RIICPL303D

Install sewer pipelines

Student Learning Resource

Student Name ______________________________________________________________

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 Student Information
Purpose:
The purpose of this learning package is to help you understand the technical and theoretical
knowledge and associated skills of your selected trade area. This package contains a number
of learning and associated documents for this unit of competency. Please read all parts of this
package to ensure that you complete and manage the process correctly. These assessment
tools address the mandatory requirements of the unit of competency including, evidence
requirements, range statements and the required skills and knowledge to achieve the learning
outcomes indicated in the document. Performance criteria are described below. The contents
of this unit will contain some or all of the following as required:

ELEMENT PERFORMANCE CRITERIA

1.Plan and 1.1 Access, interpret and apply sewer pipelines documentation and ensure the work activity
prepare for is compliant
installing
1.2 Obtain, interpret, clarify and confirm work/plans/specifications requirements
sewer
pipelines 1.3 Identify, obtain and implement traffic signage
1.4 Select, and check for faults, equipment/tools for work activities
1.5 Identify, confirm and apply environmental protection requirements
1.6 Select and wear correct personal protective equipment appropriate for work activities
1.7 Identify, address and report potential hazards and risks
1.8 Obtain and interpret emergency procedures, and be prepared for fire / accident /
emergency

2.Set out and 2.1 Prepare work area and materials

excavate 2.2 Determine and apply dewatering requirements
2.3 Determine location, alignment direction, level and grade of sewer pipeline
2.4 Set out works to specification
2.5 Advise plant operator of excavation requirements and monitor levels
2.6 Install sewer pipeline bedding

3.Install sewer 3.1 Lower pipes and place in position

pipeline 3.2 Join pipes
3.3 Place pipes and fit valves, fittings and flow control devices
3.4 Continually check alignment level and grade
3.5 Position side support and/or overlay beside the pipes
3.6 Check sewer pipeline system support structure
3.7 Monitor backfill procedure and ensure work is completed to requirements
3.8 Construct manholes, inspection and valve chambers, minor structures and thrust blocks

4.Test sewer 4.1 Perform sewer system test procedures establishing functionality and serviceability
pipeline 4.2 Record in writing and report test results

5.Clean up 5.1 Clear work area and dispose of or recycle materials

5.2 Clean, check, maintain and store plant, tools and equipment

UNIT DESCRIPTOR
RIICPL303D Install sewer pipelines - This unit of competency specifies the outcomes
required to construct multi-thickness walls and piers for different types and styles of buildings.
It includes planning, preparation, set out and construction of walls and piers.

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 ASSESSMENT
Overall Assessment Requirements
The instructional outcomes required at the completion of this training are satisfactory for each
form of evidence resulting in competent. If you do not achieve the required outcomes of
competent, for this assessment you will be required to re sit a supplementary examination within
a reasonable time of the original examination date.
To achieve successful completion of this unit you should achieve a minimum of 3 forms of
assessment. Below are some of the forms of evidence that can be used.
1. Written Assessment
2. Third party reports (usually by your employer or supervisor)
3. Workshop/ On Site Activity (generally referred to as “Practical Assessment”)
4. Logbook Evidence (a record of the tasks you carry out for each unit)
Theory Examination
During the period of this learning you will be required to complete a written theory examination to
establish the level of understanding of technical content.
Self Checks
Self-checks are to be completed on pages provided when requested by your trainer. These
exercises are used mainly as a learning tool; they may form part of your overall assessment if
deemed necessary by your Trainer.
Verbal Questions
Verbal questions may be used and recorded to establish your level of knowledge of the
competencies of this learning package.
Practical Observation / Assessment
Practical may be assessed in either of the following formats: -
Practical observations will be undertaken in the workplace. Where the assessor observes the
student completing a task in the workplace the observation will be recorded in the observation
checklist.
Where a student is not able to undertake an activity in the workplace a simulated practical activity
will be setup by the assessor. (Refer to the practical exercises outlined in this Student Learning
Resource.) The observation checklist will be used to record the student’s performances.
Where a student undertakes an activity in the workplace and the trainer is not able to be present
the employer / supervisor will confirm the activity on the Third Party Report. The student and
employer / supervisor will provide photographic evidence of the activity with an explanation of the
task undertaken.
The assessor will contact the student by phone or face to face to question the student about the
activity to confirm the students understanding and skills. The outcome of this contact will be
recorded in the Practical Assessment.

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 Log Book or Training Record Book
It is the responsibility and requirement for the learner to complete the training record based on
the on-the-job and structured training tasks received by the employer or Supervising Registered
Training Organisation (SRTO) or as indicated in the training plan, which may be produced to the
employer and SRTO at reasonable intervals of not more than 3 months. Log Book evidence from
your employer and other forms of evidence relating to this unit of competency will contribute to
the outcome of this learning package. If the required activity is not part of your employer’s scope
of activity you will be required to complete the skill learning process within a simulated
environment. Logbook evidence must reflect the “Elements” shown for this unit.
Results
A statement of Attainment may be printed for this unit if required, but in general your achievement
of this unit will be recorded and presented to you on completion of the entire qualification. Your
certificate will record all the units you have completed.
RPL and Acceleration
Recognition of prior learning is available to all students. This provides an opportunity for being
credited for previous learning. Acceleration provides an opportunity to reduce the allocated
learning hours for this unit of competency. There is a separate RPL kit for this process.
Methodology
This unit may be provided as a separate learning instruction or provided with other units of
competency in a practical or theoretical learning experience.
Due care
Every care has been taken to ensure that the information in this learning guide is correct, but trainers
are advised to check the currency and the relevance of the content to their own training package.
Copyright protects this publication. Except for purpose permitted by the Copyright Act 1968,
reproduction, adaptation, electronic storage and communication to the public is prohibited without
prior written permission.
Pre-requisites
Pre-requisite units: CPCCOHS2001A Apply OHS requirements, policies and procedures in the
construction industry
Feedback to the learner
The trainer will provide feedback to the learner on the progress of assessment
This learning package is intended for use by those completing the Competency Unit –
RIICPL303D Install sewer pipelines as part of Basic Stream Skills within the Civil
Construction Skills Stream of the National Competency Framework.

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 HISTORY OF PIPELAYING
Mohenjo-Daro, a town of 35,000 in the Indus River Valley (southern Pakistan), is considered by
many historians to be the birthplace of sewers. Beginning around 3500 BC, drains made of cut
stone or man-made masonry units, initially open topped but later covered, were developed and
became the prototype of many surface drains used throughout the ancient world – the
forerunners of pipe. The birth of pipe occurred at about the same time in Babylon (Iraq) – sun-
cured (and later baked) terra cotta pipe made on wooden mandrels, with bell and spigot joints.

The idea of sewers and pipes spread far and wide over the next few thousand years – into Asia,
the Middle East and Europe. The Roman Empire particularly had an extensive system of cut-
stone sewers and developed the use of circular lead pipes for water. Their overuse of lead is
thought to have contributed to their shortened life expectancies.

Knee and t-joints made about 4000 B.C. Found in the excavation
of the Temple of Bel at Nippur, Babylonia. Pipe was made of
baked clay. Babylonia is often referred to as the birthplace of pipe.

Pithoi in the ruined town of Knossos, Crete. Items including oak

and olive oil (first and second in importance) were stored in these
vessels for the trade with Egypt.
The stone slabs of the floor are partially removed to show part of
the extensive sewage canal system underneath the whole
settlement. Knossos was probably the first European settlement
with a well-organised water system for incoming clean water,
regular wastewater disposal (ending up in the gardens outside the
settlement) & storm sewage canals for the times of heavy rain.
Knossos was also the first place in Europe where "flush" toilets
actually functioned (although the "flush" seems to have come from
buckets of water).

A huge collection of Roman-era clay water supply pipes in a

museum in Pafos, Cyprus.

Water pipe made of lead in the ancient Roman city of

Herculaneum, Italy.

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 Lead pipe in Roman bath in Aquae Sulis (Bath) 300BC.

Cast iron pipe laid in Clermont-Ferrand, France, to bring water

overland to the Gardens of Versailles, 1748-49. Still in service in
1914.

This clay pipe, made circa 1800, was used to convey water
around the site of Mission San Luis Rey (located in modern-day
Oceanside, California). The pipe stayed in active service
delivering water until 1957.

Bored log pipes laid in Pennsylvania before 1820. Hollowed-out

logs were often used for water and sewage conveyance in early
times in the U.S. The raw material (wood) was readily available
and the 3' - 4' lengths could be hollowed out by hand augering or
burning.

Bored elm pipes from the Abbey Mills Pumping Station, England.
The use of bored elm pipes underground with quills of lead
running off into the houses of the well-to-do seems to have begun
in London as early as the 13th century.
All the old London water companies that appeared between the
16th and 18th century used bored elm pipes for distributing
water. - Text from information display at the pumping station (see
photo).

Bored hemlock (wood log) water pipe, laid about 1754. Early
wood log pipe was used often for either water or sewage
conveyance.

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 The Dark and Middle Ages saw a drastic decline in sanitation. Though cast iron pipe was used
as early as the 1600s in France, generally pipes were crudely made in this period. After several
plagues swept across Europe, Paris was one of the first cities to set about creating a
comprehensive sewer system. From the 1860s to the 1890s, the Parisians built a sewer under
almost every street – nearly 400 km in all. Their sewers incorporated many new ideas: low flow
channels; sidewalks for sewer men; unique devices to clean the sewers, including boats; and
the placement of other utility mains inside sewers.
Horrific sanitation conditions in London led to construction of a new sewer system in the 1860s.
Egg-shaped sewers and “separate” sewers (no storm water) were developed in England. The
new concepts spread rapidly throughout Europe. Typically, large sewers were built of brick or
cut stone, the smaller ones of clay, cast iron or wood.
In the United States, cholera and other diseases became a problem after the Civil War, and the
first generation of American civil engineers looked to England and Europe for solutions. The first
new separate sanitary sewer system was in Memphis, Tennessee, initially using 6” ID clay pipe
(no manholes), and later 8” ID (with manholes). Clay became the dominant pipe material for a
time across the U.S., and clay pipe factories rose throughout the United States. Many other
materials were in use as well, including wood, cast iron and concrete. In the early 1900s, the
patented Parmley System promoted the approach of assembling segmental blocks in the
trench. It proved strong but susceptible to failure of whole sections.
The availability of wood and the re-training of carpenters/furniture makers, etc., facilitated the
use of wood for water and sewer pipe, though sewage and wood did not work well together
because of the adverse effects of the sulfides and sulfuric acid common to sewage. The
simplest wood pipes were hollowed-out logs. Others were made with planking, often wound with
steel wire for strength.
The basic design of sewers has not changed substantially since the mid-to-late 1800’s, but
many pipe materials have been added to the early choices. The first U.S. cast iron foundry
appeared in New Jersey in the early 1800s, and Philadelphia was the first U.S. city to use cast
iron exclusively for a time. Steel was sometimes used but was less common due to its cost. Clay
brick (salt glazed and, later vitrified) was widely used and is still in beneficial service in sewers
throughout the US.

Today
Pipe laying is the process by which long sections of pipe are installed and aligned so that they
can be welded, glued or simply pushed together. Pipelines may be put in above ground, below
ground, and even under water. This process is typically performed by professional construction
workers who are specifically trained to lay pipes such as yourself.
Many industries use pipelines as a means of transporting various materials, such as oil, water,
natural gas, and city sewage. Oil companies use vast amounts of pipeline to carry crude oil up
from the original well source and into storage containers. These sections of pipe must withstand
weather stress and significant amounts of pressure, as they are often located kilometres
beneath the ground or ocean.
In-ground pipes are usually installed in rectangular trenches. The width and depth of the trench
will often depend on the size of the pipe. Pipes are chosen based on the substance they will
carry and may be made of steel or iron, vitrified clay, plastics such as PVC (polyvinylchloride)
and other new materials such as Kevlar.
Once the pipe is placed in the trench, it is often covered with a certain amount of backfill
material such as sand to protect the pipe. The trench may be filled in layers compacting as you
go or the pipe may be covered entirely depending on the specifications for fill. Loose topsoil,
sand, gravel, and fine stone may also comprise the backfill mixture used to cover the pipe.

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 1. PLAN AND PREPARE WORK
You should determine the job requirements from plans and specifications. Based on
these documents planning for the project can be made.
Tools and Equipment
! Square nose shovel (long or short handle);
! Posthole shovel;
! Spade;
! Pick;
! Mattock;
! Crowbar;
! Hand operated or mechanical auger;
! Pegs, string line and hammer;
! Line sighters;
! Tape measure;
! Wheelbarrow (if necessary); and
! Excavator/trench digger.
Personal Safety Equipment
! Long sleeved shirt and long trousers;
! Visibility vest;
! Hard hat;
! Safety boots;
! Gloves;
! Safety glasses; and
! Sunscreen (in warmer months).
Safety Barricades and Signage
Safety barricades and signage are to be erected when personnel and equipment are at risk. It is
important to consult with relevant workplace personnel/OH&S officers, before commencing work
on sites. So that the rules and procedures are in line with the obligations and duty of care of
every person in the workplace.

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 tion site. To ensure your personal safety and the safety or your workmates, you should ensure that
you become familiar with, and understand the following information.

WORK HAZARDS
Pipe laying is a common activity in the civil construction and building industries. However, even
though it is a well practised activity, there are a number of hazards that can be present. The exact
nature of the hazards may vary from site to site, so it is important to asses each new task that you are
about to undertake for hazards. If a hazard is identified you should take steps to remove it, or adjust
your operations to neutralise its effects. Some of the more common hazards that you are likely to
encounter on site are listed below.

•
trench collapse
•
open trenches
•
falling objects
•
confined spaces within the trench where exhaust
fumes or fumes from existing pipelines and
manholes may be present
• overhead powerlines
• slip/trip hazards
• hazardous substances
• laser radiation
• unidentified services
• mobile machinery
• suspended loads
• power tools
• pinch points
• manual handling
Topic One — Overview and Safety Page 1.6
• welding

TRENCH COLLAPSE

Trenches collapse for a number of reasons as follows:

• The depth of the trench - deep trenches

are more susceptible to collapse than
shallow trenches

• Ground condition - wet, loose or

Performance Training Pty Limited Lay Pipes
J/N 2295
fractured ground ismore susceptible to Version — 1.0
collapse than dry consolidated ground.

• Vibrations - vibrations from machinery

such as bulldozers, compactors, etc, or
shock waves if explosives are being used
to fracture hard rock can cause weak areas
of the trench to collapse.

• Loading - excessive loads close to the trench

can cause the wall to collapse. Heavy machinery
and spoils should not encroach closer than 1.5 metres
to the trench wall.

Trench collapse represents a significant risk to personnel. In order to reduce this risk, trench sup-
port is installed where there is a danger of collapse, or if the trench is deeper than 1.5 metres.
Detailed information with respect to trench support is provided later in this program.

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OPEN TRENCHES
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 Detailed information with respect to trench support is provided later in this program.

OPEN TRENCHES

Open trenches are a safety hazard for the unwary. Steps must be taken to prevent vehicles, workers
or the public falling into an open trench. Preventative measures such as the following should be
used as appropriate:

• warning signs
• barricades
• sentries
• planning and placement of access ways.
Topic One — Overview and Safety Page 1.7
Topic
The riskOne — Overview
of open and
trenches can alsoSafety Page
be reduced by ensuring that only a small 1.7 of the trench is
section
open at any one time.
FALLING OBJECTS
FALLING OBJECTS
Essentially there are two areas where falling objects represent a danger to personnel. These are from:
Essentially there are two areas where falling objects represent a danger to personnel. These are from:
• suspended loads
•• suspended loads level falling into a trench.
objects at ground
• objects at ground level falling into a trench.

Performance Training Pty Limited Lay Pipes

Suspended
J/N 2295 Loads Version — 1.0
Suspended Loads
The following points identify important safety considerations with respect to suspended loads:
The following points identify important safety considerations with respect to suspended loads:
• Do not stand under a suspended load.
• Do not stand under a suspended load.
• Do not transfer a suspended load above other personnel.
• Do not transfer a suspended load above other personnel.
• Use only certified lifting equipment.
• Use only certified lifting equipment.
• Only appropriately qualified operators may operate lifting
• Only appropriately qualified operators may operate lifting
machinery.
machinery.
• Unauthorised persons must be kept clear of the work area.
• Unauthorised persons must be kept clear of the work area.
• A Dogger may be required to supervise on some slinging
• A
andDogger
lifting may be required to supervise on some slinging
operations.
and lifting operations.
• Wear a safety helmet. Safety helmets should be worn at all
• Wear
times,awith
safety
thehelmet. Safety
exception helmets
of office or should be worn
crib rooms, at all
or while
times, with the
in the cabin exception
of mobile of office or crib rooms, or while
equipment.
in the cabin of mobile equipment.

Objects at Ground Level

Objects at Ground Level
Loose objects that are left lying near the edge of the trench can accidentally be knocked into the
Loose
trench objects
and ontothat are left lying
personnel below.near the edge of loose
Additionally, the trench
objects canrepresent
accidentally be knocked
a slip/trip hazard,into the
which
trench and onto personnel below. Additionally, loose objects represent a slip/trip
when combined with an open trench, results in the increased likelihood of the slip/trip causing a hazard, which
when combined
significant injury.with an open trench, results in the increased likelihood of the slip/trip causing a
significant injury.
The following points identify important safety considerations with respect to objects at ground level:
The following points identify important safety considerations with respect to objects at ground level:
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RIICPL303D good housekeeping
Standard 15.5 1 practices:
1 Install sewer pipelines 04/09/2014 Page 11 of 149
• Observe
- remove good
loosehousekeeping
objects frompractices:
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 Topic One — Overview and Safety Page 1.8

OVERHEAD POWERLINES

Any contact with overhead powerlines has the potential to result in fatalities. Special attention
must be paid to any overhead powerlines that encroach on to the worksite. Where possible, pipe
laying operations should be amended so that high risk tasks such as the lifting, transporting and
positioning of pipes, are conducted at a safe distance from the powerlines.

Consideration should be given to the following items in the planning and preparation stage of pipe
laying:

• Position access roads to avoid the powerlines where possible.

• Site stacking/storage/delivery areas away from any powerlines.

• Erect signage in areas where access roads pass under powerlines and where they encroach
on the trenching and pipe laying operations.

• Consider the swing arc of trenching and lifting equipment. Spoils may be better being
stacked on the side of the trench that is closest to the powerline, as only a small swing arc
is required for this operation. On the other hand, lifting, moving and positioning the pipes
is easiest and safest where there is more room to swing and where access is not restricted.

• If work is to be conducted under power lines, check with the electricity supply authority
and the government safety authority. You may need to:
- arrange for overhead cables to be diverted or protected with insulating covers
- arrange for electricity to be cut off
- put up goal post type barriers or;
- use luffing stops on the machine.

Contact with Electrical Wires

Should any mobile equipment item come in contact with overhead powerlines, you should observe
the following:

• Do not attempt to touch any powerline.

• Do not attempt to operate the mobile equipment item.

• Stay in the cabin until the power is isolated and you are instructed to dismount. If this is
not possible due to other factors such as an on-board fire, leave the machine by jumping
clear.

Performance Training Pty Limited Lay Pipes

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 Topic One — Overview and Safety Page 1.9

DANGER

Do not step down from the machine. Simultaneous contact with the machine and the
ground can result in electrocution. Always jump clear of the machine.

• Warn all personnel to stay clear.

HAZARDOUS SUBSTANCES
Most work sites have in place procedures for the storage, issue, use, and disposal of hazardous
substances. The term hazardous substances may include such items as:

• diesel and other fuels

• oils, greases and lubricants
• solvents
• cleaning agents, disinfectants and detergents
• glues.

Material Safety Data Sheets (MSDS) must be provided for all hazardous substances that are brought
on site. The MSDS will provide important substance information such as:

• Ingredients • Flammability
• Health hazards • First aid for injuries resulting from contact
• Handling precautions • Storage procedures
• Disposal procedures • Substance specific fire fighting techniques.

Performance Training Pty Limited Lay Pipes

J/N 2295 Version — 1.0

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 Topic One — Overview and Safety Page 1.10

MSDS’s are obtained from the supplier or manufacturer of the substance. Copies of the MSDS will
be provided where the substance is stored and/or used, and a copy should be kept by the OH&S
officer.

NOTE

All hazardous substances must be entered in the site register

(eg. CSIS, Chemalert System) and the appropriate MSDS must be available
before they can be stored, transported, used, and disposed of on site.

Employers are obligated to inform employees of the health and safety restrictions of
hazardous substances before the employees use the substances.

LASER RADIATION

Laser levelling devices are used in the pipe laying industry to set levels and grades. The beam
which is emitted from these devices can cause eye damage if it is directed into the eyes. Observe
the following points when using or working around a laser device:

• All laser operators must be suitably trained.

