determined in the crushing test can therefore be multiplied by a bedding
factor which represents the amount by which the stresses in the pipe are reduced because of
the spreading properties of the bedding for load and reaction.

The value of a bedding factor for a particular method of construction is not a precise figure
but is affected by the quality of workmanship. The values given whilst being conservative
assume a reasonable standard of workmanship and supervision. If the designer needs a
somewhat higher bedding factor than stated a high standard of workmanship and supervision
must be specified and guaranteed; alternatively a higher strength pipe may be considered
where available. If a higher strength pipe is available adequate time must be allowed for the
manufacturer to supply.

Factor of safety

For structural design to BS 9295:2020 unreinforced pipes should be designed with a factor of
safety (Fse) of 1.25 (generally DN225–DN600 units are unreinforced but some manufacturers
may have a different range of such pipes). The factor of safety increases to 1.5 for reinforced
pipes. Confirmation should be obtained from the manufacturer or a conservative approach
would be to use a 1.5 factor of safety.

1.2.2 Design Assumptions

Surface Conditions

The Tables in Section 1.2.5 are applicable only to a single pipeline laid in its own trench, and
have been set out to give the loads on pipes under three surface conditions, Main Roads, Light
Roads and Fields.

Alternatively, refer to www.precastdrainage.co.uk/calculators/structural-design where specific

designs can be entered (note: for single pipe trench conditions only).

Backfill loads

The Tables are calculated using an equivalent soil density of 19.6 kN/m3 (approximately
2.0 tonnes/m3).

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 1: SYSTEM DESIGN 21

Traffic loads

The loads referred to in the design principles have values as follows:-

a) Main roads

The traffic surcharge pressures given in BS 9295:2020 have been used. These have been
determined as the higher pressures calculated from Load Model 1 and Load Model 2 of BS EN
1991-2:2003. Wheel load dispersal with depth is also in accordance with BS EN 1991-2:2003.

b) Fields

Static wheel load of 30kN and an impact factor of 2.0, giving a Total Static wheel load of 60 kN;
contact pressure 400kN/m2.

Superimposed loads

These are not included in the Tables. If however such loads are encountered and are of sufficient
magnitude, an allowance should be made.

Water Loads

These are included in the Tables. If the pipe is laid below the ground water table, an allowance
for this load is not needed. However, as these loads are small by comparison with other loads
on the pipe, it has been considered appropriate to include them only for pipes of DN 600 and over.

Frictional factor K

A value of 0.13 has been used for narrow trench conditions.

Recommended minimum cover over pipe

Cover depths less than the minimum values published in industry specifications and Standards
should only be used with the appropriate authority’s permission.

a) It is common practice that pipes laid under roads should have cover over the pipe of not less
than 1.2m to avoid conflict with other services. This cover should be maintained for main roads,
light roads (which may on occasion carry main road traffic) and for pipes laid under grass
verges adjacent to a road. Where pipes have to be laid with less than 1.2m cover special
consideration is needed to reduce the risk of damage. For concrete pipes, according to TRL
tables, the cover depth under highways can be reduced down to a minimum depth of 0.6m
when installed in conjunction with a full granular bed and surround (Bedding Class S).

b) For pipes laid in fields, a minimum cover of 0.6m should be provided. At shallower depths
there is a risk of damage from agricultural operations.

Protection to shallow pipelines

Where pipes are required to be laid at cover depths less Protection to shallow pipeline with slab
than 0.6m, the pipes should be protected as per the
recommendations of BS 9295:2020 annex A, A13
1
The preferred method of protection is the use of a Ground level

reinforced concrete slab being installed over the pipeline

(see typical detail right).
2
Key
1 Backfill 5 Compressible material 3
2 Concrete slab 6 Pipe
5
3 Reinforcement 7 Granular surround 4
4 Minimum 300 mm bearing on 6
original ground 7

CONTENTS
 22 1: SYSTEM DESIGN

It is important that the slab extends sufficient distance beyond the trench and would depend on
soil conditions (minimum bearing of 300mm each side advised). A layer of compressible material
directly over the pipeline aids in the prevention of the slab loading directly onto the pipeline
should settlement occur.

Another method of protection at shallow cover depth is via the use of a concrete surround. It is
important in such installations to install compressible material at least every other pipe joint to
ensure that the pipeline retains its flexibility.

Special consideration should be given where construction plant has to cross pipelines with
shallow cover depth. Where possible, traffic should be routed over dedicated crossing points. Crossing
points may consist of heavy steel plates to transfer vehicle loads or temporary additional cover
emplaced over the pipeline.

Pipelines under embankments or laid in deep trenches

Where a pipeline is laid under an embankment, or where the pipeline is installed in a deep
trench, it can be critical for the trench width and the distance above the crown of the pipe to be
kept within the design values. Any slight increase over the designed trench width can greatly
increase the pipeline’s loading.

Multiple pipes in trench

For convenience, two or more pipelines may be installed in the same trench and at different levels.

Trenches can be excavated to the maximum depth to accept all pipelines, or they may be stepped
in construction where levels of the pipelines are different.

Careful consideration should be undertaken to assess the loading and possible implications of
installing multiple pipelines in the same trench.

The horizontal distance between adjacent pipelines will largely be dependent on the type of
bedding/backfill material used to surround the pipelines. With rounded gravels it’s possible to
achieve minimal spacing between the pipelines (just room to provide access for the gravel to
be working in and around the pipes), whereas an angular/cohesive material may require
upwards of 400mm or greater (depending on pipe sizes) to enable suitable access for placement
and compaction of the materials.

More advice can be found at BS 9295, A.8.

1.2.3 Design Method

The established method for calculation of loads on buried rigid pipes is given in BS 9295:2020.
This provides both detailed design information and guidance. Calculation examples are
provided in Annex A.26. the principles of which are explained below.

In general pipelines are laid in trenches and the pipes used are designed to carry the backfill,
traffic loads and, when the diameter is 600mm or more, some part of the water load under
working conditions.

In order to improve the load carrying capacity of the pipe it is laid on one of several classes of
bedding (see Table A2). Each type of bedding is allocated a “bedding factor” (Fm) which may
be regarded as a multiplier applied to the test load of the pipe.

The trench is excavated in the natural soil, the pipe is laid on the selected bedding and the
trench backfilled. Load on the pipe due to the backfill develops as the fill material settles. The
load on the pipe due to the backfill is therefore the weight of the backfill taken over the full
trench width but reduced by the shear force from the trench walls acting upwards (see Fig.A1).

CONTENTS
 1: SYSTEM DESIGN 23

This state is called the narrow trench condition. The backfill load is calculated by using the
Marston formula. Wide trench conditions should be considered if the trench width is expected
to exceed the widths given in the tables.

W’c = Cd w Bd2
Where:
W’c = Backfill load (kN/m)
Cd = Soil load coefficient in narrow trench conditions, dependent on soil type.
Note: This can vary dependent on soil type and ratio of cover depth to trench width, however
conservative standard assumptions are generally used.
w = Soil density (kN/m3)
Bd = Width of trench (m)

Provided that the trench width does not exceed the values given in the tables, the loads given
are conservative and may be used with confidence.
The trench widths given will provide adequate working space around the pipe for laying and
jointing and also sufficient room to place and consolidate the bedding specified.
As indicated, the friction acting against the backfill is provided by the trench walls and is roughly
constant at a particular depth. If however the trench width is increased radically, Bd2 in the
Marston formula is also increased and a reappraisal of the load on the pipe must be considered.

Fig A1. Narrow Trench Fig A2. Wide Trench

Ground level Ground level

Backfill Side Backfill in trench Side

prism width recommended prism
backfill in tables backfill

H
Bd Bd

Downward Downward
pull pull

Bc
=
Upward D Upward Upward Upward
O
friction Bedding friction friction Bedding friction

For any depth there is a trench width where friction planes from the trench walls become remote
from the pipe and no longer contribute to the reduction of the fill load. In fact the settlement of the
side prisms of backfill tend to increase the load (see Fig.A2). This state is called the wide trench
condition. It is a positive projection condition. The backfill loading on the pipe does not take any
relief from undisturbed ground.
The wide trench backfill load is calculated by using the Marston formula. In preparing the tables
for narrow trench conditions, due consideration has been given as to whether at any trench
width and depth, the narrow or wide trench condition and load is applicable, and the standard
practice of using the lesser of these values has been adopted.

W’c = Cc w Bd2
Where:
W’c = Backfill load (kN/m)
Cc = Soil load coefficient in wide trench conditions, dependant on soil type
Note: This can vary dependant on soil type and ratio of cover depth to trench width,
however conservative standard assumptions are generally used.
W = Soil density (kN/m3)
Bc = Outside diameter of pipe (m)

The tables give the total loads for pipes of all diameters specified in BS 5911-1. This load
includes loading from backfill and traffic for depths of cover over the top of the pipe as follows:
Main Roads 0.60m to 10.0m
Fields 0.60m to 10.0m
For DN 600 and above the water load shown is also included.

CONTENTS
 24 1: SYSTEM DESIGN

Table A1. Minimum crushing loads (Fn) for strength class 120 units with a circular bore
for use in a trench – BS 5911-1:2002+A2:2010.

Nominal Size Minimum crushing Load

DN kN/m
225 27
300 36
375 45
400* 48
450 54
500* 60
525 63
600 72
675 81
700* 84
750 90
800 96
825 99
900 108
1000* 120
1050 126
1200 144
1350 162
1400 168
1500 180
1600 192
1800 216

2000 240

2100 252
2200* 264
2400* 288
NOTE 1 Classic sizes, denoted by an asterisk, will be phased out if called for by further European harmonisation.
NOTE 2 Sizes DN 225 to DN 600 inclusive are normally only manufactured unreinforced in the United Kingdom.
NOTE 3 Sizes DN 1000 and above are normally only manufactured reinforced in the United Kingdom.
NOTE 4 Table NA.5 of BS EN 1295-1: recommends that the minimum value of safety factor for the structural design of reinforced
pipelines should be increased from the normal 1.25 to 1.5 if, as is the case of BS EN 1916: 2002, the proof load is 67% of the
minimum crushing load.
* Sizes marked with asterisk are not readily available in the UK

1.2.4 Pipe Bedding

The load bearing capacity of an installed pipeline relates directly to the construction of the
bedding which is intended to level out any irregularities in the formation, and provide uniform
support around and along the length of the pipe barrel.

Pipe settlement will be kept to a minimum by the proper selection and compaction of the bedding
material. The bedding should be compacted to a density not less than that of the natural soil in
the sides and bottom of the trench. The bedding directly beneath or above the pipeline must not
be over compacted otherwise line loading of the pipes will result.

On steep gradients, or where dewatering has taken place, it is important to restrict ground water
movement within the completed trench. Selection of bedding or clay dams across the full width
of the trench will assist in this.

Under no circumstances should blocks or bricks be placed beneath pipes. Any pegs used for
setting out or levelling must be removed.

CONTENTS
 1: SYSTEM DESIGN 25

Bedding materials

Any stable soil will act adequately as a bedding material provided that it is placed and compacted
around the pipeline. From a practical point of view granular material is compacted more readily
and has become widely accepted.

The bedding material should be of similar particle size to that in the trench sides. Where the
ground is clay or silt, bedding material must consist of all-in gravels to prevent the trench from
becoming a drainage channel and carrying away fines from the trench walls and bedding and
causing settlement of the pipes.

Granular bedding material

The ideal is crushed rock or gravel but similar locally available material having an angular or an
irregular shape may be used. Rounded single sized material is not recommended as it may not
provide a stable bed especially for heavy larger diameter pipes.

Water Research Centre (WRc) Information and Guidance Note (IGN) 4-08-01 provides guidance
on the particle size of material relating to pipe diameter.

Sands containing an excess of fine particles are more difficult to place and compact and will
require a greater degree of supervision on site to achieve a stable embedment for the pipeline.

Selected bedding and fill material

This should consist of uniform readily compactable material, free from tree roots, vegetable matter,
building rubbish and frozen soil. When used as fill, the material should not contain large clay
lumps or cobbles. When used as bedding, all clay lumps should be excluded.

“As dug” material may be used provided that it is readily compactable and provides stable embedment.

Classes of bedding and bedding factors

The strength of an installed pipeline depends on a combination of the strength of the pipe and
the class of bedding.

The selection of the bedding class is influenced by many factors, which include the nature of
the ground, the loads acting on the pipeline in the trench, strength class of pipe, and the local cost
and availability of the bedding material.

Taking into account the cost of labour, it is generally more economical to lay the pipes on a
bedding of non-cohesive materials, or alternatively scarify the trench bottom rather than hand
trim the formation.

Normally loading calculations are made considering the pipeline in complete lengths, between
manholes. The calculated installation condition to satisfy the most severe loading condition
between each pair of manholes is then used throughout the length.

CONTENTS
 26 1: SYSTEM DESIGN

The normally accepted classes of pipe bedding are shown in Table A2 and in Fig A3.

Table A2. Types of Bedding

Bedding Class Bedding factor Description Suitability

Class D 1.1 Hand trimmed flat Fine grained soils,

bottom/ formation relatively dry conditions

Class N 1.1 Flat bed of granular all- in Rock, mixed soils

or selected material
Class C 1.5 Shaped formation Uniform soils
(or scarify) relatively dry
Class F Narrow 1.5 Shaped bedding of General
Wide 1.9 granular material

Class B Narrow 1.9 180° granular bedding General

Wide 2.3-2.8 material
Class S Narrow 2.2 Complete surround of General
Wide 2.3-2.8 non-cohesive granular
bedding material
Class A Plain 2.6 Plain concrete cradle Seldom necessary
Higher strength
pipe with granular
bedding is more
Class A reinforced 3.4 Reinforced concrete
practicable and
cradle
economic option
Geotextiles
Where appropriate, geotextiles may be used to contain bedding materials e.g. in running sand.

Fig. A3. Types of bedding

Class D Class N
Hand trimmed flat bottom. Bedding factor = 1.1 Flat granular layer. Bedding factor = 1.1

Normal backfill Normal backfill

Degree of compaction Degree of compaction
dependent upon surface design dependent upon surface design Very lightly
requirements requirements compacted
Very lightly
compacted
Bc

Bc
300mm

300mm

Well compacted,
especially under
haunches of pipe
Well compacted,
especially under
haunches of pipe Y

Very lightly compacted

Suitable in fine grained soils and relatively dry

conditions. Hand trim formation filling in any hollows. Lay pipes on a flat layer of all-in or selected material
From socket holes as appropriate with 50mm minimum (see Note1)
clearance of sufficient length to permit jointing. Pipes
are laid directly on the formation.

