Professional Documents
Culture Documents
Industry Guidelines
Volume III
Third Edition
National Water Services Commission (SPAN)
Third Edition
January 2009
Published by
Suruhanjaya Perkhidmatan Air Negara (SPAN)
(National Water Services Commission)
Prima Avenue 7, Block 3510
Jalan Teknokrat 6
63000 Cyberjaya Selangor
Malaysia
FOREWORD
BY THE CEO OF SPAN
Table
of
Contents
Page
Section 1
1.1
Introduction
Purpose of This Volume
1.2
1.3
Section 2
2.1
13
13
15
2.1.4 Requirements and Limitations for Use of Certain
Pipe Material
14
16
17
19
21
23
18
20
21
22
24
24
25
26
27
29
31
45
45
46
2.2
2.3
Manhole
50
52
2.2.1 General
55
2.3.3 Material
2.3.5 Seating
2.4
2.3.6 Casting
2.3.8 Water-tightness
2.3.9 Safety Features
Only)
55
55
55
56
56
56
56
57
57
57
58
58
58
59
60
60
61
61
62
62
63
64
65
65
55
53
55
2.3.1 General
53
50
ii
64
64
65
Interceptors
68
68
2.6.1 Concrete
2.5
2.6
Section 3
3.1
3.2
3.3
3.4
3.5
74
75
76
77
77
80
78
Pipe Laying
80
73
70
73
69
69
73
69
Introduction
68
Pipe Jointing
80
81
82
83
83
84
84
85
85
86
87
87
88
iii
3.6
3.7
3.8
88
89
89
90
Section 4
Sewer Testing
4.1
4.3
4.2
4.4
4.5
4.6
4.7
4.8
93
98
4.5.1 General
100
4.6.2 Procedure
4.7.2 Procedure
iv
92
100
92
4.10
91
99
91
90
97
4.8.1 General
4.9
90
General
88
4.8.2 Procedure
CCTV Inspection
100
101
102
102
102
103
104
104
104
104
106
106
106
106
107
107
4.11
4.12
107
108
108
110
111
112
114
114
114
114
114
114
115
List of Tables
Table 2.1a
Table 2.1b
Table 2.2
Table 2.3
Table 2.4
Table 2.5
Table 2.6
Table 2.7
Table 2.8
Table 4.1
Table 4.2
Appendix A
Typical Drawings/Diagrams
Figure A1
Figure A2
Figure A3
Figure A4
Figure A5
Figure A6
Figure A7
Figure A8
Figure A9
Figure A10
Figure A11
Figure A 12
Figure A13(a)
vi
27
27
28
28
29
45
51
57
66
101
113
119
120
121
122
123
124
125
126
127
128
129
130
131
Figure A13(b)
Figure A14(a)
Figure A14(b)
Figure A15
Figure A16(a)
Figure A16(b)
Figure A17
Figure A19(a)
Figure A19(b)
Figure A20(a)
Figure A20(b)
Figure A20(c)
Figure A21
Figure A22
Figure A23
Figure A24
Figure A25
Figure A26
Figure A27
Figure A28
Figure A29
Appendix B
Tables
Table B1
Appendix C
Appendix C 1
Appendix C 2
Appendix C 3
Appendix C 4
Appendix C 5
Appendix C 6
132
133
134
135
136
137
138
139
140
141
141
142
143
143
144
144
145
146
147
148
149
153
157
158
159
160
161
162
vii
Section 1
Introduction
Introduction
1.1
This volume sets out the requirements of the National Water Services
Commission (SPAN) (referred to as the Commission in this document)
for the design, construction and testing of sewer networks and network
pump stations.
The owner must comply with the requirements set out in this volume
when submitting an application for the approval of the Commission.
This volume generally does not cover internal plumbing systems within
buildings. However, some guidelines are provided on the provision of
interceptors to protect public sewers from the discharge of oil and grease
from garage workshops, hotels, restaurants, canteens or any premises
that collect such matter.
1.2
1.3
This volume does not cover all aspects of design and construction of
sewer networks and network pump stations. Where information is not
covered in this volume, the designer shall follow the requirements given
in MS 1228.
MS 1228 shall take precedence over other foreign standards in the event
when there are discrepancies on the requirements.
a) Malaysian Standards
i)
MS 28
ii)
MS 29
iii)
MS 144
Volume 3
Introduction
iv)
MS 145
v)
vi)
MS 146
MS 522
vii)
MS 523
viii)
MS 628
ix)
MS 672
x)
MS 740
xi)
MS 822
xii)
MS 881
xiii)
MS 922
MS 923
xiv)
MS 979
xv)
MS 980
xvi)
MS 981
Volume 3
Malaysian Sewerage
Industry Guidelines
Introduction
xvii)
MS 982
xviii)
MS 1037
xix)
MS 1058
xx)
MS 1061
xxi)
MS 1195
xxii)
MS 1227
xxiii)
MS 1228
xxiv)
MS 1347
xxv)
MS 1292
xxvi)
MS 1389
xxvii)
MS EN
xxviii)
MS ISO/
b) British Standards
i)
BS 65
ii)
BS 915
iii)
BS 3416
Volume 3
Introduction
iv)
BS 3692
v)
BS 4147
vi)
BS 4164
vii)
viii)
BS 4248
BS 4515
ix)
BS 5153
x)
BS 5480
xi)
BS 5911
xii)
xiii)
BS 5975
BS 6076
xiv)
BS 7123
xv)
BS 7874
BS 8007
xvi)
BS 80102.1
xvii)
BS 8666
Volume 3
Malaysian Sewerage
Industry Guidelines
Introduction
xviii)
BS EN
124
xix)
BS EN
295-1
BS EN
295-7
xx)
xxi)
BS EN
545
xxii)
BS EN
598
xxiii)
BS EN
681
xxiv)
BS EN
682
xxv)
BS EN
752
BS EN
1091
BS EN
1561
BS EN
1563
BS EN
1982
BS EN
10025
BS EN
10220
BS EN
10224
xxvi)
xxvii)
xxviii)
xxix)
xxx)
xxxi)
xxxii)
Volume 3
Introduction
xxxiii)
BS EN
10277
xxxiv)
BS EN
10278
BS EN
13725
BS EN
ISO 3766
BS EN
ISO 3506
xxxv)
xxxvi)
xxxvii)
AS/NZS
1260
ii)
AS/NZS
1477
AS/NZS
2566
iii)
iv)
AS/NZS
3518
v)
AS/NZS
3582
vi)
AS/NZS
4323
vii)
AS 3725
Volume 3
Malaysian Sewerage
Industry Guidelines
Introduction
viii)
ix)
x)
xi)
d) German Standards
i)
e) International Standards
i)
ISO 1083
ii)
ISO 3506
iii)
ISO TR
10465
WIS 0432-15
ii)
WIS 0424-01
iii)
WIS 0432-14
Volume 3
Introduction
g)
h)
ASTM
3262
ASTM
2321
ASTM
894
ASTM
3350
ASTM
3212
D
D
F
D
D
The Commission will, from time to time, specify additional standards to be used in
the design and construction of sewerage works. These standards shall be referred
to as appropriate for the design and construction of sewer networks and network
pump stations.
All standards used in the design and construction of sewerage works shall be the
latest or the most updated. When any one of the above mentioned standards is
withdrawn or superseded, the latest or updated standards shall be referred to as
appropriate. This shall be the same for any applicable act, guideline, by-law, etc.
related to sewerage works endorsed by the government.
Other Guidelines in This Set
The Malaysian Sewerage Industry Guidelines comprise of 5 volumes:
a)
b)
c)
d)
e)
10
Volume
Volume
Volume
Volume
Volume
I
II
III
IV
V
Volume 3
Malaysian Sewerage
Industry Guidelines
Section 2
Planning, Material and Design
2.1
Sewers
2.1.1
Volume 3
13
2.1.2
a)
b)
c)
d)
e)
f)
g)
h)
i)
14
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Malaysian Sewerage
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j)
k)
2.1.3
Pipe Selections
1) Gravity sewers
a) Rigid pipes
b) Flexible pipes
i) VC i) GRP
ii) RC ii) Ductile Iron
iii) HDPE (Profile)
2) Force mains (Rising mains)
i) Ductile Iron
ii) GRP
iii) ABS
iv) HDPE (Solid)
v) Steel
3) Vacuum sewers
i) ABS for internal use
ii) HDPE (Solid) for external use
There are specific requirements such as pipe class, joint type, linings
etc. which the above approved pipe materials must meet in order to
suit the above applications. Also, there are certain limitations for use of
each pipe type. These requirements and limitations are specified in the
following sections.
From time to time, the Commission will publish sewer selection guides
which will provide more detailed direction on the selection and use of
sewer materials.
For other pipe materials not listed above, their use will be given
considerations in special circumstances. However, only pipes and fittings
Volume 3
15
I)
Gravity Sewer
a) VC
i) Only size 150 mm or above shall be used.
ii) The minimum size for public sewer shall be at least
225 mm.
iii) Pipe shall not be used in unstable ground.
iv) Flexible joints are recommended.
b) RC
i) Pipe protection linings are required.
ii) Only sizes 600 mm or above are allowed in compliance to
the policy.
iii) Flexible joints are recommended.
c) GRP
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
ii) Pipe shall not accept any industrial or other aggressive
discharges that may affect the pipe integrity.
iii) Pipe shall be used only when no fittings are required.
iv) Only sizes 600 mm or above are allowed.
d) DI
i) The use is only allowed for applications needed high pipe
strength.
ii) Pipe protection linings and coatings are required.
iii) P o l y e t h y l e n e s l e e v i n g i s r e q u i r e d f o r a l l b u r i e d
applications.
e) HDPE
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
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Malaysian Sewerage
Industry Guidelines
a)
DI
i) Pipe shall not be used in unstable ground.
ii) Pipe protection linings and coatings are required.
iii) P o l y e t h y l e n e s l e e v i n g i s r e q u i r e d f o r a l l b u r i e d
applications.
iv) Flexible joints are recommended.
b) GRP
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
ii) Pipe shall not accept any industrial or other aggressive
discharges that may affect the pipe integrity.
iii) Fittings shall be made of ductile iron.
iv) Only sizes 600 mm or above are allowed.
c) ABS
i) Where VC or RC pipes are not suitable.
ii) Only for nominated projects or as permitted by the relevant
authority.
d) HDPE
i) Pipe shall not be used in ground contaminated with high
concentration of chemicals such as solvent that can degrade
the pipe.
ii) Pipe shall not accept any industrial or other aggressive
discharges that may affect the pipe integrity.
e) Steel
i) Pipe is allowed only for sizes 700 mm or above.
ii) Pipe protection linings and coatings are required.
2.1.5
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17
Vitrified clay pipe has extra chemical resistance that is suitable for
sewerage applications. The VC pipe may be used even under very
corrosive sewage environment. However, the potential for infiltration is
great and must be minimised by careful laying procedures on site.
Vitrified clay pipes are permitted for gravity sewers. The minimum
permissible size for public gravity sewer shall not be less than 225 mm
and for service connection shall not be less than 150 mm.
2.1.6
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Malaysian Sewerage
Industry Guidelines
2.1.7
Pipes shall have flexible joints, i.e. spigot-socket rubber seal joints or
mechanical joints, except for pump station pipeworks and valve connections
where flange joints shall be used.
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19
Polyethylene sleeving shall be used for all the buried pipe and
fittings.