• Post relevant warning signs

• Use the laser in accordance with the manufacturer’s instruction.

• Set up the laser so that it is not at eye height while people are in the trench.

• Do not stare into the beam.

UNIDENTIFIED SERVICES

Public Utility Plant (PUP)/services will exist on many pipe laying worksites. These can be located
underground or overhead. Checks should be conducted for these services at the planning and prepa-
ration stage and the relevant authorities contacted for their exact location. In most instances, serv-
ices will be identified by surface fittings and/or markers. However, there is no guarantee that these
are in the correct location. Hand digging will be required to verify the location of each service.

In some instances PUP/services may go undetected. If a service is uncovered during the course of
excavating the trench you should observe the following:

• halt mechanical excavation and identify the service

• report any damage to the service immediately
• treat any PUP/service as live.

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Performance
Title
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Pty Limited Issue Version Ref Release date
Lay Pipes
J/N 2295 Version — 1.0
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 Before work starts the following routine should be undertaken;

An inspection of all traffic signs and devices should be made and a note made of signs out of
place or damaged during the night for subsequent rectification.

The OH&S Act requires that for excavations greater than 1500 mm in depth (where personnel
are required to work) ground support systems must adequately support against collapse.
Installing shoring or battering may be necessary in some situations to reach a depth of 1500
mm.

PROTECTIVE EQUIPMENT

When selecting PPE to minimise a risk to health and safety, the person conducting a business
or undertaking (PCBU – the new term that includes employers) must ensure the equipment is:
Suitable for the nature of the work and any hazard associated
A suitable size and fit and reasonably comfortable for the person to wear
Maintained, repaired or replaced so it continues to minimise the risk to the worker

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 SAFETY BARRICADES AND SIGNAGE
If the angle of the slope of the sides is such that the excavation can support itself, ground
support systems are not required. (You should check the regulations in your State or Territory
for further information).
It is necessary to install ground support systems because excavation destabilises ground. A
ground support system will prevent walls of an excavation from collapsing and restore an
acceptable level of stability to the ground. The excavation support system should be placed
progressively as the excavation proceeds. It is removed progressively as the excavation is
backfilled.

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 The location, depth and width of trenches are specified in construction drawings. Refer to site
plans to locate the intended excavation position on the site. The depth and width of trenches are
dependent of the type of pipeline system. If a trench is greater than 1.5 metres deep it is
necessary to batter or shore in accordance with relevant legal requirements.
Different systems of shoring will be mentioned in the specifications. If shoring is necessary the
shoring method is dependent on soil conditions. e.g. unstable ground or moisture content. For
example, for hard compact ground open sheeting with walings may be used, for trenches from
1.5 m to 2.7 m wide and up to 4.8 m deep.

Setting Out the Trench

You should check with the site plans for the trench location. Peg out the trench location and
mark it with a string line. Use a spray can of paint to mark out the trench location by spraying
along the stringline.

Assist the machine operator by using hand signals.

Topic One — Overview and Safety Page 1.18
Clean the trench using hand tools. Be sure to make the trench surface smooth by removing all
rocks and sharp objects.
Pipe Markers

Pipe markers are painted labels which are fixed

to a pipe, conduit, or duct in order to identify ELECTRICAL
its purpose or contents.
CAUSTIC
They are placed where pipes need to be
quickly identified in case of an emergency, or COOLING WATER
to distinguish one pipe from another, where
several are installed side-by-side.

A specific colour is assigned to each type of FIRE (RED)

substance or service. POTABLE WATER (MID BLUE)
WATER (GREEN)
AIR (LIGHT BLUE)
OILS (BROWN)
GASES (YELLOW OCHRE)
ACID (VIOLET)
STEAM (SILVER)
ELECTRICAL (ORANGE)
MISCELLANEOUS (BLACK)

Hazard/Barrier Demarcation Tape

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 MISCELLANEOUS (BLACK)

Hazard/Barrier Demarcation Tape

Hazard and barrier tape is used to

temporarily identify safety hazards, or define
an area into which you should not enter.

Colour codes:
Red and white — Danger: no access allowed
Topic One — Overview and Safety Page 1.19
Yellow and black — Caution: area may not be entered without authorisation.

Demarcation tape is used to permanently define the boundaries of areas such as:

• safe areas — walkways, muster

points, etc. BLUE
• clearance areas — within which the
automatic movement of machinery GREEN
creates a safety hazard GREEN/WHITE
• clear access areas — where access
to fire suppression equipment, exits, RED
etc. must be available at all times
Performance Training Pty Limited RED/WHITE Lay Pipes
• set-down areas — where materials
J/N 2295 Version — 1.0
or equipment may safely be put down YELLOW
and left.
YELLOW/BLACK
In some instances painted lines and markings
may be used instead of adhesive tape to de-
fine the area boundaries.

You should
Topic One — ensure that youand
Overview are familiar
Safetywith the signage and markersPage
used on site and you should
1.21
ensure that you follow their instructions at all times.

Protective Barricades
PROTECTIVE DEVICES/APPARATUS
• Barricades must be erected before the hole is cut and extended as the excavation progresses.
The following devices
• Numerous and items of
excavations inapparatus
one area are
mayused
be as and when
fenced they are required
off effectively arounda work
by erecting sites.
barricade
around the general area.

MACHINE GUARDS
• Flashing lights must be used on road blocks after dark.

• An equipment
All rotating entrance, opening,
must be or gatewith
fitted must be placed where practical to allow access/egress in and
out of the barricaded
a guard to ensure your safety. Accord-area.
ingly, it is essential that where guards,
• screens,
covers, Barricades must be
railings, maintained
enclosures etc.erect and square.
are found to be defective, missing or loose,
the equipment must be shut down until
CONFINED
the condition isSPACES
rectified. NEVER op-
Type erate a machine withStandard
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missing working
RIICPL303D NVR
or defective. Standard 15.5 1 1 Install sewer pipelines
with excavations and pipes, due care must be given to considering the hazards
04/09/2014 Page 18 of 149
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created by confined spaces. Australian Standard AS 2865 — 1995 defines a confined space as
 INSTALL EXCAVATION SUPPORT (This unit is more extensively covered in
RIICCM210D Install trench support)
The type of material to be excavated has a large bearing on the design of shoring. Generally,
hard compact ground requires ‘open’ sheeting, and saturated, loose or other unstable ground
requires ‘close’ sheeting.
In between these types there exists a wide variety of ground conditions where a decision on
shoring method is difficult and requires a careful and continuous assessment of ground and
site conditions. Soils may be grouped under three (3) physical types:
! Coarse grained
! Fine grained
! Organic
Coarse-grained soils, sands and gravels may be described as soils composed largely of
particles visible to the naked eye. Fine-grained soils, which are mostly made up of particles
NOT visible to the naked eye, include, silts and clays. Organic soils have either a large
proportion of organic content such as peat or are sands, silts or clays.
The granular sands and gravels derive their strength from friction between the grains which can
give a certain safe slope or angle of repose for the particular material. Sands, gravels and silts
may be stable on a vertical face due to natural soil cementing materials. This cementing
material may lose its value when affected by water or exposure to air.
Clays have cohesion, which is a force derived from the interaction of absorbed layers of
water on the microscopic particles. Clays may give way suddenly in large blocks due to
unbalanced pressures or due to the action of water seeping into cracks formed by drying out
of the soil.
Open Sheeting of Trenches
Open sheeting should be used in hard compact ground for trenches up to a depth of 4800
mm. It should consist of vertical sheeting spaced at a horizontal distance of 2400 mm and
with horizontal struts in accordance with the following:
Struts must be placed horizontally between opposing sheets and square to the sides of the
excavation at a vertical spacing not exceeding 1500 mm (unless walings are used, when the
vertical spacing should not exceed 2450 mm).
Top struts should be positioned approximately 300 mm below natural ground surface.
Extreme care must be exercised when transferring the load in shored structures to prevent
release of stresses developed in the soil. Installation loads on struts must be practically equal.
Blocks, cleats or props must be used to support walings against slipping or accidental
displacement. A softwood packing piece should be used to give each strut a tight drive fit.
Packing pieces must be applied at one end only and not more than two pieces used per strut.
At the intersection or junction of two or more trenches care must be taken to ensure that the
struts are placed to provide support for each other.
Temporary Shoring of Trenches in Hard Compact Ground
In trench excavation there is a particularly dangerous zone between the machine and the
permanent shoring when open sheeting (soldier set) is used.
In order to provide protection for personnel installing the permanent shoring it is necessary to
apply temporary support to the walls of the trench. The method for achieving this in hard
compact ground is the use of hydraulic struts.

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 Hydraulic Struts
These strut sets are available in standard 1200 mm and 2100 mm lengths covering the range
of trench widths as set out in Table 1 and consist of two (2) extruded aluminium sheets
separated by two (2) hydraulic struts, with return springs. Chains are attached to the top of
each sheet to enable the sets to be lowered into the trench.

Sets must be placed from the top of the trench to give the protection intended. Each set should
have its own hydraulic pump.

Frequent inspection of pressure hoses and rams are necessary to detect abrasion, fatigue or
damage such as buckled or notched rams.

Due to their relatively high cost, hydraulic support systems are mainly used to provide
mobile ground support while soldier sets (open sheeting) are being installed.

Under NO circumstances should a workman be permitted to enter the unprotected zone of a

trench.
TABLE 1: HYDRAULIC SAFETY STRUTS

For Trench Widths User Type Range of Strut

600mm - 850mm A 550mm - 900mm
850mm - 1200mm B 800mm - 1250mm
1050mm - 1400mm C 1000mm - 1450mm
1350mm - 1700mm D 1300mm - 1750mm

Close Sheeting of Trenches

Close sheeting must be used in saturated, loose or unstable ground.
Sheeting should be placed with edges abutting.
Where wet running material is encountered, shields or interlocking steel sheets should be used,
or the spaces in between sheeting should be caulked with hessian or any other suitable
material.
Walings must be placed at a vertical spacing not exceeding 2400 mm.
Never, should less than two (2) sets of walings be used in a trench. The bottom set should be
placed as low as practicable. Provision must be made by using blocks, cleats, hangers or props

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 to support the walings against slipping.
Struts MUST be placed horizontally between walings and square to the sides of the excavation
at a horizontal spacing not exceeding 2400 mm.
In all cases a strut should be placed not more than 300 mm from the ends or joints of the
walings.
The introduction in recent times of proprietary brand trench support systems, for example,
Shorco System 40 Trench Support, has limited the need to use close sheeting methods.
LEGISLATION
Excavation works should be carried out in accordance with relevant legislation and other
regulatory authorities in your State or Territory.
When trenching is complete the site should be cleaned and debris and unwanted excavated
material should be removed.
Tools and equipment should be cleaned to minimise deterioration. They should be stored away
in a safe environment for future use.
INSPECT SLINGS AND ACCESSORIES
Slings and accessories should be checked for damage and wear regularly. The results of the
inspection should be recorded and reported to the supervisor. Any damaged equipment should
be discarded from use. Using damaged equipment can be dangerous to all workers. Chains
and ropes should be inspected at least once a month and immediately prior to being put into
use.

Above damaged slings and wire rope should never be used as an accident is then waiting to happen
Inspection of Hooks
When inspecting hooks you should check that they have not stretched more than 5% from their
original shape. Any hook, which has stretched more than 5%, must not be used. Hooks, which
have become distorted, bent or otherwise damaged, must not be welded or heated and
reformed. This requires special metallurgical knowledge. Welding can create a dangerous
condition in certain areas of the hook.
Inspection of Shackles
A shackle should be discarded if there is wear and tear, or if it is bent, strained, deformed or
damaged. Wear and tear on the crown or pin of the shackle should not be by more than 10%
of its original diameter otherwise the shackle should be discarded.
Inspection of Slings
Ropes should be inspected in 30 cm sections. They must be inspected both internally and
externally. To inspect the rope internally, twist the rope by hand. This will open the rope up so
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 that you can see inside.
Corrosion usually takes place near the sockets. If affected discard the rope.
Signs to watch out for are “fluffing” of outer strands of the rope, severed or flattened strands,
loose strands, elongation of the lay, discolouration of the rope, bird caging (strands springing
away from the core of the rope), softening of the fibres and/or fusion of strands.
Normal usage of fibre ropes will cause “fluffing” of the outer strands. The rope should only be
discarded in extreme cases where the rope becomes severed and strands flattened. If you do
not protect the sling over sharp corners local abrasion can result. This weakens the sling and it
should no longer be used. You should check that strands are not ruptured or loose. A reduction
in diameter and excessive elongation of the lay are indications that a rope is overloaded. If a
rope fails in this situation it should be discarded. If you notice discolouration of a rope or
softening of the fibres it may be a result of contamination by a corrosive substance. This will
make the rope unusable. In severe cases fibres may rub off into a powder seriously damaging
the strength of the rope. Heat generated through friction may cause localised fusion in synthetic
ropes. Internal wear is caused by particles, which become embedded in the rope. This causes a
powdering of internal fibres. If this happens the rope is no longer suitable for use. If the rope
becomes soft it may be a cause of damp conditions and attack by mildew. The rope is not
suitable for use if this is the case. Synthetic rope is not subject to this, however.
Kinks in a wire rope are an obvious sign of damage.
Slings passing over sharp corners must be protected, particularly if the sling is likely to slide. It
will then shear through like a knife.
A proper corner pad as shown may be purchased in sets, and is best for protecting both the
sling and the load.
Where these are not available, pieces of split pipe may be used. Soft-wood timber sometimes
has a use as packing, and even carpet, old tyres conveyor belt material or several layers of
packing may be used especially on machined surfaces. Rags, cotton waste, etc. are virtually
useless.
As a general guide the following formula can be used: The total number of broken wires in
all strands of a rope must not exceed 10% in length equal to 8 diameters of the rope, eg.:
In a rope of 6 x 24 construction the total number of wires is 144.
10% of 144 = 14.4
Therefore, 15 broken wires in 8 rope diameters is the limit.
Wear due to friction on rollers, sheaves or drums; eventually cause the outer wires to
become flat on the outside, which reduces the rope diameter. This wear should never
exceed 33% of the wire diameter. Wear usually precedes broken wires, which can occur
from dragging, friction, abrasion etc.

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 CHAIN DAMAGE

EXTERNAL WEAR OF CHAINS

The inside of spliced eyes should also be inspected for wear or damage which is caused by
constant use on pins, shackles or wire reeved back through the eye.

STRETCHING OF CHAINS

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 Topic One — Overview and Safety Page 1.25

Checking Chains, Ropes and Fittings

The following general checks should be made when using slings and ropes:

Chains • Check the hammerlocks — make sure the ferrule is free to rotate.
• Check for wear — a maximum of 10% of the diameter of any section
allowable.
• Check for signs of stretching. This appears as an uneven shape and
sometimes the links are locked.
• Check that the chain and its associated gear are completely free of bends
or distortion.
• Check that a tag is in place noting the WLL of the chain/s
• Ensure that all hooks are fitted with safety latches.

Chains ARE NOT TO BE USED where electric arcing is possible.

Shackles • Check that the pin is fully seated with a full-depth threaded end.
• Check the wear — a maximum 10% of the diameter of any section is
allowable.
• Check that there are no bends and twists.

Defective shackles must be replaced.

Shackles must not be:

• Repaired
• Welded
• Re-bent to original shape
• Fitted with substitute bolts or pins.

Steel • Check for broken wires — examine closely,

Wire Ropes especially where the rope enters the fittings.
• Check for burns, especially from arc welding.
• Check for kinks and flattened areas which lead to
broken wires.
• Check for overloading, which causes the rope to have
a thin appearance in sections and an elongated lay.
• Check that the SWL marking is correct for your job.
• Check that the number of clamps and distance
between them corresponds with the size of wire rope.

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 Topic One — Overview and Safety Page 1.26

Fibre Ropes
NOTE

Use fibre rope for tag lines only. It must not be used to lift weights.

• Check for breaks (shows as a tufty brushlike appearance).

• Check for burns (shows as black marks) which can develop into breaks.
• Check for overloading (shows as thick and thin sections with the lay
lengthened).
• Life — when a rope feels dry and limp without resilience its life is
over.
• Ensure that the splices are tidy with at least three tucks and no large
tufted ends.

CAUTION

Do not use any lifting gear (chains, slings) unless the WLL is noted on the lifting gear.

LIFTING OPERATIONS
The following points should be observed when conducting lifting operations.

• All lifting operations must meet legal and occupation, health and safety requirements
applicable to the site.

• Qualified personnel must be employed for all crane operations.

• A licenced Dogger must be present when calculations for the centre of gravity of the load
have to be made and the load is out of sight.

• Lifting should be done smoothly without sudden jerking motions. Pipe movement should
be controlled by use of guide ropes.

• Lifting and placing must be carried out so that the stability of the pipe stack, crane or
vehicle is maintained.

• If you are required to guide the crane operator you should observe the following:
- use one hand and remove any gloves when signalling
- stand where you are clearly visible to the crane operator
- use the standard hand/whistle signals as shown in the following table.

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 Inspection of Chain
All chains should have a serial number for identification purposes.
Chain damage includes elongation of links, stretched sections of the chain, deformed links,
bent links and cracks and cuts of links. If any of these are present in the chain it should be
discarded from use. If you are uncertain about the condition of the chain you can have it
inspected by the manufacturer.
If the diameter of the chain materials has been reduced in any position by 10%, discard the
chain IMMEDIATELY.
To check for cracks and cuts in links a thick oil should be soaked over the link suspected and
then wiped dry. A coating of powdered chalk can then be applied to the surface of the link and
should remain there for several hours. If a crack exists, oil will remain in the crack and discolour
the powder.
Shackles
There are two principle shapes, i.e., “Dee” and “Bow”. Almost all are made from plain round bar,
and have circular eyes. Occasionally, the eyes may be elongated oval, or of tear-drop form.

DEE AND BOW SHACKLES

The pin of the common shackle screws directly into one eye and should preferably have a
collar. In better shackles the pins pass clear through both eyes and are secured by a split pin
forelock (i.e. split flat cotter pin) or nut and split pin, passing through one eye and the shackle
pin. Where it is necessary to frequently or quickly remove the pins of light shackles, drop-nose
pins are now often used
In order to eliminate projections, shackle pins are sometimes countersunk flush with the
eyes. There are many other variations, generally tending to improve design and facilitate
use.
The forelock shackle is the safest type of shackle for all purposes but is mainly used when
the shackle is more or less permanently fitted as in standard rigging.
In any position where the shackle is liable to be exposed to continued knocking or leverage
with risk of the pin working out, or in places where the shackle is not readily visible and the

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 pin not noticed, always use the forelock or the pin with nut and cotter pin.
Shackles are measured by the “nominal” size; this is the diameter of the steel in the “U” or
bow. However, the pin diameter is even more important.
Generally, if the pin diameter is larger than the shank diameter, it is a ‘lifting’ shackle.
Flexible Steel Wire Rope Slings
Talurit slings

A talurit-swaged sleeve is used in a

mechanical splicing system, to make an eye
splice in a steel wire rope. The most common
and useful type of end fitting for a wire rope is to
turn the end back to form a loop. A thimble can
be installed inside the loop to preserve the
natural shape of the loop and protect the cable
from pinching and abrading on the inside of the
loop. The loose end is then fixed back on the
wire rope by means of a swaged sleeve (ferrule).
The thimble prevents disrupting of the wires.

Slings made with Talurit splices perform all lifting duties within the safe capacity of the rope
used.
The Talurit splice consists of a special aluminium alloy ferrule machine pressed round the
looped end of a wire rope, at a pressure sufficiently high for the metal to “flow” between the
rope strands, gripping them with great power. The splice thus produced, is as strong as the
rope itself, neat in appearance, waterproof and has no protruding wires.
Single and multi-leg slings with soft or thimbled eyes are made from FSWR up to 62 mm in
diameter. All types of appropriate sling fittings can be incorporated during manufacture. On
this type of fitting the “dead end” of the rope MUST protrude past the end of the fitting after
pressing.
Australoc slings
All conventional patterns of sling are available with Australoc splices.
In making an Australoc eye splice, the rope is laid up grommet fashion to form a loop finished
with a Flemish eye splice. An Australoc steel sleeve is then swafed over the splice by special
dyes in a hydraulic press, single or double sleeves being used according to the application.
Suitable fittings may be incorporated at the time of manufacture.

Australoc spliced slings can be produced with wire rope up to 75 mm diameter. The tapered
steel sleeve prevents head injuries from protruding wires and permits the sling to be readily
withdrawn from beneath a load. The Flemish eye ensures equal distribution of load in both
parts of the eye. Australoc splices are manufactured from steel cored wire rope and have high
resistance to crushing and deformation.
Fibre Rope Slings
Fibre rope slings are flexible, that is, gentle around bends, by adapting to load contours. They
lift without scratching because of this. They are fast when lifting items because there is no
rigidity or hardness.