CONTENTS
 1: SYSTEM DESIGN 27

Class C Class F
Granular Bedding
Hand shaped bottom. Bedding factor = 1.5
Narrow = 1.5 Wide = 1.9

Normal backfill Normal backfill

Degree of compaction Degree of compaction Very lightly
dependent upon surface design dependent upon surface design compacted
requirements requirements
Very lightly
Bc
compacted

Bc 300mm

300mm
Well compacted,
especially under
haunches of pipe
Well compacted,
especially under
haunches of pipe
Y

Suitable in uniform soils and relatively dry conditions. Lay pipes on a flat layer of granular bedding material on the
Bottom of the trench, or formation, profiled to fit barrels formation, (see Note1). Scoop out socket holes with 50mm
over a width of not more than 1/2 Bc with socket holes minimum clearance; lay joint pipes which will settle slightly in
to give at least 50mm clearance under the sockets of to the bedding. Sidefill, placed and well compacted in layers.
sufficient length to permit jointing*
* Scarifying formation is generally adequate in practice

Class B Class S
180° Granular bedding 360º Granular bedding & surround.
Bedding factor Bedding factor
Narrow = 1.9 Narrow = 2.2
Wide DN < 0.75 = 2.5, DN> 0.75 = 2.33-2.8 Wide DN < 0.75 = 2.5, DN> 0.75 = 2.33-2.8

Normal backfill Normal backfill

Degree of compaction Degree of compaction
Very lightly
dependent upon surface design dependent upon surface design
compacted
requirements requirements
Bc Bc

300mm 300mm

Well compacted,
especially under
haunches of pipe

Y Y

Lay pipes on a layer of granular bedding material on the Lay, joint and bed pipes as for Class B then place bedding
formation, (see Note1). Scoop out socket holes, lay and material at each side, up to crown level, taking care not to
joint pipes, place and well compact layers in the same displace the pipes. This is followed by 300mm of granular
bedding material at each side of pipes, up to springing bedding material but lightly compacted directly over the
level, taking care not to displace them. pipe, after which ordinary backfilling is commenced.

Selected Grade
Normal Granular
backfill C20
backfill material
material concrete

CONTENTS
 28 1: SYSTEM DESIGN

Class A
Plain concrete cradle. Bedding factor = 2.6 Reinforced concrete cradle. Bedding factor = 3.4

Normal backfill Normal backfill

Degree of compaction Degree of compaction
dependent upon surface design Very lightly dependent upon surface design Very lightly
requirements compacted requirements compacted

Bc Bc

300mm 300mm

Well compacted, Well compacted,

especially under especially under
haunches of pipe haunches of pipe
120º 120º
1/4 Bc 1/4 Bc

Reinforcement 1/4DN min

1/4DN min
1/4DN min

Screed

Class A concrete bedding, either plain or reinforced each 120º cradle. Screed the formation, place blocks on the screed to support
pipes behind each socket. Lay pipes, using packers on blocks to achieve correct line and level. At pipe joints, form construction joints
through concrete bed ensure flexibility of pipeline. Minimum width of cradle 11/4 Bc or Bc plus 200mm. Minimum thickness 1/4 DN min
Pour concrete carefully from one side to prevent voids. Backfill when concrete has attained required strength.

NOTES:
1. Generally thickness of bedding (Y), minimum of 100mm under barrels and 50mm under sockets. In rock 200mm under barrels and 150mm
under sockets subject to maximum of 400mm.
2. Sidefills, whether of bedding material or of selected material, must be well consolidated.
3. Backfill material to be compacted to 300mm above the crown (only lightly compacted directly over the pipe).
4. Normal backfill to be compacted as appropriate.
5. With reasonable workmanship and supervision these bedding factors are conservative.
6. For reinforced cradle, the minimum transverse steel area should be not less than 0.4% of the concrete in longitudinal section.

1.2.5 Design Calculations

The calculated load “We”, which is the total load a concrete pipe in a trench is required to sustain,
is used in the design formula as follows:

Fm = We x Fse
Fn
Where Fm = Bedding factor required
We = Load from Tables A3 or A4 (kN/m)
Fse = Factor of safety
Fn = BS 5911-1 test strength

Test strength of pipe (Fn)

The test strength of a concrete pipe may be referred to as Fc or Fn

In the UK, standard circular pipes to BS EN 1916 and BS 5911-1 are usually to Class 120. To
calculate the test strength apply 120 x pipe nominal diameter in metres e.g. for DN450 pipe,
Fn=120 x 0.45=54kN/m (see Table A1).

For a reinforced concrete pipe Fc is the load which the pipe will sustain without developing a
crack exceeding 0.30mm in width over a length of 300mm and Wt is the load which the pipe will
sustain without collapse, irrespective of crack width. However, to further simplify the procedure it
is more straightforward to use the maximum test load Fn and applying the factor of safety of Fse.

CONTENTS
CONTENTS
Nominal Outside Recommended Total design load (We) in kN/m for cover depths ‘H’ in metres - Main Road
Diameter Diameter maximum trench
DN (mm) BC (mm) width Bd (m)
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 8.0 9.0 10.0

225 295 0.70 41 35 32 29 29 29 28 29 30 31 31 33 33 34 35 36 36 37 37 38 38 39 39

300 412 0.85 57 49 45 42 41 40 41 42 42 43 44 44 45 47 48 50 51 52 53 54 56 56 57

375 493 1.05 68 58 53 50 49 48 49 50 51 52 54 56 58 61 63 66 69 71 72 76 79 80 82

450 581 1.15 81 68 61 59 57 57 57 58 59 62 63 65 66 69 72 76 78 81 84 87 91 94 95

525 675 1.20 94 78 72 69 67 66 67 67 68 69 70 71 73 76 79 83 86 89 91 96 99 102 104

600 776 1.35 108 90 81 77 76 76 76 77 79 79 81 82 84 89 93 97 100 104 107 114 119 123 127

675 849 1.45 118 99 89 84 83 84 85 85 86 88 89 91 93 97 102 107 112 115 119 127 134 139 143

750 962 1.50 134 111 100 94 92 92 91 92 93 94 95 96 99 103 108 113 118 122 127 134 141 147 152

800/825 975 1.60 136 114 102 96 95 94 96 97 98 99 102 104 105 111 117 123 128 133 138 147 155 163 168
Table A3. Road Loading. “H” = 0.6 metres to 10.0 metres

900 1080 1.90 151 126 113 107 104 104 106 110 113 117 120 123 126 134 143 151 159 166 173 187 198 208 218

1050 1262 2.10 177 147 131 124 120 120 121 125 130 135 138 141 144 153 163 172 182 190 199 215 229 242 253

1200 1447 2.30 203 169 151 142 137 136 137 141 146 151 156 159 163 174 184 195 205 216 225 244 261 278 291

1350 1620 2.50 230 191 171 160 154 153 154 157 163 168 173 178 182 193 205 218 230 243 254 276 295 314 331

1500 1803 2.70 256 213 191 178 171 170 170 174 179 184 191 196 202 213 227 240 254 268 280 306 329 350 369

1600 1920 2.85 274 228 204 190 184 181 182 184 190 196 204 211 214 228 244 257 272 287 301 329 354 376 390

1800 2150 3.10 302 251 225 210 203 199 199 203 209 215 222 231 239 255 271 287 304 319 336 368 397 424 449

2100 2485 3.40 359 299 267 250 240 236 235 239 244 252 259 266 273 289 307 326 344 363 383 417 452 483 515

2400 2795 3.70 409 342 305 286 274 269 269 272 277 284 292 301 307 325 344 365 387 407 428 468 507 544 580
1: SYSTEM DESIGN 29
 30

CONTENTS
Nominal Outside Recommended Total design load (We) in kN/m for cover depths ‘H’ in metres - Field loading
Diameter Diameter Trench
in mm in mm width in m
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 8.0 9.0 10.0

225 295 0.70 26 21 20 18 19 19 19 21 22 24 24 26 27 28 30 31 32 33 33 35 35 36 36

300 412 0.85 36 29 27 26 26 26 28 29 30 32 33 34 35 38 40 42 44 45 46 49 50 51 52

1: SYSTEM DESIGN

375 493 1.05 42 35 32 31 31 32 33 35 37 38 41 43 46 50 54 57 60 63 65 69 72 75 76

450 581 1.15 50 41 38 36 36 37 39 41 43 46 49 51 52 57 61 65 69 72 75 80 84 87 90

525 675 1.20 58 48 43 42 42 43 45 46 48 50 52 54 56 61 65 70 73 77 80 86 90 94 97

600 776 1.35 69 57 52 51 50 52 54 56 58 60 62 64 67 73 79 84 89 93 98 105 111 116 120

675 849 1.45 76 63 57 55 55 57 59 61 63 66 68 71 74 80 87 93 99 104 108 117 124 130 135

750 962 1.50 86 71 65 64 61 61 63 62 67 70 72 75 78 85 91 98 104 109 115 123 131 138 144

800/825 975 1.60 88 73 66 64 64 65 67 70 72 75 78 81 84 92 100 106 113 120 126 136 145 153 160
Table A4. Field Loading. “H” = 0.6 metres to 10.0 metres

900 1080 1.90 97 81 74 72 71 73 77 80 84 89 94 98 102 113 123 133 142 150 158 174 187 198 208

1050 1262 2.10 114 95 87 84 84 86 90 94 99 103 108 113 117 129 140 152 163 173 183 201 217 230 243

1200 1447 2.30 132 110 101 97 97 99 103 107 112 116 121 126 132 145 158 171 184 196 207 228 247 264 279

1350 1620 2.50 148 123 113 109 110 112 115 119 124 129 134 140 146 161 177 191 205 219 232 256 278 298 316

1500 1803 2.70 165 139 126 122 122 124 127 131 136 142 148 155 162 178 195 211 227 242 257 285 310 333 354

1600 1920 2.85 177 148 135 131 130 132 135 140 146 153 159 166 173 190 209 225 244 260 276 307 333 358 382

1800 2150 3.10 200 167 153 148 147 147 152 156 164 170 177 186 193 213 233 253 272 290 308 343 375 404 431

2100 2485 3.40 234 197 179 172 169 170 173 181 187 193 201 210 219 240 263 286 307 329 351 389 426 460 494

2400 2795 3.70 266 224 204 194 191 193 198 202 210 219 227 237 246 271 295 320 345 369 392 436 478 518 555
 1: SYSTEM DESIGN 31

1.2.6 Worked examples

The symbols used in the examples are those referred to in Design Calculations (Section 1.2.5).

Example 1
Size of pipe: DN900 (reinforced) Cover depth:3.00m Design load: Main road

Nominal Outside Recommended Total design load (We) in kN/m for cover depths ‘H’ in metres - Main Road
Diameter Diameter maximum trench
DN (mm) BC (mm) width Bd (m)
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 8.0 9.0 10.0

225 295 0.70 41 35 32 29 29 29 28 29 30 31 31 33 33 34 35 36 36 37 37 38 38 39 39

300 412 0.85 57 49 45 42 41 40 41 42 42 43 44 44 43.7 47 48 50 51 52 53 54 56 56 57

375 493 1.05 68 58 53 50 49 48 49 50 51 52 54 56 58 61 63 66 69 71 72 76 79 80 82

450 581 1.15 81 68 61 59 57 57 57 58 59 62 63 65 66 69 72 76 78 81 84 87 91 94 95

525 675 1.20 94 78 72 69 67 66 67 67 68 69 70 71 73 76 79 83 86 89 85.7 96 99 102 104

600 776 1.35 108 90 81 77 76 76 76 77 79 79 81 82 84 89 93 97 100 104 107 114 119 123 127

675 849 1.45 118 99 89 84 83 84 85 85 86 88 89 91 93 97 102 107 112 115 119 127 134 139 143

750 962 1.50 134 111 100 94 92 91.4 91 92 93 94 95 96 99 103 108 113 118 122 127 134 141 147 152

800/825 975 1.60 136 114 102 96 95 94 96 97 98 99 102 104 105 111 117 123 128 133 138 147 155 163 168

900 1080 1.90 151 126 113 107 104 104 106 110 113 117 120 123 126 134 143 151 159 166 173 187 198 208 218

1050 1262 2.10 177 147 131 124 120 120 121 125 130 135 138 141 144 153 163 172 182 190 199 215 229 242 253

1200 1447 2.30 203 169 151 142 137 136 137 141 146 151 156 159 163 174 184 195 205 216 225 244 261 278 291

1350 1620 2.50 230 191 171 160 154 153 154 175 163 168 173 178 182 193 205 218 230 243 254 276 295 314 331
From Table, We (total design load) = 126kN/m
1500 1803 2.70 256 213 191 178 171 170 170 174 179 184 191 196 202 213 227 240 254 268 280 306 329 350 369
Fse = 1.5 (DN > 0.6 reinforced pipe)
1600 1920 2.85 274 228 204 190 184 181 182 Pipe strength
184 190 196 204 = 211
120214x0.9
228 =244
108kN/m
257 272 287 301 329 354 376 390

1800 2150 3.10 302 251 225 210 203 199 199 Bedding factor
203 209 215 222 required m) =
231 239 255(F271 287W304 Fse336/ Fn368= 397
e x 319 126x1.5
424 449 / 108 = 1.75

2100 2485 3.40 359 299 267 250 240 236 235 From Table
239 244 252 A2, Bedding
259 266 273 289 Class (Fm363= 1.9
307 326B 344 383 > 4171.75) and515Class S (Fm = 2.2 > 1.75) are suitable
452 483

2400 2795 3.70 409 342 305 286 274 269 269 Provide Class
272 277 284 B or307S 325
292 301 bedding.
344 365 Maximum trench
387 407 428 468 width
507 544 580 = 1.9m

Example 2
A 900mm diameter pipeline with Class B bedding is to be laid across fields.
What is the greatest cover depth that these pipes may be laid?

