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Uponor Infrastructure Solutions – Technical Handbook

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Publisher/supplier: Uponor Suomi Oy

P.O.Box 21

FIN-15561 Nastola, Finland

Tel. 020 129 211

Fax: 020 129 210

E-mail: infofi@uponor.com

Online: www.uponor.fi

Edition: 1. edition 2009

Layout: Mainostoimisto Fortuna Oy

Printing: Esa Print Oy

Copyright: We reserve the right to make changes.

The latest manual version is available online at

www.uponor.fi

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Contents1. Introduction ................................................................................................9

Uponor as a Partner ..................................................................................11

1.1 Uponor and the Environment ...................................................................16

2. Materials and Service Life ....................................................................... 17

Seals ..........................................................................................................24

Chemical resistance ..................................................................................26

3. Quality Assurance and Product Testing ..................................................29

Product Testing ........................................................................................33

4. Approvals and Certification .....................................................................37

5. Uponor Storm and Sewer Systems .........................................................47

5.1 Introduction ..............................................................................................50

Sewer System Planning & Design .............................................................52

Sewer System Flow Design .......................................................................59

Gravity Sewer Installation – General Instructions and Supervision ..........62

5.2 Uponor Sewer System Ultra Rib 2 ............................................................67

Approvals & Markings ...............................................................................70

Ultra Rib 2 Sewer System Design .............................................................72

Ultra Rib 2 Sewer System Installation .......................................................73

5.3 Uponor Dupplex Sewer System ................................................................79

Approvals & Markings ...............................................................................82

Dupplex Sewer System Design .................................................................83

Dupplex Sewer System Installation.......................................................... 84

5.4 Uponor Pre-Insulated Sewer System ........................................................87

Pre-Insulated Sewer System Design ........................................................ 90

Pre-Insulated Sewer System Installation ..................................................91

5.5 Uponor PVC Sewer System .......................................................................93

Approvals ..................................................................................................95

Markings .................................................................................................. 96

PVC Gravity Sewer System Installation .................................................... 98

5.6 Uponor PE Stormwater System...............................................................103

Approvals & Markings .............................................................................106

Handling .................................................................................................107

PE Stormwater System Design ................................................................108

PE Stormwater System Installation ......................................................... 111

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5.7 Uponor PP Stormwater System .............................................................. 117

Approvals & Markings .............................................................................120

PP Stormwater System Design ...............................................................121

PP Stormwater System Installation .........................................................122

5.8 Uponor Chamber Systems.......................................................................125

Approvals ................................................................................................129

Chambers in the Drainage Plans .............................................................130

Uponor Chamber Range .........................................................................133

Chamber Installation ...............................................................................136

5.9 Uponor Drainage System DW .................................................................141

Land Drainage Principles ........................................................................143

Approvals ................................................................................................143

Land Drain Inspection Chambers ............................................................144

Land Drainage Design ............................................................................145

Land Drainage Plan – Drawings ..............................................................146

A Building Drainage ...............................................................................147

B Green Area Drainage ..........................................................................155

C Highway Drainage ..............................................................................160

Pipe Laying and Backfilling ....................................................................161

Land Drainage Discharge ........................................................................163

5.10 Uponor Field Drainage System ...............................................................164

Field Drainage Principles ........................................................................165

6. Uponor Pressure Pipe Systems ..............................................................167

6.1 Introduction ............................................................................................169

Uponor Pressure System – Structural design .........................................170

Uponor Pressure Systems – Hydraulic Design ........................................178

Uponor Gas System Design ....................................................................181

Uponor Pressure Pipe System Installation – General Instructions and

Supervision .............................................................................................183

6.2 ProFuse Pressure System – Characteristics ............................................189

Approvals ................................................................................................192

Markings .................................................................................................193

ProFuse-Pressure Pipeline Design ..........................................................195

ProFuse Pressure Pipe Installation .........................................................196