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 Fibre rope slings are light weight and have great strength. They come in a wide range, from
throwaway sisal to long lasting, high energy shock-absorbing nylon.
Hooks
The opening or gap, between the “bill” or point of hook and shank, must be sufficiently wide to
admit the largest rope, ring, link or shackle, which has to be placed upon it. and the inside of
the bite should be rounded to avoid cutting a rope sling or damaging any fitting of a sling used
with it.

Hooks are required to be marked with safe working load. Some alloy hooks, particularly those
used with alloy chains, are marked with the size of chain with which they should be used as a
matched set.
Hooks shall not have any attachments or fittings welded to them as this requires special
techniques.

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 TYPES OF HOOKS
Wire Rope
Wire rope is made up of strands, which in turn are made up of wires. The terms ‘wire’, ‘strand’,
and ‘rope’ should not be confused; e.g., many reports are made that a rope has a broken
strand. If this is actually the case, the rope should be removed from service immediately,
however, in almost all cases of a report of this nature, the rope has only a broken wire and
whilst a single broken wire should be cause for a close examination of the rope, it is not usually
necessary for the rope to be discarded.
In this example each individual wire is arranged around a central wire to form a 7 wire strand.
Six of these strands are formed around a central core to make a wire rope. The rope is specified
as 6 x 7, i.e., six strands each of seven wires.

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 Topic Two — Job Planning and Preparation Page 2.7

UNLOADING

The unloading of the pipes from the truck is normally done by the truck driver. However, it is your
responsibility to:

• ensure that the truck has access to the unloading site

• select an unloading site that is:
- level
- firm
- close to the work site
- out of the way of all trench excavation and preparation activities
• chock all pipes in their correct position to prevent subsequent movement
• Check the ties or support on pipes that are bundled or crated to ensure that it is not damaged.

CAUTION
Unchocked pipes represent a
significant safety hazard. If pipes are
not chocked, soft ground, vibration
from equipment, or a slight slope can
cause the pipes to start rolling. This
can result in personal injury and/or
equipment damage.

STORING CONCRETE PIPES

As identified earlier, some types of concrete

Pipes Stacked Socket
pipes have elliptical steel reinforcing. These to Spigot
pipes will have the word ‘top’ stencilled onto
them. If the pipe is equipped with a lifting hole,
it will be positioned on the top of the pipe.

Concrete pipes can be stored in a simple layer,

or stacked as shown. Important points to re-
member when stacking pipes are as follows.
Pipes Double
• Stack the pipes on timber battens that Chocked
are thick enough to raise the sockets
CONCRETE PIPE STACK
off the ground so that they do not carry
any load.

• Double-chock the bottom row of pipes.

• Pipes should be stacked socket to spigot so that the stacks are level.

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 Topic Two — Job Planning and Preparation Page 2.8

• Ensure that all pipes are stacked with the top side uppermost. This reduces the risk of a
pipe cracking due to stress being applied to the side of the pipe.

• Store any accessories such as hole plugs, sealing rings/bands etc inside the pipes. Ensure
that you cover any objects which could be affected by sunlight.

Always stack pipes so that the stencilled ‘top’ is uppermost.

MOVING AND HANDLING CONCRETE PIPES

Concrete pipes should not be rolled as a means of moving them around the site. The elliptical rein-
forcing in many pipes means that the sides are more prone to cracking if they are placed under pres-
sure. Pipes should be lifted with a sling, or slings and lifting bar and then transported as required.

Care should be taken when moving and handling the pipes. The pipes, particularly
the pipe ends, are susceptible to damage if the pipes are dropped or knocked to-
gether. The use of guide lines and/or providing placement directions to the lifting
equipment operator will help reduce accidental damage.

If you have to move a pipe from the stack to enable

lifting and transport, it is possible for one or more
of the remaining pipes to move. Always chock the
pipe next in line to the one that you are removing.
This should be done before the pipe is removed.

CAUTION
Always chock the pipe/s next to the one that you are removing.

Pipes are grouped by weight and the weight of the heaviest type of pipe in the group is stencilled on
all pipes in the group. This ensures that the appropriate machine for lifting and transporting the
pipe can be selected with respect to the maximum load that it will be required to lift.

NOTE
Not all the pipes in the group will weigh as much as the indicated weight.

There are two methods of lifting concrete pipes. The method you use will depend on the type of
pipe being lifted.

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 Topic Two — Job Planning and Preparation Page 2.9

Pipes Equipped with a Lifting Hole

Pipes that are equipped with a lifting hole are lifted as follows.

• Position the pipe so that the lifting hole

is at the top.

• Pass a wire snotter down through the

lifting hole and then insert a steel bar
lengthwise into the pipe and through
the eye of the snotter as shown.

LIFTING PIPES EQUIPPED

WITH A LIFTING HOLE

MOVING A PIPE WITH A LIFTING HOLE

Pipes that are Not Equipped with a Lifting Hole

Pipes that are not equipped with a lifting hole are lifted as follows.

• Position the pipe so that the top is

uppermost.

• Attach a chocked sling around the pipe.

NOTE

A chocked sling is one that is wrapped

around the pipe and through itself.
LIFTING PIPES WITHOUT A LIFTING HOLE

• Position the sling near the pipe’s centre

of gravity so that the pipe is evenly
balanced.

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 Chains
Bush roller chain is generally used over sprockets. It can be used under circumstances of a
straight pull, a good example of this being the bicycle chain. It will not stand forces other than a
straight pull in line with the sprocket. This type of chain is never to be used for lifting purposes.
Stud link chain is mainly used for marine purposes (anchors, etc). To look at Stud Chains
one would think they were stronger than Open Link Chains, but this is not the case,
because under strain, a stud link chain will NOT STRETCH like an open link chain
therefore, the breaking strength of the stud chain is reduced.
Short link crane chain provides greater strength and greater elasticity than other types of
chains. The sides of the links are slightly bowed, and the size of the chain is determined by the
diameter of the material in the link.
The link length should not exceed 4.5 times this diameter and the link width should not exceed
3.5 times this diameter. Short link chain, other than crane chain may exceed these
measurements by one quarter. These Types of Chain Are Used For General Lifting
How Lifting Angles Reduce Working Load Limits of Slings

Common Types of Chain

Grade 30 Proof Coil Chain - Made from low-grade carbon steel, Grade 30 is an economical
utility chain for applications not requiring a high strength to weight ratio. Its wide range of uses
includes logging, guardrails, tailgate, and towing. NOT FOR OVERHEAD LIFTING.
Grade 43 High Test Chain - A high quality of carbon steel provides increased strength to
weight ratio and excellent resistance to wear and abrasion. Industrial applications inlcude
lumbering, construction, binding and tie-down assemblies. NOT FOR OVERHEAD LIFTING.
Grade 70 Binding Chain - The breaking strength of Grade 70 is 20% higher than that of Grade
43 in equal chain size, but has the same weight. Ideal for the transportation industry, where
lighter weight chain is desired for ease of handling. NOT FOR OVERHEAD LIFTING.
Grade 100 Alloy Chain - Alloy chain is made from specially selected alloy steel. Engineered to
provide the highest strength to weight ratio. Assures maximum durability and minimum
elongation. Alloy chain is the only chain designed for overhead lifting.

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 CARRY OUT SAFE SLINGING
Prepare Destination of Load
It is important that the worksite is inspected before load slinging is carried out. The inspection
results should be recorded and used to identify potential hazards in order to create a safer
workplace. The investigation will further your understanding of your working environment. You
many find any of the following potential hazards:
! Overhead power lines
! Unstable surface
! Trees
! Overhead service lines (steam, gas water, telephone)
! Underground services
! Allowable floor loading as appropriate
! Other workers and persons
! Surrounding buildings/vessels/structures/equipment
! Hazardous materials
! Corrosive substances
! Barricades
! Inadequate lighting
! Radio interference
! Wet and windy conditions

It is advisable to consult with the OH&S officers on your worksite to ensure that you are aware
of workplace rules and procedures. Make sure your site is safe before carrying out load
slinging.
When the method of applying the sling is changed, it may greatly alter the tension in some
parts of the sling.
The maximum tension induced in part of the sling is governed by the angle ‘A’ between the
parts attached to the load. It is in these parts that the maximum tension will be imposed, the
vertical parts carrying the actual load. This applies equally well to fibre rope, chain, webbing
slings or any other type.

Although 170 degrees is shown by way of example, 120 degrees must not be exceeded.
If a sling having 2 legs is also reeved or back hooked, and all parts are at 120° a factor or
4 is applied. Thus, for a 2,000 kgs load we need a sling with an SWL or 8,000 kgs.

The figure of 120 degrees has been extensively as an example to stress the fact that slings may

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 be stressed much more than would appear just from the weight of the load alone. 120° is the
maximum angle to be used and is not to be exceeded. In no circumstances should reeving (or
back hooking) be used in combination with 120 degrees of spread.
In such a case the spread should be limited to 60 degrees, which is easily judged as the
spread between attachment points is equal to the length of one leg.

Safe Use of Slings Synthetic Webbing Flat Slings

The sling material will resist chemicals, heat and exposure to sunlight to the degree necessary
in the circumstances of its use.
The lighting capacity (SWL) is consistent with the method of lift and reeving is NOT
exceeded. Allowance is to be made for shock, loading, unusual or severe working conditions
and particular dangers, e.g., when the load is unavoidably lifted over people.
Slings should be placed around the load so that it is balanced. The sling must not be
crossed or twisted and the splice of endless slings must not be bent around the hook or
load.
When used in pairs the slings are vertical (use a spreader beam if necessary).
The sling should be protected where necessary from abrasion or cutting by the load, which may
cause serious loss of strength.
Slings should not be dropped from a height.
Slings should not be pulled from under a load when the load is resting on the sling.

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 Rubber rings should be stored in a cool dry place, out of the sun and away
from petroleum products.

MOVING AND HANDLING STEEL PIPES

As explained earlier, any protective coating on the steel pipes must be maintained with as little
amount of damage as possible. By observing the following points during lifting and handling
operations, the pipes can be manoeuvred with little or no damage to the coating.

• Handle the pipes one at a time.

• Use twin slings or other approved Hairpin

lifting devices such as a spreader bar
for larger pipes or a hairpin when pipes Guide Ropes
are to be green sleeved.
Twin Sling

• Slings or lifting devices should offer

protection against damage to externally
Guide Ropes
coated pipes. This applies when lifting
and when withdrawing the sling from Spreader
under the pipe, once it has been bedded. Bar

• Reversed eye, synthetic webbing slings

or round slings (of endless fibre Guide Ropes
construction) are recommended for use LIFTING STEEL PIPES
Topic Two —
in Job Planning
the assembly and pipes.
of steel Preparation Page 2.12

Performance Training Pty Limited Lay Pipes

Woven synthetic slings must be sheathed to prevent penetration of the fabric by
J/N 2295 grit which
Version — 1.0
causes abrasion and deterioration. The slings are fitted to the pipe using a ‘chocker’ hitch
and in this configuration the sling is rated to the SWL limit marked on the webbing.

• Wire ropes and chains should be

sleeved with rubber hose or tube. The Steel Chain
wall of the hose should be at least
10mm thick with a minimum 10mm min. wall thickness
45 min. durometer hardness
durometer hardness (Shore D) of 45. (Store D)

• Lifting hooks must not be attached to

the pipe ends as damage to the Wire Rope
protective coating can result. 10mm min. wall thickness
45 min. durometer harness
(Store D)

WIRE ROPE & CHAIN PROTECTION

STORING PVC PIPES

Even though PVC pipe is robust and flexible, it can still be damaged by rough handling and incorrect
storage techniques. The following points identify the steps you should take when storing PVC pipes.

• Pipes should be given adequate support at

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 5. MOVE THE LOAD
Signals to indicate to the crane driver the required movement of the load or crane shall be given
by hand, whistle, bell or buzzer. Only one person on site should give signals at a time.
Hand Signals
Hand signals shall be as stated below and as shown in Figure 8. One hand only shall be used
for signals. Where the crane chaser or dogman or spotter is signalling the movement of two
hoisting motions, he/she shall arrange with the crane driver for one raised finger to indicate
one particular hoisting motion, and, two raised fingers the other.

HAND & WHISTLE SIGNALS

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 CLEAN, MAINTAIN AND STORE SLINGS
Maintenance of Chains
o
The strength of the sling, is adversely affected by temperatures above 200 C.
o
However, temperatures as low as -30 C need no reduction in SWL.
Acidic conditions. Alloy steels are subject to hydrogen embrittlement when exposed to acids.
Some component load pins are retained by roll pins - these pins are hollow and would be
quickly attacked by acids. Chain slings are not suitable for highly corrosive atmosphere.
The safe working load of the sling must be marked on the “TAB” attached to the end link or
clearly shown on load charts. Multi-leg slings must show the included angle at which the SWL
applies. The safe working load for hazardous conditions must be set by a competent person and
it is always less than the working load limit for the sling.
Storage of Chains
Chains should be carefully stored by hanging in a clean, dry area. If care is not taken, chains,
dust and grit will cause damage to them. Chains, which are intended to be stored for a long
time, should be oiled and allowed to hang. The sling should not touch the floor and a drip tray
should be placed under the chain to collect any excess oil.
Care and Maintenance of Synthetic Webbing Slings
Slings should be checked for wearing or damage and discarded if damage occurs. After
being in contact with acids or alkalis, slings should be washed thoroughly prior to storage.
This will minimise deterioration.
Wire Ropes
When storing wire ropes care should be taken to avoid kinks. Kinks weaken the rope and they
will no longer be useable should the rope become kinked.

LAY PIPES
The third component of this competency deals with laying pipes.

PLAN AND PREPARE WORK

Pipes come in a wide range of sizes and are made from a variety of materials.
Pipes, their fittings and installation procedures must comply with the relevant standard
specifications in your state. They come in a wide range of sizes and are made from a variety
of materials. The following list contains common materials used for the construction of
pipes.
! Iron;
! Steel;
! Copper;
! Polyethylene (PVC);
! Concrete; and
! Vitrified clay.

For the purpose of this module we will focus on two types of pipes. Ductile pipes and UPVC
pipes.

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 Common uses for pipes include:
! Sewer;
! Effluent;
! Stormwater; and
! Water reticulation.
Tools and Equipment
Hand Tools
Spade;
Square nose shovel (long and/or short handle);
Pick;
Mattock;
Crowbar;
Spirit level;
Stanley knife;
Ropes;
Tape measure;
Marker pen/pencil;
Wheelbarrow (if necessary);
Pegs, stringline and hammer;
Fine toothed saw and file;
Tamping bars; and a range of spanners.

Equipment
Laser levels; Ladders;
Shoring tackle and wooden battens/chocks;
Pumps (if wet);
Compactor ;
Various pipe joining equipment (e.g. Fork tool, wooden
block);
Abrasive disk cutter and grinder; and< drill and or tapping tools.
Plant
Trenching machine, excavator or backhoe;< approved lifting device/crane or crane attachment;
and< roller (vibrating)
Personal Protective Equipment
When laying pipes you must use appropriate protective clothing and devices. These
provide protection for the head, the eyes and the body.

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 Head Protection
Always wear a safety helmet. The Occupational Health and Safety Authority states that
approved safety helmets must be worn on all sites. Safety helmets should be inspected at
least weekly for damage to the materials of that hat. This is a requirement of AS 1800.
To ensure that your safety helmet is maintained in a safe condition follow this advice:
-replace helmet if it is damaged due to severe impact or deterioration;-do not modify or remove
parts;-replace complete harness only; and-avoid contact with substances such as petrol, paint,
adhesives, texta colours, aerosol sprays or cleaning agents, as these can cause severe
damage.
Eye Protection
If you work in an area where small flying fragments, dust, splashing hot metals, or splashing
liquids are a hazard, then protect your eyes by wearing safety glasses, goggles, or face shields.
Body Protection
Wear plain, tough clothes that are close-fitting, and keep them buttoned up. Loose sleeves,
unbuttoned or torn shirts or sweaters, ties, or loose belts can easily become caught in
revolving machinery.
Transport and Stack Materials
Pipes should be checked for damage before and after they are unloaded from the truck. Pipes
should be stacked on flat surfaces. The site should be cleared from sharp objects and debris.
You should not stack the pipes too high. The height of the stack should not be greater than the
width. The actual height will vary depending on the site conditions. There are three ways to
stack ductile iron pipes.
Square Stacking

SQUARE STACKING OF PIPES

1 The stack is as high as it is wide (square)

2 Pipes are laid at right angles
3 Pipes should be laid socket to spigot

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 Parallel Stacking

1 Pipes are laid next to one another (parallel), refer Figure 10.
2 Each layer of pipes should have a layer of timber between them.
3 Pipes should be laid at opposite ends, i.e. socket to spigot.
4 Chocks should be wedged under the outer pipe and nailed to the timbers.

Pyramid stacking

1 The bottom row of pipes should be chocked securely.

2 The maximum height of the stack should be less that 1 metre..
3 Pipes should be laid in a row with their sockets at the same end.
4 Alternate layers should be facing alternate directions i.e., socket to spigot
5 Each layer will have one less pipe than the layer below it.
You should note that the above methods may not be suitable for pipes of other materials
depending on the weights, flexibility etc. of the pipes. Extra reinforcements may be needed for
support etc.

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 SET OUT AND EXCAVATE TRENCHES

Location, Depths and Width of Trenches

The location, depth and width of trenches are specified in construction drawings. The depth and
width of trenches are dependent of the type of pipeline system. If a trench is too narrow
compaction can be made difficult. Fill materials may not get right around the pipe to provide
sufficient support. If this happens, the pipeline may not be able to support the loads it was
designed to. If a trench is too wide the extra load placed on the pipe can cause it to crack. Make
sure the trench is the width specified in the plans. If it is too wide or narrow the pipe installation
may be put under unnecessary stress and therefore be unable to cope with the task for which it
was designed. If a trench is greater than 1.5 metres deep it is necessary to batter or shore the
sides in accordance with relevant legal requirements.

Different systems of shoring will be mentioned in the specifications. If shoring is necessary

the shoring method is dependent on soil conditions. e.g.. Unstable ground or moisture
content.

For example, for hard compact ground open sheeting with walings may be used, for trenches
from 1.5m to 2.7m wide and up to 4.8m deep.

Setting out the Trench

You should check with the site plans for the trench location. Peg out the trench location and
mark it with a string line. Use a spray can of paint to mark out the trench location by spraying
along the stringline.

Assist the machine operator by using hand signals.

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 Battering of trenches is usually done by hand. Using a square nosed long handle trenching
shovel ensure that the bottom corners of the trench are left square. Remove rocks, debris and
other sharp materials from the trench to avoid damage to pipes. If you are unable to remove
all sharp objects bedding should be placed.
Trench depth and grade
1. Check the depth of the trench and the grade against the drawings and specifications.
2. The depth should allow for:
a) Bedding;
b) Pipe diameter; and
c) Filling to cover the pipe.

The consulting engineers will determine the depth depending on overall load or weight of fill
materials and conditions that the area is subject to. This depth will be specified on the site
plan, which you should follow.

The grade is the amount of fall or slope of a pipeline. In general large pipes are laid with less fall
and smaller pipes are laid with more fall. The grade for the pipes will be given in the
specifications. A laser level is generally used to set the grade of pipes. A stringline and boning
rods are alternatives.

Compact the ground firmly. Don’t leave gaps. The trench should be tamped firmly to provide
full support for the pipes.

Bedding

Refer to specifications/drawings regarding bedding depths. Bedding depth will change

depending on the type of pipe being used. Bedding materials are generally sand or fine
granular material. There should be no sharp objects in bedding materials that could damage
the pipe surface. Ensure that the pipe is fully supported. In excessively wet conditions de-
watering may be necessary. In swampy conditions it may be necessary to place gravel in the
bottom of the trench for drainage before bedding in the pipes. The trench will need to be
deeper than otherwise expected to accommodate for this drainage material.
Bedding material should provide a firm and smooth base to fully support the pipe length.

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 Embedment and Backfilling
There are two zones when filling the trench to support the pipe. The first zone is the Embedment
Zone. The second zone is the Backfill Zone. Embedment protects the pipe from damage and
provides support. There are three layers in the embedment zone. They are the underlay
(bedding), side support, and overlay.

Specifications and plans will indicate the required depth of each zone for your purpose.