Nominal Outside Recommended Total design load (We) in n kN/m for cover depths ‘H’ in metres - Field loading
Diameter Diameter Trench
in mm in mm width in m
0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.5 4.0 4.5 5.0 5.5 6.0 7.0 8.0 9.0 10.0

225 295 0.70 26 21 20 18 19 19 19 21 22 24 24 26 27 28 30 31 32 33 33 35 35 36 36

300 412 0.85 36 29 27 26 26 26 28 29 30 32 33 34 35 38 40 42 44 45 46 49 50 51 52

375 493 1.05 42 35 32 31 31 32 33 35 37 38 41 43 46 50 54 57 60 63 65 69 72 75 76

450 581 1.15 50 41 38 36 36 37 39 41 43 46 49 51 52 57 61 65 69 72 75 80 84 87 90

525 675 1.20 58 48 43 42 42 43 45 46 48 50 52 54 56 61 65 70 73 77 80 86 90 94 97

600 776 1.35 69 57 52 51 50 52 54 56 58 60 62 64 67 73 79 84 89 93 98 105 111 116 120

675 849 1.45 76 63 57 55 55 57 59 61 63 66 68 71 74 80 87 93 99 104 108 117 124 130 135

750 962 1.50 86 71 65 64 61 61 63 62 67 70 72 75 78 85 91 98 104 109 115 123 131 138 144

800/825 975 1.60 88 73 66 64 64 65 67 70 72 75 78 81 84 92 100 106 113 120 126 136 145 153 160

900 1080 1.90 97 81 74 72 71 73 77 80 84 89 94 98 102 113 123 133 142 150 158 174 187 198 208

1050 1262 2.10 114 95 87 84 84 86 90 94 99 103 108 113 117 129 140 152 163 173 183 201 217 230 243

1200 1447 2.30 132 110 101 97 97 99 103 F107

se =1121.5116(DN
121 >1260.6
132reinforced
145 158 171pipe)
184 196 207 228 247 264 279

1350 1620 2.50 148 123 113 109 110 112

Pipe strength = 120 x0.9 = 108kN/m
115 119 124 129 134 140 146 161 177 191 205 219 232 256 278 298 316
Bedding factor provided (Fm) = 1.9
1500 1803 2.70 165 139 126 122 122 124 127 131 136 142 148 155 162 178 195 211 227 242 257 285 310 333 354
Maximum design external load We = Fm x Fn / Fse = 1.9 x 108 /1.5 = 136.8kN/m
1600 1920 2.85 177 148 135 131 130 132 135 140 146 153 159 166 173 190 209 225 244 260 276 307 333 358 382
From Table A4, Total load at 4.5m = 133 kN/m
1800 2150 3.10 200 167 153 148 147 147 152 156 164 170 177 186 193 213 233 253 272 290 308 343 375 404 431
Total load at 5.0m = 142kN/m.
2100 2485 3.40 234 197 179 172 169 170 173 By
181 interpolation
187 193 201 210 219 240 263 286 307 329 351 389 426 460 494

2400 2795 3.70 266 224 204 194 191 193 198 202 210 219 227 237 246 271 295 320 345 369 392 436 478 518 555
Maximum permissible depth H = 4.7m / Maximum trench width = 1.9m

BDPA has developed online Structural and Material Cost calculators and a web App to help with the calculation and optimisation of the
structural design and material cost of underground sewer pipeline systems.
The App offers a two-stage process:
Stage 1 Structural Design Calculator enables users to quickly establish acceptable structural bedding Classes for buried pipes based on
the recommendations in BS EN 1295-1 “Structural design of buried pipelines”.
Stage 2 Material Cost Calculator where users can compare the cost of materials required for each bedding Class option. The calculator
takes into account the pipe cost (including connectors, gaskets, etc), imported granular bedding material and the disposal of surplus
excavated material removed from the trench.
The App not only helps to improve pipeline construction cost efficiency by enabling users to minimise the amount of expensive imported
granular bedding used during construction, it can also reduce the embodied carbon of the installation.

CONTENTS
 32 1: SYSTEM DESIGN

1.3 MANHOLE DESIGN

1.3.1 Manhole Positions
Manholes are recommended:

• At intervals of up to 90m, or 200m for man entry pipe runs.

• Whenever there is a significant change of direction in a sewer.
• Where another sewer is connecting with the main run of a sewer.
• Where there is a change of size or gradient of pipeline.
• Where there is a change of design loading or bedding design.

1.3.2 Precast Components

The following standard precast concrete components are manufactured in accordance
with BS EN 1917 & BS 5911-3 for assembly into complete manholes;

• Adjusting units and corbel slabs

• Cover slabs
• Shaft sections
• Reducing slabs
• Chamber sections
• Landing slabs
• Base units

Fig. A4. Typical Manhole Layout

Fig. A4a. Typical Cast In-situ Manhole Base with Fig. A4b. Typical Precast Manhole Base with
Tongue and Groove Jointed Rings Elastomeric Seal Jointed Rings

Manhole Cover

Adjusting Units
Manhole Cover

Cover Slab
Adjusting Units
Seal

Cover Slab
Shaft section

Shaft section Seal

Reducing Slab
150mm Reducing Slab
Cast In Situ Seal
Surround
Landing Slab
Chamber Section
Seal

Landing Slab
Chamber Section

Chamber Section
Seal
Spigot
Spigot Butt Pipe
Butt Pipe Socket Butt Pipe Socket Butt Pipe

Cast In Situ Base Precast Base

Flow Flow

Cut Away Detail Cut away assembly detail Cut Away Detail Cutaway illustration of
available components

CONTENTS
 1: SYSTEM DESIGN 33

Base units can be supplied with circular or semicircular holes (cut-outs or ‘dog kennels’) cut in
the chamber walls or with factory made flexible joints to incorporate a sealing ring to connect
pipes to the chamber.

1.3.3 Advantages

The main advantages of manholes using precast concrete components are:

1. Reduced construction time and cost

2. Less operative risk exposure in trench during construction

3. Its self-weight provides natural resistance to flotation

4. Can accommodate new build and retro-fitting of new connections

5. Units are produced in a controlled factory environment to BS EN 1917 & BS 5911-3 to

ensure consistent quality and performance.

6. All BPDA member factories are licensed to manufacture ‘Kitemarked’ standard units
under BS EN ISO 9001 quality management systems.

7. They are manufactured in a range of standard sizes and depths.

8. They are simple to assemble requiring relatively unskilled labour on site.

9. Units are watertight structures without the need for a concrete surround. Soil backfill is
normally sufficient.

10.They can be supplied ready fitted with double steps complying with BS EN 13101.

11. The structure is durable with its own inherent strength.

1.3.4 Types of Manholes

Manholes should be designed and constructed in accordance with BS EN 752. Table NA.22
provides recommendations for dimensions for manholes and manhole shafts for UK applications
(with personnel entry) and Sewers for Adoption provides details of manholes suitable for
adoption purposes.

Manholes are built on a run of sewer with or without side connections. Where conditions permit,
the soffit level of sewers connecting to a manhole should be the same.

Manholes may be constructed with or without a shaft. It is recommended that reducing slabs
and shafts are only used for DN1800 manholes and larger. Landing slabs are generally required
for manholes 6 metres deep or greater.

Smaller diameter chambers should be constructed up to full height and use a cover slab. There
are also inspection chambers which are constructed over a subsidiary drain or sewer of not
more than DN 225 to permit inspection and access for rodding. Most manholes are sited
symmetrically over the main sewer pipeline. Side-entry manholes which are formed integral to
the crown of the pipe are also manufactured. These can be advantageous in terms of installation
time and cost savings.

When contemplating the installation of rectangular or square manhole/s, reference should be

made to Annex F of BS 5911-3+A1.

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 34 1: SYSTEM DESIGN

1) Precast base systems

Inlet(s) and outlet positions are configured to site requirements and delivered with all channels and benching complete.
Watertight joints and thicker walls means units do not require a concrete surround, unless specified. A faster, safer,
higher quality, lower installed cost and reduced carbon footprint alternative to conventional manholes, (the product’s
finish is not subject to the skills of site operatives).

Precast concrete manhole sections and cover

slab to be bedded with mortar, plastomeric
or elastomeric seal conforming to
BS EN 1917 and BS 5911-3
Chamber wall to be minimum 125 mm

Benching slope to be 1:10 to 1:30

Surface of benching and channel formed
monolithically with high-strength concrete
base or a proprietary liner

150 mm to underside of channel

2) In-situ manholes

Concrete base, channel/s and benching installed in-situ. With the bottom section of the first manhole ring being built
in to the base concrete by a minimum of 75mm. Distance between top of pipe and underside of first manhole ring to
be minimum of 50mm to a maximum of 300mm. Generally and in accordance with ‘Sewers For Adoption’ a concrete
surround is required with this type of manhole construction.

Precast concrete manhole sections and cover

slab to be bedded with mortar, plastomeric
or elastomeric seal conforming to
In-situ concrete to be GEN3 BS EN 1917 and BS 5911-3
(designed to BRE Special Digest 1
Concrete in Aggressive Ground) Concrete surround 150 mm thick

The bottom precast section to be built into

base concrete minimum 75 mm

High-strength concrete topping to be brought Benching slope to be 1:10 to 1:30

up to a dense, smooth face, neatly shaped and
finished to all branch connections Construction joint
(minimum thickness 20 mm)
Distance between top of pipe and underside
of precast section to be minimum 50 mm to
maximum 300 mm

225 mm to underside of channel

For more information on precast manhole base systems, refer to BPDA and member product information:

Marshalls CPM http://www.cpm-group.com/products/drainage/sealed-manholes/the-perfect-manholes

FP McCann Ltd http://fpmccann.co.uk/easi-base
Stanton Bonna http://www.stanton-bonna.co.uk/drainage-systems/watertight-manhole-system/
BPDA https://www.precastdrainage.co.uk/page/precast-manhole-design-construction

CONTENTS
 1: SYSTEM DESIGN 35

3) Side-entry manholes

Side-entry can be provided for sewers larger

than DN 1200. The side-entry shaft is fitted
to the main sewer pipe by the manufacturer
before delivery.

4) Backdrop manholes

Where one sewer connects with another at a substantially different level, the manhole is built
on the lower sewer and incorporates a vertical or ramped drop pipe from the higher sewer. The
drop pipe, which may be inside or outside the manhole chamber, has its lower end discharging
into the main sewer, and at its upper end has a rodding eye for cleaning through the higher sewer.

Wherever possible, steeper gradients are preferred over the use of backdrops in ‘Sewers For Adoption’.

5) Dual and crossing manholes

Where surface water and foul sewers are laid in the same trench, the surface water being normally
above the foul, a normal manhole chamber is built for the foul sewer and the surface water is
carried across the chamber in a separate pipe which may have a sealed inspection cover.

1.3.5 Sizes of Manholes

The diameter of the chamber is determined by the number and the diameter of the sewer pipes
coming into the manhole and the working space required.

The chamber should be a minimum of DN 1050 and is the smallest size that may be fitted
with steps, but are only permitted to be used to a depth of 1.5m. DN 1200 is the smallest size
that can be used deeper than 1.5m and to which ladders may be fitted. It should have ample
benching at least 225mm wide on one side of the channels. On the other side, the benching
should be wide enough to stand on, at least 450mm.

For deep manholes, the chamber should be large enough to provide benching or a landing
adequate for two persons to stand upon.

A guide for the minimum chamber diameters required for various sizes of sewer pipes entering
the manhole is given in Table A6. When a manhole is sited on a curve, or where additional pipes
enter at the sides a larger size may be required.

Table A5. Sizes of pipe and manhole chamber diameters

Maximum size of pipe (DN) through chamber Minimum Chamber diameter (DN)

Less than 375 1200

375 – 450 1350
500 –700 1500
750 – 900 1800
Greater than 900 Pipe diameter + 900

1.3.6 Pipes Adjacent to Manholes

There may be differential settlement between a structure and the pipeline resulting in angular
deflection of the joint. This creates no problem for the joint itself but when this movement is
“excessive” there is a shear force that can cause structural failure on the pipe, either shear
behind the collar or from beam fracture of the pipe barrel.

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 36 1: SYSTEM DESIGN

To prevent this, the first pipe in the line can be restricted in length. This is known as a “rocker
pipe”. The likelihood of differential settlement should be assessed and rocker pipes used as
appropriate.

Guidance on rocker pipes may be found in “Civil Engineering Specification for the Water
Industry” and ‘Sewers for Adoption’.

Fig. A5. Typical Rocker Pipe

Acceptable angular deflection Full length pipe

Short pipe length Rocker pipe

In certain conditions where excessive differential movement is possible, for pipes ≥ DN750,
it may be advisable to use multiple rocker pipes to avoid unacceptable angular deflection or
shear force at the joint.

1.3.7 Cover, landing and reducing slabs

The minimum clear access opening for any manhole is 600 x 600mm. For manholes with
depths less than 1.5m, a 1200x 675mm opening should be used.

The range of access opening sizes that are provided with precast concrete cover slabs
manufactured and inspected in accordance with the scope of BS5911-3 are as follows:

Opening Configuration
Nominal chamber size (mm)
Size (mm) Location
DN900 600 x 600 Central
675 x 675 Central
DN1050 600 x 600 Eccentric
675 x 675 Eccentric
750 x 750 Central
DN1200, 1350 & 1500 600 x 600 Eccentric
675 x 675 Eccentric
750 x 600 Eccentric
1200 x 675 Central
DN1800, 2100, 2400, 2700 & 3000 600 x 600 Eccentric
675 x 675 Eccentric
750 x 600 Eccentric
1200 x 675 Eccentric
1200 x 750 rectangular 600 x 600 Eccentric
675 x 675 Eccentric
750 x 600 Eccentric

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 1: SYSTEM DESIGN 37

Slabs with other sized accesses/multiple accesses or rebated accesses are quite often
required in cases of split wall chambers, pumping stations, where flow control devices are
fitted within the chamber etc. (these would be made to order products).

Cover Slabs – UKCA/CE Marking

Only cover slabs covered by the European Standard (DN900 – DN1200) may be UKCA/CE
Marked.