6.3 Uponor Pressure System PVC – Characteristics .................................... 209

Approvals ................................................................................................212

Markings .................................................................................................213

Uponor PVC Pressure Pipe Installation...................................................214

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6.4 Uponor Pressure System PE80 – Characteristics ....................................219

Approvals ............................................................................................... 222

Markings ................................................................................................ 223

PE80 Pressure Pipe Installation ..............................................................224

6.5 Uponor Pressure Pipe System PE100 – Characteristics ..........................227

Approvals ............................................................................................... 230

Markings .................................................................................................231

6.6 Uponor Pressure Fittings – Characteristics ........................................... 233

Approvals & markings ............................................................................ 236

PE100 Pressure Fittings, Installation..................................................... 238

7. Uponor waste water treatment system.................................................239

7.1 Waste water treatment system – Introduction .......................................242

Dimensioning ..........................................................................................245

Uponor infiltration system ..................................................................... 258

General advice ........................................................................................261

The purification process ........................................................................ 262

Site of waste water treatment system ................................................... 263

How to install an Uponor septic tank 2 m3 .............................................265

How to install an Uponor septic tank 4 m3 ............................................ 267

How to install an Uponor septic tank 6 m3 ............................................ 268

Risers – installation instructions .............................................................270

How to install an Uponor distribution chamber ......................................271

How to install an Uponor infiltration/sand filter trench system ............ 273

How to install an integrated pump system from Uponor .......................276

How to install a pump chamber from Uponor .........................................278

How to install a holding tank ................................................................. 280

Inspection and maintenance instructions .............................................. 284

Uponor infiltration module system ........................................................ 286

How to install an infiltration module system ......................................... 289

Dimensioning ..........................................................................................291

Positioning with regard to the groundwater table .................................292

Infiltration trench – size and design .......................................................293

Sand filter trench – size and design ....................................................... 294

Parallel sand filter trench – size and design .......................................... 296

Self-monitoring – inspection and maintenance ..................................... 298

Uponor anchoring system installation ................................................... 300

Uponor Holding Tank 5.3 m3 ................................................................. 305

Installation instructions for holding tank 10 m3 .................................... 309

Assembly instructions .............................................................................315

Operating instructions ............................................................................316

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7.2 Uponor Small Sewage Treatment Plants and Phosphorous

Removal Solutions ..................................................................................317

General presentation ..............................................................................320

Planning ..................................................................................................323

Installation and Commissioning of Clean I ..............................................325

Commissioning of wireless alarm system ................................................332

The usage .............................................................................................. 334

Troubleshooting chart for Clean I ...........................................................337

Installation of Small Sewage Treatment Plant 10 and 15 ...................... 338

Installing the Switch Cabinet, Small Sewage Treatment

Plant 10 and 15 .......................................................................................339

Operation ............................................................................................... 342

Service ................................................................................................... 347

Sludge emptying instruction, Uponor Small Sewage Treatment

Plant 10 and 15 ...................................................................................... 349

Troubleshooting chart ........................................................................... 350

Clean Easy function ............................................................................... 354

Installing Uponor Clean Easy ..................................................................355

Self-inspection/maintenance instruction Uponor Clean Easy ............... 358

Uponor Phosphorous Removal Chamber - easy to install,

maintain and use.................................................................................... 360

Cost-effective phosphorous removal .....................................................361

Packing list - Uponor Phosphorous Removal Chamber ......................... 362

Phosphorous Removal Chamber Function ............................................. 363

Installing Uponor Phosphorous Removal Chamber ............................... 364

Self-inspection/maintenance instruction Phosphorous

Removal Chamber ...................................................................................370

Self-check/maintenance instruction - Other ........................................ 372

Contact information ...............................................................................374

8. Uponor cable and telecom systems .......................................................375

8.1 Introduction ........................................................................................... 377

8.2 Uponor cable ducting system .................................................................379

Smooth, polythene cable conduits .........................................................381