Embedment Zone
Material under the entire barrel of the pipe should be compacted solidly to provide firm and
continuous support for the pipeline. There should be provided even support along the length of the
pipe. If there are gaps in the bed zone the pipe will be subject to extra stress and could crack.
Compaction can be made by walking on the surface, hand-held tools or light mechanical
equipment. Material used to fill should be granular, such as sand. Granular materials are easy to
spread and give even support to the pipe. There should be no sharp objects or stones in the fill.

Backfill Zone
The backfill zone comes between the embedment zone and the ground surface. It should be
compacted well enough to support any traffic passing over the pipeline. If it is left loose, the
surface will move, creating dangerous holes.

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 Clean up site and Maintain Equipment

When pipes have been laid you should ensure that the site is cleaned and debris is removed, for
safety reasons. Tools and equipment should be cleaned after use. Cleaning of tools and
equipment will minimise deterioration caused by dirt and grit. They should be safely stored to
maintain high quality of equipment.

INSTALLATION OF PIPES
The following details are for reinforced concrete pipe installation. Some requirements will be
typical for all pipes regardless of their constructed material. However, the relevant manufacturers
installation guide should be consulted before construction commences.

Handling Concrete Pipes

Storing
When concrete pipes are delivered on site, they should be stored on level ground near the work
site but not in the way of the construction activities.

Pipes should be chocked so that they cannot roll away.

When pipes are stacked on top of each other, the bottom row should be double chocked.

Stack pipes with top up as marked on the pipe to reduce risk of cracking the pipe

Each row of pipes with sockets in a stack should be stacked opposite to the previous row i.e.
socket to spigot.

Figure 1 STORING CONCRETE PIPES

Moving Pipes around Site

Concrete pipes should be lifted using the correct equipment rather than roll or push the pipes
around the site. If they are rolled, the pipes could crack because many of the pipes have oval
shaped reinforcing cages and rolling puts pressure on the sides,
The ends of the pipes could also be damaged which could result in poor jointing.
When lifting pipes, remember to take the necessary safety precautions, wear a hardhat and safety
boots, check and use the correct lifting gear. Check with your local OH & S authority to see if a
crane chaser or dogger certificate is required for lifting these loads.

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 Lifting Pipes with a Lifting Hole
Ensure that the lifting hole is at the top, making sure the pipe will not accidentally roll
Check the safe working load limit of lifting gear
Pass a “snotter” through the lifting hole and secure with a steel bar as shown in Figure 43 - the
manufacturer will supply specifications on what diameter and length of steel bar is required to suit
the diameter of the pipe

Figure 2 WITH A LIFTING HOLE HANDLING

CONCRETE PIPES

Lifting Pipes Without a Lifting Hole

Check all lifting gear

Position the pipe so that the “top” is up
Use a choked sling to lift the pipe
Position the sling correctly for the pipe to be lifted evenly

Figure 3 HANDLING CONCRETE

PIPES WITHOUT A LIFTING
HOLE

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 Setting Out and Preparation of Bedding
You will need to refer to the construction drawings for the information to locate the centre line of
the drain/culvert and peg out the extent of the excavation. The width of the excavation will be
determined by the diameter of the pipe(s) plus the required space for the compaction equipment to
work between the side of the pipe and the excavation. The smaller the compaction equipment, the
smaller the excavation and less selected backfill material required.

The depth of excavation will be determined by transferring the levels on the drawing to the
construction pegs on site. Over excavation will require additional compacted specified fill or
concrete to bring the subgrade up to the required level, adding to the cost of the job.

Pipes can be laid in one of two situations:

Figure 4 TRENCH INSTALLATION

In a Trench
Narrow Trenches
If the trench is too narrow, the fill material may not get right around the pipe and there might be
gaps in the haunch zone and can also make compaction difficult This could mean that the pipe
may end up with less support than it was designed to have and the pipeline may not be able to
take the loads it was designed to bear.

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 Wide Trenches

A trench that is too wide can put extra load on the pipe and cause it to crack, even if you use the
correct bedding and compaction. A wide trench can develop a shear line which can push the
bedding sideways and upwards and crack the pipe.
A wide trench will also cost more to backfill because more fill material will be required plus more
compactive effort is required.
Make sure the trench is always the correct width as specified in the drawings. If it is too wide or too
narrow the pipe installation may not last as it was designed to:
In an embankment

Figure 5 EMBANKMENT INSTALLATION

All bedding and backfilling for concrete pipes in trenches should be in accordance to the Australian
Standard AS3725 - Loads on buried concrete pipes.

Terminology Used In Preparation Of Bedding For Concrete Pipes

Foundation
The ground, or the subgrade in the bottom of the trench, supporting the pipe. This can vary from
rock, sand, silt or clay. The type of foundation is one factor influencing the design of the drain.

Bed Zone
The area of cushioning material between the pipe and foundation providing even support to the
pipe and helps to maintain grade.
Even support along the length of the pipe is essential to eliminate cracks in the pipe from loading
above the pipe.
The depth of the bed zone will be designed by an engineer and details will be on drawings and
specifications.
In granular soils, it may not be necessary to include bedding material. where bedding is required it
should be at least 75 mm under the pipes.

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 Bedding materials should be screeded so they are on grade, but generally they should not be
compacted. They should remain loose to provide a soft even support for the pipe.
Dig into the bedding to allow for the pipe sockets but make sure there are no gaps under the pipe
after the joint is assembled.

BEDDING CONCRETE PIPES

The Australian Standard AS3725 - Loads on buried concrete pipes classifies pipe installations and
specifies the requirements for soil materials around the pipes and the compaction of these
materials. The engineer would refer to AS3725 when setting the specifications for a job. This
information will also be on the drawings that you will be using to lay the pipes.
There are three main types of pipe support:
• Type U support for uncontrolled pipe installations

• Type H support for pipes installed with haunch support

• Type HS support for pipes installed with haunch and side support
The different types of support (U, H and HS) are needed to give the pipeline good support in
different ground and load conditions. For example in good soil conditions and with light loads type
H embedment might give the same strength to the pipeline as type HS embedment in poor soil or
under greater loads.
Concrete pipes have a built in strength of their own which is why type U installations where the
pipe has very little support are possible.
This module will not cover any more detail on pipe supports because this is determined at the
design stage and the information provided so far is for information purposes only.
Laying Concrete Pipes
After the preparation of the bedding for the pipe, the pipes can be lowered in position following the
guidelines discussed earlier under Handling Of Concrete Pipes.

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 Terminology Used in Laying Concrete Pipes

Haunch Zone

The area from the bottom of the pipe and up to one third of the way up the side of the pipe.

Side Zone

The area from the top of the haunch zone to two thirds of the way up the side of the pipe.

Overlay

The area from the last zone to 300mm above the top of the pipe.

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 Topic Four — Laying and Jointing Pipes Page 4.1

LAYING AND JOINTING PIPES

INTRODUCTION
Now that you have completed the first three topics in this program you should have a good working
knowledge of the general aspects of pipe laying including safety, pipe storage, trench preparation
and compaction. We will now move on to the actual laying and jointing of the pipeline. The
following sections contain information on the three main pipe type PVC, steel and concrete.

The quality of the finished pipeline will only be as good as the initial preparation of
trenches and bedding etc.

PREPARATION
Before the pipes are laid and jointed you should complete any necessary preparations so that the
stringing process is accomplished without interruptions. Preparations should include the following.

• Bedding material is correct height.

• Levelling devices set up.

• Ensure that the correct quantity and type of fill material is available.

• Remove the required pipes from the storage area and lay them beside the tench on the side
opposite to where the spoil is stacked.

Pipes strung with sockets Socket Sand Bags/Chocks

facing direction of laying Spigot End

Pipes in Trench
Direction of Flow

Trench

Laying Direction

Spoil
PREPARING THE PIPES FOR LAYING

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Title Training PtyStandard
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 Topic Four — Laying and Jointing Pipes Page 4.2

• When placing the pipes beside the trench you should:

- place each pipe so that its socket is facing the direction of laying such that during laying
operations the spigot is inserted into an already laid socket

NOTE
Pipes should be laid with their spigot ends pointing downstream so that laying and joining
starts from the downstream end of the pipeline and progresses upstream. This allows:
• stormwater to escape during construction
• any forces on the pipes to cause the joints to consolidate rather than weaken
• easy identification of the direction of flow if the pipes are excavated at a later date.

- ensure that the pipe is handled in accordance with its type. For example, concrete pipes
should be placed with the stencilled ‘Top’ uppermost, steel pipes should not be placed
directly onto the ground etc
- ensure that all pipes are chocked to prevent movement.

• Ensure that sealing rings, fittings etc are available in sufficient quantities.

• Ensure that machinery, equipment and personnel are available to commence laying:
- levelling devices in place (laser)
- access to trench
- atmosphere monitoring (if required).

• Ensure that trench support is in place if required.

• Ensure that each pipe is free from damage such as cracking, or severe cuts or dents in the
case of PVC pipes.

LAYING PIPES
Depending on the class and type of pipe, bed- Load Load
ding may or may not be required. If bedding is
required, it must be of the correct depth, grade Crack
and material type as specified on the construc-
tion drawings/specification.

Bedding should provide even support along the

length of each pipe. If the bedding contains large
rocks, or contains high and low points, the pipe Gaps in Bedding
will be subject to point loads which can: INSUFFICIENT BEDDING SUPPORT

• cause cracking in concrete pipes

• affect the grade of individual sections of the pipeline which can result in pooling and/or
inferior joints.

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 Topic Four — Laying and Jointing Pipes Page 4.3

Bedding should be screened to provide an even resting surface for the pipe, but should not be
compacted unless compaction is specified for that pipe type.

A recess should be dug into the bedding to make

room for the pipe sockets, otherwise the pipe
will rest on the sockets with very little support
over its length. Socket recesses also help pre-
vent the ingress of bedding material into the joint
during the jointing process.
Dig to Here
The recess should be slightly larger than the
socket to allow for the pipe to be pushed home
during jointing. Once the pipe has been joined, Push
Home
any gaps left in the bedding around the join
Neat Fit
should be filled in.
SOCKET RECESS

JOINTING PVC PIPES

PVC pipes are jointed using either a solvent cement or rubber rings. The following sections outline
the correct procedure to use for both these jointing methods.

JOINT TYPES

There are a number of joint types that can be used to join PVC pipes. The type of joint that is used
is dependant on the application of the pipe and its configuration.

Deflection Joints

Deflection joints allow a predetermined angle

to be inserted into the pipeline. These joints are
used where the deflection angle is greater than
that which is able to be achieved using the natu-
ral flexibility of the pipe. The amount of de-
flection allowed at a joint (if any) is normally
specified. PVC DEFLECTION PIPE JOINT

NOTE

Deflected joints are not applicable to sewer or pressure lines.

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 Topic Four — Laying and Jointing Pipes Page 4.7

Thrust Blocks

Underground PVC pipelines jointed with rub-

ber ring joints require concrete thrust blocks to
prevent movement of the pipeline when a pres-
sure load is applied. In some circumstances,
thrust support may also be advisable in solvent
cement jointed systems. Uneven thrust will be
Tee (Plan) Tee (Elevation)
present at most fittings. The thrust block trans-
fers the load from the fittings, around which it
is placed, to the larger bearing surface of the
solid trench wall.

Construction of Thrust Blocks Horizontal Bend (Plan) Reducer (Plan)

Concrete should be placed around the fitting in a

wedge shape with its widest part against the solid
trench wall. Some forming may be necessary to
achieve an adequate bearing area with a minimum
of concrete. The concrete mix should be allowed
Vertical Bend (Elevation) Blank End - Elevation
to cure for seven days before pressurisation.

A thrust block should bear firmly against the

side of the trench and to achieve this, it may be
necessary to hand trim the trench side or hand
excavate the trench wall to form a recess. The
thrust acts through the centre line of the fitting Valve (Elevation) Hydrant at EOL
(Elevation)
and the thrust block should be constructed sym-
THRUST BLOCK APPLICATIONS
metrically about this centre line.

Pipes and fittings should be protected with a covering such as felt when adjacent to concrete so that
they can move without being damaged.

NOTE
Thrust blocks must no contact the pipes entering the bend or Tee, as this will restrict the
flexibility of the joints.

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 Topic Four — Laying and Jointing Pipes Page 4.16

JOINTING CONCRETE PIPES

Concrete pipe joints are generally accomplished using rubber rings, or by using flush jointed pipes
that are sealed with mortar or external bands. The type of joint that is required will be specified in
the construction drawings/specifications and is dependant upon:

• the type of foundation and backfill

• expected ground movement
• water pressures that will be applied to the pipe both internally and externally.

RUBBER RING JOINTS

There are two types of rubber ring joints for concrete pipes. These are classified as rolling ring
joints and skid ring joints.

As their names suggest, the rolling ring joints are

made by rolling the rubber ring into position when Ring sits
in Groove
the joints are assembled, while the skid ring
joints are made by sliding or skidding the pipe
over the ring during assembly. Rolling ring joints Pipe Spigot
are assembled dry and without the use of lubri- Rolling Rubber Ring
cant, whereas the sliding or skid type joint re- Ring sits against
quires lubricant and can be assembled when wet, Spigot Step
or while partly or fully submerged.

Both types of rubber ring joints are compressed Pipe Spigot

to form a watertight seal once the pipe is in its Skid Ring
final position. RUBBER RING TYPES

Rolling Ring Joints

Rolling ring joints are the most commonly used rubber ring joint in concrete pipelines as they are the easiest
to install. The following procedure outlines the steps that should be taken when making this type of joint.

• Inspect the joint surfaces and:

- repair or set aside any damaged pipes
- remove any foreign material such as dust, caked mud etc.

• Inspect the ring and ensure that:

- the ring is the correct size and type for the pipe
- the ring is free from defects — discard any damaged rings.

• Place the ring on the pipe using one of the following two methods.

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Method One

• Fit the ring in the groove on the spigot.

• Pull the ring away from the pipe and

let it snap back — do this in several
placed around the circumference, this
helps to uniformly tension the ring.

Method Two

• Place the ring on the pipe at the

shoulder.

• Pull the ring away from the pipe and

let it snap back — do this in several PULL AND RELEASE
placed around the circumference.

• Roll the ring forward along the spigot rebate and into the groove.

NOTE

For larger pipes, two people may be required to roll the ring.

• Check for twists in the ring additional rolling may be required to remove these.

• Place the spigot of the pipe being laid into the socket of the previously laid pipe so that the
rubber ring is just touching the socket lead-in.

NOTE
Ensure that the ring is touching the socket lead-in at all points around the circumference
of the lead-in. If not, the pipe is not correctly aligned and adjustments should be made to
rectify this.

• Push the pipe home. This can be done by using one or both of the following methods.

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Method One

• use a bar and block to push the pipe

home — ensure that the block of wood
is between the bar and the pipe to Crow Bar
prevent damage to the socket.

Timber Block

BAR AND BLOCK METHOD

JOINTING PIPES WITH THE BAR AND
BLOCK METHOD

Method Two

• Insert a ‘deadman’ pull point into a HW Timber Dead Man

previously laid pipe two to three pipe located 2 to 3 pipes in Rubber Ring
the laid pipeline on Spigot
lengths back from the joint being made.
This consists of a length of hardwood
timber, that is slightly longer than the
internal diameter of the pipe, and to
which a wire rope or chain is attached.
Wire Rope Come-along HW Timber
A second length of timber is placed or Chain Winch Bearer placed
across the face of the socket and attached in socket
to the wire rope/chain. A winch is then WINCH METHOD
connected to the wire ropes/chains and
used to pull the pipes together.

NOTE
Ensure that the pipe being jointed is pulled evenly into the socket of the laid pipe.

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 Topic Four — Laying and Jointing Pipes Page 4.19

• Watch the joint as it is being made. The 1 Rubber ring on spigot groove
illustration opposite shows how the
rubber ring is rolled and compressed
during jointing.
Spigot about to
enter socket
• Ensure that the pipe does not rebound
after it has been pushed home. 2 Rubber ring rolling along
spigot as joint is made
• Check to see if the ring is visible after the
pipe has been pushed home. If the ring is Spigot entering
visible the joint will have to be remade. socket
3 Feeler gauge to check
• Check that the ring is in place around rubber ring pisition
the joint. A feeler gauge can be used
to confirm that it is the same distance
from the lip of the socket around the Joint completed
entire circumference.
RUBBER RING JOINTING
Skid Ring Joints

Observe the following procedure when making skid ring joints.

• Inspect the joint surfaces and:

- repair or set aside any damaged pipes
- remove any foreign material such as dust, caked mud, etc.

• Inspect the ring and ensure that:

- the ring is the correct size and type for the pipe
- the ring is free from defects — discard damaged rings.

• Place the skid ring on the groove on the spigot.

NOTE
The ring must be free of twists or tension. If required, run a screwdriver or similar tool
under the ring to release any twists or tension.

• Apply a liberal coating of joint

lubricant to the inside surface of the Socket
socket and to the skid ring. Joint Lubricant

Skid Ring

Lubricant is supplied for use with the skid

rings. Only the supplied lubricant should
be used when making these joints. Do not Spigot
use petroleum products such as grease or
SKID RING ASSEMBLY
oil as a substitute lubricant, as these will
cause rapid deterioration of the seal.

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• Place the spigot of the pipe being laid, into the socket of the previously laid pipe, so that
the skid ring is just touching the socket of the laid pipe.

NOTE

Ensure that the ring is touching the socket lead-in at all points around the circumference of the
lead-in. If not, the pipe is not correctly aligned and adjustments should be made to rectify this.

• Push or pull the pipe home using the bar and block or winch methods.

FLUSH JOINTS
Flush jointed pipes come in two different classes.
These are as follows.

• Internal flush joint — these joints are

provided on pipes that are 525mm in
diameter and smaller. These pipes are
too small to enter after jointing, so they Bottom of Pipe
are sealed with sand bands on the outside. Internal Flush Joint

• External flush joint — these joints are

provided on pipes that are larger than
525mm in diameter. These pipes are
large enough to enter after jointing, so Bottom of Pipe
they are sealed with mortar on the inside. External Flush Joint
FLUSH JOINTS

Making Flush Joints with Mortar

Observe the following procedure when making flush joints with mortar.

• Inspect the joints surfaces and:

- repair or set aside any damaged pipes
- remove any foreign material such as dirt caked mud etc.

• Place the spigot of the pipe being laid into the socket of the previously laid pipe.

• Push or pull the pipe home using the bar and block, or winch methods.

• Ensure that the area to be mortared is clean and dry.

• Pack the mortar into the joint. Make sure that it fills the joint all the way around the pipe.

NOTE
Only complete this task after backfilling is complete, otherwise vibration will cause the
mortar to fall out.

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 TYPES OF CONCRETE PIPES

Concrete pipes are divided into five different classes according to the strength of the pipe.
Each class is identified by coloured markers or stencilling.

CLASS DESCRIPTION MARKER COLOUR

LDU Un-reinforced No marker
2 Standard reinforced White
3 Extra strength reinforced Red
4 Special strength Yellow
5 reinforced Green
Special strength
reinforced

Special large sizes may be obtained by arrangement from the manufacturer.

Welded steel reinforcement is used to add to the strength of the concrete pipe. The
reinforcement may be circular or oval in shape. In the pipes, which the steel reinforcing mesh
or bars are placed in an oval shape, it is essential that they be placed in the correct manner. All
manufacturers place marks on pipes for this purpose if applicable, generally on the inside of the
pipe barrel. The pipe is usually correctly placed if the mark is top centre or bottom centre, but
check with the manufacturer is recommended.

It is also important to store and lift these pipes with the top up otherwise they may crack
because they are not designed to take as much load on the sides of the pipe.

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 Receiving
When receiving pipe shipments at the job site, the contractor or purchaser should exercise
established precautions. Each pipe shipment should be inventoried and inspected with care upon
arrival. The pipe was inspected and loaded with due care at the factory using methods acceptable
to the carrier. It is the carrier’s responsibility to deliver the shipment in good condition and it is the
receiver’s responsibility to ensure that there has been no loss or damage.
The following procedures are general recommendations for acceptance of delivery:
Make overall examination of the load. If the load is intact, ordinary inspection while unloading
should be sufficient to ensure that the pipe has arrived in good condition.
If the load has shifted, has broken packaging, or shows rough treatment, carefully inspect each
piece for damage.

Check total quantities of each item against shipping records.

Note any damaged or missing items on the delivery receipt.
Notify the carrier immediately and make a claim according to his instructions.
Do not dispose of any damaged material. The carrier will notify you of the procedure to follow.
Shortages and damaged materials are not re-shipped without request. If replacement materials are
needed, reorder Pipe from your distributor.

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 Unloading
The means by which the pipe is unloaded in the field is the decision and the responsibility of the
receiver. These general recommendations should be followed:
Remove restraints from the top unit loads. These may be either straps, ropes, or chains with
padding.
Remove any boards on the top or sides of the load which are not part of the pipe packaging.
Using a forklift with thin chisel forks (or a front-end loader equipped with forks), remove the top
units one at a time from the truck.