Slabs covered by the British Standard may be Kite-marked. Thus most Slabs DN900 – DN1200
carry both Kite-mark and a UKCA/CE Marking whereas most slabs of DN1350 and above
would only carry a Kite-mark. Exceptions to this rule exist, for example a DN1200 Slab with a
750x750mm opening carries UKCA/CE Marking but not a Kite-mark as the opening size is not
contained within the British Standard.

Cover Slabs – Loading

EN1917 :2010 is the European standard and together with BS5911-3:2014 as the UK National
standard for Manhole Cover Slabs and provides a full product specification. The scope of the
standard covers manholes ’intended to be installed in carriageways of roads (including pedestrian
streets), hard shoulders and parking areas for all types of road vehicles’.

BS-5911-3:2014 ‘Specification for reinforced and unreinforced manholes’ has been revised such
that the test loads for standard slabs covered by BS5911-3 are consistent with Eurocode Loadings.

The standards include test requirements for the cover slabs to ensure suitability for use in all UK
Road categories. There is no requirement in BS5911-3 for the slabs to comply with a reinforced
concrete design code of practice such as BS EN 1992-1-1.

The cover slabs are subjected to routine batch load testing. The test is deemed a ‘proof load’
test and does not take the slab to ultimate (failure) but requires compliance with a maximum
permitted crack width after removal of the test load being 0.15mm. This is therefore comparable
with serviceability requirements in a design code of practice where the design considers a service
load not ultimate load.

Consequently, if loads are compared between test loads and design loading it would
be as follows.

• BS EN 1917
DN900- DN1200 120kN load applied around the access

• BS 5911-3:2014 Figure 11 ‘Loading arrangements for cover slabs’

DN1350-DN1800 250kN load applied around the access
DN2100-DN3000 2 x 250kN at 1.2m centres applied over a 400mm x 400mm
contact area

• BS EN 1991-2 ‘Traffic loads on bridges’

Load Model 1 (Covering most of the effects on normal roads from lorries and cars)
150kN wheel load in lane 1 & 100kN wheel load in lane 2 at 1.0m centres

In concluding the above demonstrates that the test loads required to comply with BS5911-3
are at least equivalent to the loading required under BS EN 1991-2 when considering crack
width requirements. The principal difference between the cover slab product standard and the
Eurocode design standard being slabs to the BS 5911-3 are tested as opposed to a structural
design required for compliance with BS EN 1991-2.

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 38 1: SYSTEM DESIGN

Generally, slabs manufactured and inspected in accordance with BS5911-3 are suitable for
use in applications where an A15 - D400 rated manhole cover, manufactured and inspected in
accordance with BS EN 124, is intended to be used.

In concluding the above demonstrates that the test loads required to comply with BS5911-3
are at least equivalent to the loading required under BS EN 1991-2 when considering crack
width requirements. The principal difference between the cover slab product standard and the
Eurocode design standard being slabs to the BS 5911-3 are tested as opposed to a structural
design required for compliance with BS EN 1991-2.

Generally, slabs manufactured and inspected in accordance with BS5911-3 are suitable for
use in applications where an A15 - D400 rated manhole cover, manufactured and inspected in
accordance with BS EN 124, is intended to be used.

Slabs that are to be used in differing loading conditions, or with multiple access holes or access
hole sizes outside of the scope of BS5911-3, can be manufactured in precast concrete but this
will be a bespoke design and manufactured in accordance with the relevant Standards; i.e. they
will not be tested.

Landing slabs

Landing slabs are generally required on manholes greater than 6m depth (landing slabs should
be installed at minimum of 2 metres and maximum of 6 metres spacing for the depth of the
manhole).

Reducing slabs
On large, deep chambers (usually DN1800 or greater), it is common practice to reduce the
upper access shaft to a smaller, more economic solution of typically DN1200 size. Where
double steps are fitted in the main chamber, the steps alignment is maintained through the
reduced shaft section.

Opening Configuration
Nominal chamber size (mm)
Size (mm) Location
Landing Slabs
DN1800, 2100, 2400, 2700 & 3000 DN900 Eccentric
Reducing Slabs
DN1800, 2100, 2400, 2700 & 3000 DN900 Eccentric
DN1050 Eccentric
DN1200 Eccentric

Adjusting units and Corbel units

Adjusting units can be installed between the concrete cover slab and the access cover and
frame (can be used in replacement of engineering brickwork in most situations).

The access in the concrete cover slab may be reduced in size (typically from 750 x 600 mm to
600 x 600 mm) via the use of corbel units.

In order to meet the maximum distance from cover level to the first step (typically 675mm), it is
recommended that no more than three adjusting/corbel units are used in total.

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 1: SYSTEM DESIGN 39

1.4. BOX CULVERTS

1.4.1 BOX CULVERT DESIGN
Introduction
Box culverts can be used for a wide variety of applications. For further information please refer
to the BPDA website. Prior to the formation of the BPDA the trade body representing box
culverts was the Box Culvert Association (BCA).

The design of headwalls/wingwalls/aprons is not covered in this guide. For further information
please contact the BPDA member companies.

Box culverts are manufactured to BS EN 14844 +A2: 2011. This standard provides guidance on
materials, durability, testing methods, geometry, tolerances, settlement, and production
requirements. Figure E1 shows the geometrical terminology used for box culverts. The standard
also offers references to design criteria as explained in 5.1.3. The harmonised European
standard also references other standards, including the precast products Common Rules
standard BS EN 13369: 2013.

Note: EN 14844 covers monolithic box culvert units only. U-shaped units or boxes consisting of
more than a single element are not covered by that European standard and should be
manufactured to BS EN 13369.

Figure A6. Culvert geometry / terminology

tr roof/floor slab thickness

tw wall thickness

e,f - geometry of the splay (refer to diagram below)

Effective roof span (We) = W + tw

Effective wall span (He) = H + tr
Effective and Socket inner and overlapping nibs of a rebated joint profile (refer to diagram below)

f
L tr

H tw
W

CONTENTS
 40

CONTENTS
Width mm (internal span)
500 600 800 1000 1100 1200 1250 1375 1500 1750 1800 2000 2100 2250 2400 2500 2700 3000 3300 3600 3900 4200 4500 4800 5100 5400 5700 6000

300 0.15

400 0.24 0.32 0.38

1: SYSTEM DESIGN

500 0.46 0.56 0.59 0.71 0.86 1.01

550 0.56

600 0.53 0.65 0.71 0.83 1.01 1.19

625 0.826

650 0.61 0.74 0.93 1.13 1.32 1.52 1.71

700 1
1.4.2 Box Culvert Hydraulic Design
Table A6 BPDA standard box culvert range -

750 0.735 0.9 1.06 1.25 1.74 1.965 2.19 2.415 2.64 2.865 3.09

800 0.73 0.89 1.13 1.37 1.61 1.85 2.09 2.33 2.57 2.81 3.05

1000 0.93 1.13 1.341 1.42 1.69 1.73 1.92 2.03 2.33 2.63 2.92 3.23 3.53 3.83 4.13 4.43 4.73

1200 1.37 1.73 2.09 2.45 2.81 3.17 3.53 3.89 4.25 4.61 4.97 5.33 5.69 6.02 6.38 6.74 7.09
internal dimensions (mm) & cross-sectional flow area (m2)

1250 1.815

1500 1.42 2.17 2.57 2.63 2.92 3.08 3.315 3.53 3.67 3.98 4.42 4.88 5.33 5.78 6.23 6.68 7.13 7.55 8 8.45 8.9

1800 3.17 3.71 4.25 4.79 5.33 5.87 6.41 6.95 7.49 8.03 8.57 9.08 9.62 10.16 10.7

Height mm (internal span)

2000 1.92 2.92 3.92 4.92 5.92

2100 4.34 4.97 5.6 6.23 6.86 7.49 8.12 8.75 9.38 10.01 10.61 11.24 11.87 12.5

2400 5.69 6.41 7.13 7.85 8.57 9.29 10.01 10.73 11.45 12.14 12.86 13.58 14.3

2500 3.67 4.92 6.17

2700 7.22 8.03 8.84 9.65 10.46 11.27 12.08 12.89 13.67 14.48 15.29 16.1

3000 2.92 4.42 5.92 8.93 9.83 10.73 11.63 12.53 13.43 14.33 15.2 16.1 17 17.9

3300 10.82 11.81 12.8 13.79 14.78 15.77 16.73 17.72 18.71 19.7

3600 12.89 13.97 15.05 16.13 17.21 18.26 19.34 20.42 21.5

NOTES
1. The cross-sectional area of box culverts may be useful for calculating the storage capacity of surface water drainage attenuation systems and up to full bore flow capacity in steady, uniform flow conditions.
It is not advisable to use the full cross-sectional area for the hydraulic design of culverted watercourses.
2. The cross-sectional areas shown in this table may vary between box culverts produced by BPDA members. The minimum value is shown and should be used for guidance only.
For an accurate value of the actual cross-sectional area and the box culvert sizes available from each BPDA member, please refer to the product data published by the manufacturer.
 1: SYSTEM DESIGN 41

Design principles

The overall scheme designer is responsible for the hydraulic design of a box culvert, taking into
account all parameters relevant to the project.

For example:
• conditions upstream and downstream of the culvert (before and after culvert construction)
• inlet and outlet hydraulic energy losses
• compound hydraulic roughness of culvert
• longitudinal flow profiles (such as backwater, headwater and tailwater depths), afflux and
freeboard through the culvert during maximum design flows
• cross-section restriction due to sediment deposition
• benching for fish / mammal passage
• low flow channel provision
• safe access and screening requirements
• appropriate maintenance regime to ensure effective performance over asset lifetime
• flood routing in the event of a blockage

BPDA members can provide discharge capacities based on flows through the full cross-
section of box culvert units, i.e. full-bore flow. In practice, this is likely to over-estimate
the actual capacity of the culvert and may not represent the actual conditions.

The following example, based on CIRIA Culvert design and operation guide (C689) is
provided to demonstrate the basic hydraulic design process for culverts. Users should
acquire the full publication or seek alternative guidance in order to carry out their own
hydraulic design for projects.

Example 5.A

It is proposed to build an access road over a stream using a highway culvert under the road.
The culvert is required to carry a design flood of 4.0m3/s under free flow conditions with partial
sedimentation. Normal flow conditions may be assumed and there are no hydraulic structures
at the culvert site to consider. The bed slope So is gentle at 1:200 (i.e. 0.005m/m).

Design steps

i) Calculate the tailwater depth at the culvert for the design flood
ii) Check suitability of proposed culvert dimensions

Data references

• BPDA Table of Standard box culvert dimensions (see Table A6)

• CIRIA Culvert design and operation guide (C689) Table A1.6 geometrical formulae

Manning’s equation for open channel flow

V = n-1R 2/3So1/2
Where
V = mean velocity (m/s)
R = hydraulic radius (m) = A/P
A = cross-sectional area of flow (m2)
P = wetted perimeter (m)
So = slope of energy line (bed slope)
n = coefficient of roughness (Manning’s n)

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 42 1: SYSTEM DESIGN

For any flow, the discharge Q at a channel section is expressed by

Q = VA

Where

Q = flow rate (m3/s)

V = mean velocity (m/s)
A = cross-sectional area of flow (m2)

i) Tailwater depth

The stream has a trapezoidal cross-section, see below. Use Manning’s equation for normal
flow (assume n = 0.035) to estimate the tailwater depth at the culvert location.

Figure A7

1.8m
Y 1

Z=1

B=2.0m

The initial estimates for tailwater depth based on the geometrical properties and flows are
given in the table below.

Table A7

B 2

z 1

So 0.005

n 0.035

Cross-sectional Wetted Hydraulic

Tallwater depth y Flow Q (m3/s)
flow area A (m2) perimeter P (m) Radius R (m) R2/3 So1/2
(m) AR2/3So1/2/n
(B + zy)y B + 2y√(1+z2) (B+zy)y/B+2y√(1+z2)

0.80 2.24 4.26 0.53 0.34 0.07 1.55

1.20 3.84 5.39 0.71 0.57 0.07 4.40
1.10 3.41 5.11 0.67 0.51 0.07 3.51
1.15 3.62 5.25 0.69 0.54 0.07 3.94
1.16 3.67 5.28 0.69 0.54 0.07 4.03*

*Closest to 4.0m3

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 1: SYSTEM DESIGN 43

Use tailwater depth ydc = 1.15m.

Figure which results is flow Q nearest to the design flow of 4.0m3/s.

ii) Culvert sizing

The developer intends installing a 2.7m wide by 1.8m high precast concrete box culvert with
the invert below bed level to allow for the formation of a natural bed and re-grading of the
stream. Is the proposed culvert suitable? Can any improvements be made?

Step 1.

Estimate the required culvert size using the barrel velocity method. Calculate velocity in the
downstream channel Vdc (use area from (i)).

Vdc = Q/A = 4.0/3.6 = 1.1m/s

Step 2.

Calculate the required culvert flow area assuming that the barrel velocity is 10% higher than
the downstream channel. (N.B. It is generally considered good practice for the channel flow
velocity to be greater within the culvert).

A = Q/(1.1 x Vdc) = 4.0/(1.1 x 1.1) = 3.31m2

Step 3
Estimate the freeboard (F) and sedimentation depth (S). Then determine the overall culvert
height (H) for free flow conditions by adding these to the tailwater depth ydc from (i).

Assume F and S are both 0.25m.

Figure A8

F FREEBOARD

Ydc
FLOW AREA, A H

S SEDIMENT

B (orW)

H = ydc + F + S = 1.15 + 0.25 + 0.25 = 1.65m

Step 4
Estimate the culvert width B to give the required flow area. (N.B. It is common in hydraulic
design for the channel width to be termed “B”. Box culvert manufacturers usually refer to the
culvert width as “W”). Check for suitable sizes of box culvert from the Table of standard box
culvert dimensions (page 40).
B = A/ydc = 3.31/1.15 = 2.88m

A 2.88m wide by 1.65m high box culvert would be acceptable, but it is not a Standard size.
The nearest Standard size is 2.7m wide by 1.8m high or 3.0m wide by 1.8m high.

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 44 1: SYSTEM DESIGN

Step 5
The proposed 2.7m wide by 1.8m high box culvert is suitable. The soffit of the culvert will be
below the top of the bank of the stream when units are set 0.25m below the invert level of the
stream (i.e. sedimentation depth, S). The barrel of the culvert is wider than the natural channel
at invert level but narrower at water level.