2.1.8
Steel Pipe
Steel pipes will undergo corrosion when in contact with aggressive soil
and sewage and, thus, require an internal lining and an external coating.
Pipe internal linings normally include high alumina cement mortar, coal
tar enamel, coal tar epoxy, sulphate resistant cement lining, or bitumen.
Pipe external coatings often include coal tar enamel, bitumen enamel or
asphalt enamel and glass fibre.
Steel pipes are permitted only for inverted siphons (depressed sewers)
and internal pump station pipework. For force main larger than 700
mm, steel pipe may be used if the approval from the Commission is
obtained.
The internal and external surfaces of the pipes and fittings shall be
coated with thermosetting (epoxy paint or powder or epoxy tar resin)
or thermoplastic (polyethylene or polyurethane) material. The type of
external protection shall be determined by the Qualified Person based
on soil condition. Following the completion of pipe jointing, exposed
steel at the joints shall be protected from corrosion by manually applied
external tape wrap and internal cement mortar lining.
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Malaysian Sewerage
Industry Guidelines
A spigot and socket joint welded both externally and internally shall
be used for pipe joints except for pump station pipeworks and valve
connections where flange joints shall be used. Mechanical joints are
only permitted for cut pipe lengths, where internal cement mortar lining
at joints is not possible and where movement of the pipeline is to be
allowed for.
2.1.9
Solid wall HDPE pipes are suitable for buried pressure sewer and buried
vacuum sewer installations. Butt fusion joints shall be used for PE pipe.
uPVC fittings are not permitted for force mains. Solid wall pipe for
pressure main application shall be of minimum PE80-PN10. The use
of specific strength shall depend on the depth and nature of the soil as
confirmed by the Qualified Person. Solid wall pipes for vacuum sewer
shall be minimum of PE80-PN8 and at least PN10 for heavy vehicle
loading.
2.1.10
A profiled wall pipe is a pipe with a plain inside surface and with a
ribbed or corrugated outside surface. The ribs or corrugations are normally
either aligned circumferentially or helically. These corrugated or ribbed
profiles optimise the pipe ring stiffness to weight ratio. The pipe can be
designed with double-wall profile or triple-wall profile.
Volume 3
21
2.1.11
There are two principal manufacturing methods for GRP pipes, centrifugal
casting and filament winding. The centrifugal casting GRP pipe incorporates
silica sand in the wall structure in addition to resin and chopped strand
mat glass fibres. The silica sand shall have a maximum particles size
of 10 mm. The centrifugal casting GRP pipe shall be according to AS
3751.
The filament winding GRP pipe does not normally incorporate sand, which
permits centrifugal casting GRP pipe to have a much thicker wall, and
thus much higher ring stiffness than the filament winding GRP pipe. The
filament winding GRP pipe uses continuous glass fibres wound helically
about the pipe. The design of filament winding GRP pipe shall be in
accordance with BS 5480.
Centrifugal casting GRP pipe is available in sizes from 200 mm to 2400 mm and
standard length of 6 m. The inner surface of the pipe is usually finished
with a resin rich lining which is resistance to attack by sulphuric acid
that may result from septic sewage. Centrifugal casting GRP pipe has a
rubber sealing sleeve joint which is supplied fitted to one end. So jointing
is similar to a spigot-socket joint. These pipes can also be supplied with
flange joints, sleeve-locking joints and sleeve recessed joints for special
applications such as pipe jacking and pipeline towing.
22
Volume 3
Malaysian Sewerage
Industry Guidelines
rich inner surface although the thickness of this resin surface layer is often
limited by the manufacturing method. Some filament winding GRP pipe
manufacturers incorporate corrosion resistant glass fibres. This feature can
be essential with this GRP pipe because its resin rich surface (gelcoat)
is thinner or, sometimes, removed for fabrication purposes. Filament
winding GRP pipe currently being offered can be jointed using a sleeve
and two rubber O rings. Filament winding GRP pipe does not have a
smooth outer surface like centrifugal casting GRP pipe. Machining may
be required for the outer surface where rubber sealing rings are used.
Flange joints and mechanical couplings are also available for special
applications.
Approval for the use of GRP pipe shall be sought from the Commission
for each project intending its use. GRP pipes are permitted for gravity
and pressure sewers. For gravity sewers, GRP pipes are only permitted
for sizes of 600 mm nominal diameter and larger where no fittings
are required. The minimum pipe stiffness shall be SN 5000 with the
appropriate stiffness determined in accordance with structural design
to AS 2566. For pressure sewers, fittings must only be of ductile iron
meeting the coating, lining and other requirements.
2.1.12
Volume 3
23
ABS, like uPVC and PE, is resistant to corrosion in the most corrosive
sewage environment that could occur. ABS is used in a range of
applications requiring pressure pipe. Because of its excellent resistance
to abrasion and UV degradation, ABS has found use in industrial and
mining applications and also in treatment plants for sewage and water.
ABS pipes may be permitted for force mains under special circumstances
which require the benefits of such pipes. If used, the approval of the
Commission is required. ABS pipes may be permitted for use in buried
forced mains and buried interconnecting pipe-works within pump
stations.
2.1.13
2.1.14
24
Volume 3
Malaysian Sewerage
Industry Guidelines
I) Average Flow
The flow used to determine the diameter and gradient of the pipeline
is the peak flow. Peak flow is the most severe flow that could occur
on any day when considering daily flow fluctuations and infiltrations.
The peak flow is derived from the average flow by applying a peak
factor for daily flow fluctuations. The peak factor shall be estimated
from the following formula:
III) Infiltration
2.1.15
I) Sediment Cleansing
Volume 3
25
2.1.16
Pipe Roughness
Except for very high velocities, slime will always be present, which will
increase the pipe roughness. Abrasion by sediments will also impart a
permanent increase in roughness. Pipeline roughness decreases as the
velocity increases. However, there is insufficient data to accurately
determine the pipeline roughness for a wide range of velocities or at
small incremental changes in velocity. In addition, the velocity of the
sewage flow varies due to the factors such as daily fluctuations, different
type of catchment, different stage of catchment maturity, etc. Therefore,
it is not possible to select the pipe roughness with great accuracy.
26
Volume 3
Malaysian Sewerage
Industry Guidelines
Pipe Material
Vitrified Clay
Concrete:
Plastic
New
Old
0.06
0.15
0.06
1.5
3.0
0.6
Old and new roughness values shall be used to determine the sewer
cleansing and maximum design velocities respectively.
Table 2.1b Normal Pipe Roughness for Force Mains for All
Pipe Materials
Roughness, ks (mm)
0.6
0.3
0.15
2.1.17
Unless special arrangements have been agreed for the structural protection
of pipes, the minimum depth of soil cover over the sewer shall be
1.2 m. Sewers are not to be constructed under buildings.
The design shall be based on the worst case scenario. The selection of
the gravity sewer diameter and gradient to cope with the peak flow shall
be based on the following equations:
N
J'6 ORJ V
'
J'6
'
ZKHUH
9
6
'
J
NV
YHORFLW\
K\GUDXOLFJUDGLHQWPP
NLQHPDWLFYLVFRVLW\RIZDWHUPV
LQWHUQDOGLDPHWHUP
DFFHOHUDWLRQGXHWRJUDYLW\PV
URXJKQHVVFRHIILFLHQWP
Volume 3
27
Typical ks values for various types of sewer pipes are presented in Table
2.2 below:
Table 2.2 Typical Roughness Coefficient, ks
Material
Concrete
0.3 to 3
Cast iron
0.26
0.12
Ductile iron
0.046
2. Manning Equations
9
ZKHUH
5 6
Q
9
6
5
Q
YHORFLW\PVHF
K\GUDXOLFJUDGLHQW
K\GUDXOLFUDGLXV
0DQQLQJFRHIILFLHQW
Typical n values for various types of sewer pipes are presented in Table
2.3 below:
Table 2.3 Typical Manning Coefficient, n
Material
28
Manning Coefficient, n
Good Condition
Bad Condition
Uncoated cast-iron
0.012
0.015
0.011
0.013
Ductile iron
0.012
0.015
0.010
0.017
Concrete
0.012
0.016
Volume 3
Malaysian Sewerage
Industry Guidelines
3.
Hazen - Williams Equations
9 &56
ZKHUH
9
6
5
&
YHORFLW\PVHF
K\GUDXOLFJUDGLHQW
K\GUDXOLFUDGLXV
+D]HQ:LOOLDPVFRHIILFLHQW
Typical C values for various types of sewer pipes are presented in Table
2.4 below:
Table 2.4 Typical Hazen-Williams Coefficient, C
Material
Hazen-Williams Coefficient, C
130 to 140
Smooth masonry
120
Vitrified clay
110
100
60 to 80
2.1.18
For long and undulating force mains, hydraulic pressure transient analyses
may be required to ensure that the force main can cope with water
hammer pressures.
Volume 3
29
Retention times in force mains must not exceed 2 hours without special
precautions to mitigate septicity.
All force main shall be designed to withstand at least 1.5 times the
working pressure. Approval from the Commission is required if any
force main is to be designed to withstand pressure less than the pressure
stated above.
Where retention times in the force mains exceed two hours and where
concrete pipe are laid downstream of the force mains, an induct vent
shall be provided at manholes receiving pumping discharges.
1. Darcy-Weisbach Equation
I/9
J'
=
KI
ZKHUH
K I
I
9
J
'
/
)ULFWLRQORVV
&RHIILFLHQWRIIULFWLRQ
9HORFLW\LQWKHSLSH
$FFHOHUDWLRQGXHWRJUDYLW\
(TXLYDOHQWGLDPHWHURIWKHSLSH
/HQJWKRISLSH
I
ORJ NV
'
5H I
5H
9'
Y
The above equations together with the Moody Diagram are used to
30
Volume 3
Malaysian Sewerage
Industry Guidelines
KI
9
=
&
/
'
ZKHUH
K I
&
9
/
'
)ULFWLRQORVV
+D]HQ:LOOLDP&RHIILFLHQWUHIHUWR7DEOH
9HORFLW\LQWKHSLSH
/HQJWKRISLSH
(TXLYDOHQWGLDPHWHURIWKHSLSH
Force mains shall be designed to handle the full range of flows from
present minimum to future peak.
The design velocity shall fall within the range of 0.8 to 3.0m/sec over
the full range of design flows.
The hydraulic resistance of force main fittings and bends shall be included
in the hydraulic design.
2.1.19
2.1.19.1 General
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31
The vacuum sewer discharges into the vacuum vessel at the vacuum
station. The vacuum is maintained by vacuum pumps at a predetermined
level. The sewage is generally pumped from the vacuum station by
sewage discharge pumps.
32
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Malaysian Sewerage
Industry Guidelines
b) Vacuum Station
Volume 3
33
pre-cast concrete. The two sections (the valve compartment and the
collection sump) may be mounted vertically one on top of the other
as shown in typical drawings in Appendix A. The diameter of the
sections may be as small as 1200 mm or as large as 1500 mm.
34
Some vacuum interface valves inhale and exhale air during their
operation. This is accomplished through a screened air pipe known
as a breather.
Volume 3
Malaysian Sewerage
Industry Guidelines
Each breather pipe shall be fitted inside the breather bell located
at the top of the collection chamber in an accessible location to
allow their removal for maintenance purposes.
I) General
The interface valve shall fail safe in the closed position and shall
prevent backflows from the crossover pipes to the collection sump.