If a forklift is not available, use a spreader bar with fabric straps capable of carrying the load.
Space straps approximately eight feet apart. Loop straps under the load. Cables may be used only
if they are cushioned to prevent damage to the pipe.
During the removal and handling, ensure that the units do not impact anything (especially in cold
weather).
Place pipe package units on level ground.
Do not handle units with individual chains or single cables, even if padded.
Do not attach lifting cables to unit frames or bands.
Do not stack package units more than 3 metres high.
Protect units with packing materials the same way they were protected while on the truck.
To unload lower units, repeat the unloading process described above.
Do not unload by hand.

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 WARNING: DO NOT STAND OR CLIMB ON CRATES OR CONTAINERS.
Storage
The following procedures are recommended to prevent damage to the pipe:
Store the pipe, at the site, in unit packages.
Avoid compression, deformation or damage to bell ends of the pipe.
When unit packages are stacked, ensure that the weight of upper units does not cause
deformation to pipe in lower units.
Support pipe unit packages on wood blocking to prevent damage to the bottom surfaces during
storage. Space supports to prevent pipe bending.
Store solvent cement in tightly sealed containers away from excessive heat.
Do not store pipe where gaskets may be exposed to ozone, grease or oil.

Protect pipe interior and sealing surfaces from dirt and foreign matter.

When unit packages are stacked, ensure that the stack remains stable.

Handling

The following procedures are recommended:

1. When using mechanical equipment, exercise care to prevent damage to the pipe.

2. Lower pipe carefully from trucks and into trenches. Do not drop pipe.

3. In subfreezing temperatures, use caution to prevent impact damage. Handling methods

considered acceptable for warm weather may be unacceptable during very cold weather.

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 When distributing pipes along a trench (stringing), place pipe on the opposite side of the trench
from the excavated earth. Place pipe with bell ends in the direction of the work progress.

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 Bedding
Bedding is required to bring the trench bottom up to grade and to provide longitudinal support
under the pipe. Blocking must not be used to bring the pipe to grade.
Bell holes are necessary at each joint to maintain continuous support for the pipe.
Bedding thickness of 100 to 150mm of compacted material is usually adequate.
Use of well-graded material is recommended where trench native soil is fine-grained.

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 Haunching
Haunching provides side support to the pipe. This area is the most important for controlling pipe
deflection.
Haunching material should be worked under the side’s of the pipe to ensure side support.
Where coarse materials have been used for bedding, the same materials should be used for
haunching.
Haunching should extend to the spring line of the pipe.

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 Initial Backfill
Initial backfill is placed to protect the pipe from impact damage during final backfill.
Since initial backfill provides little additional structural support, special compaction is not required.

Final Backfill
The material used for final backfill need not be as carefully selected as material in the embedment
zone, but should not contain boulders, frozen clumps or rubble which could damage the pipe.
Under open fields, natural compaction should be ad- equate. Under improved surfaces, special
compaction (as specified by the design engineer) is required.

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 Gasketed Pipe
Pipe gasketed pipe is an integrally belled product. All gaskets are installed at the factory.
The joint is engineered to provide problem-free service for the life of the pipe, but proper
procedures must be followed to ensure its effectiveness:

Clean the gasket area. Remove sand, dirt, grease, and debris. Do not remove gaskets from bells
— removal could cause improper reinstallation.
Check the gasket. Make sure it is seated uniformly in the groove by running your finger around the
inner edge of the gasket.
Clean the spigot. Use a rag to wipe the spigot clean.
Lower the pipe into the trench. Lower carefully to avoid getting dirt into the bell or spigot.
Lubricate. Apply lubricant only to the bevel of the spigot end and approximately mid-way back to
the stop line. WARNING: Use only those lubricants supplied by Pipe manufacturer — the use of
other lubricants may cause deterioration of pipe or gasket especially if they are petroleum based.

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 Keep lubricated areas clean. If dirt or sand adhere to lubricated areas, clean and re-lubricate.
Assemble pipe. Insert the spigot end into the bell until it contacts the gasket uniformly. Straight
alignment is essential for ease of assembly. Apply steady pressure by hand or by mechanical
means until the spigot slips through the gasket. Insert pipe until the stop line is flush with the bell
end. Bar and block assembly is recommended where possible because a worker is able to feel the
amount of force being used and whether the joint goes together smoothly. Special jointing
methods, such as ratchets, jacks, or backhoes can also be used if care is taken to insure that the
spigot is not over-inserted and that previously assembled pipe joints are not disturbed.

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 If undue resistance to pipe insertion is encountered or if the pipe cannot be inserted to the
reference mark, disassemble the joint and check the position of the gasket.
If the gasket has been dislodged from the race, inspect the pipe and gasket for damage, replace
damaged items, clean the components, and repeat the assembly steps, assuring straight
alignment.
If the gasket is still properly positioned, verify proper positioning of the reference mark. Relocate
the mark if it is not correctly positioned. In general, fittings allow less pipe insertion than do pipe
bells. If the pipe still cannot be inserted properly, call supervisor for assistance.

If the pipe must be field-cut, mark the entire circumference of the pipe to ensure a square cut. The
pipe can be cut with a hacksaw, handsaw, or portable power saw with a steel blade or abrasive
disc. Bevel the cut end using a pipe beveling tool, a portable sander, or abrasive disc. Round off
any sharp edges on the leading edge of the bevel with a pocket knife or a file. Mark cut end with
an insertion line similar to uncut pipe.

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 Bevel requirements vary with different joint types:

Joint

a. PVC pipe bell

b. PVC push-on fitting

c. Other pipe bell/push- on fitting

Bevel Same as factory bevel

Same as factory bevel

Shorter bevel length

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 Solvent-Cemented Pipe

Specifications: Solvent-cemented joints should be made in accordance with A “Standard

Recommended Practice for Making Solvent-Cemented Joints with Polyvinyl Chloride (PVC) Pipe
and Fittings.” The solvent cement should conform to AS/NZS 3879:2011 “Standard Specification
for Solvent Cements for Polyvinyl Chloride (PVC) Plastic Pipe and Fittings,” and the primer should
conform to AS/NZS 3879:2011 Joints of PVC Plastic Pipe and Fittings.” The handling of solvent
cements should also be in accordance with AS/NZS 3879:2011 “

Basic principles of solvent-cemented joints:

The joining surfaces must be clean and dry.

The joining surfaces must be softened and made semi-fluid.

Sufficient cement must be applied to fill the gap between male and female ends.

The assembly must be made while the surfaces are still wet and fluid.
Joint strength develops as the cement dries. In the tight part of the joint, the surfaces will fuse
together. In the loose part, the cement will bond with both surfaces.

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 Completed joints should not be disturbed until they have cured sufficiently to withstand handling.
Storage: PVC solvent cements should be stored in a cool place except when actually in use at the
job site. Consult the cement manufacturer for specific storage recommendations on storage
conditions and shelf life.
Procedure: a. Cutting the Pipe — Cut pipe square with the axis, using a fine-tooth saw with a
miter box or guide.

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 Joint Preparation — Remove all burrs and break the sharp lead edges.

Cleaning — Surfaces to be joined must be cleaned and free of dirt, moisture, oil, and other foreign
material.

Handling Cement — Keep cement can closed and shaded when not actually in use. Discard the
cement when a noticeable change in viscosity occurs, when the cement does not flow freely from
the brush, or when the cement appears lumpy and stringy. Keep the brush immersed in cement
be- tween applications.
Application of Primer and Cement — The time necessary for the primer to etch the pipe surface is
dependent on ambient temperature. PVC solvent cement is fast drying and should be applied as
quickly as possible, consistent with good workman- ship. Follow the manufacturer’s
recommendations for application of primer and cement.
Assembly of Joint — While both the inside socket surface and the outside surface of the male end
of the pipe are SOFT and WET with solvent cement, forcefully bottom the male end in the socket.
Turn the pipe or fitting ¼ turn during assembly (but not after the pipe is bottomed) to distribute the
cement evenly. Assembly should be completed within 20 seconds after the last application of
cement.

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 After assembly, wipe excess cement from the pipe at the end of the socket. Any gaps in the
cement bead around the pipe perimeter may indicate a defective assembly.

Set Time — Handle the newly assembled joints carefully until after the set period as follows:

Installation:
After the set period, the pipe may be carefully placed in a prepared ditch.
Safe Handling of Solvent Cement:
Keep solvent cements and primers away from all sources of ignition.
Provide adequate ventilation to reduce fire hazard and to minimize breathing of vapors.
Avoid contact with skin and eyes.
Refer to AS/NZS 3879:2011 for more information.

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 General
This chapter gives recommendations for project testing, but the final authority on testing
requirements is the project engineer.
Sewer pipe installations are tested for alignment, leakage, and deflection. Sections of the system
that fail to pass testing should be located, repaired, and re- tested until tests are passed.
Prior to the start of testing, all sewer lines should be cleaned. The use of a sewer cleaning ball or
high velocity jet may be necessary.
Visual Testing
Sewer lines may be visually inspected:
Purpose — To verify accuracy of alignment and freedom from major defects, debris, and
obstructions.
Methods — Usual methods are photography, closed circuit television, or lamping with mirrors and
lights.

Leakage Testing
Methods of testing are air exfiltration, water infiltration, or water exfiltration. We recommend the
use of low pressure air exfiltration. Only those lines tested after backfilling to final grade should be
accepted.
Air Exfiltration Testing
Safety — All plugs and caps should be secured to prevent blowouts. All pressurizing equipment
should include a relief valve set no higher than 9 psig to avoid over-pressurizing.
Line Preparation — During construction, all laterals, stubs, and fittings should be plugged or
capped to prevent air loss that could affect air test results.
Isolation of Test Section—Pneumatic or mechanical testing plugs should be installed at each end
of the pipe sections to be tested.
Line Pressurization — Low pressure air should be slowly introduced into the test section until the
air pressure reaches 4.0 psi greater than the average external pressure of any groundwater above
the pipe. Maintain this internal pressure for at least two minutes to allow pressure stabilization, and
then shut off the air supply.

Timing of Pressure Loss — At any convenient observed pressure reading between 3.5 and 4.0 psi
greater than the average external pressure of any groundwater above the pipe, begin timing the
pressure loss. If the time shown in Table 5.1 for the designated pipe size and length elapses
before the air pressure drops 0.5 psig, the section is considered to have passed the test. The test
may be discontinued once the prescribed time has elapsed, even though the 0.5 psi loss has not
occurred.

Technical data

Allowable air loss rate (Q) — The value for Q is 0.0015 cubic feet per minute per square foot of
internal surface.

Test time table — If the specified pressure drop is 1.0 psig, the time values in Table 5.1 should be
doubled.

Testing main sewers with lateral sewers — If lateral sewers are included in the test, their lengths
may be ignored for computing test times. (Ignoring the laterals results in a slightly more severe
test.)
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 Water Infiltration Testing

Ground water requirements — This method of testing is acceptable only when the ground water
level is above the top of the pipe throughout the length being tested.

Allowable infiltration — as measured by a weir or current meter, infiltration should not exceed 50
gallons per inch of internal pipe diameter per mile per day (4.6 liters/mm/km/day).

Water Exfiltration Testing

Ground water requirements — Ground water must be low enough that external pressures
generated by the ground water above the pipe do not interfere with the test.

Test head — The maximum internal water head should not exceed 25 feet (7.6m) at the lowest
end, and the water level in the manhole should be 2 feet (0.6m) higher than the top of the pipe or 2
feet (0.6m) higher than the ground water level, which- ever is greater.

Allowable exfiltration — Water exfiltration should not exceed 50 gallons per inch of internal pipe
diameter per mile per day (4.6 liters/mm/km/day).

Deflection Testing

The engineer chooses locations and methods for deflection tests.

Purpose — To verify proper installation of the pipe in areas where difficult construction conditions
were encountered .

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 Method — The recommended method is a mandrel sized for the allowable deflection.
Allowable deflection — The maximum allowable reduction in inside diameter should be 7½%.
Inside diameter and 7½%. mandrel dimensions are as follows:

Special Considerations
Longitudinal Bending
The ability of PVC pipe to bend is a significant advantage over rigid pipes.
Longitudinal bending may be done deliberately during construction or may be the result of changes
that occur in the pipe-soil system after construction.

Longitudinal bending is accomplished by axial flexure of the pipe combined with deflection of the
gasketed joints:
Axial flexure — The minimum bending radius is recommended to be 160 times the pipe OD.
Joint deflection — For design purposes, joint de- flection should be zero; in the field the maximum
allowable joint deflection is one degree.
Where bending is required, it should be done manually. The use of mechanical equipment may
cause damage to the pipe or joining system.

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 Thermal Expansion and Contraction

All materials expand and contract with changes in temperature. Linear expansion of pipe in the
longitudinal direction is dependent on:

Variation in temperature

Coefficient of thermal expansion of the material. It is important to note that the rate of thermal
expansion and contraction is not dependent on pipe size or wall thickness.

The coefficient of thermal expansion for PVC is 3.0 x 10-5in/in/°F (5.4 x 10-5mm/mm/°C).

Allowance for thermal movement: a. 0.36 inch of length variation for every 100 feet of pipe for
each 10° F change in temperature. b. 5.4 mm of length variation for every 10 meters of pipe for
each 10° C change in temperature.

Gasketed joints — When gasketed joints are used, thermal movement is not a significant design
factor as long as: a. Pipe temperatures are kept within accepted limits for PVC pipe. b. Joints are
properly installed with the pipe spigots inserted into the bells to the insertion line.

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 WARNING: IF PIPE SPIGOTS ARE INSERTED PAST THE INSERTION LINE, THERMAL
EXPANSION MAY CAUSE SIGNIFICANT STRESSES IN THE PIPE BELLS.

Solvent cemented joints — When solvent cemented joints are used, thermal movement cannot be
accommodated in the pipe joints. After the joints are properly cured, pipe should be installed in
straight alignment. Before backfill to the extent that restricts longitudinal movement, the product
temperature should be adjusted to within 15° F (8° C) of operating temperature.

Where the operating temperature cannot be closely controlled, the stresses resulting from extreme
temperature variations must be considered in the design. The design engineer should be
consulted for guidance.

Thermal Effects on PVC Properties The physical properties of PVC vary with changes
in temperature. The rated values for PVC properties are established at 73.4° F (23° C).

As temperature decreases below 73.4° F, pipe stiff- ness and tensile strength increase while
impact strength decreases. This decrease in impact strength requires that more care be taken
during installation in cold temperatures.

Conversely, as temperatures increase, pipe stiffness and tensile strength decrease while impact
strength increases. Decreases in pipe stiffness require that more care be taken during installation
in hot weather.

Ultraviolet (UV) Radiation

Like most plastics, PVC can experience degradation when exposed to UV radiation. This
degradation occurs only on surfaces exposed to the sun and pen- etrates only about .001 inch into
the pipe wall. The affected areas often turn a yellow color. When the pipe is no longer exposed to
the sun, further degradation does not occur.

Ultraviolet exposure does not significantly affect pipe stiffness or tensile modulus properties.
However, there is a measurable reduction in values for impact strength.

PVC pipe’s high initial impact strength means that reductions in impact properties due to UV
radiation are of little concern. If good construction practice is fol- lowed in unloading, handling, and
installation, pipe breakage due to impact loads will not be a problem.

Appurtenances

Manholes

Purpose — Manholes provide access to the sewer line for inspection and maintenance, and
provide control of hydraulic flow at flow discontinuities.

Spacing — The interval between sanitary sewer manholes is usually 300 to 500 feet.

Foundations — A stable foundation is essential to prevent settlement which could damage the
pipe/ manhole connection.

Connections — An elastomeric water stop gasket should be used to prevent leakage and allow
longitudinal movement of the pipe. A non-shrink or expansive grout should be used for
connections to manhole walls.

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 Fittings — Fittings are required at all house connections, cleanout accesses, and changes in line
direction or size not occurring at manholes. Fittings may be molded or fabricated.

Saddles — Taps into existing lines should use a gasketed PVC saddle wye or tee. Saddles should
be installed per the manufacturer’s recommendations.
Service lines — Lines from the property line to the collection sewer should be at a minimum depth
of 3 feet (1 m) at the property line.

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 TYPICAL EXAMPLE of GUIDELINES FOR SEWER PIPELINES REQUIREMENTS
(1) MINIMUM REQUIREMENTS FOR SEWER - PIPELINES

(a) Capacity:
Sewers shall be of such diameter as to pass without overflow, bypass, or back flow onto
damageable property of a user the design peak flow including sewage and infiltration. All
unavoidable inflow from roof, surface, footing, foundation, or other groundwater or surface water
sources shall be excluded from capacity allowance.

(2) GUIDELINES FOR SEWER PIPELINES

(a) Capacity:
(A) Collection sewers should be designed for the ultimate development of the tributary areas as
determined by master sewerage and land use plans of the owner.

(B) The design of sewers should be based upon initial and ultimate flows. Flows should be broken
down into domestic, industrial, and infiltration/inflow fractions. A peaking factor should be applied
to domestic and industrial fractions.

(C) Domestic flows should be between 50 and 100 (gallons or 200-400 litres per capita per day
(gpcd). Peaking factors should be between 1.8 and 4.0. Infiltration allowance should be normally
less than 2,000 gallons / 7500 litres per acre per day; any greater allowance should be justified.
Any significant inflow allowance should be justified.

(D) The minimum diameter of sewers should be 8 inches /200mm for maintenance purposes.
Short non extendable 6 inch/150mm sections of up to 250 feet / 75m are permissible.

(E) Replacement sewers should be designed commensurate with flow conditions.

(b)Velocity:
Sewers shall be designed to have a velocity to "self clean" or transport constituent solids to the
treatment facility or the owner shall periodically service sewers to flush, transport, or remove solids
from sewers with minimal velocity.

(b)Velocity:
(A) Sewers should be laid on a gradient which will produce a mean velocity, when flowing full or
half full, of at least (2) two feet o 600mm per second, based upon the Manning formula with "n",
the coefficient of roughness, valued at 0.013.

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 (B) Sewers with minimal flow such as upper reaches of laterals or those sewers serving few
dwellings should be steepened and/or reduced in diameter to approach a (2) two feet /600mm per
second self cleaning velocity. Actual flows during initial years of use should be carefully evaluated
in this regard.

C) Force mains and inverted siphons should be designed for (3) three feet/900mm per second at
average flows.

(D) The minimum gradient for 8 inch/200mm sewers should be no less than 0.4 percent
regardless of pipe material.

(E) The minimum gradient for 6 inch / 150mm sewers should be no less than 0.6 percent,
preferably 0.75 percent.

(F) The flow channel(s) through manhole bases should be smooth and conform to the shape and
slope of the inlet sewer(s).

(G) Intersecting sewers, sewer connections, etc., should be made without causing backup into the
smaller sewer. For intersecting unequal sized sewers in manholes, the elevation at 0.8 of
full depth of flow in each sewer should match.

(c) Watertightness: (English Dictionary -adjective. not permitting the passage of water either in or out)

Completed sewer construction shall result in limited infiltration/exfiltration through pipe walls, joints,
fittings, and connection fittings, etc., and no inflow. The limit shall be consistent with the pipe and
manhole materials and with what is obtainable at the time by the construction industry on
representative jobs for the same type of construction using high quality materials and state-of-the-
art methods of workmanship. All completed sewer lines in new work shall be tested for
watertightness using either recognized air or water testing requirements and procedures.

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 (c) Watertightness:
(A) Watertightness begins with good material and finally depends upon sound field practices. Good
inspection and tests should be supplemented with an initial television inspection after trench
backfilling is complete. Since many defects do not appear initially, an eleventh month final
inspection should be performed where that capability is available and determined necessary to
obtain acceptable in-place work. If only one television inspection is considered, the eleventh month
inspection is recommended.
(B) Exfiltration testing or the low pressure air test for sanitary sewers should be a pressure at least
6 feet/2m greater than the groundwater conditions which the sewer is subject to at test time.
(C) Pipe materials, joints, fittings, and appurtenances should be selected for their
watertight capabilities.
(D) Acceptance or performance standards should not necessarily be uniform for all pipe materials
since average testing results with good workmanship for work will vary depending upon pipe
materials. The range of allowable exfiltration/infiltration for work acceptance should be between 50
and 200 gallons per day per inch-of-diameter per mile (gpdidm). Nonporous (non-airpermeable)
pipe should sustain pressure for twice the computed time for the same one pound per square inch
(psi) air pressure drop required by the air test. Test sections should be from manhole-to-manhole
or about 700 feet maximum.
(E) The watertightness of all building sewers should conform to the State Plumbing Code and be
tested without exception.
(F) Manholes should be water tested for exfiltration during construction and/or visually inspected
during first wet weather season after construction for infiltration. Leaks should be promptly
repaired.
(G) Curved sewers should be as watertight as other sewers and be tested. While not
recommended, horizontal/vertical curves at times may be allowed but should be limited in use.
When used, the minimum radius of curvature should be not less than 200 feet and the maximum
computed joint opening no more than 3/8 inch. Complete and accurate records should be kept of
the exact location of such curved sewers for future reference. Reasonable field control should be
exercised to not compound joint deflections and compromise watertightness.
(d) Structural Strength:
The completed installation including the excavated trench, the pipe, the bedding, and the pipe
zone materials shall resist imposed loads from backfill, impact, and live loads (construction and
design) without pipe failure through crushing, loss of watertightness, settlement, or significant
capacity loss.