Corrugated, polythene cable ducts ....................................................... 383

Double-walled PE cable ducts ............................................................... 384

Uponor Cable Ducting System Tripla – Characteristics ......................... 386

Design .................................................................................................... 388

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Installation ............................................................................................. 389

Split duct ............................................................................................... 400

Cable cover ............................................................................................ 401

Marker tape ........................................................................................... 402

Marker netting ....................................................................................... 403

Laying method/Installation ................................................................... 405

8.3 Uponor Opto cable ducting system ....................................................... 409

Installation ..............................................................................................411

8.4 Uponor Opto Net cable ducting systems ...............................................413

Approvals and requirements specifications ............................................418

Marking ..................................................................................................419

Installation ..............................................................................................420

Dimensioning ..........................................................................................428

9. Operation and Maintenance of Uponor Infrastructure

Pipe Solutions .........................................................................................431

9.1 General ...................................................................................................433

9.2 Pipe System User Instructions ............................................................... 434

9.3 Inspection of pipe lines ..........................................................................436

9.4 Maintenance and Servicing of Sewer and Storm Drains .........................439

9.5 Maintenance and Servicing of Chambers .............................................. 441

9.6 Maintenance and Servicing of Pressure Sewer Systems ........................ 442

9.7 Maintenance and Servicing of Pressure Pipe Systems .......................... 443

10. Handling ..................................................................................................445

Transport ............................................................................................... 447

Storage .................................................................................................. 448

11. On-site Inspection of Uponor Products................................................449

12. Terms, Symbols and Abbreviations .......................................................453

13. Technical literature ................................................................................459

14. Standards ................................................................................................461

Design charts 1.1 - 9 .......................................................................................467

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9I N T r O d u C T I O N

UPONOR INFRASTRUCTURE

INTRODUCTION

10 I N T r O d u C T I O N

1. Foreword

Clean water is our most precious resource.

Only a tiny fraction of the world's water

resources are fit for human consumption.

Water management is crucial to human

health and productivity and is a vital

public service.

uponor plays its own part in meeting

these challenges. Our core purpose is

to partner with professionals in creating

better human environments. We have a

long tradition in the development of pro-

environmental, long-lasting , watertight

and reliable products that save clean wa-

ter and energy throughout their service

life. uponor products are also made from

highly recyclable materials.

The technical development of the infra-

structure solutions sector is a key aspect

of our operations. uponor is represented

in a number of official and standardisation

working groups tasked with creating prac-

tices and guidelines for the industry. We

also promote the industry's development

through our own training and publica-

tions. This Technical Handbook is our

latest significant contribution in this area.

The manual is intended for the de-

sign and installation of infrastructure

systems and to ensure the proper use of

uponor's products. A correctly designed

and installed system will guarantee reli-

able operation for decades to come.

The manual is a continuation of our

designer’s Handbook for Municipal Pipe

Systems. It is the culmination of years of

dedicated product and service develop-

ment and close collaboration between

uponor and our Nordic partners, and

represents the latest in uponor know-

how, expertise and innovation.

uponor Suomi Oy

Infrastructure and Environment

I n t r o d u c t I o n 11

uponor specialises in creating innovative,

high-quality housing and infrastructure

systems that improve people’s well-being

and quality of life.

uponor’s broad Infrastructure Solutions

range covers gravity sewers, manholes,

chambers and catchpits, cable protection

conduits and pressure pipe systems. Its

Building Solutions range includes heating

and water supply plumbing systems, ven-

tilation systems, wastewater treatment

tanks and many other products.

our comprehensive solutions are based

on more than 40 years of experience and

know-how. In addition, non-stop product

development ensures our ability to deliver

ever better solutions and ecologically

friendly production methods well into

the future.

close customer cooperation has always

been at the heart of what we do. We

promote such cooperation by offering

our customers professional training and

cutting-edge technical expertise. A strong

customer focus forms the foundation of

our operations.