Figure A9

1.8m
H=1.8m

B=2.0m

W=2.7m

Training walls could be installed to improve the transitions. Benching would increase flow depth
and velocity at low flows.

Other hydraulic design considerations

After determining the required size of a culvert, there will be other design factors and checks to
consider to ensure that the culvert will perform satisfactorily.

Typical initial assessments include calculations relating to maximum permissible headwater

level and afflux.

Barrel velocity should also be checked such that sedimentation within the culvert is not a problem.

More detailed assessments would look into inlet and outlet control conditions, determining
discharge capacity for a given headwater level and headwater level for a given discharge. The
use of screens should be assessed for sizing and head loss.

1.4.3 Box Culvert Structural Design

The design of box culverts has always required reference and understanding of traffic loading on
bridges, and this remains a fundamental requirement when undertaking a box culvert design. In
addition to BS EN 1990, BS EN 1991 and BS EN 1992, and National Annex’s, there is now a specific
product standard, BS EN 14844+A2:2011 ‘Precast concrete Products – Box culverts’, dealing
with aspects of design, manufacture and installation. This document in turn, cross references
BS EN 13369:2013 ‘Common rules for precast concrete products’. Additionally there is non-
contradictory complementary information in the form of PD 6694+A1:2020. Recommendations
for the design of structures subject to traffic loading to BS EN 1997- 1:2004 and PD 6687-2:2008
Recommendations for the design of structures to BS EN 1992- 2:2005.

BPDA member companies can design the culverts for the required traffic load models as part of
the contract. Assistance can be given at enquiry stage on the design.

Generally, within the Eurocodes, the principles of reinforced concrete design for Ultimate Limit
State bending and shear are the same as for designs to British Standards. There are small

CONTENTS
 1: SYSTEM DESIGN 45

differences in the allowable shear stresses but this does not significantly affect the design of
box culvert units. However, the loadings now required by the BS EN 1991-2 are significantly
greater than former British Standards. This results in the need to provide a structure with
increased structural capacity.

1.4.4 Relevant Standards

There are documents which need to be consulted to achieve an appropriate and compliant
design for a box culvert. It is essential that the initial design parameters are clearly defined at
an early stage, to ensure the Client is provided with a product which meets their requirements.

Table A8. Standards used in the design of box culverts

Standard How the standard is used

BS EN 1991-2:2003 Eurocode This document sets out the loading classes for road bridges and defines a series of Load
1:Actions on Structures - Part 2: Models (LM1-LM3),
Traffic Loads on Bridges
• Load Model 1 - Concentrated and Distributed Load

• Load Model 2 - Single axle loads

• Load Model 3 - Loads for Special vehicles which includes types SV80, SV100 and SV196

• Load Model 4 - Crowd Loading (this load model is not used as the UDL value is less
than the base UDL used in LM1)

Each Load Model describes a configuration of wheel loading to represent different

wheeled vehicles. It is significant that the wheel loads within these models is now 150kN
(LM1) and 200kN (LM2) & 165kN (LM3). This is compared to the previous wheel load of
30HB at 75kN.

The design is progressed, generally adopting the worst case effects of these Load
Models. The loads are applied to the culvert structure by considering the zones of
influence as described in PD 6694 (Fig 11). PD 6694 (Table 7), also defines the horizontal
surcharge pressures to be applied to the structure.

Horizontal loads in terms of braking and acceleration forces are defined within the
Eurocode, and these are applied in conjunction with the relevant vertical loads.

BS EN 1992-1-1:2004+A1:2014 Having established the appropriate applied loads, and from an analysis to determine the
– Eurocode 2:Design of concrete resultant bending moments and shear forces, the detailed concrete design is undertaken,
structures - Part 1-1: General rules in accordance with this document.
and rules for buildings

BS 8500-1:2015+A2:2019– The performance of the culvert structure and its defined working life will be determined
Concrete - Complementary by defining a suitable concrete specification, and by adopting suitable cover to the
reinforcement.

British Standard to BS EN 206-1, Section 4 of BS EN 1992-1 covers durability and cover requirements. The Exposure
Part 1: method of specifying and Classes are as EN 206-1, but in the UK BS BS8500-1 is adopted, to define a suitable
guidance for the specifier concrete specification, taking account of corrosion due to carbonation (XC), chlorides
(XD), sea water (XS), & freeze/thaw (XF). Generally, XD2 is adopted for buried highway
structures more than 1.0m below an adjacent carriageway and XD3 for buried highway
structures less than 1.0m below the carriageway level. For a structure that is not buried
adjacent to a carriageway XD1 is adopted. The required concrete specification for XD3 is
described by it’s a strength class C40/50 with an associated minimum cement content of
380kg/m3 and maximum water cement ratio of 0.35 when cement types IIB-V or IIIA are
used. In some circumstance a client may request that the internal surface and external
face are designed with different exposure classes.

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 46 1: SYSTEM DESIGN

Table A8 (Continued)

Standard How the standard is used

For particular cases of exposure (high sulphate conditions), it may be necessary to refer to
the BRE Special Digest 1:2005 - Concrete in aggressive ground, which gives guidance on
concrete specification and additional protective measures.

Intended working life is generally specified at 100 years. However, the clause 1704 of Series
1700 accepts that concrete complying with the 100 years requirement of BS8500 will provide
a working life of 120 years. In addition NA.2.1.1 EN 1990 recognises that a design working
life category 5 will have a working life of 120 years.

Precast concrete generally adopts a higher concrete specification, when compared to

in-situ concrete; this is mainly due to the addition of increase amounts of cement to achieve
faster curing times. This allows the adoption of lower cover to the reinforcement, and when
considered in conjunction with a smaller Δc value, (allowance for rebar deviation due to
tighter QC controls), will result in a more economic design.

BS EN 13369:2013 - Common This standard is a generic document, which sets out requirements to the range of products
rules for precast concrete which are produced in a factory environment. It is intended to act as a reference document
products which provides guidance on the various issues associated with precast concrete elements
and their manufacturing, (e.g. durability, tolerances material requirements, testing). It is
intended to provide a more consistent approach to standardisation in the field of precast
concrete products. General references to more specific Eurocodes are included.

BS EN 14844:2006 - Precast In a similar manner to BS EN 13369, the standard provides guidance on materials, testing,
concrete products - Box and geometry etc., and production requirements, together with reference to design criteria, al-
though this is generally in the form of cross references to the standards mentioned previously.
This is a ‘harmonized’ standard and fully encompasses the requirements of the EC. Conse-
quently this standard leads to the CE/UKCA marking now required on box culverts

Traffic Loads on Highway Structures

Prior to March 2010 the design of box culverts was to BS5400 / BCA specification / BS8110
as noted in table E1. Since March 2010 these have been superseded and box culverts are
designed to Eurocodes.

Table E2 shows the traffic load options to be used in the design of box culverts and compares
the design criteria prior to the introduction of the Eurocodes. In addition the load reduction factor
‘α’ is introduced which recognises where the applied load can be reduced on non-major roads.

Table A9

Road Category Traction

(HA Interim advice Prior to March 2010 Eurocode loading and α
Note 124/11) braking

Motorways / Trunk Roads/ HA / 45 Units HB LM1-3

Yes 1.0
Principal Roads BS 5400-2 BS EN 1991-2

Other Public Roads / HA / 45 Units HB LM1-3

Yes 0.8
Principal Roads BS 5400-2 BS EN 1991-2

Category G 120kN axle

Light traffic / Field loading Field Loading
load (2 x 60kN wheels) No *
(3T-16T vehicle) BCA Specification
BS EN 1991-1

*A value of 0.4 in combination with LM1 can be considered equivalent

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 1: SYSTEM DESIGN 47

Figure A10. Load Model 1 (LM1)

150kN 150kN
150kN 150kN

5.5kN/m2 2.0m
1.2m

Application of Load Model 1 for General Verifications CI 4.3.2(1) (a)

Notes:

LM3 should be determined for the individual project in LANE 1 LANE 2

accordance with BS EN 1991-2 and NA 2.16. However it is 2000 1000 2000
generally not critical on short spans up to 5m.

Values of α correspond to classes of road traffic. For

common applications EN 1991-2 Cl4.3.1 Note 2 permits a
moderate reduction of α factors (10-20%) 150kN 150kN 100kN 100kN
1200
Culverts can be designed for other traffic loading categories 400
which are to be agreed with the scheme designer.
400

‘General Effects’ are considered for flexure and shear, i.e.

150kN 150kN 100kN 100kN
stability checks are not undertaken.

Any plant equipment that is required to traffic over the culvert

must be designed for as it may exert a higher loading than Bridge longitudinal axis
the normal traffic load exerted in the installed state.
Axle loads to be applied in conjunction with a UDL as a Table 4.2 BS EN 1991– 2:2003

Figure A11. Load Model 2 (LM2) Application of Load Model 2 (applied any loacation on carriage way

200kN 200kN 2000

2.0m

200kN 200kN

Bridge longitudinal axis

Figure A12. Load Model 3 (LM3)

130 130 130 130 130 130 165 165 165 165 165 165
kN kN kN kN kN kN kN kN kN kN kN kN
1.2 1.2
or 5.0 or 5.0
1.2 1.2 or 9.0 1.2 1.2 1.2 1.2 or 9.0 1.2 1.2

SV80 SV100

165 165 165 165 165 165 165 165 165 180 180 100
kN kN kN kN kN kN kN kN kN kN kN kN
1.2
or 5.0
1.2 1.2 1.2 1.2 or 9.0 1.2 1.2 1.2 4.0 1.6 4.4

SV196
Direction of travel

http://www.bridgedesign.org.uk/tutorial/tulm1_4.html

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 48 1: SYSTEM DESIGN

Early Age Thermal Cracking

Early thermal cracking need not be considered for precast segmental construction where the
segments are monolithic and of 3m length ( Lj) or less. Additionally it is not applicable to precast
concrete box culvert sections that are cast monolithically under strict quality controlled factory
conditions in unrestrained moulds.

Figure A13. Box culvert terminology used in PD6694

Longitudinal joints

HC
Ground level
L J*

L J*

Xclear L J*

LT*

LL

Fatigue

Fatigue verification for road bridges (culverts considered as similar structures) is not necessary
where:

• The clear span to overall depth ratio of the slab does not exceed 18

• Buried arch and frame structures have a cover depth of 1.00m for road and 1.50m for railway
bridges Ref: BS EN 1992-2 Table NA.1 cl 6.8.1

For example see figure E6 which has a ratio of 3000 / 225 = 13.3 < 18 OK

Figure A14. Fatigue criteria

1000 mm

3000 mm 225 mm

Stability

Considerations regarding overturning and sliding are not considered by BPDA members. This
is the responsibility of the overall scheme designer.

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 2: INSTALLATION - PIPES 49

2 - INSTALLATION: PIPES
This section describes the recommended procedure for the installation of concrete pipelines
in trenches for non-pressure (gravity) applications or when occasional periods of hydraulic
surcharge may occur. It covers the types of laying conditions most commonly encountered
in practice. In situations beyond these general conditions, the pipeline designer and the site
engineer should give suitable instructions to supplement this guidance.

Pipelines laid under embankments require special consideration whilst those installed by pipe
jacking require the use of specialised techniques.

2.1 Planning
General

Prior to constructing the pipeline, the contractor will need to organise the work from the contract
documents, specification, drawings and bill of quantities.

The line and level of the sewer, any side connections and the positions of the manholes will have
been determined at the design stage but some flexibility in construction should be permitted to
cater for circumstances such as foundations or buried services not shown on the drawings. An
agreed re-siting of a manhole may save time and additional expense.

Sequence of operations

a) Plan and set out the work including location of manholes.

b) Receive, check against specification and store deliveries of materials on site.

c) Excavate trench and install trench support system.

d) Lay bedding material forming socket holes as appropriate.

e) Check for damage, lay and joint pipes, air testing every third or fourth pipe as laying
proceeds. Check line and level.

f) Place and compact sidefills with bedding or selected materials.

g) Continue placing and compacting sidefills withdrawing trench sheeting in stages.

h) Place initial backfill above pipe continuing withdrawal of sheeting.

i) Air and/or water test or inspect visually prior to final backfill.

j) Complete backfill, compacting as appropriate.

k) Final acceptance, air and/or water test or inspection.

l) Reinstatement of surface as appropriate

2.2 Handling and storage

Lifting equipment

Time and place of off-loading should be agreed before units arrive on site. The contractor should
have suitable equipment for off-loading, stacking and stringing out pipes and other units on site.

All lifting tackle must be of good sound construction and should be regularly tested and certificated.

Off-loading

Whenever possible, pipes and other units should be off-loaded in the reverse order that they
were loaded. The vehicle must not be moved if any part of the load is unsecured. Off-loading

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 50 2: INSTALLATION - PIPES

should take place at the nearest hard standing to the point of installation; all units must be left in
a stable position well clear of the edge of the trench.

For further information, refer to the BPDA Health & Safety Off-loading Guide
http://www.precastdrainage.co.uk/page/pipe-laying-lifting

BPDA member companies are also available to advise on general handling of products and
appropriate lifting equipment. Member companies contact details can be found here:
http://www.precastdrainage.co.uk/suppliers

Use of tackle

Where provided, lifting holes, anchors etc. must be used with the correct equipment to lift the
units (note - installed lifting points may not necessarily be suitable for the transportation of a
product across a site).

Pipes

Pipes should be handled individually using a properly designed “C” hook, beam sling or other
purpose-designed system. Small diameter pipes may be slung through the bore providing the
sling is sleeved and protected around the joint. This is important in order to avoid damage to
jointing surfaces and consequent leakage of the laid pipe. ‘Pipe hooks’ must not be used. Slings
may be made of cordage, canvas, or man-made fibres, but not chains.

Many manufacturers offer a combined lifting and jointing system using a three-legged chain and
cast-in facilities (larger pipe sizes only). A special concrete pipe lifter is also available providing
improved site safety, reduced installation time, labour and cost savings. Further details relating
to the concrete pipe lifter and other proprietary lifting devices can be found in the BPDA Site
Guide, available at www.precastdrainage.co.uk and directly from BPDA members.