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 (d) Structural Strength:
(A) Bedding material should be placed full trench width from at least 4 inches under to spring line
of all pipe for a leveling course and proper pipe support. Hand shaping of the native trench bottom
for rigid pipe is not recommended but may be allowed, if appropriate, and uniform pipe support can
be obtained and grade/ alignment can be maintained.
(B) Cantilevering of non reinforced rigid pipe at manholes should be limited to the least distance
practicable to make a flexible connection. A flexible joint should be within 12 inches of manhole for
smaller pipe sizes. A second flexible joint should be provided within 4 feet of the manhole.
(C) Where cover from top of pipe to finished grade is less than 36 inches, special design and/or
construction requirements should be considered including, but not limited to, raising finish grade,
increasing class of pipe and/or pipe bedding, use of ductile iron, concrete encasement and
restriction of construction equipment from travel over partially backfilled trench.

(e) Ability to Pass Solids:

Sewer systems shall be free of depressions, sharp edges, roughness, side sewer projections,
obstructions, restrictions, displaced "0" rings, etc., which can cause solids to accumulate or
deposit.
(e) Ability to Pass Solids:
(A) New sewers should be thoroughly flushed and visually inspected for accumulated debris prior
to use.
(B) Building sewer connections should be made with fittings which prevent any projection into the
main sewer. The main sewer should not be cracked, crushed, or otherwise damaged in making
taps. All taps should be watertight.
(C) A tolerance for vertical deviation from true grade line should be plus or minus 0.02 feet.
Depressions for solids deposition should be avoided. Similarly, the horizontal tolerance for
deviation from line should be plus or minus 3/8 inch.
(D) Drop manhole piping should be easily maintained, self cleaning or able to "overflow" into the
manhole. Pressure sewer piping connections, flow measuring devices, etc., in manholes
should be designed to not obstruct flow.
(E) Flow channels in manholes should slope at least 0.1 feet from inlet to outlet.
(f) Durability:
(A) The materials and details of construction shall provide an in place sewerage system which will
resist corrosion of the pipe and manhole materials caused by any source or condition. Any
corrosive effect shall be consistent with the design life of the sewer.
(B) Resistance to erosion of surfaces by grit, high velocity flow, etc., shall be addressed if
appropriate.
(C) Temperature effect upon thermoplastic materials shall be appropriate.

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 (f) Durability:

(A) Sewers should be constructed of materials resistant to or protected from biological

degradation, acid and alkaline solutions, normal sewer temperature variations, abrasion and
industrial wastes (where applicable), or other harmful service conditions which may exist in the
sewerage system.
The owner should have a user ordinance which restricts discharge of harmful substances into
the sewerage system.

(B) Velocities over 15 feet per second in sewers should have special consideration for erosion
control.

(g) Stability:

(A) Line and Grade: Horizontal alignment and vertical grade of in place sewers upon construction
completion and construction acceptance shall be relatively stable.

Design considerations, construction specifications, inspections, etc., shall preclude pipe

settlement, shifting, or flotation such that capacity, watertightness structural integrity, ability to pass
solids, maintainability, etc., are not compromised either at construction or any later time.

(B) Diameter: Rigid, flexible and semi flexible pipes tend to lose minimum inside diameter if not
designed and/or installed properly. Design considerations, construction specifications, field
inspections, etc., shall preclude diameter loss such that capacity, watertightness, structural
integrity, ability to pass solids, maintainability, etc., are not compromised either at construction or
any later time.
(g) Stability:
(A) Appropriate foundation stabilization or soils should be employed in unstable soils. Back fill
should be in small lifts and compacted uniformly to specified density along and around the pipe.
(B) The Soil Class and density for bedding and pipe zone materials should be carefully selected
and then compacted in the field to the required in-place density.
PVC and ABS composite sewer pipe should be deflection tested upon construction completion
prior to acceptance with an approved nine blade go-no-go gauge. Initial deflection at construction
completion should be no more than the following:
i) PVC (ASTM D-3034) sewer pipe should deflect no more than 4 to 5 percent based upon inside
base diameters of 7.76, 9.71, 11.56 and 14.14 inches for 8, 10, 12, and 15 inch nominal pipe
respectively.

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 (ii) ABS (ASTM D-2680) composite sewer pipe should deflect no more than 2 to 3 percent based
upon inside average diameters of 7.75, 9.75, 11.75 and 14.75 inches for 8, 10, 12, and 15 inch
nominal pipe respectively.
(C) Sewers on slopes over 25 percent should be evaluated for slippage or pipe bedding depending
upon soil type, groundwater presence, construction conditions, etc. Appropriate anchors should
be provided if necessary.
(h) Operation, Maintenance, and Safety:
Sewer systems require periodic and unscheduled maintenance for sustained operation. Designs
shall conform to requirements of the sewage works owner for manhole construction, spacing, size,
details and easements. All parts of the sewerage system shall be readily accessible. The minimum
inside bottom diameter of manholes shall be 42 inches.
(h) Operation, Maintenance, and Safety:
(A) Access to the sewer by the sewer owner is essential to perform maintenance tasks.
Easements should be granted along the sewer line to the system owner for any sewer for
emergency repairs. Manholes and cleanouts are necessary for routine access. Structures should
not be located over sewers.
(B) Owners should review own procedures, equipment, construction standards, etc., for sewer
maintenance. Requirements of the owner should be obtained by designers upon start of sewer
design since the owner must assume all future maintenance. Stricter standards of the owner
should prevail if in conflict with these guidelines.
(C) General Manhole/Cleanout Standards for Sewers:
(i) The minimum inside bottom diameter should be no less than 48 inches. The least inside
dimension may be reduced 38 inches where an inside drop is acceptable to the owner. No more
than one inside drop should be installed in a manhole.
(ii) Minimum cover opening diameter should be 22 inches.
(iii) Manholes should be located at:
(I) Every change in grade or alignment of sewer.
(II) Every point of change in size or elevation of sewer.
(III) Each intersection or junction of sewers.
(IV) Upper end of a lateral sewer.
(V) At intervals of 500 feet or less except for 24 inch and larger sewers.
(iv) Cleanouts should not be substituted for manholes except at the upper end of lateral sewers
250 feet or less in length.
(v) Channel width and depth should be equal pipe diameter. Manhole base ledges should be
sloped to drain at least I in 12.
(vi) Access to manholes may be by portable ladder. Manhole rungs and in-place ladders which are
subject to considerable corrosion and sliming are not recommended.
(vii) Where free fall of sewage into a manhole exceeds 24 inches from inlet pipe invert to manhole
invert, an approved drop manhole should be used.
(D) Inverted siphons should include at least two pipe lines of such size and hydraulic gradient as to
maintain a velocity of at least 3 feet per second in one pipe under conditions of average dry
weather flow. Control manholes must be provided at both ends of the inverted siphon line. The
inlet and outlet details shall be so arranged that the normal flow is diverted to either barrel so that
the other barrel may be removed from service for maintenance.

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 (i) Separation of Water and Sewer Lines:
Protection of the water supply, be it distribution system, production facilities or source is not only
prudent but mandatory and absolutely necessary.
Sanitary sewers and appurtenances thereto shall not physically connect to a public or private
potable water supply system so as to permit the passage of any sewage or polluted water into the
potable supply.
Sewer construction shall not disturb, degrade, or decrease the watertightness of any existing water
supply line.

(i) Separation of Water and Sewer Lines:

(A) Parallel Water and Sewer Lines

(i) Sewer lines should conform to Figure A-1.
(ii) Common trench construction for water and sewer should be avoided where practical. Where
used, the minimum pipe separations of Figure A-1 should be maintained.
(B) Vertical Separation at Crossings of Water and Sewer Lines:
No special precautions should be necessary where top of sewer line is at least 1.5 feet below
bottom of waterline and adequate structural protection for each line is provided.
(C) Exceptions: Use of Pressure Pipe Material for Sewer Line:
(i) Where the above horizontal or vertical separations cannot be maintained, the following pressure
pipe materials should be used in addition to whatever waterline improvements or reconstruction
that may be advisable or required for protection of water. The use of these pressure pipe materials
from manhole-to-manhole is encouraged to avoid discontinuity of materials
(I) Ductile iron pipe, class 50, ANSI Standard A21.51 (AWWA C- 15 1) with either Push-on or
mechanical rubber gasket joints in accordance with ANSI Standard A21. 11 (AWWA-C I 11).
(II) PVC pressure pipe, ASTM D-2241, SDR 32.5, (125 psi) with rubber-gasket joint in accordance
with UNI-Bell Plastic Pipe Association recommended Standard Specification UNI-B-1 for a
pressure-joint assembly.
(III) Asbestos-Cement pressure pipe, class 100, ASTMC-296 (AWWA C-400) with rubberring
gaskets in accordance with ASTM D-1869.
(IV) High density polyethylene pipe (Driscopipe 1000) PE 3406, minimum SDR 32.5, with butt
fused joints.
(V) Other materials approved by the State Health Division.
At crossings requiring pressure pipe materials, the following should apply with one standard length
of special pressure pipe centered over the waterline in all cases:

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 (D) Soil Restoration at Crossings:
Soil removed in sewer line trench construction at waterline crossings where sewer crosses over
water should be replaced in all areas to as near natural densities as possible through mechanical
compaction to restore any natural resistance to groundwater movement which did exist prior to
construction. Soil should include no rock fragments over 1-1/2 inch in the pipe zone.
(E) Well Protection:
No sewer pipe should be laid less than 50 feet from any well without specific Health Division
approval. Pressure pipe materials should be used to protect wells where minimum setbacks are
not obtainable or where additional protection is required as determined by the State Health
Division.

(F) Pipe Testing:

Whenever a pressure pipe material is used for any of the above purposes of separation, an
appropriate pressure test should be conducted on the pressure pipe to confirm watertightness.
Test pressures should be no less than 15 psig where use will be for a gravity sewer and higher
where use will be for a pressure sewer (force main).

(G) Other Exceptions should be resolved jointly with the water purveyor and the State Health
Division.

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 PLANT AND EQUIPMENT REQUIREMENTS

The plant and equipment requirements will depend on the complexity of the drainage system. The
following items of plant, equipment and tools could be used:
• Hand Tools
< Pick
< Shovel
< Crow bar
< Broom
< Spade
< Hoe
< Heavy rake
< Spirit level
< Straight edge
< String line
• Equipment
< Dumpy or automatic level, staff and tripod
< Pipe laser level
< 100m tape measure
< Suitable timber for shoring trenches or
< Commercially available trench support equipment
< Appropriate chains and slings for lowering pipes into position
• Plant
On smaller drainage systems, a backhoe will be able to be used to excavate and then backfill the
trenching system.
An excavator would be more suitable for larger excavation work, but can still be used on smaller
projects. If an excavator is used, a front end loader will be required for backfilling the trenches.

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 Compaction equipment is required in backfilling the trenches to specification. The different types
of compaction equipment used will depend on the size of the trench being backfilled. Illustrated
below are some of the types of compaction equipment available for trenching applications.

VIBRATORY PLATE MACHINE

RAMMER OR
TAMPER MACHINE

VIBRATOR ROLLER MACHINE

More information on all these items of plant are available in the Plant Modules.

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 PROTECTION OF PERSONNEL AND PUBLIC
The Construction Industry has had a poor record of work related injury and disease and history is
littered with examples of construction projects that can be measured, not only by the engineering
challenge they provided, but by the number of workers killed or maimed on the job.

It must be remembered that both the employer and employee also have the responsibility to
protect the public from hazards to their health welfare and safety. In particular to drainage
applications where deep excavations are required.

Some statistics to bear in mind:

The Australian Construction The average workers' compensation

Industry compensation costs, when cost per employee in construction
compared to the cost of labour, are industry (1991) was $1,021, nearly
higher than any other industry in twice the average cost for all
the country, followed closely by the industries which was $650 per
manufacturing and mining employee.
industries.

(WorkSafe Australia: "Occupational Health and Safety Performance, Australia" 1993)

The following list provides brief details of some recent fatalities involving plant operators and
construction workers. The list is by no means complete and is provided as an example of the type
of incidents occurring far too frequently throughout Australia.
• An employee was killed when a trench 500 mm by 2.4m deep for drainage pipes collapsed.
The trench had not been shored.
• A plant operator, working alone on a weekend shift, drowned in a reservoir while attempting
to remove debris from the water. Access ladders and life buoys were of no use without the
assistance of another person.
• An operator was killed when brakes on the dump truck he was reversing down a steep
slope failed. He was aware of the faulty brakes and had failed to report this to the
mechanics.
• An employee was crushed when his foot knocked a pedal operating the lift arms of a
backhoe accidentally activating the machine.
• An employee steadying a load was electrocuted when the mobile crane touched power
lines.
• A construction worker was killed while standing in a 2.7 m shored trench giving instructions
to an operator lowering pipes. The connection between the pipe and excavator gave way.
• A construction worker was killed in a 3 m shored trench while assisting with the removal of
equipment. As the excavator slewed around the quick hitch failed dropping the bucket on
the worker. The hitch safety pin was in the excavator cab at the time.
• A engineer was killed when the operator of a scraper reversed over him while he was
conducting soil tests.

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 You should be familiar with the basics of the Occupational Health, Safety and Welfare laws and
the Australian Standard AS1470-1986 (Health and Safety at Work)

Health and Safety laws require employers to identify hazards in the workplace, assess the risk
those hazards pose to employees and other persons and introduce control measures to remove or
minimise those risks.

These include:

• The selection, correct fitting and use to manufacturers standards of appropriate personal
protective equipment such as safety hat; respirators or breathing apparatus; safety
footwear; safety glasses, goggles or face shields hearing protectors; high visibility vests
safety clothing and gloves;

• Setting up and removing bollards, cones, bunting, barriers etc. when working in areas that
need to be separated from other work or public areas;

• Safety Precautions for Trenches

Check with your relevant authority regarding regulations for excavation work.

The definition of a trench is an excavation the length of which exceeds its depth or width.

• The Pre-Construction Survey

The intention of the pre-construction survey is to enable hazards at the work site to be identified
and control measures planned before any work commences.

If no knowledge of the ground conditions can be obtained, test holes using an excavator should be
dug in doubtful areas to observe ground conditions and determine suitable ground support
systems.

During the pre-construction survey the following checks must be made:

Power Lines and Telecom Lines

If present and it is intended to use machinery that could come in contact with, or near these lines,
the relevant Authority must be contacted. Isolation or sheathing of the lines at the time of
construction may be necessary.

Stobie or Telecom Poles

If in close proximity to the line of a proposed excavation, the relevant authority must be notified.
That authority can arrange to stabilise the pole during the excavation process.

Nature of the Ground

This should include checking the soil or rock for moisture content, the water table level and faults
or bedding planes.

Possibility of Flooding
Check storm water drains, surface run off after a heavy rain. Look for swamp, dam, reservoir, lake
or river. Flooding can be sudden and tragic, so precautions should be taken, which could include
drainage run-off control and availability of pumps on site.

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 Underground Services
Proximity of underground services such as gas, electricity, sewer, water mains or telephone
lines. Enquiries should be made to the appropriate authority in regard to location of their
services prior to excavating. Previously dug excavations have a weakening effect on a trench
wall if they are in close proximity, close sheeting or shields may be necessary. This shoring
should also be used in unstable ground, reverting to soldier sets when stable ground is
encountered.

Hazards (Natural or Artificial)

Check for intersecting old trenches, manholes and other shafts, bends in an excavation line,
leaking services, trees, and threat to health and safety from the past dumping of toxic waste.

Static Loads
This includes checking for the spoil pile (an excavation in wet clay 3m deep by 1 m wide will
create a spoil pile having a mass of approximately 6 tonnes/metre of excavation), buildings
(including garages and outbuildings), water tanks or towers, brick or stone walls or earth
embankments. In case of static loads nearby, additional shoring should be installed.

Dynamic Loads
Dynamic loads include traffic (highway and rail), excavation equipment and other items of plant.

Extreme caution must be employed when excavating, always dial 1100 (dial before you dig and even then
use a spotter to help guide and spot. You should use the spotter to do a little potholing when close to
services. Failure to do so will often end catastrophically as depicted above.

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 POTENTIAL HAZARDS AND CONTROL MEASURES
Underground/overhe Locate, mark and expose any underground services by HAND
ad Utilities Gas, prior to the machine excavating. Visually inspect the site,
Telecom, EWS, Elect. especially for overhead wires. CHECK all other authorities site
Transmission. plans.
Waterlogged Ground Install dewatering system. Use CLOSED sheeting or “Shorco"
type shoring to prevent collapse.
Pockets of Unstable Shore trenches using CLOSED sheeting or Trench shields
Ground where the unstable ground is located.
Other Trenches Check plans and leave an adequate distance between the
Close By existing trench and the new trench. Shore the new trench using
the appropriate method e.g. Closed, Open. Shields or Struts etc.
Uneven/Sloping Level a track for the excavating equipment. Place the SPOIL
Ground from the trench on the DOWNHILL side of the excavation.
Watercourses/Creeks Install extra shoring when necessary, check for seepage. Check
etc. all shoring and monitor regularly.
Buildings and Install EXTRA strength shoring to avoid property damage.
Structures Under some circumstances it may be necessary to leave the
shoring in place and backfill the lot.
Traffic Barricade and protect the work area. Install extra shoring if
required. Keep the traffic well clear of the trench line and be
aware of the problems with traffic vibration, inspect the trench for
danger signs.
Machinery and Plant Keep all plant and machinery well back from edges of the trench.
Strengthen shoring if vibration is likely to cause the trench to
collapse.
lntersecting lnstall extra shoring where trenches intersect. Close shore if
Trenches necessary.
Lack of/Inadequate Install adequate shoring and ensure it is installed correctly.
Shoring
Hazardous Ensure exhaust fumes of plant and machinery DO NOT enter the
Atmospheres trench. Check the atmosphere with a Gas Detector if doubtful of
air quality, ventilate mechanically if required.
Spoil and Material Keep spoil and materials a minimum of 1000mm from edge of
near Trench Edges trench. lnstall spill boards. Chock pipes with wedges
Vermin Clear all underbrush. Visually inspect all trenches before
entering. Plug all pipe openings when completed each day.

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 Causes of Trench Collapse

− Neglect to install shoring / ground support

− Inadequate or poorly applied shoring
− Mechanical failure of soil to support its own weight
− Breakdown of soil strength due to moisture
− Vibration from vehicle and/or plant movement
− Surcharge of spoil or weights close to trench edge
− Change in soil composition. (Sand pockets etc.)
− Previously disturbed ground. (Landfill, old trenches)
− Trench walls being struck by heavy loads
− Undercutting
− Premature removal of shoring

Causes of Work Site Accidents in Trenching Operations

The most frequent causes of accidents are due to:

− Collapse of earthwork due to lack of, inadequate or weak shoring.

− Persons falling into excavations due to lack of barriers or inadequate fencing.
− Asphyxiation from toxic gases, which have collected in the bottom of the excavation or
trench.
− Soil from excavations not being thrown clear of the sides, which then become
overloaded and collapse.
− Failure to maintain shoring, particularly after inclement weather.
− Water seepage.
− Persons working too close together.
− Asphyxiation by carbon dioxide which can be present in excavations caused by air
stagnation through lack of ventilation, especially on damp foggy days. Physical signs
are dizziness, pounding in the ears and shortness of breath. The atmosphere will not
support combustion.
− Person not being provided with or not using proper tools for the job.
− Vehicles or plant too close to the edge, causing the edge to collapse.
− Workers in the excavation being struck by soil or materials or tools falling into the
excavation.
− Falls through unsafe means of access into or out of the excavations.
− Workers being struck by excavation machinery, e.g. the bucket of the excavator.
− Vehicles being driven into the excavation due to driving errors, inadequate barriers, or
the absence of stop blocks
− The striking of other utilities services, e.g. electricity cables, gas pipes, water mains etc.
− Changing weather conditions.
− Lack of training or technical knowledge.
− Physical and psychological conditions of workers

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 Safety in Relation to Trenching

The purpose of shoring is to protect the worker. There are other factors that must be
considered. Below are examples of hazards that should be avoided when trenching.