When the valve is open, the flow path shall not be obstructed by the
valve mechanism. The valve shall evacuate at least the batch volume
each time per cycle. Valves installed in the sump shall be capable
of operating when submerged provided that the breather pipe is not
submerged.
The controller shall open the valve only if there is a minimum partial
vacuum of 0.2bar below atmospheric available and shall maintain the
valve fully open until at least the batch volume has been evacuated.
If the design provides for the introduction of air after the sewage
has been evacuated, the controller shall maintain the valve open for
a further period. The controller shall be adjustable so that a range of
air to sewage ratios can be obtained. Controllers installed in sumps
shall be capable of operating when submerged.
Volume 3
35
I) General
a)
b)
c)
d)
Minimise lift.
Minimise length.
Equalise flows on each vacuum main.
Provide adequate access for operation and maintenance.
When sewers are not buried, they shall be protected from extremes
of temperature, ultra-violet radiation and possibility of vandalisms.
36
Volume 3
Malaysian Sewerage
Industry Guidelines
a) Design Tolerances
b) Lift Design
Crossover pipe shall initially fall away from the interface valve
and shall connect into the top sector of the vacuum sewer contained
within the angle of 60 about the vertical axis as shown in
Appendix A.
d) Branch Connections
Volume 3
37
e) Water-logging
a) Pipe Size
The suction pipe DN/ID shall not be greater than the DN/ID of the
interface valve. The minimum diameter of crossover pipe shall be
DN/ID 50 and shall be greater than the DN/ID of the suction pipe.
Vacuum sewer shall have a minimum diameter of DN/ID 80.
c) Warning System
V) Isolation Valve
38
The isolation valve clear opening shall be not less than the DN/ID
of the pipe, and be capable of sustaining a vacuum pressure of -0.8
bar(g).
Volume 3
Malaysian Sewerage
Industry Guidelines
Isolation valves shall be resilient seated gate valves with the body,
bonnet, gate and bridge fabricated from ductile or cast iron. The
stem shall be stainless steel, and the gate shall be encapsulated with
Ethylene Propylene Diene Monomer (EPDM). End connections to
the valves shall be flanged.
When isolation valves are buried, they shall have extension spindles
and surface boxes.
I) General
The floor level of the dry well shall be designed to suit the invert
levels of the incoming sewers, the vacuum vessel diameter and the
dimensions of the selected sewage discharge pumps.
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The vacuum vessel, the sewage discharge pumps, valves and pipework
associated with the sewage discharge pumps and a small sump to
collect washdown water shall be located in the dry well.
The plant room shall contain the vacuum pumps, control panel,
standby diesel generator, vacuum pressure gauges, and moisture
trap.
Sewer inlets shall be provided with short radius elbows inside the
vessel to direct the sewage inflow away from the sewage discharge
pump suction connections and the vessel walls.
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V) Vacuum Pumps
a) Evacuation Time
W=
4YS
:KHUH
W V\VWHPHYDFXDWLRQWLPHPLQXWHV
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41
The system evacuation time, which is defined as the time period between
the vacuum pump start and stop, shall be between 2 and 5 minutes.
c) Vacuum Pipework
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valve and a resilient seated gate valve on the discharge side. Where
the discharge pipework is manifold, the final discharge pipe shall
also be fitted with a non return valve. The valves shall be able to
be operated from the vacuum station floor.
Odour Control
X)
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43
b)
Level Control
The level control system shall respond to the following sewage levels
in the vacuum vessel:
Emergency stop level
Start level
Stop level
c)
The controls shall permit the selection of duty, duty assist (where
provided) and standby vacuum pumps and sewage discharge pumps
and shall provide for the automatic introduction of the standby units
in the event of failure.
d)
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INPUT / OUTPUT
Station power
Failed / OK
Isolated / OK
Isolated / OK
Tripped / OK
Tripped / OK
Vacuum level
Low / OK
Vacuum level
High / OK
Sewage level
High / OK
Intruder alarm
Activated / OK
Fire alarm
Activated / OK
2.1.20
2.1.21
Inverted siphons are introduced along a gravity sewer line in order to pass
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Longer siphons shall be provided with hatch box with access for
maintenance and cleaning. These siphons shall have independent washout
facilities.
2.1.22
The structural design of a buried sewer can be divided into the following
two categories:
a) Rigid pipe.
b) Flexible pipe.
All two structural designs shall take account of how the sewer is supported
to determine the loading which the sewer can safely withstand.
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the structural integrity of the pipe cross section, the considerations for
the ground conditions and sewer installation practices that will affect
the longitudinal structural integrity shall not be omitted.
There are many design approaches for each of the two structural design
categories. However, there are only minor alterations among these
different approaches. Some design approaches tend to give a more
favourable prediction of performance for a particular pipe material than
other approaches. The use of standard design approaches given in this
guideline will prevent the selection of a particular design approach purely
to favour one material over another. Also, the following recommendations
are only meant for general design aspects. Any design aspects that are
not covered by this Volume, the designer shall refer to BS EN 752 or
any other standards deemed appropriate by the Commission.
When a buried rigid pipe is supported, the load which the pipe can
safely withstand is higher than the load which caused failure in the
three point loading test.
By varying the pipe ring strength and the pipe support, different
load resistance can be achieved.
The pipe support designs permitted by this Volume are limited to those
in typical beddings in Appendix A. They include the following:
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47
i)
ii)
iii)
iv)
Where vehicles will pass over the sewer and the sewer is laid with
a cover depth of less than 2.5 m, the sewer will be subjected to
additional loads from such vehicles. The Boussinesq Theory should
be used to determine the loads from vehicles in the design.
Loads on buried rigid pipe for field conditions and for main roads
can be found in Simplified Tables of External Loads on Buried
Pipelines published by the UK Transport Research Laboratory.
48
Granular
Concrete
Concrete
Concrete
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Malaysian Sewerage
Industry Guidelines
i)
ii)
iii)
iv)
Similar to rigid pipe, the loading which a flexible pipe can withstand
can be increased when the pipe is supported. For flexible pipes, this
external ring support is more critical. Without it, a flexible pipe
would fail under the loads applied by usual soil cover for gravity
sewers and under vehicle loads for shallow cover force mains.
The soil load used for structural design for flexible pipe support shall
be the prism load or the weight of the column of soil directly above
the pipe. Marston Load Theory mentions that this column of soil
PE pipe
GRP pipe
ABS pipe
Steel pipe
Volume 3
soil stiffness,
pipe. Flexible
with the rock
Crushed rock
49
Where vehicles will pass over the sewer and the sewer is laid with
a cover depth of less than 2.5 m, the pipe will be subjected to
additional loads from such vehicles. The Boussinesq Theory should
be used to determine the loads from vehicles in the design approach
in this guideline.
2.2
Manhole
2.2.1
General
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Brick manholes shall not be used, due to the high risk of excessive
infiltration.
< 1.5
> 1.5
DN Largest Pipe in
Manhole (mm)
< 150
225 to 300
375 to 450
525 to 710
820 to 900
> 900
< 300
375 to 450
525 to 710
820 to 900
> 900
Volume 3
Min. Internal
Dimensionsa (mm)
1000
1200
1350
1500
1800
Subject to designers
requirements based on
site condition
1200
1350
1500
1800
Subject to designers
requirements based on
site condition
51
Note:
a) These sizes apply to straight-through pipes; larger sizes may be
required for turning chambers or chambers with several side branches or
where specific maintenance requirements are necessary, e.g disconnecting
traps.
2.2.2
Manhole Location
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2.2.3
2.2.4
c) The base of the manhole shall not be less than 300 mm thickness,
which is measured from the channel invert.
d) Channel inverts shall be laid accurately to meet entry and exit pipe
inverts.
e) The channel invert shall be graded evenly between the entry and
exit pipes.
f) Flexible joints shall be provided at the exit and entry of the manholes
and shall be placed immediately outside any poured-in-situ concrete
surround.
g) Joints between the pre-cast chamber rings shall be sealed with suitable
mortar, which can be high alumina cement mortar or equivalent.
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k) Box outs sealed with bricks or equivalent shall be made for any
proposed connections.
o) Manhole covers in roads shall be set to the road profile and shall
be flushed with the road surface.
u) Maximum depth shall be equal or less than 9 meter and all manholes
deeper than 6 meter are subjected to the Commissions prior
approval. Depending on the catchment area and size of sewer
pipe, manholes deeper than 9 meter may be considered for the
Commission approval.
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2.3
2.3.1
General
Manhole covers and frames shall comply with the specifications in this
Guideline and BS EN124. Where the specifications in this Guidelines
contradict the specifications given in BS EN124, the specifications in
this Guidelines shall take precedence.
2.3.2
Load Class
2.3.3
Material
The production, quality and testing of spheroidal graphite cast iron shall
comply with ISO 1083.
2.3.4
The manhole covers shall be free of defects which might impair their
fitness for use.
2.3.5
Seating
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55
2.3.6
Casting
2.3.7
Protective Coating
All surfaces of manhole covers and frames shall be supplied coated with
either a:
All cast units shall be cleanly cast and free from air holes, sand holes,
cold shuts and chill. They shall be neatly dressed and carefully fettled.
All castings shall be free from voids, whether due to shrinkage, gas
inclusions or other causes.
2.3.8
Water-tightness
No visible leakage shall occur between the manhole cover and its seating
in the frame when tested in accordance with Appendix E of AS 3996.
2.3.9
Safety Features
a) Locking Devices
b) Hinge
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2.3.10
Product Certification
The quality control of the certified manhole covers and frames shall
meet the requirements given in Clause 10 of BS EN 124. However, the
final inspection and tests and the frequency of tests/inspection shall not
be as shown in Table A3 of BS EN 124. Instead, the specifications as
shown in Table 2.7 below must be followed. All final inspection and
test documents shall be retained for at least 5 years.
Table 2.7 Final inspection and testing
Final Test/Inspection
Frequency
Every unit
Every unit
Every unit
Every unit
1 per 20
1 per 100
1 per 100
1 per 100
1 per 200
2.4
2.4.1
iii) Sewage needs to be delivered from an area that is outside the natural
drainage catchment of a sewage treatment plant.
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57
2.4.2
General Requirements
i)
2.4.3
Buffer Requirements
Under conditions where there exists the potential of odour nuisance to the
nearest habitable building property line within residential and commercial
development despite having the minimum buffer zone, such odour shall
be minimised to the lowest possible level and in compliance with the
Environmental Quality Act.
2.4.4
Pipeworks Requirements
i)
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2.4.5
Wet-well Requirements
i)
ii)
iii)
iv)
v)
vi) The minimum sump volume required shall accommodate the pumping
cycle as per Table 2.4.
vii) Benching shall be designed to minimise deposition of solid matter
on the floor or walls of wet-wells. The minimum slope of benching
shall be 450 to the horizontal.
viii) Benching shall preferably extend up to the pump intake.
ix) Self cleansing pumps shall be provided.
x) Access into wet-wells can be by vertical rung ladders with a maximum
height of 6 m. When the height exceeds 6 m, intermediate platforms
shall be provided with a change in direction of the ladder. Safety
cages shall be provided for ladders exceeding 6 m.
xi) Access covers shall have a minimum clear opening of 600 mm
diameter and be sufficiently large to withdraw pumps vertically.
xii) Access covers shall be capable of being lifted by, at most, two
operators.
xiii) On small pump stations (PE < 500), the practice is to provide
difference between the cut-in and cut-out levels, the storage volume
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equal to 2 to 3 times the peak flow into the wet-well in litres per
minute merely to protect the starting equipment from overheating
and failure caused by too frequent starting and stopping.
xiv) Emergency bypass shall be provided either at any suitable manhole
or wet-well. The discharge of the bypass is preferred to the nearest
watercourse and not to the perimeter drain of the pumping station.