The Concrete Pipe Lifter is designed

to improve site safety and increase
efficiency during the lifting and
installation of precast concrete pipes.
It is connected to an excavator via a
quick hitch attachment.
www.concretepipelifter.co.uk

How to Use

• Perform appropriate pre-work checks to ensure all equipment is working properly and has valid
operating certificates, where required.

• Connect Pipe Lifter to excavator via quick hitch coupling, ensuring correctly attached and locked
in position.

• Fully insert the long lifting arm horizontally into the barrel of the pipe and carefully raise to make
contact with the internal crown. When installing pipes, ensure it is lifted from the socket end.

• The clamp arm will slowly press down onto the top of the pipe and hold it in position.

• The pipe may now be lifted and transferred to a suitable storage location or placed into the
prepared trench and jointed following the application of an approved joint lubricant to the pipe

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 2: INSTALLATION - PIPES 51

spigot. Care should be taken to avoid lubricant coming into contact with the lifting area as this
can cause the pipe to slip.

• Depending on the weight of pipe, depth of installation and lifting capacity of site plant, the
pipe may be tilted up to 30 degrees from horizontal and maneuvered between struts on trench
support systems. It can also be used to push the pipe home to ensure formation of the correct
joint gap.

• Check limits of use before operation including lifting capacity and the compatibility of trench
support system with the Pipe Lifter to ensure that struts do not interfere with the removal of
the lifter from the pipe.

• When installing a pipe, no personnel should be in the working area or come into contact with
the Pipe Lifter, excavator or any pipe in transit.

Other units

Where lifting eyes or lifting holes are provided they should be used. Extra care should be taken
when lifting bends and junctions (pipes with inlet).

Chocks

When pipes are loaded, transported or stacked, sufficient timber chocks should be provided.
Chocks or packing between individual units should not be removed until lifting tackle is secured.

Care in handling

Pipes and other units must never be dropped. Pipes which have to be moved should be lifted
and never dragged. When pipes have to be rolled, beware of rocks or boulders. Care should be
taken to avoid damage especially to jointing profiles.

Stacking on site

Ideally, pipes should be strung out and secured beside the trench where they are to be used.
Where stacking is necessary this should be on level ground and the bottom layer of pipes securely
chocked to prevent the stack from collapsing. Pipes should be supported under the barrel so that
the socket is free of load and so that the jointing faces are not damaged. They should be stacked
barrel to barrel with sockets overhanging, or with spigots protruding as preferred.

Fig. B1. Typical stacking arrangement

2.0 M Max

Chocks Socket clear of the Ground

For safety reasons and to prevent damage to the lower layers of pipes in the stack, pipes should
not be loaded or stacked in a greater number of layers than shown in Table B1 overleaf.

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 52 2: INSTALLATION - PIPES

Table B1. Pipe stacking layers

Nominal size (DN) Number of layers

150-225 6
300-375 4
450-600 3
675-900 2
above 900 1

Storage of loose jointing materials

Precast concrete pipes are normally supplied with an elastomeric sealing gasket integrally-cast
into the socket of the pipe. For other forms of joint seal, the quantity, type and diameter of
jointing rings or other jointing materials should be checked with the delivery note at the time
of off-loading. Elastomeric rings should be carefully stored and protected from sunlight, oils,
greases and heat. If the rings have been tied they should be separated a few days before use
in order to eliminate minor impressions which the ties may have caused. Rings should not be
stored hanging from a hook.

2.3 Excavation and laying

Trench excavation

The trench should be dug to the line, gradient and width indicated on the drawings or in the
specification or as agreed with the Engineer. The safety of the public and site personnel is of
paramount importance.

Trench width

Any increase in trench width above that specified could increase the load on the pipe and
increase the quantity of the excavation and of bedding material.

A trench narrower than that specified may impede the proper placing and compaction of the
bedding material and restrict working conditions in the trench during pipe laying.

A trench adjacent to a manhole may need to be wider but this should be taken into account at
the design stage.

The trench width should allow for safe working alongside the pipeline. For recommended trench
widths see load tables A3 & A4, pages 29 & 30.

Formation

Uniform support along the pipeline is essential.

Rock outcrops and soft zones such as peat or boggy material which can cause differential
settlement should be dug out and replaced with well tamped selected material.

Ground water should be kept below the bottom of the trench during pipe laying operations by the
use of temporary drains, sumps or a designed well-point system. The water level should not be
allowed to rise before backfilling is completed.

If the trench bottom is likely to be disturbed by trampling during pipe laying, selected material
should be placed to protect it.

Where the trench bottom is unstable, for example in marshy ground or running sands, special
measures are necessary to ensure proper embedment.

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 2: INSTALLATION - PIPES 53

A trench excavated in clay should not be kept open any longer than necessary to avoid instability
due to change in moisture content.

Pipe laying

Before lowering into the trench, each unit should be inspected carefully for any damage which
may have occurred in transit or during handling and storage on site. Pay special attention to
jointing surfaces. Units should be lowered carefully into the trench with tackle suitable for their
weight and for the depth of the trench.

The contractor should have available, at the required time, all material and equipment necessary
for carrying out the work in accordance with the specification and statutory safety requirements.

The contractor must ensure that the size and strength class of pipes or other units conform to the
contract specifications and manufacturer’s recommendations. In the case of integrated seals,
the joint must be prepared i.e. the application of the correct lubricant and the removal of the seal
positioning strip (where present).

Normal gradients

Pipes should be supported by the bedding over the length of their barrels and their weight must
never be carried by the sockets or by bricks and rocks in the trench bottom. Bedding under the
pipe should be scooped out to accommodate pipe sockets at each joint. The pipes should be laid
and assembled in correct alignment.

If, in order to curve the pipeline it is necessary to deflect the pipes at the joints, the deflection
should be applied only after the joint has been made in the normal manner and should be limited
to 75% of the manufacturer’s recommended limits to allow for any subsequent movement.

Mechanical plant must not be used to press pipes down to their correct level.

Changing direction

Change in direction, either horizontal or vertical, should be made at a manhole or by means of

a precast bend unit.

Passing through rigid structures

For a pipeline connection to a manhole or passing through a wall it is essential that the pipeline
joint retains its flexibility. This may be achieved by casting a short length of pipe into the wall of
the structure and providing a flexible joint adjacent to the wall. Depending on ground conditions,
short length pipes (rockers) should be used (see Section 1.3.6).

Unstable ground

In unstable ground an appropriate installation method should be determined. The following

possibilities should be taken into account:

• Use of short lengths of pipe.

• Use of continuous support on pile caps/beams.

• Special preparation of trench bottom.

• Trenchless methods of construction such as pipe jacking or heading.

Passing under highways or railways

If disruption of traffic is to be avoided, pipes should be installed by jacking or in heading.

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2.4 Jointing
A number of different joint designs are manufactured, all of which comply with the performance
requirements of BS EN 1916 and BS 5911-1.

The pipe manufacturer’s jointing instructions should be complied with but the basic requirements
for jointing concrete pipes are:

• Pipes should always be handled in a way to avoid damage, especially the spigot and socket
ends and joint surfaces.

• Prior to jointing, the socket and spigot should be cleaned and inspected to ensure they are in
good condition.

• Most standard concrete pipes are supplied with an elastomeric seal integrally cast into the
socket of the pipe

For Integrated Seal Joints

• Remove the protective polystyrene strip (where present) by using the tape provided. Grip the
tab of the tape and pull firmly towards the centre of the pipe. Residual polystyrene in the rear
corner of the socket is acceptable but the area behind the seal must be clear.

• Lubricant should be applied to the spigot end of the pipe, ensuring the radius area and entire
length of the spigot is covered. Additional lubrication may be also applied to the seal face to
assist jointing.

• Only use lubricant as recommended/supplied by the manufacturer.

• Enter the spigot carefully into the socket, ensuring that the pipes are correctly aligned.

• Always follow the manufacturer’s instructions.

For Spigot Seal Joints (Rolling and Sliding Seals)

• Stretch and position the seal onto the spigot of the pipe ensuring it is not twisted. Even out
the stretch by lifting and releasing at several points around the spigot.

• The seal should be located on the spigot in accordance with the manufacturer’s instructions.

• Rolling seal joints do not require lubrication. Most sliding seal are internally pre-lubricated
and do not require additional lubrication. If the joint design does require lubrication then
follow the manufacturer’s instructions.

• With rolling ring joints, offer up the pipe spigot to the socket, but keep clear of engagement
by 25mm so that the joint ring is not disturbed. With sliding ring joints, the joint ring should be
just in contact with the socket.

• Enter the spigot carefully into the socket, ensuring that the gasket is correctly positioned and
that the pipes are correctly aligned.

• Always follow the manufacturer’s instructions.

• Jointing tackle or chain systems should be used in accordance with the pipe manufacturer’s
instructions.

• Fully support the pipe so that it does not exert undue weight on the seal whilst closing the
joint to the recommended joint gap.

• Joint the pipes in accordance with the manufacturer’s recommendations, making sure that
the pipe moves without excessive slew or misalignment, that extraneous matter does not
enter the joint and that the joint is not damaged and correctly positioned. For jointing bends,
special procedures may be appropriate.

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 2: INSTALLATION - PIPES 55

• After adjusting for line and level, release the tackle. Care should be taken not to disturb the
pipe or bedding material when removing slings.

• The finished internal pipe joint gaps should be within the tolerances as specified by the manufacturer.

• It is advisable to carry out an air test on the installed pipeline after the laying of at least every
3-4 pipes to ensure satisfactory installation has been achieved.

Back laying

In special circumstances, such as at manhole connections, it may be necessary to joint a pipe

socket onto the spigot of a pipe already laid.

When this is done, additional care is necessary to ensure that the joint is properly made with
the joint ring correctly positioned and that bedding material is not scooped into the joint.

Fig. B2. Integral sealing ring - standard for most UK concrete pipes

Fig. B3. Pre-lubricated Sliding Ring

Fig. B4. Rolling Ring – circular / tear drop / ’G’ ring

NOTES:
1. Each joint type is diagrammatic and typical.
2. Rolling and fixed rings may be one of a variety of different profiles / cross sections / designs.
3. Tolerances of joint profiles shall be determined by the pipe manufacturer and described in factory documents.
4. Joint assembly shall be watertight / airtight when constructed in strict accordance with the manufacturer’s recommendations.
5. Pipes with integral seals offer some protection to the seal, however the same precautions should still apply to protect the seal.

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2.5 Reinstatement
Trench reinstatement
After inspection and testing, backfilling should proceed whilst withdrawing trench sheeting in
stages where practicable.

The sidefill is of great importance and close attention to its selection, placing and compaction
will protect a new pipeline.

Good trenching practice including controlled removal of temporary supports and compaction
of backfilling as described above not only protects the pipeline but will also reduce settlement
and the risk of damage to adjacent underground services or structures.

The trench should be backfilled as soon as possible after the pipes are laid bearing in mind any
specified test and inspection requirements. Compaction of the envelope of material immediately
around the pipe is extremely important. In trench installations, as space is limited, mechanical
compactors are commonly used but caution should be exercised so as not to damage or
displace the pipe. The material should be compacted at near optimum moisture content and
should be brought up evenly in layers on both sides of the pipe, withdrawing trench sheeting as
backfill proceeds. Backfill material should not be pushed into the trench from the surface nor
dropped in bulk directly onto the pipe.

Heavy mechanical equipment should not be allowed to traverse pipelines with limited cover
except at prepared crossing places.

Fill material

Material for sidefill, initial and final backfill should be similar in character to the surrounding soil;
for example, the use of single size granular material in clay soil will create a natural drainage
channel that could cause subsequent settlement.

Sidefill and initial backfill should be free from large stones, heavy lumps of clay, frozen soil, tree
roots and other rubbish, and should be readily compactable.

Sidefill

The sidefill should be placed and compacted as soon as possible after laying, or as soon as it
is safe to do so without damaging concrete beddings. Compaction should be carried out evenly
on each side of the pipe to prevent lateral or vertical displacement.

Initial backfill

This should also be placed as soon as possible in order to provide protective cover of not less
than 300mm compacted depth. This should consist of bedding or selected material placed
carefully and evenly over the top of the pipe and lightly compacted by hand.

Removal of trench supports

As backfilling proceeds, trench sheeting should be removed as soon as it is both safe and
practicable to do so.

Remaining backfill

This should be placed evenly in layers and compacted as appropriate.

2.6 Testing
Acceptance tests on the completed pipeline give an indication of the level of control of
workmanship and materials during construction.

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 2: INSTALLATION - PIPES 57

Visual inspection

Check for: -

a) Obstructions and debris. c) Joints properly sealed.

b) Structural soundness of pipes. d) Line and level within tolerance.

Man entry sized pipelines can be physically inspected whilst smaller diameters can be visually
inspected from manholes or by means of CCTV cameras.

Air and water tests

All lengths of drain and sewer up to DN 1000 should be tested for leakage by means of air or
water tests.

These tests should be carried out after laying and before backfilling. Some backfill may be placed
at the centre of each pipe to prevent movement during testing. Short branch drains connected
to a main sewer between manholes should be tested as one system with the main sewer. Long
branches should be separately tested.

Air Test

The air test is more convenient than the water test, but the leakage rate cannot be measured
accurately. An excessive drop in pressure in the air test may indicate a fault in the line such
as a displaced sealing ring or it may be due to faults in the testing apparatus. Therefore, the first
check must be on the apparatus, especially the seals of the stop ends and all connections.

The point of a leakage may be difficult to detect but spraying with soap solution could indicate
such leakage by the presence of bubbles.

Failure to pass this test is not conclusive. When marginal failure does occur, a water test should
be performed and the leakage rate determined before a decision on rejection is made.

Air test requirements are specified in ‘Civil Engineering Specification for the Water Industry’.

It is strongly recommended that inflatable stoppers are used for air testing.

A successful test is achieved if the equipment shows a fall in pressure of no more than 25mm
after 5 minutes, having allowed a suitable period for stabilisation.

If the pressure falls sharply and the pipes appear to have failed, check the test equipment is in
good condition, that the stoppers are not leaking (use industrial soap around the edge of the
stopper to provide an effective seal if necessary) and check the joint rings are correctly located
or re-test after allowing temperature to settle.