HAZARDS TO BE AVOIDED WHEN TRENCHING

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 Trench Rescue Procedures

Trench collapse happens very fast with virtually no time for escape.

If only for these reasons, no person should be in a trench unless there is another person in
attendance at ground level.

If a collapse occurs, the following procedure should be adopted:

• Do not panic! Allow no one into the unprotected trench.

• Send someone to contact the emergency services and your local management.
• Try to locate the victim, look for evidence of where they were, eg: their helmet, shovel or
tools.
• Clear the area of unnecessary personnel.
• Batter the sides of the trench.
• Secure the rescuers to the surface: they should be wearing a harness that is attached to a
lifeline.
• Remove soil by hand digging with shovels.
• For deep trenches, dig a new trench alongside the existing one with a machine so the soil
can fall into the new trench as the victim is uncovered.
• Extreme caution is required with this method so the victim will not be injured further.
• When close to the victim, use hands to clear the remaining soil.
• Clear the soil from around the victims head and chest.
• Commence basic life support.
• Clear the remaining soil from around the victim.
• Do not remove the victim. Let the Emergency Services do this.

• Battering Trench Walls

Trenches 1.5m or over in depth must be battered or shored. Battering a trench is acceptable in
lieu of shoring. Battering starts at 1m in height.

Excavations carried out 1.5m or more in depth constitute notifiable work and the relevant OH&S
authority must be notified.

ACROW STEEL SUPPORTS

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 Shields
Used in deep and wide excavations where considerable disturbance of the ground occurs. They
are excellent for unstable ground. Shields provide only minimal support to trench walls, but they
are a very effective means of preventing injury to workers in the trench.

PORTABLE STEEL SHIELD

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 PROTECTION OF THE ENVIRONMENT

Adequate care of the environment is an important part of any construction project, including
drainage systems. Protection of the environment can be considered in two areas with regard to
drainage systems:

• During the construction process

• Erosion and sediment control of the drainage system itself

• During the Construction Process

< Native tree, shrubs and grasses are valuable because they:
< Are easier to maintain than introduced vegetation
< Provide an important source of food and shelter for wildlife
< Provide wildlife corridors linking other areas of native vegetation
< Often contain rare and endangered plants and animals
< Are a vital source of local seed for replanting

Protect native vegetation by minimising disturbance. Disturbing the soil unnecessarily may
encourage weeds and destroy native plants and risk soil erosion.

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 Avoid working within the
drip line of a tree to reduce
damage to the roots, trunk
and limbs

The drip line of a tree

Avoid storing materials

and equipment under
trees. Don’t drive vehicles
under trees or over other
native plants.

Control vehicular access and stockpiling

Keep fill material clear of

the drip line of trees or
shrubs

Do not place fill around the trunk

Avoid cutting within the

drip line of a tree

Incorrect Correct

Avoid root removal

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 Trenching Activities

The following points should be noted for care of the environment in regard to trenching:

− Save topsoil from the area to be disturbed;

− Spoil should not be stored or disposed of in , or adjacent to, natural drainage lines or
other water flow paths;
− Soil used to backfill trenches should be well compacted. Poorly compacted backfill can
slump and increase the risk of erosion along the trench line; and
− Trenches should be backfilled to a level higher than the adjacent ground to allow for any
settlement.
−

ENVIRONMENTAL CARE FOR TRENCHING

MATERIAL REQUIREMENTS FOR INSTALLATION

Determining material requirements will have to be done in conjunction with reading the plans and
specifications and the manufacturers technical data.

Materials will include:

• Selected fill material for bedding and backfilling drain;

• Pipe or culvert;
• Standard fittings, junctions etc.
• Special fittings;
• Jointing material; and
• Concrete for in situ construction of fittings etc.

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 Fill Material
Selected fill material will be specified on the drawings and be in accordance with the drain
manufacturers specification. In calculating the volumes of fill materials, it must be remembered to
make allowances for the compacted quantities.

Pipe/Culvert Quantities
Refer to the manufacturers guides and specifications to calculate the number of lengths of pipe
required. Only the effective length of the pipe should be considered. (Refer Figure 25)

THE EFFECTIVE LENGTH OF CONCRETE PIPES

Standard Fittings
The drainage system should have been designed around the manufacturers standard fittings and
junctions. This would keep the costs down and increase the availability of fittings. The drawings
will schedule the standard fittings to assist with determining the number required.

Special Fittings
Special fittings will be detailed on drawings for construction purposes. These can be
manufactured in the factory as precast units or cast in situ on site. The cost will determine which
system will be viable.
If the fitting is to be manufactured off site, adequate lead up time will have to be allowed for the
order so that it will not delay construction.

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 Jointing Material
Depending on the type of material and the type of jointing system selected for the drain, orders will
also have to be placed for the appropriate jointing materials.
Rubber rings will be required for rubber ring joint concrete pipes. Order a surplus to allow for lost,
damaged or faulty rubber rings.
Another type of joint is the flush sand band joints, used with flush concrete pipe joints
In the event of using neither of the above, mortar joints will probably be used. In these cases sand
and cement will need to be ordered. Manufacturers will specify the sand and cement ratio of the
mortar mix which will allow quantities to be calculated.

In situ Fittings and Structures

In determining materials requirements for fittings and structures poured on site, consideration will
have to be given to:

< Concrete quantities, whether pre-mixed or mixed on site;

< Reinforcement; and
< Formwork.
Checking Materials are According to Supply Orders
When taking delivery of materials, especially precast concrete products, the following points
should be considered:

• Inspect the product to check that they are fit for use.
• While the truck is still loaded, check that they match the delivery docket for:
< Number;
< Class;
< Size; and
< Accessories (rubber rings, sand bands etc.).

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 • Check that they are not damaged in any way, such as:
< Broken sections;
< The reinforced cage showing; and/or
< Cracks.

• If you come across any damage, check with your supervisor to see if the damage is serious
and whether or not the pipe can be used.

• Any damaged or defective product should be noted on the delivery docket and signed by
both the driver and the person receiving the materials. Mark the defective product with a
mark so it is easy to find again.
Procedure for assembling rubber ring joints
< Inspect joint surfaces. Spigots, sockets and rings must be clean and dry

INSPECT AND CLEAN

Joint Surfaces
< Remove any dust or dirt and repair or set aside damaged pipes.
< Check that the ring is the right size for the pipe.
< Inspect the ring for defects. Do not use damaged rings.
< Place the ring on the pipe.

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 < The ring must be free of twists or kinks so it can
roll evenly. Some ways of making sure the ring
is free of twists include placing the ring in the
groove on the spigot of the pipe pull the ring
away from the pipe in several places and let it
snap back. Roll the ring along the spigot rebate
to the shoulder, check that it is rolled evenly and
then roll it back into the groove. This will remove
any twists remaining in the ring.
< Below applying the jointing seals to inspection
chamber rings.

FITTING THE RUBBER RING

CHECKING THE RUBBER RING IS FREE OF TWISTS

< Place the ring on the pipe at the shoulder. Pull the ring away from the pipe in several
places and let it snap back. Roll the ring forward along the spigot rebate into the
groove. This method is particularly effective with large diameter pipes and avoids the
ring dislodging in the process.
< Rolling the ring along the spigot rebate is helpful for all pipes and essential for large
pipes. For larger pipes this may take two people.
< When the ring is in place, look at it and check that the seam in the ring is running
straight all the way around without any obvious twists.
< Align the pipe by placing the spigot end of the pipe to be laid in the socket lead-in of the
last pipe. Make sure the entire rubber ring is touching the socket lead-in of the last pipe
all the way around. (To do this the spigot needs to be centred in the socket lead-in so
you will need to support the pipe by ensuring the bedding material is at the correct level
or by placing a piece of timber under the barrel of the pipe at the correct level.)
< Push the pipe home.

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 PUSHING THE PIPE HOME

Bar the pipe home (when you do this you should put a block of wood on the ground between the
bar and the pipe to protect the socket); or

USING A COME-A-LONG

Use a come-a-long, making sure the pipe being jointed is pulled evenly into the socket of the laid
pipe so you get an even joint.

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 ASSEMBLING THE RUBBER RING JOINT
NOTE: If the spigot tends to creep out of its socket for no apparent reason, it is usually an
indication that the rubber ring has not rolled evenly. The pipe should then be pulled out
and the joint made again.

< Immediately after assembly, check the joint gap against the specification and use a
feeler gauge around the spigot circumference as illustrated in Figure 17, to ensure that
the rubber ring is in the correct position and that there is clearance between the spigot
and socket.
Skid Ring Joints
The assembly of skid ring pipes is similar to rubber ring joints up to where the ring is placed on the
pipe.
< Place the skid ring in the groove on the spigot.
< The ring must be free of twists or pressure. You can run a screw driver or similar tool
around under the ring to ease twists and tension.
< Apply a generous coating of jointing lubricant to the inside surface of the socket and to
the ring. The lubricant is supplied with the pipes and rings.
NOTE: The lubricant supplied for use with skid rings is a special mix of soft soap solution.
Never use petroleum products (eg grease) as a substitute for lubricant.
< Align the pipe making sure the spigot is touching the socket all the way round.
< Push or pull the pipe home.
Flush Joints
Similar preparation requirements for rubber ring joints are required for flush joints and the same
procedures should be observed in the jointing of pipes with an internal and external mortar joint.
With internal flush joints, it is necessary to ensure suitable mortar consistency in accordance with
specifications.

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 Mortar should be made with 3 parts graded sand to 1 part cement, using just enough water to
make the mortar workable. If too much water is used, the strength of the mortar is reduced and
excessive shrinkage may occur.
Mortared joints are only suitable in areas where the ground is stable with little or no movement.
In making mortar joints, the annular space provided must be well filled.
< Make sure the area to be jointed is clean and dry.
< Pack the mortar generously into the joint, making sure it goes right around the pipe.
< Wipe the pipe smooth.
< Protect the joint from movement and from drying out too fast.
< Drying out too fast reduces the strength of the mortar.

FLUSH MORTAR JOINTS

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 Sandband Joint (or External Band)

External bands (EB's) are flat rubber bands for flush jointing pipes. External band joints are
flexible and can be used instead of mortaring joints. They stop sand from getting into the pipeline
and eroding the backfill. External bands are mainly used in installations with sandy backfill
conditions.

How to join pipes using external bands

− Inspect joint surfaces.

− Remove any dirt and repair or set aside damaged pipes.
− Check that the band is the right size for the pipe.
− Inspect the band for damage.
− Do not use damaged bands.
− Fit half of the width of the band over the end of the pipe and fold back the remaining
half.

FIRST STAGE OF ASSEMBLING

SAND BAND JOINT

− Line up the other pipe and push it home.

− Flip the folded half of the band over the joint.
− Make sure the band is correctly folded over and covers the joint all around.

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 FINAL STAGE OF
ASSEMBLING A SAND
BAND JOINT
Curves and Bends
Deflection in a pipeline can be achieved a number of ways depending on how much deflection is
required.
< Small Deflections - The pipe joints can be opened up to the maximum recommended
deflection after each joint has been completed. The pipe manufacturers will specify the
maximum deflection allowed.

< Larger Deflections - For larger deflections, specially made splay pipes can be used.
These are flush jointed pipes with one or both ends offset (angled) so that when you
join them together they curve around.

Even Larger Deflections - A prefabricated bend made from sections of a standard pipe can be
installed for extremely large deflections. These must be custom made in the factory to meet the
designed curve.

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 LARGE RADIUS BENDS AND CURVES
Backfilling
Backfilling of the trench is a critical phase of construction. During backfilling, it is important not to
dislodge or damage the pipe and the backfill material needs to be placed in accordance to
specifications.
To be effective, compaction must be done the right way. Compaction is critical in the haunch zone
where there must be no voids.
The fill should be brought up on both sides of the pipe and compacted together in layers of about
150 mm.
Compaction can be achieved by using:
• A crowbar
• Mechanical Compaction

Crowbar
It is important to work the crowbar over the entire area that requires compaction without missing
sections.

Mechanical Compaction
Mechanical compaction refers to compaction using equipment such as a wacker.
< Appropriate chains and slings for lowering concrete skip into position
< Concrete skip
< Concrete vibrator
< Concrete formwork

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 Plant
On smaller drainage systems, a backhoe will be able to be used to excavate and then backfill the
trenching system.
An excavator would be more suitable for larger excavation work, but can still be used on smaller
projects.
If an excavator is used, a front end loader will be required for backfilling the trenches.
Compaction equipment is required in backfilling the trenches to specification. The different types
of compaction equipment used will depend on the size of the trench being backfilled.
A suitable crane may be required for the concrete skips. In most situations, an excavator, loader
or backhoe that has been suitably modified (see relevant plant module) can be used to crane
smaller pipes loads.
Manholes
Manholes are generally used where several pipes feed into another pipe in the system, as well as
for major changes in direction and/or levels. There is generally a hollow chamber where the pipes
enter and exit, topped by a top plate.
Depending on the depth of the chamber, the finishing ring and lid may be placed directly on top of
the hole in the top plate, or may be connected via another shaft of similar diameter to the ring and
lid.
Manholes are constructed using the same guidelines as for the gully pit, although there may be a
need to provide step irons to allow access to the manhole. These can be either cast-in-place or
can be epoxy mortared into drilled holes. As with the gullies, manholes can be bought as precast
segments and simply joined on site, or can be cast in situ using standardised formwork.

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 Installation of Precast Manhole

Preparation of In Situ Base

The installation of a permanent and effective modular manhole structure depends largely on the
correct placement of the first shaft section or starter shaft. Following the correct positioning of this
first shaft, subsequent units are placed progressively one upon the other.

There are a number of methods of constructing the base in situ to produce a water resistant joint
between the base and the first shaft section. In all these methods, it is important that the base be
vibrated to obtain the best possible footing for the structure.

Starter Shaft "Set-Into" the Base

The starter shaft is the first precast section to be put into place. Firstly, all the inlet and outlet pipe
work should be positioned correctly for both line and level, and stoppers inserted into the pipe work
to prevent concrete entry. Next, mounting blocks are placed to fit under the starter shaft. These
are adjusted to obtain the required level of the starter shaft in accordance with the drawing in
Figure 66. Concrete is placed in the base and vibrated into place, particular care being taken to
ensure that:

− The base is a minimum of 150 mm thick; and

− Concrete extends above and beyond the bottom of the starter shaft by a minimum of 100 mm.

The channels can then be shaped.

CAST IN SITU BASE FOR PRECAST MANHOLE

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 If it is desired that the starter shall be placed without use of the mounting blocks, then concrete
should be placed and vibrated and the starter shaft then placed in position, paying attention to the
layout drawing for minimum dimensions.

Care must be taken to ensure that the starter shaft does not sink or tilt.

Channels in the base can then be shaped in the wet concrete.

An alternative to shaping the channel manually involves the use of foam formwork. The formwork
is in the form of semi circular foam blocks that sit in the wet concrete base.

A precast base is also available from suppliers.

Joints Between Sections

− Precast manhole system components fit easily and securely together. To ensure a
water resistant joint, follow these steps:
−

− Make sure both joint surfaces are undamaged and clean.

−

− Remove mud, sand, concrete or other foreign matter.

−

− Attach the sealing compound by pressing it against the primed sloping face of the
component as shown in the diagram below.
−

− Provided no foreign matter gets into the joint both methods give excellent results.
−

− Make sure the strip is placed all the way around the joint, overlapping at the ends. All
the pre cut lengths of sealing strip provide reasonable overlap. There must be no
gaps in the strip if the joint is to provide an effective barrier to water penetration, nor
excessive overlap.
−

− Position the component so that its sides are aligned with the sides of the component
in position below it.
−

− Lower the product carefully and let it settle under its own weight.
−

− When placing a component with step irons, ensure the step irons are correctly
aligned with respect to the inlet/outlet pipe work and the components already
installed. Care must also be taken when selecting shafts for installation that the step
iron sequence is maintained.
−

− When constructed as described, the joint is water resistant and allows some
movement

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 ASSEMBLING JOINTS FOR PRECAST MANHOLE UNITS

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 Plant
− On smaller drainage systems, a backhoe will be able to be used for excavation.
− An excavator would be more suitable for larger excavation work, but can still be used on
smaller projects.
− If an excavator is used, a front end loader may be required for finishing work along the drain.
− A bulldozer or even a scraper could be used for large open drains
− A grader will be required for finishing work
− Compaction equipment as required for rolling the batters and base of the drain. The different
types of compaction equipment used will depend on the size of the drain being constructed and
any backfilling requirements behind precast units.
− A suitable crane may be required to place precast units or concrete skips for in situ lining. In
most situations, an excavator, loader or backhoe that has been suitably modified (see relevant
plant module) can be used to crane smaller loads.
− Alternatively, a concrete pump could be used and in most situations would be the most cost
effective concrete placement method for lined drains.
− Materials required for construction of the culvert will be discussed later in this module as part of
the construction procedure.
Backfilling
The same backfilling requirements apply to both precast and in situ concrete drains. Do not
backfill in situ drains until the formwork has been stripped and the concrete fully cured.

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 Tools and Equipment Clean Up

Concrete mixers, trucks, pumps and equipment must not be washed down on roadways,
footpaths or reserves. They must be washed down within a designated contained area within
the site or in their depot wash down facility.
The key to doing a concrete project without ruining your tools is to clean up as you go. Do not
stack dirty tools in a pile and then plan on cleaning them up at the end. Chances are you will
have a big pile of dirty tools that are stuck together. Keep a hose nearby so that you can spray
down each tool as soon as you are done with it and set it aside to dry.
There may be some excess concrete that ends up drying outside the form. If you shovel it up,
it makes great fill around foundations or if you ever have any posts to sink. If not, it can be
disposed of at the landfill. The boards that you used to create the form are certainly reusable.
While they probably aren't going be used for finish work, they will do just fine for any structural
work. The exposure to the wet concrete will not harm them at all.
There are some simple things that can help decrease the amount of injuries and in turn keep
the site cleaner and safer for those working around it. Here are some guidelines in keeping
your construction site clean and safe Construction sites that are not kept clean are the
frequent cause of workplace incidents and work injuries. Often these types of incidents can
be easily be prevented just by cleaning up the construction site. A clean site makes jobs more
efficient and safe.

A rotary broom is a really great attachment for cleaning up sites.

Scraps and off cuts that come from construction come in all shapes and sizes, so it can be a
hassle to clean up. Also as workers are busily working packaging gets removed and then just
thrown on the ground. This creates tripping and slipping hazards. If the ground is covered
then it also makes other potential problems hard to see. When the site is not cleaned up, no
one cares about leaving garbage where it drops. This is extremely dangerous!

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 Just by carefully making sure that the job site is clean is one of the easiest ways to improve
the safety of the workers during the job. When the workplace isn't continually kept clean then
this creates incidents waiting to happen.
It is easy to keep a construction site clean during. The problem is that far too often workers
are careless about the mess that is made. Cleaning up on the job means cleaning up scrap
material, trash and debris and putting it in the appropriate containers, and making sure the
containers are emptied regularly. Also proper storage of materials and equipment will help to
make a clean and safe work site.
All waste should be recycled where possible.
Here are some other key things you can do to help keep your construction site clean and safe
during the life of the job:
− Don't handle materials multiple times. Have one person take it and throw it out to ensure
others aren't dropping pieces as they walk.
− Minimize how far workers have to take the materials to where they are being used.
− Make sure that materials can easily pass to where they need to go. Keep all walkways
and paths clear.
− Clean all equipment during the day and especially at the end of the day to ensure the
next day will start clean and safe and ready for work.
Make sure that these guidelines are done throughout the day, instead of when workers
clean up to go home. If the precautions are continually being done throughout the day then
this will greatly decrease the injuries that occur.
Following these guidelines in keeping your construction site clean and safe during a job.
This will greatly reduce sickness and injury. Having a safe workplace means that everyone
around it will be safe from any harm. Take the time to follow these guidelines so your job
goes smoothly and without any injury.
Care of Tools and Equipment
You should remove excess concrete or cement residue from tools immediately after their use has
finished. Failure to do so will make the tools and equipment difficult to use and inefficient to
operate, and could mark or damage the finished work. A system I have employed is a wheel
barrow of water on the job, let the tools soak a couple of minutes and scrub with a brush and allow
to dry then oiled or greased as required and stored in a dry secure place.
During storage, handling and use, finishing tools should be stored in such a way that the surface in
contact with the concrete is not accidentally damaged or bent.
If storage is to be for a considerable period of time, then tools can be coated with a light application
of WD40 oil to prevent corrosion.
The care and maintenance of tools is vital to all tradespersons. Paving tools and equipment are no
exception to this. Although some tools are of basic design, they still require care and maintenance.