However, if this is not available then discharge to the nearest surface
drain is allowed.
xv) All wet-well shall be opened and come with stainless steel or other
non-corrosive handrails. If stainless steel tubing is used, it shall be
in-filled with concrete.
2.4.6
Dry-well Requirements
i)
ii)
iii)
iv)
v)
2.4.7
Structural Requirements
i)
vi) For safety and operational reasons, a double penstock system may
be required at specific plant.
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vii) The penstock spindle shall extend to pump station ground level and
shall be suitably positioned to allow unrestricted operation of the
penstock.
ix) Access covers shall be hinged with a lifting weight not exceeding
16 kg.
2.4.8
Ventilation Requirements
i)
ii)
iii)
iv)
v)
vi)
2.4.9
Odour Control
i)
The potential for odour generation, its impact and treatment, shall
be considered in all aspects of design.
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iv) The local exhaust odorous air shall be conveyed through well designed
and balanced ductworks by a centrifugal fan to an effective odour
treatment equipment.
2.4.10
i)
iii) If lights are fitted outside the well, then a spotlight system may be
used to provide adequate illumination.
2.4.11
i)
ii) Screw
Guide rail, lifting device and other wet-well fittings must be fabricated of
stainless steel, that is corrosion resistant. The use of hot dip galvanised
iron is not recommended.
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2.4.12
Valve Requirements
2.4.12.1 General
i)
ii) All valves shall be suitable for use with wastewater and shall be
designed to prevent retention of solids.
iv) Bodies and cover for all valves shall be made of ductile iron to BS
EN 1563: 1997. Special protective surfaces finishing by short blasting
and finished externally with epoxy corrosion resistant coating shall
be provided.
i)
Gate valves shall be of the non-rising screw wedge-gate type, doublefaced ductile iron made and with resilient seated.
iii) The wedge of the gate valves shall be coupled and integral to the
wedge hut in dezincification resistant high tensile brass (CZ 132)
conforming to BS EN 2287 2: 1993, ISO 2872: 1985.
iv) The spindle of the gate valve shall be of the inside screw non-rising
with machined square or acme threads and operated by a handed or
tee-key.
i)
iv) The uses of internal counter weights are not permitted for Check
Valve.
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v) Type non-slam Check valve shall be of the full body type, with a
domed access cover and only on moving pant, the flexible disc.
vi) Disc of Check valve shall be of precision molded Nitrile Butadiene
Rubber (NBR) to BS EN 681-2: 2000. the disc shall be of onepiece construction, precision molded with an integral o-ring type
sealing surface, and contain alloy steel and nylon reinforcement in
the flexible use area.
vii) In the absence of check valve, the reverse rotation of the pump
shall not exceed 150% of the rated speed or limit set by the
manufacturer.
viii) Tapping (12 mm British Standard Parallel (BSP)) shall be located
upstream and downstream of check valves.
2.4.13
i)
ii)
iii)
iv)
v)
vi)
2.4.14
i)
2.4.15
i) System curves.
ii) Pump curves.
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iii) Operating point of pumps with respect to flow and total dynamic
head (TDH).
iv) Operating characteristics such as efficiency, horsepower, motor rating
and Net Positive Suction Head (NPSH).
2.4.16
Maintenance Considerations
i)
2.4.17
i)
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65
66
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mm
start/
hour
Pumping cycle
(average flow conditions)
A gantry with motorised hoist shall be arranged to allow items to be projected on a 1.2m truck tray and
positioned at 2m above road level truck tray.
6 - 15
100
75
30
16 kg Weight 250 kg: A davit or A frame shall be arranged to allow items lifted by using manual chain
hoist to be projected on a 1.2 m truck tray and positioned at 2m above road level. In the pump station,
motorized hoist is required for lifting weight exceeding 100kg.
lifting davit
6 - 15
100
75
30
each at Qpeak
2
1 duty,
1 standby
(100 % standby)
2
1 duty,
1 standby
(100 % standby)
each at Qpeak
Wet-well
Wet-well
PE 1,000
Manual lifting
mm
Lifting device*
min
Unit
Number of pumps
(all identical and work sequentially)
Type of station
Description
Design Parameters
Malaysian Sewerage
Industry Guidelines
Volume 3
start/
hour
Pumping cycle
(average flow conditions)
A gantry with motorised hoist shall be arranged to allow items to be projected on a 1.2 m truck tray
and positioned at 2 m above road level truck tray.
mechanical
6 - 15
100
75
30
16 kg Weight 250 kg: A davit or A frame shall be arranged to allow items lifted by using manual chain
hoist to be projected on a 1.2 m truck tray and positioned at 2 m above road level. In the pump station,
motorized hoist is required for lifting weight exceeding 100 kg.
6 - 15
100
75
30
peak
each at 0.25 Q
Manual lifting
mm
Lifting device*
mm
peak
each at 0.5 Q
6 (3 sets)
1 duty, 1 assist,
per set
(50 % standby)
PE > 20,000
Number of pumps
(all identical and work sequentially)
min
Unit
Design Parameters
Type of station
Description
Table 2.8
67
2.5
Interceptors
2.5.1
Oil Interceptors
Oil interceptors shall be designed in such a way that pollutants that are
lighter than water liquid are trapped in a chamber and are prevented from
being discharged to the public sewer. The chamber shall be normally
fitted with a device to trap sediments and heavy particles that settle to
the bottom. The removal of these sediments is required periodically.
Intercepted oils shall be capable of being drained off for storage from
suitable draw off points on a continuous operational basis.
2.5.2
Grease Traps
Grease traps shall be provided in drain lines from areas such as restaurants,
canteens, food processing and animal product or feeds factories, where
grease and fat are likely to present in wash down waters or sullage.
Grease traps shall be designed in such a way that solidified grease and
fats are trapped in a chamber prior to discharge and may be skimmed
off by means of a perforated strainer or bucket.
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2.6
2.6.1
Concrete
i)
iii) Concrete for purposes other than manholes and pumping stations shall
have a strength grade not less than Grade C20 where unreinforced,
and not less than Grade C30 where reinforced.
iv) Structures that are designed for retaining sewage or other aqueous
liquids shall be in accordance with BS8007, which specifies C35A
concrete. Where required, higher strength grades may be specified
by the Commission.
vi) Concrete and cement mortar shall be made using a cement with
sufficient resistance to sulphate attack if contacted with sewage.
2.6.2
Cement
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2.6.3
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Section 3
Construction and Installation
3.1
Introduction
b) Trench Excavation
c) Pipe Laying
d) Pipe Jointing
f)
3.2
3.2.1
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3.2.2
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3.2.3
Pipe Storage
a) The pipe and fittings storage area shall be away from traffic and
shall not obstruct any property access or pedestrian route.
b) The pipe and fittings storage area shall be at a location that allows
lifting machinery to position easily and safely for lifting pipes and
fittings.
c) Pipes shall be stacked on a flat and level firm ground or the base
of the pipe stack shall be made level using additional solid timbers
under base bearers.
d) There shall be no rocks, tree roots, etc. under the pipe stack, which
may cause point load.
e) The sockets shall be alternated to different ends for each pipe stack
layer. The sockets shall be protruded out of the stack.
f) The base timber bearers shall be sound and without protrusions. The
cross section of each timber shall be at least 75 mm by 75 mm. The
base bearers shall provide support near the pipe ends, but placed
behind sockets. The placement of base bears shall not be more than
1.5 m apart.
g) VC, RC, DI, Steel and GRP pipe layers shall be separated using
timber spacers of at least 50 mm wide and 50 mm thick. These
spacers shall not be placed more than 1.5 m apart. These spacers
will prevent pipes in each layer from touching pipes in the next
layer.
h) For VC and RC pipes that are not crated, the pipes shall not be
stacked more than 3 pipes high. The pipe stacks shall be wedged
to prevent them from rolling off the stack.
i) Thermoplastic pipes (PE and ABS) shall be stacked in such a way
to prevent them from being twisted or bowed.
j) Thermoplastic pipes shall be either stacked in a pyramid with no
more than 1 m high or in a square with vertical side supports for
more than 2 pipes high.
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k) Plastic pipes and fittings shall be kept under a cover that prevents
direct exposure to sun light.
l) Plastic pipes and fittings shall not be covered with plastic
sheeting.
m) Plastic pipes and fittings shall be stored away from oils, greases,
solvents and other aggressive chemicals.
n) Plastic pipe shall be stored away from sources of heat such as engine
exhausts.
o) Care shall be taken to prevent scoring and scratching of plastic pipe
and fittings.
p) Joint lubricants, rubber rings and other jointing materials shall be
stored in a secured area that cannot be accessed by the public.
q) Any safe pipe stacking procedure not covered above, but recommended
by the manufacturer, shall be adopted.
r) The rubber rings that are not delivered fitted to the pipe socket or
sleeve shall be stored away from direct sunlight or continual artificial
light. Also, the rubber rings shall be stored in a cool area that is
away from oils, greases or other petroleum products.
s) When rubber rings are delivered fitted to a pipe socket or sleeve,
the pipe ends with the rubber ring shall be shielded from sunlight
using a hessian cloth.
t) Rubber rings shall be retained in the original sealed packaging until
they are required.
3.2.4
Pipe Damage
a) Pipes, fittings (including coatings and linings) and rubber rings shall
be inspected for damage on delivery, immediately before laying and
after laying.
b) Damaged pipes and fittings shall be identified and marked with
an indelible marking of Damaged in a clearly distinguishable
colour.
c) Damaged rubber rings shall be cut through completely to prevent
inadvertent use.
d) Damaged pipes, fittings, and rubber rings shall be set aside and
separated from the undamaged components.
e) Pipes or fittings shall only be repaired if they can be restored back
to a satisfactory state. Approval for repair shall be sought from the
Commission before the repair.
f) Pipes or fittings that are damaged and are in a repairable state shall
be repaired according to the manufacturers instructions.
g) Damaged pipes and fittings that are not permitted to be repaired
shall be removed from the site as soon as possible.
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h) PE and ABS pipes with damage in the barrel, shall have the damaged
section and at least 100 mm either side of the damage cut from the
barrel.
i) Repaired pipes and fittings shall be used only after the approval for
reuse from the Commission is granted.
3.3
Trench Excavation
3.3.1
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77
3.3.2
Excavation Requirements
a) The required line of the sewer and manhole locations shall be set
out using accepted surveying practices.
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3.3.3
Bored Excavation
a) The bore shall be on the line, level and grade and of sufficient
diameter to allow pipes to be inserted without over-stressing the
joints or damaging the pipes.
3.4
Pipe Laying
3.4.1
Pipe Bedding
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b) The bedding material shall be placed as soon as possible after the base
of the trench is prepared and excess water has been removed.
c) Granular bedding shall be placed, compacted and graded so that
it offers continuous support to the sewer. The compacting, where
required, shall achieve a uniform density.
d) A small hole shall be left in granular bedding for each socket, jointing
sleeve, flange, etc. that may project into the bedding. The holes
shall be of size that is just sufficient for projections to be clear of
bedding. Long and large holes that may undermine the pipe barrel
support are not allowed.
e) A recess shall be made in the bedding to permit the withdrawal of
the sling without disturbing the remaining bedding.
f) Where the bedding is disturbed, the pipe shall be raised again to
repair the bedding.
g) Pegs or other temporary aids to levelling shall be removed before
pipe laying.