A video on how to air test concrete

pipelines is available at the BPDA
channel in Youtube:
Link: https://www.youtube.com/
watch?v=UdohjdbKP0o

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 58 2: INSTALLATION - PIPES

Water Test

A water test is the more conclusive method of testing a completed pipeline but problems of
availability and disposal of the quantity of water involved may cause difficulty. Before backfilling,
leakage can be clearly located, its amount assessed and where necessary, appropriate
remedies applied.

To test the pipeline:

a) Insert plugs in both ends of the drain or sewer and in connections if necessary. Precautions
should be taken by strutting or otherwise, to prevent any movement of the drain or sewer
during testing.

b) Fill the system with water ensuring all the air has been expelled.

c) Allow at least two hours before test readings are taken to permit conditions to stabilize,
adding water to maintain test head.

It may be necessary to extend this period for large diameter pipes, up to twenty-four hours
or more before a stable condition is reached.

d) Apply required test head at the upper end by means of a flexible pipe leading from a graduated
container or stand pipe.

e) Apply the test pressure of 1.2m head of water above the soffit of the drain or sewer at the
high end with a maximum of 6m head at the low end. If this exceeds 6m test the drain or
sewer in stages.

f) Measure the loss of water over a period of 30 minutes by adding and metering quantities of
water at intervals of 5 minutes to maintain original water level in the standpipe.

Over this 30 minute period, the quantity of water added should not exceed 0.05 litre per 100 linear
metres per millimetre of nominal size of the drain or sewer.

Over this 30 minute period, the quantity of water added should not exceed 0.05 litre per 100
For example:
linear metres per millimetre of nominal size of the drain or sewer.
For a 150m length of DN 800 pipe the allowable leakage would be:

0.05 X 150 X 800 = 60 litres

100

Should the pipeline not comply with these requirements it will probably be attributable
to one of the following:-

a) Leakage from test equipment.

b) Trapped air.

c) Leakage from joints, e.g. displaced ring.

d) Leakage from damaged or defective pipe.

2.7 Jetting

A jetting resistance of 12 MPa (120 bar) using a moving nozzle and/or 28 MPa (280 bar) using
a stationary nozzle can be assumed acceptable for use on precast concrete drainage systems.

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 3: INSTALLATION - JACKING PIPES 59

3: INSTALLATION - JACKING PIPES

3.1 Introduction
The installation of pipelines for drainage purposes has traditionally been carried out using
open-cut trenches in both urban and rural locations. However, in recent years an increasing
proportion of pipeline construction projects have utilized pipe jacking or the form of the miniaturized
tunneling technique known as microtunneling.

The basic pipe jacking method has been used in various forms for centuries but only in the past
decades have we seen significant advances in equipment and technology.

This has raised confidence in the technique and numerous successful pipeline engineering
schemes have used pipe jacking and microtunneling.

Normally, for pipelines constructed in this manner up to DN 900 the technique is referred to as
microtunneling and above this as pipe jacking, but the principle remains the same.

3.2 Technique and equipment

The pipe jacking or microtunneling method consists of the construction of a number of excavated
shafts from which a tunneling shield is launched and behind which a succession of smooth-
walled concrete pipes are jacked. When the shield reaches the destination or reception shaft,
it is either re-launched in a different direction or removed to another location and the process
repeated. The excavated drive and reception shafts are usually converted to finished manholes
once pipeline installation is complete.

Spoil excavated by the rotating cutting head in the front of the shield is removed by an auger flight
or by mixing with water and pumping to the ground surface for treatment and disposal. Some
progress has been made with the development of machines which can compact soil to the sides
of the shield as it advances. Other equipment types use vacuum systems for the removal of
excavated material to the surface.

Particularly high levels of installation accuracy can be achieved with these systems since they
use sophisticated steering and guidance methods based on laser technology and optional
automatic computer control. Finished bores have frequently been described “like rifle barrels”.
Equipment has been developed which can install pipes in small diameters down to DN150 for
house connections and lateral drains without the need for a trench.

3.3 Advantages
The advantage of using a trenchless method can be substantial. Any attempt to dig up long
trenches within an urban area often results in severe disruption, delays and diversions to traffic,
environmental pollution through noise, dust and dirt, loss of profit for local businesses, damage
to properties or other buried pipes and cables and so on. These items are usually referred to
as social costs and are nearly always absorbed by the community rather than paid as direct
engineering costs.

However, when one considers further, other equally serious problems become apparent. Sometimes,
the as-dug material excavated from the trench is not suitable for re-use as backfill. This waste
spoil must be transported away from the area and disposed at a suitable landfill site. Such sites
are becoming more difficult to find and the cost of using them is increasing. Also, new backfill
material such as crushed stone has to be imported to the site and these operations usually
involve heavy wagons inflicting damage to roads and using fuel which in turn produces more
pollution. These environmental costs are compounded by the damage and visual impact to the
countryside from landfill and quarrying sites.

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 60 3: INSTALLATION - JACKING PIPES

Pipe jacking and microtunneling can dramatically reduce many of these social and environmental
problems. The technique offers significant benefits in reduced excavation since they only
require relatively small launch and reception shafts for the tunneling equipment. Streets and
roadways can often be kept open to traffic with little hindrance or disruption. The environment in
general benefits from a no-dig approach because far less transportation of trench reinstatement
materials is required, normally limited to only the displaced spoil from the pipes and manholes.

Reduced levels of reinstatement lead to cost savings, as much of the cost of a pipeline scheme
is in the excavation and subsequent reinstatement. Installation depths of up to 35m have
successfully been achieved which would not have been possible with open cut methods.

3.4 Products
The UK concrete pipe manufacturing industry is playing a leading role in the advancement of
trenchless techniques. Several BPDA member companies produce jacking and microtunnelling
pipes in a range of sizes. These pipes are manufactured to produce accurate joint surfaces
with square faces and a strong high density concrete with a smooth surface finish to assist in
reducing jacking forces.

Jacking and microtunneling pipes are available in sizes from DN 450 up to DN 2500 and utilise
elastomeric seals in a steel banded joint. These pipes are manufactured to comply with the
requirements of European Standard EN 1916:2002 and the UK complementary standard BS
5911-1:2002. The external surface of the pipeline is smooth for easy insertion through the ground
during installation. For steel banded joints, both mild and stainless steel are available. Jacking
pipes can be supplied with grout holes and cast-in lifting sockets as required.

Other products for use with this trenchless method include caisson sections in sizes from DN
2000 to DN4000 complete with base sections fitted with cutting shoe. Also produced are lead
pipes which are rebated to accommodate the tunneling shield and interjack pipes (leading and
trailing pipes in pairs) for use with intermediate jacking stations.

3.5 Further information

More information on the pipe jacking and microtunnelling method can be found in the publications
of the Pipe Jacking Association (PJA) http://www.pipejacking.org/publications.

The United Kingdom Society for Trenchless Technology (UKSTT) is another useful source of
information on trenchless techniques including pipe jacking.

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 4: INSTALLATION - MANHOLES 61

4: INSTALLATION - MANHOLES
Manholes may be installed using fresh concrete to construct the base, channels and benching
in-situ or by using a precast base system where units are manufactured and delivered to site with
predetermined positions for connecting pipework using flexible, watertight elastomeric joints.

4.1 Planning

Sequence of operations

a) Place the bottom unit with either integral precast or in-situ concrete base.

b) Erect the required number of standard components and seal the joints as
appropriate in accordance with the design/chosen method of construction.

c) Place a precast reinforced concrete cover slab on top.

d) If required, place a corbel slab then add the appropriate number of adjusting units.

e) Fit the access cover and frame.

4.2 Handling and storage

1) Chamber rings may be supplied with lifting holes for the use with specialist lifting pins and
chain/sling sets. Alternatively they may have pins cast into them for use with universal head-
links and chain/sling sets.

2) Cover, landing and reducing slabs are usually cast with anchors allowing the use of hook
and chain/sling sets.

Note: Apparatus used for lifting, may not necessary be suitable for the transporting of products
across a site.

Other lifting methods may be available or available to order – check with manufacture for full details.

All products should be lifted individually.

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

Chamber rings should be stored ‘chimney’ fashion i.e. not on their side, or rolled.

Chamber rings and all types of slabs should be stacked on level and stable ground and on
timbers wherever possible.

4.3 Construction
To ensure that the manhole structure is vertical, accurate levelling of the formation for the
precast base unit or the in-situ concrete foundation is essential. The depths of precast manhole
components are nominal and therefore subject to manufacturing tolerance; this, along with the
formation of joints, should be considered during the setting out process.

Normal considerations should be taken into account when assessing the suitability of the
formation. Units should be laid on a prepared level foundation of adequate bearing capacity

The manhole can be built of either;-

-15-20mm graded, 14mm or 20mm single-sized, suitably compacted aggregate to provide a

level base with a minimum depth of 150mm, with an additional blinding layer of fine material
where required to account for unevenness or any other environmental factors.

- 150mm deep GEN 1(C8/10) concrete. The base unit should be placed whilst concrete is wet
so it can be set level. Where the concrete has already cured, a levelling screed with a minimum

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 62 4: INSTALLATION - MANHOLES

depth of 15mm-50mm sand/cement will be required between the foundation and the unit to
prevent point loading.

Note: Normally, a granular bedding is recommended where the safe ground bearing pressure
>200kN/m2. In poor or wet ground conditions a concrete pad is advised. The manufacturer of
the manholes can advise where required.

Shaft and chamber sections with tongued and grooved joints should be installed with the
socket / groove facing upwards, whereas units with ogee joints should have the spigot upwards.
Precast cover slabs can be installed onto the shaft or chamber rings (with appropriate mastic,
mortar or seal). Suitable cover and frame can then be bedded on adjusting units to achieve the
finished level required.

Note that the distance from ground level to the first step in the manhole is usually specified as
not to exceed 675mm (where units are fitted with step or ladder system)

Jointing to pipeline

To allow for differential settlement between manhole and pipeline, short “butt” pipes, either
spigot or socket, should be built into the wall of manholes constructed with an in-situ concrete
base and a flexible joint incorporated as close as possible to the outside of the manhole wall
or concrete surround, if used.

Depending on ground conditions, short length pipes (rockers) then connect the butt pipes to the
incoming pipe runs. Additional care must be taken to ensure that the joints are properly made.

4.4 Jointing
Precast manhole components are provided with joints formed within the wall section (see typical
figures below) and are sealed with proprietary mastic seals, sand / cement mortar, or with
elastomeric joints. Precast concrete manhole units, well jointed, provide an adequate seal under
normal conditions. Any lifting holes will need to be sealed with sand / cement mortar or a proprietary
non-shrink mortar.

Joint strips typically have a thickness of 12mm and are offered in one or two layers as demonstrated
in the table below.

Fig. D1. Examples of Manhole Joints

a) Cover, Landing and reducing slab joints

1 or 2 strips

(DN675-1200) (DN 1350-3000)

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 4: INSTALLATION - MANHOLES 63

Fig. D1 cont. Examples of Manhole Joints

Reducing slab, shaft and chamber joint Other joints

b) Tongue and groove c) Ogee d) Landing platform joint

1 or 2 strips

Fig. D2. Example of Manhole Joint with Elastomeric Seal

Load Distribution Seal

Joint

4.5 Reinstatement
In-situ concrete surround

In-situ concrete surround to precast concrete manholes, except for side-entry manholes, is
unnecessary other than for exceptional structural reasons such as embankments, in sloping
or unstable ground, where there is a large opening into the manhole, where it is a requirement
due to a permanent head of water or where an individual specification requires it i.e. as in some
types of adoptable manholes specified in Sewers For Adoption.

Note: Sewers For Adoption includes for the use of thicker walled (minimum 125mm thick) manhole
rings without the requirement for a concrete surround.

Side entry manholes should be provided with a suitably designed GEN 3 concrete surround of
at least 150mm thick extending the whole length of the pipe in which the manhole is placed.

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 64 5: INSTALLATION - BOX CULVERTS

Backfilling

As each precast manhole section is placed, backfill should be returned in layers and
compacted as for pipelines. Backfill must be brought up evenly around the manhole to prevent
displacement. Additionally, care should be taken to avoid damaging the connecting pipelines.

Special consideration should be given where construction plant is working in the vicinity of
manholes. Where possible, traffic should be routed away from such structures and may require
temporary protection with heavy steel plates or temporary additional cover material.

4.6 Testing
In working conditions manholes are not normally full of water. This only happens under rare
conditions of surcharge. Prevention of infiltration is of more relevance than exfiltration and
where this occurs, it can be remedied by sealing using an appropriate method.

Where testing of manholes is required, see Sewers For Adoption or Civil Engineering Specification
for the Water Industry for suitable method.

5: INSTALLATION - BOX CULVERT

This section provides an overview for all parties engaged in the installation of box culverts.
Where site conditions vary, for example, fluctuating ground conditions or vehicle loadings,
supplementary instructions may be required. In this case more advice should be sought from
the overall scheme engineer.

5.1 Planning
Prior to constructing the culvert run, the contractor will need to organise the work from the contract
documents, specification, drawings and bill of quantities. The line and level of the culvert, any
side connections and the position of any access openings will have been determined at the
design stage.

Sequence of operations:

1. Plan and set out the working including the location of any incoming pipes and access openings

2. Prepare the ground ready to receive the delivery vehicle and act as temporary storage of
the units if required

3. If using a crane undertake the required lift plan paying special attention to the ground
conditions and that they are suitable for the crane

4. Arrival - Box Culverts arrive onto site in the pre-constructed / designated off-loading point

5. Inspection - items visually checked and identified / cross referenced from drawings

6. Offload - transport strapping released and culverts are off loaded, placing them in a
holding location

7. Excavate the trench with a suitable angle of repose or install trench support system

8. Preparation the trench base by laying the granular bedding material (min 200mm thick) or
pouring the concrete blinding (min 75mm thick) with 50mm deep granular overlay

9. Prepare the joint of the culvert in the holding area

10. Lift the units into place – checking the level

11. Pull the units together using a proprietary puller

12. Once installed and other connection are made (if any) back filling can commence

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 5: INSTALLATION - BOX CULVERTS 65

Note: this shows a twin arrangement which

is used for large culverts. single puller
Figure E1. Culvert puller arrangement is used for small units.