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 WD-40 literally stands for Water Displacement, 40th attempt.

Rust Prevention for Your Tools

It is much easier to protect your tools from rust than to deal with the consequences of rusty tools
later. You have three main choices in protecting your tools from rust: Apply a protective coating,
reduce the moisture level, or use a rust-inhibiting vapour.

SUMMARY
This topic has explained the many and varied requirements of transporting, placing and finishing
concrete pavers. Many of these procedures are common throughout the construction industry,
however, some sites or companies may have different techniques and theories on certain
procedures. As a paving worker, it is up to you to utilise what knowledge you have gained from this
module and transfer it to your workplace.
As with any other task on construction sites, safety is of paramount importance. If any of the
procedures or methods described within this training module contradict or contravene standard
safety practices, your duty is to notify your supervisor immediately.
Due to safety requirements, you should keep your equipment in good condition through regular
maintenance and safety checks to test that the components are working correctly. Your supervisor
will also instruct you on the equipment’s safety features and how to correctly operate it. Any
equipment destined for storage after being out on site should be cleaned and serviced checking for
any damage or loose parts. Any defective machine should be tagged as such. This will lead to it
being repaired quickly and prevent it going back out on site in a poor condition. It may be that the
damage is also electrical and could cause serious injury.!

Most companies have a shed where tools, plant and equipment can be safely stored away from the
effects of the elements. It is important that these are thoroughly cleaned prior to storage.

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 Self-Checks

Question 1.
Where do we find out information regarding hazards and amenities on various sites?

A. Tool box meetings C. Supervisor

B. Site induction D. All of the above

Question 2.
Name the two most common plans that are used on site to do with traffic control and pipe layout
including pipe invert levels?

a._________________________________________________

b._________________________________________________

Question 3.
3. Name four hand Tools that are normally used when laying pipes?

1._________________________ 2.___________________________

3._________________________ 4.___________________________

Question 4.
Before starting up and using a vibrating plate what must we check if this is the first time that the
machine is being used for the day?

____________________________________________________________________________

____________________________________________________________________________

Question 5.
Environmental protection and control is always done when the job is finished?

A. True B. False

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 Question 6.
What are Australian standards and what is their relevance to pipe laying??

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

Question 7.
We need to take notice of the Australian standards and codes of practice when laying pipes?

A. True B. False

Question 8.
The Environmental protection ................................... are found in the

................................... Environmental ..................................... plan normally kept in the

........................................ office.

Question 9.
When we find a problem with a piece of plant we are about to use what should we do?

A. Hide it and tell no one C. Bury it with soil

B. Report it and tag it D. Do nothing ,just find

another piece of plant
and use it instead to get
on with the job

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 Question 10.
List 8 articles of PPE that you would use in Pipelaying and describe their uses?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

Question 11.
11. Once the trench is marked on the ground what must you do before proceeding with any
digging to check for any existing services that might be there?

a. Dial before you dig b. Dig by hand to locate any services

c. Use a sucker truck d. All of the above

Question 12.
This the correct way to store pipes before use? True False

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 Question 13.
If you were left to mark out the position of the proposed trench where would you find the
relevant information? Name 2 places!

____________________________________________________________________________

____________________________________________________________________________

Question 14.
If you were given a grade for the pipe that was 1 in 50 what would this mean to you as a pipe
layer in relation to fall?

____________________________________________________________________________

____________________________________________________________________________

Question 15.
What can we read to find out the proper Company procedures for laying water mains? Name 3!

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

Question 16.
On the drawing below which way is the direction of flow? Explain?

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 ____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

Question 17.
The specified grade at which a pipeline must be laid is only a general indication and does not
need to be followed too closely otherwise you will not be able to do the job correctly.

A. True B. False

Question 18.
What information do we have to tell the plant operator before he starts to excavate the ground?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

Question 19.
When the trench is dug there is no need to clean out the loose dirt we can put the bedding
material straight in ready for compacting.

A. True B. False

Question 20.
Once we have informed the plant operator of what is required we can then go to the crib room
and work out the required gradient as this must be done to check on completion of the job.

A. True B .False

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 Question 21.
Name four hazards that you would encounter with laying pipes.

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

Question 22.
Why is it very important to get the bedding material to the right grade and compacted?

____________________________________________________________________________

____________________________________________________________________________

Question 23.
If you come across a hazard that you can’t fix and there is no one to report it to what would you
do?

____________________________________________________________________________

____________________________________________________________________________

Question 24.
Number the following steps in order of 1-7 in jointing a PVC Rubber ringed pipe.

☐ Push the spigot end into the socket & make sure it goes all the way in to the desired
length.
Mark on the spigot end the length of the joint
Clean the ring and make sure it is clean
Lay the pipes on top of the ground next to the trench ready to lower them in.
Straighten up pipe when together
Re check fall and back fill to top of pipe
Check the grade of the bedding material

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 Question 25.
You can enter any confined space as long as you can fit in the opening easily and wont get
stuck?

A. True B .False

Question 26.
Before we use chains or slings to do any sort of lifting what must they be checked for?

A. Tagged and in date B. Less than 10% wear

C. No Cracks or splits D. All of the above

Question 27.
Before using any machine as a crane to lift a pipe the machine must have ...................... plate
and a ................ chart placed on the machine and a certified ................ device

Question 28.
Which lifting technique causes fewer disturbances to the bedding material and the pipe when
the chain has to be released from the pipe? Tick!

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 Question 29.
As you are laying the pipes what has to be constantly checked and adjusted if need be so it
remains spot on?

A. The lunch van C. Your watch

B. Oil in the backhoe D. Levels, grades and fall

Question 30.
The placement of sand or quarry dust around the pipe to hold it in place is called what?

A. Back filling B. Sand placement

C. Dust placement D. Haunching

Question 31.

Before we can commence the backfilling process what must be installed on top of the pipe so it
can be easily identified in the future?

A. Trace wire B. Rubbish that’s laying around

C. Coloured tape D. Any pits, fittings or thrust

blocks

Question 32.
When you have a trench open and preparing to lay pipes you don’t need to have signs or
barricades for protection anymore as the public will see the big machines and keep away.

A. True B. False

Question 33.
If we need to de water the trench can we pump the dirty water into the nearest creek or storm
water drain without any pollution control or silt eradication?

____________________________________________________________________________

____________________________________________________________________________

____________________________________________________________________________

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 Question 34.
At what depth do we require trench support?

A 1.6 m
B. 1.4 m
C 1.8 m
D 2.0 m
E 1.3 m
F 1.5m

Question 35.
Pipe systems need some sort of testing whether it be for pressure, leaks or flow!

A. True B. False

Question 36.
When cleaning up and you find a material that you are not familiar with where could you find out
any relevant information about the handling and disposal of the material?

____________________________________________________________________________

____________________________________________________________________________

Question 37.
Why is it very important to sort out the material that is left over?

____________________________________________________________________________

____________________________________________________________________________

Question 38.
It important to take down signs when we have finished with them so the public and workmates
don’t get confused?

A. True B. False

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 Question 39.
When we have picked up all the ........................ we should .................... them to make sure they
are in .................... order, if they are not they should be ..................... and reported the
supervisor, also perform any ...........................that is due

Question 40.
Why should all tools and equipment be put back in their containers when we have finished
them?

____________________________________________________________________________

____________________________________________________________________________

Question 41.
When we are cleaning up and we find left over chemicals it is best to

a. Tip them down the closest storm water drain son nobody will accidently use them
b. Put a new label on the container that reads non potable water for special disposal
c. Mix it up with any leftover diesel and burn it at a later date as recommended by fire
brigade
d. Dispose of it according to all relevant MSDS and company policies

Question 42.

Name the two methods that are used in joint PVC pipes.

____________________________________________________________________________

____________________________________________________________________________

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 Question 43.
Name each of the zones in the illustration

1. ___________________________

2. ___________________________

3. ___________________________

4. ___________________________

5. ___________________________

6. ___________________________

Question 44
What work instructions, plans, specifications, quality requirements and operational details would
you receive or have access to regarding the installation of stormwater systems.?

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 Question 45
List the five (5) items you would include in a safety plan for a stormwater or similar project you
have worked on project.

Question 46
What is the name of the document that most signage requirements are accessed from when
preparing a traffic management plan.

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 Question 47
A. List the plant, tools and equipment required to carry out the tasks on a particular
stormwater/drainage project you worked.

B. Explain how the serviceability of the small plant items and other equipment listed in the previous
question are maintained and faults rectified or reported.

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 Question 48
For a stormwater/drainage project you have worked on list (2) two x environmental protection
devices that were applied and explain their use.

(a)

(b)

Question 49
What are 3 x factors that could affect the design of a drainage project?

(a)

(b)

(c)

Question 50
Why is it important for grades to be kept to a minimum in Open Earth Drains?

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 Question 51
Explain the most effective way to reduce water velocity in an open lined drain

Question 52
Explain why Box drains (Box Culverts) would be used on some projects instead of concrete pipes

Question 53
List 3 x advantages plastic pipes have over concrete or steel pipes

(a)

(b)

(c)

Question 54
Why is it important to ensure that temporary drainage is installed prior to the commencement of
earthworks?

Question 55
What are 3 x sources of water that can affect the construction process?

(a)

(b)

(c)

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 Question 56 List 5 x pieces of plant & equipment used on a drainage project

(a)

(b)

(c)

(d)

(e)

Question 57
List 4 x common causes of Work site accidents in Trenching Operations?

(a)

(b)

(c)

(d)

Question 58
At what depth do trenches need to be benched battered or shored.

Question 59 When taking delivery of materials what are some points that need to be considered.

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 Question 60 List the key elements of a Well point Dewatering System

(a)

(b)

(c)

(d)

Question 61
Explain the term Bed Zone

Question 62.
Explain the term Haunch Zone

Question 63.
When laying pipes you should always start at the bottom of the hill (downstream) and work your
way towards the top (upstream). Explain why

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 Question 64
What advantages do Rubber Ring Joints have over normal flush joint pipes

Question 65 What is a side entry pit?

Question 66. Where are manholes generally used?

Question 67. What 2 x advantages do Open Drains have over Concrete lined drains

(a)

(b)

Question 68. What does a profile board show during the construction of an open drain.

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 Practical Exercise 1
Complete the JSA
You are to lay a stormwater drain at a depth of 1.6 m in the nature strip together with all
associated gully pits and inlets for the local council (see plan below).

Make up a job safety analysis for the unloading of gear, setting up the site, delivery of all
materials, marking out of trench, excavation and fill, laying of pipes and clean up of the job
using correct OH&S and Pipelaying procedures and methods of work.
Complete the JSA and make notes for it below.
You will need to inspect the work site or training area with your Trainer and discuss the activity to be
undertaken, and the possible hazards and the safety controls you would implement. Make notes on the
next page of conditions or hazards that will prevent you working effectively and safely. Doing this as part
of team or think tank is preferable to identify hazards, although the final JSA should be your own
individual work effort.
List the tasks or job steps in the first column of the JSA for your proposed work activity.
Inspect the proposed work area making a list in the second column of any hazards you are able
to identify which could include any of the following but is not limited to:- Falls from working at
height, Crush injuries in excavation work, Slips and trips, Being struck by falling objects, Moving
heavy loads, Bad working positions, often in confined spaces, Being struck or crushed by a
workplace vehicle, Receiving injuries from hand tools, Inhalation of dust, Handling of rough
materials, Exposure to dangerous substances (chemical and biological), Working near, in, or
over water, Exposure to radiation, Loud noise, or Vibration from tools or vibrating machinery,
underground or overhead services - possible electric shock, open trenches and many more.
Assign your hazards a risk index number using the “Risk Matrix” comparing the ‘likelihood’
against the ‘consequences’ of something happening involving those hazards if nothing is done
to downgrade or eliminate them.

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 Make a list under the ‘control measures’ column of the steps or control measures you will be
implementing to reduce or eliminate the risk of that hazard.
Give each of these ‘control measures’ a risk index number using the “Risk Matrix” comparing
the ‘likelihood’ against the ‘consequences’ now that the control measure will be implemented.
Seek input and give feedback to other students or work mates to ensure that you have not
missed any critical work steps or hazards and that they are also aware of the JSA results.
Your goal is to achieve a reduction and where possible a large reduction in the ‘Risk
Index Number’ where possible to at least the medium rage or lower. Ultimately your ‘job
site’ should be now a lot safer to work on as you and your work mates are aware of the
inherent dangers.
NOTE: If your work task still remains in the extreme range after completion of this JSA
then further control measures are required before commencing work.
Assessors “Complete the JSA” Checklist (Activity 1) Yes No

Procedures – Work site activity steps listed

Possible Hazards Identified
Consequences & their effect determined
Risk score determined & given
Safety control measures a implemented
Revised risk score determined & given
The candidate’s performance was: Not Satisfactory Satisfactory
Assessors Name Date

Signature

List all the possible site hazards you can think of & their required control measures here individually or as
part of a team-working group before attempting to complete the JSA!

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

___

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 Practical Exercise 2

Install stormwater system Occasion 1 ____________________________________________

____________________________________________________________________________
List the job site address/date above, type of pipe and the length, as this must be completed on a
minimum of 3 occasions with a total of a minimum of 100 metres of pipeline being laid.
To carry out this activity you will require:
Detailed plans and specification;
Stormwater pipe
Excavator
Safety gear including fencing, barricades and signs
Appropriate Pipelaying tools and equipment

All work must be carried out according to the assessment criteria and tolerances specified in
Assessors marking guide

You may find it useful to refer back to relevant segments of the instructional material while
carrying out this activity or the example below. You may make notes and sketches on the
following page for detailing set out and other incidentals. Either way describe the project and
how you completed it.

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

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 ______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Yes No
Assessors “Install water mains pipelines” checklist (Activity 2)
1 Materials selected and checked against specifications/instructions.

2 Tools and equipment selected in accordance with the requirements of the

project and checked for safe operation.
3 Personal protective equipment correctly selected and used safely.

4 Safety hazards identified through JSA and correct procedures adopted to reduce hazards
to self and others.
5 Correct procedures, documents and legislation adhered to

6 Communicates and works effectively with others to receive, clarify and pass on
instructions
7 Location determined and marked out for excavator

8 Pipeline installed in a safe, timely and efficient manner, meeting all the requirements

9 All Pipe joins done to meet specifications

10 Testing or pressurisation carried out to specifications

11 Written and verbal reporting requirements carried out

12 Trench closed with pipes being correctly covered

13 Reusable materials stacked/stored safely.

14 Work site cleaned up and waste materials disposed of in a safe and environmentally sound
manner.
15 Tools and equipment cleaned, maintained and stored correctly.

The candidate’s performance was: Not Satisfactory Satisfactory

Assessors Name Date

Signature

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 Practical Exercise 3
Install stormwater system Occasion 2 ____________________________________________

____________________________________________________________________________
List the job site address/date above, type of pipe and the length, as this must be completed on a
minimum of 3 occasions with a total of a minimum of 100 metres of pipeline being laid.
To carry out this activity you will require:
Detailed plans and specification;
Stormwater pipe
Excavator
Safety gear including fencing, barricades and signs
Appropriate Pipelaying tools and equipment

All work must be carried out according to the assessment criteria and tolerances specified in
Assessors marking guide

You may find it useful to refer back to relevant segments of the instructional material while
carrying out this activity or the example below. You may make notes and sketches on the
following page for detailing set out and other incidentals. Either way describe the project and
how you completed it.

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

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 ______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Yes No
Assessors “Install water mains pipelines” checklist (Activity 3)
1 Materials selected and checked against specifications/instructions.

2 Tools and equipment selected in accordance with the requirements of the

project and checked for safe operation.
3 Personal protective equipment correctly selected and used safely.

4 Safety hazards identified through JSA and correct procedures adopted to reduce hazards
to self and others.
5 Correct procedures, documents and legislation adhered to

6 Communicates and works effectively with others to receive, clarify and pass on
instructions
7 Location determined and marked out for excavator

8 Pipeline installed in a safe, timely and efficient manner, meeting all the requirements

9 All Pipe joins done to meet specifications

10 Testing or pressurisation carried out to specifications

11 Written and verbal reporting requirements carried out

12 Trench closed with pipes being correctly covered

13 Reusable materials stacked/stored safely.

14 Work site cleaned up and waste materials disposed of in a safe and environmentally sound
manner.
15 Tools and equipment cleaned, maintained and stored correctly.

The candidate’s performance was: Not Satisfactory Satisfactory

Assessors Name Date

Signature

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 Practical Exercise 4
Install stormwater system Occasion 3 ____________________________________________

____________________________________________________________________________
List the job site address/date above, type of pipe and the length, as this must be completed on a
minimum of 3 occasions with a total of a minimum of 100 metres of pipeline being laid.
To carry out this activity you will require:
Detailed plans and specification;
Stormwater pipe
Excavator
Safety gear including fencing, barricades and signs
Appropriate Pipelaying tools and equipment

All work must be carried out according to the assessment criteria and tolerances specified in
Assessors marking guide

You may find it useful to refer back to relevant segments of the instructional material while
carrying out this activity or the example below. You may make notes and sketches on the
following page for detailing set out and other incidentals. Either way describe the project and
how you completed it.

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

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 ______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Yes No
Assessors “Install water mains pipelines” checklist (Activity 3)
1 Materials selected and checked against specifications/instructions.

2 Tools and equipment selected in accordance with the requirements of the

project and checked for safe operation.
3 Personal protective equipment correctly selected and used safely.

4 Safety hazards identified through JSA and correct procedures adopted to reduce hazards
to self and others.
5 Correct procedures, documents and legislation adhered to

6 Communicates and works effectively with others to receive, clarify and pass on
instructions
7 Location determined and marked out for excavator

8 Pipeline installed in a safe, timely and efficient manner, meeting all the requirements

9 All Pipe joins done to meet specifications

10 Testing or pressurisation carried out to specifications

11 Written and verbal reporting requirements carried out

12 Trench closed with pipes being correctly covered

13 Reusable materials stacked/stored safely.

14 Work site cleaned up and waste materials disposed of in a safe and environmentally sound
manner.
15 Tools and equipment cleaned, maintained and stored correctly.

The candidate’s performance was: Not Satisfactory Satisfactory

Assessors Name Date

Signature

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 How to use this Risk Assessment Matrix
Step 1 List work steps in order and then the possible hazards & determine “Likelihood”
What is the possibility that the effect will occur?

Criteria Description
Almost Expected in most circumstances Effect a common result
certain Effect is known to have occurred at this site or it has
Likely Will probably occur in most circumstances
happened

Effect could occur at the site or I have heard of it

Possible Might occur at some time
happening

Effect is not likely to occur at this site or I have not

Unlikely Could occur at some time
heard of it happening

Rare May occur in exceptional circumstances Effect is practically impossible

Step 2 Determine the Consequence

What will be the expected effect?
Level of effect: Example of each level:
Insignificant / No effect – or so minor that effect is acceptable
Acceptable First aid treatment only, no lost time from injury
Minor
Moderate Medical treatment, serious injury, temporary partial disability, lost time < 7days

Hospital admittance, Extensive injuries, Lost time injury > 7 days, Permanent total
Major Disability, injury or death

Catastrophic Multiple Permanent Total Disability injuries, multiple deaths

Step 3 Determine the Risk Score

Consequence
Likelihood Insignificant Minor Moderate Major Catastrophic
A (Almost Certain) 11 16 20 23 25
B (Likely) 7 12 17 21 24
C (Possible) 4 8 13 18 22
D (Unlikely) 2 5 9 14 19
E (Rare) 1 3 6 10 15
Low Medium High Extreme

Step 4 Record risk score on JSA worksheet (Note – Risk scores have no absolute value and should
only be used for comparison and to stimulate discussion) What will be the expected effect?
Score Action
DO NOT PROCEED – This requires immediate attention. Introduce further high-level controls to
Red - Extreme
lower the risk level. Reassess before proceeding
Review before commencing work. Introduce new controls and or maintain high-level controls
Yellow - High to lower the risk level. Monitor frequently to ensure control measures are working

Maintain control measures. Proceed with work. Monitor and review regularly, and if any
Blue - Medium equipment/people/work processes or procedures change

Record and monitor. Proceed with work. Review regularly, and if any equipment/people/work
Green - Low processes or procedures change

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 Job Safety Analysis – 1 Copy to be completed for this unit

Student Name : Student Signature:

Project : Trainers Name:

Location : Date : Accepted : Yes ! No !

Procedure - List of steps Possible Hazards – What things can happen or go wrong, Safety Control – How can I stop or minimize these
in doing a Job on a site. also what hidden dangers are there on this Job Site?
Risk
things happening or going wrong or injuries occurring?
Risk

Signature Trainer / Site Leader_____________________________________ Signature Building Supervisor___________________________________

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