3.4.2
a) Before lowering the pipes into the trench, pipes shall be placed
next to the trench away from the trench edge. The pipes shall be
placed on the opposite side of the spoil beside the trench with their
sockets facing upstream. Where required, the pipes shall be blocked
or chocked to prevent any rolling.
b) Pipes and fittings (including linings, sheathings and protective
paintworks) shall be checked for damage before and after laying in
the trench.
c) VC pipes shall be carefully tapped at mid length and either end
with a wooden mallet or, otherwise, a metal bar. This is to detect
a clear ring that indicates soundness. This is best undertaken while
each pipe is lifted in free air with a lifting sling.
d) Pipe and fittings shall not be dropped into the trench. Instead, pipes
shall be lowered into the trench using approved slings.
e) Pipes shall be laid from the downstream end towards the upstream
end.
f) The laying of pipes shall proceed carefully to ensure the line, level
and grade are within the specified tolerances.
g) Pipes shall not be dropped or impacted forcefully into the bedding
to obtain the specified level or grade.
h) Concrete pipes with elliptical reinforcement shall be laid with the
load line on the vertical axis at the top or bottom position.
i) Holes made in granular bedding for projections of sockets, flanges,
etc. shall be lightly filled where necessary without pushing the pipe/
fitting off line, level or grade.
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81
3.4.3
Pipe Jacking
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c) The setting out of the guide rails for the pipe and the actual jacking
operation shall maintain a high accuracy level of line and grade.
d) The direction and grade for jacked sewer shall not deviate from the
designed alignment for more than 100 mm for every 100 meters of
sewer.
e) All the joints used for connecting the jacked pipes shall be watertight
and durable.
3.4.4
3.4.5
Pipe Cutting
a) Only VC, HDPE, ABS and DI pipes are permitted to be cut in the
field. However prior approval from the Director General is required
should the HDPE helically wound profile wall pipe needs to be
cut in the field. All pipes shall be cut in accordance to approved
methods.
b) Rough edges and burrs shall be removed from inside and outside of
HDPE and ABS pipe with a rasp or file.
c) Pipes shall be cut in a neat and skilful manner by workers experienced
in pipe cutting.
d) Pipes shall be cut perpendicularly to the pipe axis.
e) Any damage to the cement lining of DI pipe shall be repaired to
the satisfaction of the Commission.
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83
3.4.6
Backfill of Trench
3.4.7
a) Reference shall be made to the approved longitudinal and crosssectional drawings of sewer profiles of both gravity sewers and
force mains. These drawings submitted for approval must include
details of bedding types and manhole types, and their design must
be supported by soil reports.
b) Pipe laying shall be such that there is adequate access for operations
and maintenance of completed sewers, especially in undulating ground
profiles, with a minimum width of 6 metres, which shall be supported
by drawings with ground profiles during drawings approval stage.
c) For easy identification of underground forced sewer mains, their
layout shall be planted with marker posts at every 200 m length and
at every change of pipe directions. Valve chambers provided shall
have adequate access for operations and maintenance.
d) There shall be adequate site supervision of construction, and
at least these documents must be submitted before approval of
construction:
i) Photographs showing sewer pipe laying during an after construction
for all lengths.
ii) Testing certificates from the consultants (see Section 4 on Sewer
Testing)
iii) Supervision certification from the consultants
iv) As-built drawings certified by the consultants
e) The construction and installation works shall incorporate the
consideration of health and safety.
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3.5
Pipe Jointing
3.5.1
Flexible Joints
f) The rubber ring shall be placed correctly around the pipe joint.
g) The rubber ring shall not be twisted in any way prior to jointing
and shall be seated in the correct position.
h) For skid type of joints (i.e. the sealing ring remains stationary and
does not roll into place), the spigot shall be lubricated with an
approved lubricant.
i) The pipe to be jointed shall be aligned with the laid sewer before
pushing in the joint.
j) The pipe to be laid shall be orientated so that the offset inside the
pipe at the joint is minimise at the invert.
k) The pipe that is already laid and to be connected to another pipe shall
be restrained to prevent its pipe joints being further stressed and to
prevent the laid pipe from being pushed off grade or alignment.
l) Pipe joints shall be connected using a bar and block (crow bar and
a block of wood to protect the pipe end) or a pipe puller.
m) A machine bucket shall only be used to connect a pipe joint where
approval is given by the Commission. This method shall only be
used for large diameter pipes (larger than 600 mm diameter pipe)
where the jointing compression force makes it impossible to use a
bar and block or pipe puller. A timber shall be placed across the
pipe end to protect the pipe from damage. Pressure shall be applied
by the bucket gently while the insertion shall be carefully monitored
and directed by a person next to the joint.
n) No excessive force shall be applied to make the joint.
o) After pushing the spigot into the socket, the seal shall be checked
to ensure the seal is correctly located and the spigot is properly
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3.5.2
a) The socket and spigot shall be checked for damage before and after
jointing.
b) Damaged spigot ends shall be cut from the pipe with 100 mm
clearance to the damage. The spigot end shall be cut perpendicularly
to the pipe and any burrs shall be removed.
c) The spigot shall be inserted up to the witness mark.
d) If a witness mark is not already on the pipe, the mark shall be made
to ensure that the spigot is inserted to the appropriate length.
e) Witness marks drawn on site shall be made with a soft pencil or
felt pen marker that would not score or scratch the pipe.
f) The witness mark shall be of the depth of the socket and shall be
measured from the pipe end.
g) A dry fit of the joint shall be made before the jointing.
h) Jointing surfaces shall be wiped clean and dried with a clean
cloth.
i) Jointing surfaces shall be primed using an approved priming solution.
The priming shall be applied with a clean cloth or swab freshly
dipped in the fluid immediately before jointing.
j) A thin and even coat of solvent cement shall be applied to the socket
and the spigot, which should then be inserted up to the witness
mark.
k) The jointing surfaces shall not be contaminated with water, dirt,
etc.
l) The jointing shall be made immediately after the application of
solvent cement.
m) After the spigot is pushed firmly into the socket, the joint shall be
hold in the same position for at least 30 seconds without moving.
n) The jointed pipes shall not be moved for at least 5 minutes after
jointing. The jointed pipes shall be handled with extreme care for
at least another hour.
o) Joints shall be left to dry for at least 24 hours before pressure
testing.
p) Containers of solvent cement and primer shall be kept tightly sealed
when not in use.
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3.5.3
Flanged Joints
3.5.4
a) The welded joint shall use a socket-spigot joint with taper sleeve
wherever possible.
b) Welding surfaces shall be cleaned to a bright metallic finish before
welding.
c) Welders shall be qualified in accordance with the requirements of
British Standard BS 4515 Specification for welding of steel pipelines
on land and offshore.
d) Welding procedures shall be tested, qualified and approved in
accordance with BS 4515.
e) Welds shall be inspected and tested in accordance with BS 4515.
f) After welding, exposed external surfaces shall be cleaned by sand
blasting or wire brushing. The dry surfaces shall be wrapped in
an approved manner with an approved wrapping tape to provide
corrosion resistance.
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3.5.5
3.6
3.6.1
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d) The thrust block shall bear firmly against a recess at the side of the
trench.
e) The trench face which the thrust block bears against shall be freshly
cut and undisturbed.
f) Each thrust block shall have sufficient bearing area.
g) Thrust block shall be cast-in-place with 20 MPa concrete.
h) For plastic pipe or pipe with a protective coating, a compressible
membrane of rubber, felt or cork shall be placed on the pipe to
protect it from damage from its movement in the thrust block.
i) Formwork shall be used to cast the thrust block to the required
dimensions.
j) Formwork shall be removed before any testing.
k) Reference shall made to the standard drawings for thrust block to
ensure proper shape and size, which must be designed for each
individual thrust blocks.
3.6.2
3.6.3
a) The embedment material type and its grading shall take considerations
of the sewer type or length.
b) Reference shall be made to the approved longitudinal and crosssectional drawings of the sewers showing the bedding types, which
shall be designed based on supporting soil reports.
c) Embedment material shall not be contaminated with other soils.
d) Embedment material shall be brought up evenly in layers on each
side of the pipe.
e) Each embedment layer shall be placed to a depth that permits the
compaction equipment to achieve the specified density.
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f) The pipe shall not be pushed off alignment, level or grade while
placing the embedment.
g) Where the embedment requires tamping, tamping equipment shall
not come into contact with the pipe.
h) Temporary trench wall support shall be lifted when the embedment
is compacted.
i) While placing the embedment for the pipe haunches, unnecessarily
voided areas shall be avoided.
j) At least 300 mm of cover shall be placed over the pipe before
light mechanical compaction, such as a hand operated whacker, can
commence.
3.6.4
3.6.5
3.7
Reinstatement
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3.8
3.8.1
General
a) The owner must seek the approval of the Commission for any
connections that involve physical work to an existing public sewer.
The initial notification must be made on the appropriate form.
b) Once approved, the owner may make the connection only if his
contractor is licensed by the Commission for this category of
work.
c) The type and location of connections shall be determined by the
Commission. The type of connection could be a connection to a
manhole or a connection to a sewer through junction or saddle
fittings.
d) The cost of the work in making the connection shall be borne by
the owner, regardless of whether the work is undertaken by his
licensed contractor or a licensed contractor employed by Services
Licensee.
e) The connection must be correctly made by the licensed contractor
under the supervision of an authorised inspection person.
f) When the connection is ready for inspection, the owner must notify
the Commission on the appropriate form. At the same time, he must
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91
g)
h)
i)
j)
3.8.2
Junction Connections
3.8.3
Saddle Connections
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The hole prepared for the saddle connection on the existing sewer shall
not have any rough edges that might cause blockage. The location of
the hole on the pipe shall be at a 45 to 60 angle to the horizontal.
The hole shall be made at the middle of the pipe to avoid damages or
excessive loading to the existing sewer pipe joints. The existing pipe may
require extra strengthening by additional concrete surround to withstand
the extra load from the connection pipe and fittings.
The connection pipe must not protrude into the existing sewer.
Any debris falling into the existing sewer during the connection shall
be removed.
3.8.4
Manhole Connections
a)
b)
c)
d)
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Section 4
Sewer Testing
Sewer Testing
4.1
General
Sewers and ancillary works shall be tested and inspected for watertightness to prevent infiltration and exfiltration and to ensure the pipes
are laid correctly according to the designed straightness and grade. The
testing of the sewers and ancillary works before backfill will facilitate
the replacement of any identified faulty pipes and joints. The testing of
the sewers and ancillary works after backfill will reveal the leakages
caused by the displacement of joints and subsequent damage. The testing
shall be supervised by consultants and their testing certificates issued
by the consultants shall be submitted to the Commission before final
approval.
I) Before Backfill
a) Gravity Sewer:
i) Exfiltration Test (either low pressure air or water tests).
ii) Check for straightness, obstruction and grade.
b)
Force Main:
i) Exfiltration Test (when required).
ii) High pressure water test.
iii) High pressure leakage test (following high pressure water
test).
iv) Check for straightness, obstruction and grade.
c) Manhole and others:
i) Visual inspection.
ii) Watertightness test (when required).
For pipe or part that is made of material that will deteriorate under the
sun, the exposed parts of the pipe shall be shielded from direct exposure
to the sun during testing.