5.2 Delivery, Handling and Storage

Prior to Delivery

Prior to taking the delivery on site there is a need to:

1. Agree with the BPDA member a delivery commencement date

2. Check item weights to ensure the correct lifting equipment is available

Taking Delivery:

1 On receipt of delivery ensure that the delivery note corresponds to goods ordered and that
they are checked for quality.

2 The contractor is responsible for off-loading box culverts and should:

• Provide suitable access and a hard standing which can be used safely by standard
delivery vehicle

• Provide a suitable crane and plant of adequate capacity to safely off-load and install the
culvert units. Allowance should be made for tolerances and lifting tackle.

• The load recipient should be aware that to be on the back of a lorry during the off-
loading process constitutes “working at height” and as such, the requirements of the
current Working at Height Regulations (2005) must be satisfied. It is the contractor’s
responsibility to carry out a risk assessment of the operation and to provide all suitable
measures to access the vehicle trailer safely with fall protection provisions provided, as
deemed necessary

3 Lifting methods differ between box culvert manufacturers, Holes for eye-bolts, threaded
lifting sockets or projecting loops are commonly used but other methods can be employed,
The contractor should

• Ascertain details of the lifting method used by the BPDA member

• Provide all handling equipment necessary to operate a safe lifting method on site

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 66 5: INSTALLATION - BOX CULVERTS

• Ensure that any non-standard attachment to the lifting point is supplied and that full
instruction are given for its use.

• Under all risk assessments in addition to providing all handling equipment necessary to
safely operate the lifting method on site

4 Where other methods, such as lifting forks, beams or slings are to be used, the contractor
should:

• Consult the BPDA member to ensure that the proposed method is acceptable
• Protect the box culvert and particularly the joining surfaces from damage while lifting
• Ensure complete safety of operatives

5 Generally box culverts are transported as laid, but for safety reasons such as load stability
or economy, the box culverts may be transported on end. The contractor should:

• Check with the BPDA member how the box culverts will be delivered

• Where box culverts are delivered on end, establish a safe method of turning the units to
the as laid orientation.

• Provide any equipment necessary for the operation

6 The box culverts may be off-loaded into a storage area or they may be placed in line
alongside the trench in which they are to be laid. In either situation:

• Before off-loading, visually inspect the units and check the identification label by cross
referencing against the layout drawings

• Lower them carefully on to a firm level base away from the edge of the trench

• Box culvert units should be moved by lifting and never by dragging

• In cold weather, protect open lifting sockets from freezing and bursting

5.3 Construction
Trench Preparation

Keeping to the specified line and gradient, the trench should be excavated ideally to a width
equal to the box culvert width plus a minimum of 300mm to either side to allow for access to
aid installation. However, specific site conditions regarding the excavation and ground stability
will prevail. Reference should be made to BD31/01 section 5.0.

In certain circumstances with unstable ground, e.g. clay soils, it may be necessary to undertake
additional works to provide stable ground conditions.

Bedding

Bedding is intended to level out any irregularities in the trench bottom and ensure uniform
support under the full width and length of the box culvert.

1. Lay granular material over the full width of the trench to a minimum depth of 200mm having
first removed any protective layer ensuring that it is sufficiently compacted.

2. Lay the bedding material only a minimum distance ahead of laying the box culverts.

3. Keep off the prepared base so far as practicable. Having achieved a flat, well prepared
base, it should not be allowed to deteriorate.

As an alternative to granular bedding, a suitable concrete blinding slab can be used. Lay a flat
apron of unreinforced lean-mix concrete, minimum 75mm thick in the prepared trench. On top
of the blinding place a 50mm thick layer of granular bedding material.

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 5: INSTALLATION - BOX CULVERTS 67

Jointing

BPDA members employ different methods of joining the culverts together. Please refer to
BPDA members for further information.

Reinstatement & Backfilling

Backfilling should commence as soon as possible after the box culverts have been laid.

• Fill the trench to the level of the top of the box culvert working evenly on each side

• Use appropriate backfill material well-compacted in layers not exceeding 200mm

• Do not use heavy vibratory equipment

• Continue filling over the box culvert and compact in layers

• Do not run heavy rollers or construction plant over the box culvert without protection

Care must be taken if the construction traffic passes over or close to the culvert and
imposes loadings greater than those for which the box culvert has been designed for.
In such cases protective measures will be required.

5.4. References
• BS EN 14844 - 2006 + A2:2011 - Precast Concrete product - Box culverts

• BS EN 13369:2013- Common rules for precast concrete products

• BS EN 1990:2002 Eurocode – basis of structural design (A new version will be published in

November 2018)

• BS EN 1992-1-1:2004+A1:2014 – Eurocode 2:Design of concrete structures - Part 1-1:

General rules and rules for buildings

• BS EN 1991-2:2003 Eurocode 1:Actions on Structures - Part 2: Traffic Loads on Bridges

• BS EN 1992-2:2005 - Eurocode 2 – Design of concrete structures –Part 2: Concrete

bridges – Design and detailing rules

• PD 6687-2:2008 Recommendations for the design of structures to BS EN 1992-2:2005

• BD31/01 The design of buried concrete box and portal frame structures Design Manual for
Roads and Bridges: Volume 2, Section 2, Part 12 (2001)

• CIRIA C689 Culvert design and operation guide (2010)

• PD6694-1 2011+A1:2020: Recommendations for the design of structures subject to traffic

loading to BS EN 1997-1:2004

• BS 8500-1:2015+A2:2019 – Concrete - Complementary British Standard to BS EN 206-1,

Part 1: method of specifying and guidance for the specifier

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 68 6: REFERENCES AND FURTHER READING

6: REFERENCES AND FURTHER READING

6.1 British Standards

1 BS EN 197-1:2011 Cement. Composition, specifications and conformity 2011 BSI

criteria for common cements.
2 BS EN 206+A1:2016 Concrete. Specification, performance, production 2013 BSI
and conformity.
3 BS EN 450 (various parts) Fly ash for concrete. 2005- BSI
2015
4 BS EN 681-1:1996 – Elastomeric seals. Material requirements for pipe joint 1996 BSI
seals used in water and drainage applications. Vulcanised rubber.
5 BS EN 752:2008 Drain and sewer systems outside buildings. 2008 BSI

6 BS EN 1295-1 Structural design of buried pipelines under various 2019 BSI

conditions of loading – Part 1: General requirements.
7 BS 1881 (various parts) Testing Concrete. 1983- BSI
2015
8 BS EN 1916 – Concrete pipes and fittings, unreinforced, steel fibre 2002 BSI
and reinforced.
9 BS EN 1917 – concrete manholes and inspection chambers, unreinforced, 2002 BSI
steel fibre and reinforced.
10 BS 4449: 2005+A3:2016 Steel for the reinforcement of concrete. Weldable 2016 BSI
reinforcing steel, Bar, coil and decoiled product. Specification.
11 BS 4482:2005 Steel wire for the reinforcement of concrete products. 2005 BSI
Specification.
12 BS 4483:2005 Steel fabric for the reinforcement of concrete. Specification. 2005 BSI

13 BS 5911 – 1 : 2002 + A2 : 2010 - Specification for unreinforced and 2002 BSI

reinforced pipes
14 BS 5911 – 3 : 2010 + A1:2014 - Specification for unreinforced and 2010 BSI
reinforced manholes and soakaways.
15 BS 5911 – 4 : 2002 +A2 : 2010 - Specification for unreinforced and 2010 BSI
reinforced inspection chambers.
16 BS 5911 – 6 : 2004 + A1 : 2010 - Specification for road gulley and gulley 2010 BSI
cover slabs.
17 BS 6031:2009 Code of Practice for earthworks. 2009 BSI

18 BS 8500-1: 2015+A2 Concrete. Complementary British Standard to 2019 BSI

BS EN 206. Method of specifying and guidance for the specifier.
19 BS 8500-2: 2015+A2 Concrete. Complementary British Standard to 2019 BSI
BS EN 206. Specification for constituent materials and concrete.
20 BS EN ISO 9001:2015 - Quality management systems: Requirements. 2015 BSI

21 BS 9295:2020 Guide to the structural design of buried pipelines. 2020 BSI

22 BS EN 13101:2002 Steps for underground man entry chambers. 2002 BSI

Requirements, marking, testing and evaluation of conformity.

- BS EN 16933-2:2017 Drain and sewer systems outside buildings — Design. Part 2:

— Hydraulic design
- Also see SuDS references on page 16

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 6: REFERENCES AND FURTHER READING 69

6.2 Industry References

1 Design and Construction Guidance for foul and surface March 2020 Water UK
water sewers offered for adoption - v2.0
2 Sewers for Adoption 6th and 7th Editions March 2006 Water UK / WRc
& August
2012
3 Sewers for Adoption 6th Edition – Combined March 2006 Water UK / WRc
Addendum
4 Civil Engineering Specification for the Water Industry March 2011 WRc
(CESWI) 7th edition

5 Simplified Tables of External 1986 TRL HMSO

Loads on Buried Pipelines

6 Guide to Design-Loadings for Buried Pipelines (Out of 1983 TRL HMSO

print)

7 Tables for the Hydraulic Design of Pipes, Sewers and 2005 HR Wallingford
Channels 8th edition and D H Barr

8 Specification for Highway Works 2001 Department of

Transport HMSO

9 An introduction to pipe jacking and microtunnelling 1995 Pipe Jacking As-

design sociation PJA

10 Guide to Best Practice for the Installation of Pipe Jacks 1995 Pipe Jacking
and Microtunnels Association (PJA)

11 Concrete in Aggressive Ground - BRE Special Digest 1 2005 BRE

12 Imported Granular and Selected As-dug Bedding and 1994 WRc

Side Fill Materials for Buried Pipelines Water Industry
Specification 4-08-01

13 Precast Concrete Pipes - Unreinforced and Reinforced, 1991 WRc

with Flexible Joints - Water Industry Specification 4-12-
01

14 Specification for Polypropylene Encapsulated Steps 1990 WRc

for Use in Manholes and Access Chambers - Water
Industry Specification 4-33-01
15 Specification for Flexible Couplings for Gravity Sewage 1993 WRc
and Drainage Pipes - Water Industry Specification
4-41-01

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 70 6: REFERENCES AND FURTHER READING

6.3 Relevant Organisations

British Precast • Telephone: +44 (0) 116 232 5170

The Old Rectory • Fax: +44 (0)116 232 5197
Main Street • [email protected]
Glenfield LE3 8DG • www.britishprecast.org

British Water • Telephone: 02035670950

Vox Studios • [email protected]
Unit V03 1-45 • www.britishwater.co.uk
1 Durham Street
London SE11 5JH

BRE • Telephone: +44 (0)1923 664000

Building Research Establishment • Fax: +44 (0)1923 664010
Garston, • [email protected]
Watford WD25 9XX • www.bre.co.uk

BSI • Telephone: +44 (0)20 8996 9000

British Standards Institution • Fax: +44 (0)20 8996 7001
389 Chiswick High Road • [email protected]
London W4 4AL • www.bsi-global.com

CIRIA • Telephone: +44 (0) 20 7549 3300

Griffin Court • Fax: +44 (0) 20 7549 3349
15 Long Lane • [email protected]
London EC1A 9PN • www.ciria.org.uk

EA • Telephone: 03708 506 506

Environment Agency • [email protected]
Head Office • www.environment-agency.gov.uk
Horizon House
Deanery Road
Bristol BS1 5AH

Highways England • Telephone: 0300 123 5000

Bridge House, • [email protected]
1 Walnut Tree Close, • www.highwaysengland.co.uk
Guildford GU1 4LZ

Office of Public Sector Information / • Telephone: +44 (0)870 600 5522

The Stationery Office (Previously • Fax: +44 (0)870 600 5533
HMSO) • [email protected]
Whilst
TSO every effort isCash
Orders/Post made to ensure that the
Dept information in this Technical Guide is accurate, it
• www.tso.co.uk
PO Box 29
is the user’s responsibility to check that any Standard or other material referred to in the Guide
is Norwich NR3and
still relevant 1GNis the most current version.

HR Wallingford (Formerly HRS) • Telephone: +44 (0) 1491 835381

HR Wallingford Ltd, • Fax: +44 (0) 1491 832233
Howbery Park • [email protected]
Wallingford • www.hrwallingford.co.uk
Oxfordshire OX10 8BA

PJA • Telephone: +44 (0)845 0705201

Pipe Jacking Association • Fax: +44 (0)845 0705202
10 Greycoat Place • [email protected]
London SW1P 1SB • www.pipejacking.org

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 6: REFERENCES AND FURTHER READING 71

TRL • Telephone: +44 (0)1344 773131

Transport Research Laboratory • Fax: +44 (0)1344 770356
Crowthorne House • [email protected]
Nine Mile Ride • www.trl.co.uk
Wokingham
Berkshire RG40 3GA

UKSTT • Telephone: +44 (0)1926 330 935

United Kingdom Society for Trench- • Fax: +44 (0)1926 330 935
less Technology • [email protected]
38 Holly Walk • www.ukstt.org.uk
Leamington Spa
Warwickshire CV32 4LY
United Kingdom

UK Water Industry Research Ltd • Telephone: +44(0)20 7152 4537

BCSC • [email protected]
8th Floor • www.ukwir.org/
50 Broadway,
London SW1H 0RG

Water UK • Telephone: +44 (0)20 7344 1844

3rd Floor • [email protected]
36 Broadway • www.water.org.uk
London SW1H 0BH

WRc plc • Telephone: 01793 865000

Frankland Road • Fax: 01793 865001
Blagrove • [email protected]
Swindon • www.wrcplc.co.uk
Wiltshire SN5 8YF

For further information contact:

British Precast Drainage Association

The Old Rectory, Main Street
Glenfield, Leicester
LE3 8DG
Tel: 0116 232 5170
Fax: 0116 232 5197
[email protected]
precastdrainage.co.uk

The information in this guide is to the best of our knowledge true and accurate, but all information provided
is for guidance only and made without guarantee. Since the conditions of use are beyond their control, the
British Precast Drainage Association disclaims any liability for loss or damage resulting from the use of
this guide. Furthermore, no liability is accepted if use of any products in accordance with this data or these
suggestions infringes any patent. The British Precast Drainage Association reserves the right to change
product specifications and references without notice.

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