The concrete used for supporting the pipe or resisting thrust shall be
cured for at least seven days prior to testing.
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Sewer Testing
Gravity Sewer:
Before and after any test, the sewer pipeline to be tested shall be clean,
which shall be flushed clean when necessary. Any leaks or defects
identified from any test shall be located and repaired. After testing has
been completed, the cleaned sewer shall be plugged at open ends to
prevent dirt or soil from getting into the sewer.
4.2
An exfiltration test, which can be either a low pressure air test or a water
test shall be performed on the sewer before any concrete pipe encasement
or backfill. After backfilling, an exfiltration test is required again on the
sewer laid. In addition, an infiltration test shall be conducted if:
When infiltration has been confirmed by the infiltration test, light and
mirror method or CCTV may be used to isolate the locations of leaks.
If a CCTV inspection is conducted, a video and written record of the
CCTV inspection shall be provided to the Commission no later than 7
days after the inspection.
For gravity sewers, the sewer length to be tested shall be the length
between manholes or proposed manhole locations. The test length for
water test may be shorter where the gradient is so steep as to cause too
high a head at the downstream end. The pressure head on the sewer being
tested shall not be less than 2 m above pipe crown at the upstream end
and shall not be more than 7 m above pipe crown at the downstream
end.
When desired, the air and water tests may be undertaken on shorter
lengths of the laid sewer before backfill. This is to prevent any faulty
joint to go unnoticed until it is revealed by a test on the complete length,
which will be more costly and time consuming to rectify the defects.
Testing of shorter lengths may also be necessary where it is required to
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backfill the sewer to surface level quickly. This early backfill may be
encountered when there is wet weather, traffic crossings or site safety
requirements.
4.3
For pressure sewers, the normal tests during the sewer laying may include,
where required, the low pressure air or water exfiltration tests on short
individual sections. These low pressure air or water exfiltration test are
conducted, when required, to ensure that the joints are watertight.
For the high pressure water test, the test length will depend on:
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Sewer Testing
4.4
a)
b)
c)
d)
e)
f)
4.5
4.5.1
General
Low pressure air test is one of the two sewer exfiltration tests recommended
for sewer testing. The air test is quicker to conduct than the water test.
Furthermore, no large quantity of water needed to be disposed off after
the test. This test provides a quick mean for checking any damage pipe
or joints. Sometimes the test is conducted on a short length to prevent
damage pipe or joints from passing without noticed until the final sewer
test, which could be more costly and time consuming to rectify. However,
these tests on the shorter length should not replace the final test.
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4.5.2
a) Seal the open ends, including sideline ends, using approved plugs.
Strut the plugs to prevent movement. Provide temporary bracing
where necessary to prevent pipeline movement during testing.
(One of the end plugs will require a connection point to permit
injection of air).
b) Connect a hand or motorised pump to the pressure injection line
at the end plug. Pressurise the test length at a slow and constant
rate.
c) Use dial pressure gauges to measure pressure. Apply an air pressure
of:
i) 30 kPa for vitrified clay and reinforced concrete pipelines.
ii) 50 kPa for all other pipelines.
(Two gauges in series shall be used so that the accuracy of one
gauge can be confirmed by the other. The dial gauges shall be able
to be read to an accuracy of 0.1 kPa).
d) Wait five minutes for air pressure to stabilise due to temperature
absorption into pipe wall and other effects. Adjust the pressure to
the required test pressure during this period.
e) Check for leaks at plugs and test apparatus. Release the air pressure
where leakage occurs. Make necessary repairs and adjustments of
apparatus to prevent leakages. Repressurise the sewer pipeline in
accordance with the preceding steps again.
f) Start the test and record the pressure loss for the test duration after
the final gauge adjustment to the test pressure. Conduct the test for
the test duration given in Table 4.1.
Test Duration
(minutes)
2
4
6
8
11
14
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Sewer Testing
g) Pass the test if the pressure loss over the test duration does not
exceed:
4.5.3
I) Before Backfill
a) Readjust the pipe pressure to the specified test pressure and examine
for leakage by pouring a solution of soft soap and water over the
exposed joints if the test fail.
b) Repair leaks and repeat testing where leaks are found at joints.
c) Where leaks are not found at joints, move the plug, the one that is
not used to exert air pressure, along the pipeline to isolate lengths
with leakage. Uncover pipe barrels in the isolated lengths where
leakage in pipe barrels is suspected. Replace leaking pipe lengths
and repeat testing.
d) Conduct low pressure water testing to verify that the air test was
not erroneous where the test length fails the air test but no source
of leakage can be identified.
a) Move the plug up from the other end along the sewer pipeline to
isolate the lengths that fail the air test.
b) Exhume the failed length of pipeline and replace pipe lengths.
c) Repeat the air test.
d) Conduct water testing to check that the air test was not erroneous
when failed lengths could not be isolated using the air test.
e) Use CCTV, when required or available, to identify the leakage if
the fail section can not be isolated by the air test or water test.
4.6
4.6.1
General
The low pressure water test is commonly used for checking the watertightness of the joints and the integrity of the sewer pipes. Unlike the
high pressure water test, this test can not be used to check the mechanical
strength of the sewer pipe. Compared with low pressure air test, this test
requires more time to set up the test. Also, the water used for the test
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Procedure
a) Seal the open ends, including sideline ends, using approved plugs.
Strut the plugs to prevent movement. Provide temporary bracing
where necessary to prevent sewer movement during testing.
b) Establish appropriate arrangements involving a standpipe to apply
the water head at the upstream end.
Acceptable arrangements include:
i) temporarily fitting a 90 bend to the upstream end, which should
then be connected with a vertical riser of straight pipe to used
as a standpipe.
ii) sealing the upstream end with a plug which has a connection
point for a hose, which can be connected to a tube acting as a
standpipe.
d) Fill in water from the upstream end. Ensure water head is not less
than 2 m above pipe crown at the upstream end and not greater
than 7 m above pipe crown at the downstream end. Shorten the test
length if the sewer gradient is so steep as to cause these water head
requirements not to be met.
e) Fill the sewer slowly to the required head and bleed air from behind
the upstream plugs.
(Air may be released by slightly loosening the plug and pushing in
a piece of wire between the seal and the pipe.)
f) Maintain the water head for two hours. Top up the water as
required.
g) Check for leakage at the plugs and the test apparatus during the
pressurising period and the constant pressure holding period. Release
the water pressure if leakage occurs. Make the necessary repairs and
adjustments before repressurising again.
h) Commence the test immediately after the last adjustment of water
head in the preceding two hours period.
i) Add water to maintain the starting water head every 5 minutes
during the test period of 30 minutes. Record the total amount of
water required for readjustment.
j) Pass the water test if:
i) the loss of water does not exceed 1 litre per hour per linear
metre per metre internal diameter for vitrified clay and reinforced
concrete pipes.
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Sewer Testing
ii) there is no loss of water for pipe other than vitrified clay and
reinforced concrete pipe.
iii) these is no visible leakage at the joints for all pipe types.
4.6.3
I) Before Backfill
a) Readjust the internal water head to the specified test head if the
test section fails the water test. Examine visually for leakage at the
external surface of joints.
b) Uncover pipe barrels and inspect for leakage if leakage is not evident
at joints. Drain the water and move the downstream plug towards
upstream, where necessary, to isolate pipe lengths that fail the water
test.
c) Repair or replace pipes before repeating the low pressure water test
until the sewer passes the test.
a) Isolate pipe lengths that fail the water test by moving the downstream
plug towards the upstream end in sections when the test sewer fails
the water test. Alternatively, conduct a CCTV inspection, where
required, to identify the source of leakage if the source of leakage
can not be isolated.
b) Exhume failed pipe lengths and replace.
c) Repeat test until the sewer pipeline passes the test.
4.7
4.7.1
General
High pressure water test is normally used for testing the pressure sewers
and pipeworks within the pump station. The main aims of the test are
to ensure the mechanical stability of the pipe and joints can withstand
the working pressure. Since the test is conducted under high pressure,
the anchorage of the sewer is more critical than the low pressure tests.
Preferably, the test should be conducted before backfill. During the test,
the test pumps should not be subjected to hydrostatic pressure.
4.7.2
Procedure
a) Seal the sewer pipeline ends using test-end units consisting of short
lengths of pipe permanently fitted with caps or valves. Connected the
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b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
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Sewer Testing
l) Pass the pressure test if there is no reduction from the test pressure
in the next 10 minutes after the test pressure is conducted. Do not
reduce the pressure as the high pressure leakage test should be
conducted immediately after this.
4.8
4.8.1
General
High pressure leakage test normally follows the high pressure water test
immediately. This is to avoid any unnecessary pressurising and water
filling, which could take time and is costly. The purpose of this test
is to ensure the pipe and joint will remain intact under the pressure
environment.
4.8.2
Procedure
a) Conduct the test immediately after the high pressure water test.
Maintain the following test pressures (whichever is lower) for 24
hours by pumping in make-up water if necessary:
i) The maximum rated pressure of the pipes laid, or
ii) 1.5 times the design operating pressure of the pipeline (includes
surge allowance).
b) Measure the amount of make-up water pumped into the pipe to
maintain the test pressure.
c) Pass the test if the measured amount of make-up water does not
exceed 0.1 litre per millimetre of pipe diameter per kilometre of
pipe per day for each 3 bars of pressure applied.
d) Reset the test pressure and check all visible joints to locate leakage
when the test length fails the test.
4.9
a) Visual inspection
b) Insertion of mandrel
c) CCTV inspection
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a)
b)
c)
d)
e)
The first three methods will provide a more exact assurance for both
the gradient and straightness of sewers, which shall be used whenever
possible. The latter two methods will provide a rough idea on whether
the sewers are laid in certain gradient or straight, which should be used
only for a quick check.
4.10
CCTV Inspection
4.10.1
4.10.2
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Sewer Testing
a) Solid state colour CCTV camera with pan & rotate features, together
with a lighting unit, automatic date/ metre age.
b) A self powered tractor or crawler on which the camera is conveyed
along a pipeline under inspection in a stable manner.
c) Calibration chart for various sizes of sewer for the camera used.
d) Test device for the CCTV camera using Marconi Resolution Chart
No.1 or its derivative to demonstrate satisfactory performance of
the camera.
e) Test device for the monitor and video recorder to establish the
effectiveness and accuracy of the on-site monitor and video
recorder.
f) The control unit comprises the camera unit, crawler control and
screenwriter. This console can be mounted permanently in a vehicle
or use as portable system.
g) A video recorder for recording high quality video images.
h) A mean of producing still images from the monitor screen.
i) A PC-based site reporting system capable of producing reports
customised to the Contractors needs and to include photographs
captured directly from video.
For the diameter pipe greater than 600 mm, it shall have zooming
capabilities.
4.10.4
The following areas are identified as the minimum coverage for CCTV
inspection.
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A 100% CCTV inspection shall be conducted for sewers laid in the ground
with high risk of failure and having the following characteristics:
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Sewer Testing
4.10.5
a) The list of sewer segments and house connections selected for CCTV
inspection shall be recorded and the parties witnessing the selection
process shall duly sign the record.
b) Names and designations of all persons involved in the random selection
process as well as the time, date and place where the selection were
carried out shall be recorded in the report on the random selection
process. Record of the sewer segments randomly selected for CCTV
inspection shall be included as appendix in the report.
c) The random selection process shall be completed in a single
session.
110
a) The CCTV inspection shall be carried out 7 days after notice issued
by the Commission.
b) Inspection shall be carried out within 24 hours after random selection
has been completed.
c) Once started, CCTV inspection for a project shall be carried out
without any break. Should for any reason a break/delay of more than
24 hours become necessary, the random selection process shall be
repeated to select the remaining sewer segments for the inspection.
Reasons for the break/delay shall be recorded.
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v) Grade 5 : Red
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Sewer Testing
4.10.7
a) For Grade 1 and Grade 2, the developer shall rectify and make
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Sewer Testing
4.11
Infiltration Test
4.11.1
General
4.11.2
Procedure
a) Plug the inlets at all upstream open ends, after the groundwater level
4.11.3
4.12
Watertightness Test
4.12.1
General
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Sewer Testing
a)
b)
c)
d)
e)
The test should be carried out only after the structures have achieved
sufficient strength to withstand the test pressure. Where possible, the
test shall be carried out before backfilled or concrete surrounded.
For manhole less than 1.5 m in depth, the manhole shall be filled with
clean water to the bottom of cover. For manhole more than 1.5 m in
depth, the water head for the test shall not be less than 1.5 m or the
mean groundwater level, whichever is larger. For any other ancillary
structure, the water shall be filled to the top of the structure unless
otherwise specified by the authorised inspection person.
The procedures for testing the manhole are listed below. For other
ancillary structures, the procedures can still be adopted. However, the
height which the water level should be tested shall follow the instruction
from the authorised inspection person.
4.12.2
Procedures
d)
e)
f)
g)
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Appendix A
Appendix A
HINGE DEVICE
Y
16mm BOLT
HOLE
STAINLESS STEEL
BOLT AND NUT
10mm , 100mm
LONG
BAHAYA
RUANG TERKURUNG
DILARANG MASUK
A
MODEL NO.
AND THE
MARKING " EN 124
CLASS D400 "
DANGER
CONFINED SPACE
DO NOT ENTER
SERIAL NO.
LOCKING AND
LIFTING DEVICE
PLAN
TYPICAL DETAILS OF HEAVY DUTY
D.I. MANHOLE COVER AND FRAME
SECTION A - A
TYPICAL SECTION OF HEAVY DUTY
3mm 0.5
ALL CORNERS
TO BE ROUNDED OFF
SECTION Z - Z
DETAIL '1'
( TYPICAL SURFACE DETAIL )
10mm STAINLESS
STEEL BOLT
SECTION B - B
SECTION C - C
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Appendix A
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Appendix A
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Appendix A
>
Figure A
TypicalShallow
ShallowPrecast
PrecastConcrete
Concrete Manhole
Manhole with
Figure
A4
4 :Typical
with Backdrop
Backdrop
(Ground
Level
to
Invert
of
Pipe
1.2m
Depth
<
2.5m)
(Ground Level to Invert of Pipe 1.2 m Depth < 2.5 m)
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Appendix A
Figure
TypicalMedium
MediumPrecast
PrecastConcrete
ConcreteManhole
Manhole
Figure A
A 55 :Typical
(Ground
Level
to
Invert
of
Pipe
2.5m
Depth
(Ground Level to Invert of Pipe 2.5 m Depth << 55m)
m)
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Appendix A
>
FigureAA66 Typical
: TypicalMedium
MediumPrecast
PrecastConcrete
Concrete Manhole
Manhole with Backdrop
Figure
backdrop
(Ground
Level
to
Invert
of
Pipe
2.5m
Depth
<
5m)
(Ground Level to Invert of Pipe 2.5 m Depth < 5 m)
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Appendix A
FigureAA77Typical
: Typical
Deep
Precast
ConcreteManhole
Manhole
Figure
Deep
Precast
Concrete
(Ground
Level
to
Invert
of
Pipe
5m
Depth
(Ground Level to Invert of Pipe 5 m Depth 99m)
m)
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125
Appendix A
>
Figure A8
A 8Typical
: TypicalDeep
DeepPrecast
PrecastConcrete
ConcreteManhole
Manhole with
with Backdrop
Backdrop
Figure
(Ground
Level
to
Invert
of
Pipe
5m
Depth
9m)
(Ground Level to Invert of Pipe 5 m Depth 9 m)
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Appendix A
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127
Appendix A
Induct Vent
Centreline of manhole
150 Min.
750 Min.
150 Min.
Column Support
Notes :
1. All dimmensions are in millimetres.
2. Diameter of induct vent shall be approximately 1/2
of the forcemain but shall not exceed 300mm.
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Appendix A
VARIES
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Appendix A
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Appendix A
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Appendix A
Figure A 14a
14(a): Typical
: TypicalDetails
Details
Force
Main
Scour
Valve
and
Receiving
forfor
Force
Main
Scour
Valve
and
Receiving
Manhole
Manhole
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Appendix A
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Appendix A
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Appendix A
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Appendix A
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Appendix A
crossover pipe
vacuum sewer
collection chamber
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incoming sewer
mains
washdown sump
service platform
Volume 3
up
sight glass
service platform
discharge
pumps
non-return valve
force main
chart recorder
PLAN
handrail
vacuum pumps
moisture trap
control panel /
telemetry system
vacuum gauges
fuel tank
standby diesel
generator
AMF board
fire-fighting system
toilet
biofilter
Appendix A
139
bypass
connection
140
Volume 3
discharge
pumps
vacuum vessel
moisture trap
drainage pipe
moisture trap
ELEVATION
vacuum pump
cast in-situ
plinth
ABS pipework to
vacuum pumps
biofilter media
Appendix A
Malaysian Sewerage
Industry Guidelines
Appendix A
breather pipe
breather pipe
interface
valve
valve controller
chamber ring
interface
valve
to vacuum sewer
landing slab
chamber ring
to vacuum sewer
landing slab
gravity lateral swer
150mm thick
concrete surround
gravity lateral
sewer
sensor pipe
suction pipe
sensor pipe
chamber ring
with base and
conical
benching
suction pipe
150mm thick
concrete surround
landing slab
float
150mm thick
concrete surround
chamber ring
with base and
conical
benching
suction pipe
Volume 3
141
Appendix A
A
landing slab
150mm thick
concrete surround
Plan
150mm thick
concrete surround
Section A - A
142
Volume 3
Malaysian Sewerage
Industry Guidelines
Appendix A
300mm
150m
flow
100-200mm
150m
flow
15m
10m
15m
100-200mm
10m
10m
flow
L/2
L/2
L/2
L/2
L
flow
0.2% min.
slope
6m min.
flow
0 .2
%m
Volume 3
in . s
lo p e
143
Appendix A
Figure
: Y-Branch
for
Vacuum
Sewer
Figure
AA
2323
: Y-Branch
for
Vacuum
Sewer
Direction
of flow
Direction
of flow
branch
branch
60 60
vertical
angle
vertical
angle
flow
flow
Figure
: Method
Joining
Crossover
Pipes
and
Branch
Sewers
Figure
AA
2424
: Method
ofof
Joining
Crossover
Pipes
and
Branch
Sewers
toto
Vacuum
Mains
Vacuum
Mains
45 elbow
45 elbow
45 elbow
45 elbow
45 elbow
45 elbow
vacuum
vacuum
mainmain
flow flow
flow flow
Plan
Plan
crossover
/
crossover
pipe pipe
/
branch
sewer
branch
sewer
flow flow
flow flow
flow flow
vacuum
vacuum
mainmain
Elevation
Elevation
45fitting
`Y' fitting
45 `Y'
be fabricated)
(may(may
be fabricated)
min. cover
900mm
min. cover
900mm
ground
ground
levellevel
flow flow
flow flow
60 max
60 max
End
View
End
View
144
Volume 3
Malaysian Sewerage
Industry Guidelines
Appendix A
OVERFLOW CHAMBER
DRAIN
RAMP DOWN
WP
FORCEMAIN
MECHANICAL COARSE SCREEN
GATE VALVE.
INCOMING SEWER
AIR EXTRACTOR FAN
14 15 16 17 18 19 20 21
3 LAYER CONC.
VENTILATION BLOCK
AT TOP AND BOTTOM
LEVEL
CHECK VALVE.
12
11
10
9
8
7
6
5
4
3
2
1
EXTRACTOR FAN
R.C STAIRCASE TO ENGR'S DETAIL.
CONCRETE VENTILATION
BLOCK AT TOP AND BOTTOM LEVEL
DN
CHAIN GUARD.
DN
13 12 11 10 9 8 7 6 5 4 3 2 1
13
14
15
16
17
18
19
20
21
22
23
ADJUSTABLE GLASS
LOUVRES WINDOW
SPOT LIGHT
CHEQUER PLATE
DOOR
PLAN VIEW
COPPER TYPE
LIGHTNING ARRESTOR
PENSTOCK
HANDRAIL
DOOR
BRICKWALL C/W
CEMENT PLASTER ON BOTH SIDES
WINDOW
CHEQUER PLATE
HANDRAIL
R.C STAIRCASE TO ENGR'S DETAIL
WET WELL
DRY WELL
PERFORATED SLAB
CAT LADDER
OPENINGS
INCOMING SEWER
(FLOAT SWITCH)
CHECK VALVE
GATE VALVE
ALARM
1st. STANDBY PUMP START
STOP LOG
SUMP BWL
DEWATERING PUMP
SECTION VIEW
Volume 3
145
Appendix A
146
Volume 3
Malaysian Sewerage
Industry Guidelines
Appendix A
Volume 3
147
Appendix A
148
Volume 3
Malaysian Sewerage
Industry Guidelines
Appendix A
Symbols
PI PE
BUILDING (WOODEN OR
BUILDING
(MASONRY)
DN 375 R.C.P
DIRECTION OF
DN 375 R.C.P
1:80
1:72
SEW ER
GATE
POND
P ON
FIRE
PAVED
RAIL
ROAD
CULVER
BRIDGE
PAVED CHANNEL AND FLOW
EXIST ING MANHOLE AND SEWER IN
PROFILE
UNPAVED SIDE
SLOPES
CHAINLINK
FENCE
UT ILIT Y
GAS
T ELEPHONE
POLE
ELECT RIC
STREET
T ELEPHONE CONDUIT
(GENERALLY 1.5m DEEP)
LIGHT SIDE
P OLE SIDE
SEPT IC
T ANK
ST
BOREHOL
Abbreviations
A.C.P.
C.I.
CH.
CL.
CONC.
CRS
D.I.
DIA.()
D.M.H.
DN.
DRG.
EXIST.
GD.
GR.
H.A.
HORZ
I.D.
INV.
JLN.
KG.
LRG.
LT
MAX.
M.H.
MIN.
MOD.
NO.
ASBESTOS CEMENT
CAST
CHAINAG
CLASS
CONCRET
CENTRE
DUCTILE
DIAMETE
DROP
NOMINAL
DRAWIN
EXISTIN
GROUND
GRADE
HIGH
HORIZONTA
INSIDE
INVER
JALAN
KAMPUN
LORON
LEFT
MAXIMU
MANHOL
MINIMU
MODIFIE
NUMBE
N.T.S.
O.D.
R.C.
R.C.P
RET.
RT
S
SG.
SHT.
SPEC
STD.
SCW.
STL.
STA.
TYP.
VAR.
VERT.
V.C.P
HDPE
Volume 3
NOT TO
OUTSIDE
REINFORCED
REINFORCED CONCRETE
RETICULATION
RIGHT
SLOPE
STREAM OR
SHEET
SPECIFICATIO
STANDAR
STANDARD CUT-OUT
STEEL
STATIO
TYPICA
VARIE
VERTICA
VITRIFIED CLAY
HIGH DENSITY
149
Appendix B
Appendix B
Appendix B
CLAY PIPE
TABLE B.1
CLASSES OF RIGID PIPE REQUIRED FOR VARIOUS DEPTH
Table B1
Volume 3
Volume 3
Page 127
153
Appendix C
Appendix C
Appendix C
Appendix C 1
Contractor :
Project-Information
Project Name :
Client
Contact
Position
Road
Town
State
Telephone
Fax
Mobile
E- Mail
Site
Contact
Position
Road
Town
State
Telephone
Fax
Mobile
E-Mail
Contractor
Contact
Position
Road
Town
State
Telephone
Fax
Mobile
E-Mail
Project Number :
Contact :
Date :
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Volume 3
Volume 3
157
Page 129
Appendix C
Appendix C
Appendix C 2
Contractor :
Inspection Report
Date:
Job nr:
Weather
Operator
Section Number
PLR:
Present:
Vehicle:
Camera:
Preset:
Cleaned:
Grade:
Road:
Division:
Start MH:
Place:
District:
End MH:
Location:
Tape No.:
Total Length:
Purpose:
Size/Shape:
Use:
Material:
Catchment:
Lining:
Category:
Comment:
Location details:
Slope
Position Code
Observation
Counter
Photo
Grade
MH
No.
130
158
Volume33
Volume
Malaysian Sewerage
Industry
Industry Guidelines
Guidelines
Appendix C
Appendix C
Appendix C 3
Contractor :
Inspection Photos
Town :
Road :
Date :
Volume 3
Volume 3
Section Nmber :
PLR :
159
Page 131
160132
End MH
(mm)
Pipe Dia.
Material
Pipe
Length (M)
Seeping
Dripping
Infiltration
Running
Volume
3 3
Volume
Date Of Report :
Prepared By :
Prepared By :
Wide
Joints
Fractures
Cracks or
Others
When more than one defect is recorded at the same chainage, the most severe defect is counted.
Start MH
To MH :
Comments
Date
Total
Section
Appendix C 4
N.B :
Item
From MH :
Appendix C
Appendix C
Malaysian
Sewerage
Malaysian
Sewerage
Industry
Guidelines
Industry
Guidelines
Appendix C
Appendix C
Appendix C 5
Start MH
To MH :
Finish MH
Position
(M)
Code
Description
Volume 3
Volume 3
Grade
161
Page 133
162
5.31
5.31
5.31
5.32
5.62
SURFACE
DAMAGE
Missing Wall
Mechanical
Chemical Attack
Not Evident
POINT REPAIR
Pipe Replaced
Defective
Patch Repair
Not Evident
SRIM
SRIC
SRIZ
SMV
SMWM
SMWC
SMWZ
RP
RPR
RPRD
RPP
SMWZ
Volume 3
134
SRI
5.62
5.62
5.62
5.32
5.30
5.31
5.31
5.32
5.30
5.30
SURFACE
DAMAGE
Roughness
Increased
Mechanical
Chemical Attack
Not Evident
5.1
5.2
5.2
5.2
5.2
CRACK
Longitudinal
Circumferential
Multiple
Spiral
C
CL
CC
CM
CS
SURFACE
DAMAGE
Surface Spalling
Mechanical
Chemical Attack
Not Evident
SURFACE
DAMAGE
Aggregate Visible
Mechanical
Chemical Attack
Not Evident
FRACTURE
Longitudinal
Circumferential
Multiple
Spiral
RP POINT REPAIR
(continues)
RPL Localized Pipeliner
RPLD Defective
RPZ Other
SSS
SSSM
SSSC
SSSZ
SAV
SAVM
SAVC
SAVZ
F
FL
FC
FM
FS
5.62
5.62
5.62
5.62
5.31
5.31
5.31
5.32
5.30
5.30
5.31
5.31
5.32
5.30
5.7
5.7
5.7
5.7
5.7
SZ
SZM
SZC
SZZ
SAPM
SAPC
SAPZ
SAP
SURFACE
DAMAGE
Other
Mechanical
Chemical Attack
Not Evident
SURFACE
DAMAGE
Aggregate
Projecting
Mechanical
Chemical Attack
Not Evident
B BROKEN
BSV Soil Visible Beyond
Defect
BVV Vold Visible Beyond
Defect
5.31
5.31
5.31
5.32
5.30
5.31
5.31
5.32
5.30
5.30
5.14
5.14
5.14
SURFACE
DAMAGE
5.31
5.31
5.30
5.31
5.31
5.32
5.30
5.30
5.16
5.16
5.16
LFD
LFDE
LFB
LFCS
LFAC
LF
SRVM
SRVC
SRVZ
SRV
DH
D
DV
Detached Lining
Defective End
Blistered Lining
Service Cut Shifted
Abandoned
Connection
LINING FAILURE
SURFACE
DAMAGE
Reinforcement
Visible
Mechanical
Chemical Attack
Not Evident
DEFORMED
Deformed Vertically
(brick)
Deformed
Horizontally (brick)
Modules
Volume 3
SURFACE
DAMAGE
Aggregate
Missing
Mechanical
Chemical Attack
Not Evident
SCP Corrosion
(metal pipe)
SAMM
SAMC
SAMZ
SAM
H HOLE
HSV Soil Visible Beyond
Defect
HSV Vold Visible Beyond
Defect
Appendix C 6
5.44
5.44
5.44
5.44
5.44
5.44
5.31
5.31
5.32
5.30
5.30
5.18
5.18
5.18
LINING FAILURE
(continue)
Overcut Service
Undercut Service
Buokled Lining
Wrinkled Lining
SURFACE
DAMAGE
Reinforcement
Projecting
Mechanical
Chemical Attack
Not Evident
LFZ Other
LFOC
LFUC
LFBK
LFW
LF
SRPM
SRPC
SRPZ
SRP
COLLAPSE
Pipe Collapse
Brick Collapse
X
XP
XB
5.22
5.44
5.44
5.44
5.44
5.44
5.44
5.31
5.31
5.32
5.30
5.30
5.22
5.22
SURFACE DAMAGE
JOINT
Joint Offset (Displaced)
Joint Separated (Open)
Joint Angular
Longitudinal
Circumferental
Multiple
Spiral
5.56
5.56
5.56
5.56
5.56
5.56
5.31
5.31
5.32
5.30
5.30
5.25
5.25
5.25
5.25
Malaysian Sewerage
WFZ Unidentified
WFL
WFG
WFM
WFS
WF WELD FAILURE
SAPM Mechanical
SAPC Chemical Attack
SAPZ Not Evident
J
JO
JS
JA
Appendix C
Appendix C
Malaysian Sewerage
Industry Guidelines
INFILITRATION
Weeper
Dripper
Runner
Gusher
DEPOSIT
Attached
Encrustation
Grease
Ragging
Other
6.13
6.13
6.13
6.13
6.13
6.1
6.1
6.2
6.2
6.2
6.2
OBSTACLES/
Obstructions
Brick or Masonry
DEPOSIT (continue)
Settled
Fine
Gravel
Hard/Compacted
Other
Volume 3
ACCESSPOINT
Manhole
Wastewater Access
Discharge Point
Tee Connection
TFA
TFC
TFD
TFL
A
AMH
AWA
ADP
ATC
TAP (continue)
Break in/Hammer
(connection)
Intruding
Active
Capped
Defective
Leaking
ACCESSPOINT
(continue)
AOC Other Special
Chamber
AM Meter
AWW Wet Well
AJB Junction Box
TBI
TBA
TBC
TBD
TFL
7.2
7.2
7.2
7.2
7.13
7.13
7.13
7.13
7.13
T
TB
7.1
7.1
ACCESSPOINT
Cmaera Underwater
General Observation
General Photograph
8.1
8.1
8.1
8.1
MJL
MSC
MISC.FEATURES
(continue)
Shape/Size Change
(Sewer Dims/
Vertical/Horizontal)
Pipe Joint Length
M
MCU
MGO
MGP
TAP
Factory Made
(junction)
Active
Capped
Defective
Leaking
T
TF
6.19
6.19
6.1
6.2
6.2
6.2
6.2
8.1
8.1
8.1
MLC
MMC
MSA
MWL
ACO
ACOM
ACOP
ACOH
7.14
7.14
7.14
7.14
TSI
TSA
TSC
TSD
TSL
T
TS
MISC.FEATURES
(continue)
Lining Change
Material Change
Survey Abandoned
Water Level
ACCESSPOINT
(continue)
Clean Out
Machine
Property
House
TAP (continue)
Saddle
(connection)
Intruding
Active
Capped
Defective
Leaking
OBSTACLES/
Obstructions (cont)
OBI Object protruding
through wall
OBI Object wedged
in joint
OB
D DEPOSIT (continue)
DN Ingress
DNF Fine Material
(silt & sand)
DNGV Gravel
DNZ Other
7.13
7.1
7.2
7.2
7.2
7.2
7.2
7.2
7.2
OBB
OB
D
DS
DSF
DSG
DSC
DSZ
I
IW
ID
IR
IG
D
DA
DAE
DAGS
DAR
DAZ
8.10
8.10
8.20
8.2
8.1
7.14
7.14
7.14
7.14
7.13
7.10
7.2
7.2
7.2
7.2
7.2
7.2
7.2
6.19
6.19
6.19
6.3
6.3
6.1
6.1
6.3
ROOTS
Fine
Barrel
Lateral
Connection
ACCESSPOINT
(continue)
8.2
8.2
8.2
8.2
8.1
7.14
7.14
7.13
7.8
7.8
7.8
7.8
Volume 3
MISC.FEATURES
(continue)
MWM Water Mark
MY Dye Test
MYV Dye Visible
MYN Not Visible
IS INTRUDING
SEAL MATERIAL
ISSR Sealing Ring
ISSRH Hanging
ISSRB Broken
6.19
6.19
6.19
6.7
6.7
6.7
6.7
6.7
OBSTACLES/
Obstructions (cont)
Built into structure
Construction Debris
Rocks
Other
ROOTS (continue)
Tap
Barrel
Lateral
Connection
IS INTRUDING
SEAL MATERIAL
ISGT Grout
ISZ Other
OBS
OBN
OBR
OBZ
OB
R
RT
RTB
RTL
RTC
Modules (Cont)
OBSTACLES/
Obstructions (cont)
OBC Object through
connection/juriction
OBP External Pipe Cable
OB
R
RF
RFB
RFL
RFC
Appendix C 6
7.8
7.8
7.8
6.19
6.19
6.20
6.20
6.20
6.7
6.7
6.7
6.7
6.7
LL
LLLU
LLD
LR
VR
VC
VZ
R
RM
RMB
RML
RMC
Left
Left & Up
Left & Down
Left & Right
(of sewer)
LINE
Rat
Cockroach
Other
VERMIN
ROOTS (continue)
Medium
Barrel
Lateral
Connection
7.11
7.11
7.11
7.11
7.11
6.31
6.31
6.31
6.31
6.7
6.7
6.7
6.7
6.7
ROOTS (continue)
Ball
Barrel
Lateral
Connection
Page 135
LINE
(of sewer)
(continue)
LRU Right & Up
LRD Right & Down
LU Up
LD Down
R
RB
RBB
RBL
RBC
Appendix C
Appendix C
163
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