Uponor as a Partner

12 I n t r o d u c t I o n

Our Customers

We count our ability to maintain good,

close relationships with our customers

among our key strengths. We view our

customers as our cooperation partners.

together, we develop the industry, new

technologies and best practices. the

opinions and feedback of our customers

are essential ingredients in the develop-

ment and improvement of our products.

We invest strongly in maintaining a

strong presence, and in exhibitions, fairs

and annual meetings. this ensures that

customers find it as easy as possible to

keep in touch and give feedback. the

result is open, fruitful dialogue.

our large group of sales experts engages

actively in productive discussions with

the customer, receiving feedback and

addressing any questions or issues.

I n t r o d u c t I o n 13

Uponor Academy

uponor makes professional training easy.

our uponor Academy has been training

professional partners and customers in

uponor systems installation since 2006.

Academy programmes are designed for all

professionals in the HVAc/plumbing field,

including distributors, designers, installers,

authorities, contractors and educators.

the uponor Academy will provide you

with practical instructions and advice on

the correct and effective use of uponor

products, and on how to interpret regula-

tions regarding their use and installation.

Each training day includes a compre-

hensive theory component, followed by

hands-on training on uponor products.

We also offer bespoke workshops tailored

to specific installations.

uponor Academy holds several training

workshops, throughout the year. the

training content is based on six core top-

ics, each of which can be modified and

supplemented as needed. For a precise

training schedule, check the training cal-

endar online at www.uponor.fi/Academy.

14 I n t r o d u c t I o n

Uponor expertise

uponor offers more than just product sys-

tems. We offer our customers comprehen-

sive expertise, from installation planning

and design to system handover, drawing

on our more than 40 years of know-how

and experience. In this way, we help our

customers find the very best technical and

economic solutions for their needs.

We invest strongly in close dialogue with

the customer throughout the process.

this helps ensure that all parties are kept

fully informed and that the project is car-

ried out as cost-effectively as possible.

close cooperation also guarantees the

right choice of systems and products.

Whenever advice or technical support is

needed, uponor’s specialists are always

on hand and ready to assist. our sales

representatives are able to provide expert

assistance in resolving technical issues,

and the very latest know-how in the

field is available direct from our product

management team, which is responsible

for all uponor publications.

this technical Handbook is designed to

meet the need for technical information

on uponor’s products, enabling our cus-

tomers, product advisors and end users to

make the best possible product choices.

It also provides important guidance on

the transportation, storage and instal-

lation of uponor products. our ultimate

goal is to provide comprehensive, high-

quality systems with a long and flawless

service life.

I n t r o d u c t I o n 15

the manual is also supplemented by our

uponor website, from which you can

download cAd images of our products

and check the latest system approvals.

If you need any additional information

or advice, you can always get in direct

touch with your uponor contact person.

16 I n t r o d u c t I o n

uponor is continuing its long history of

investment in environmental performance

improvement. An environmental pro-

gramme was approved for uponor in the

year 2000, redefining the Group’s principal

environmental operating policies and

standards, and establishing indicators for

monitoring our work. the main principal

behind the programme lies in taking more

active account of the environmental im-

pacts of our operations. By developing our

working environment, we seek to become

a leading provider of environmentally

friendly solutions within our sector.

our main objectives:

•development of environmental

products

•continuous development of our

manufacturing processes

•waste minimisation

•use of recyclable plastics

Environmental considerations are an

intergral aspect of our operational system,

which encompasses the requirements

of the SFS-En ISo 9001:2000 quality

management system and ISo 14001:2004

standards at our nastola and Forssa plants.

the goal of our operational policy is to

secure uponor’s position as a reliable sup-

plier of high-quality plastic pipe systems

in its chosen business areas, in the most

environmentally responsible way possible.

our quality management system has been

certified since 1991 and our environ-

mental management system since 1999.

uponor aims to become an environmental

pioneer in the industry by exceeding

official environmental standards. We are

increasing staff awareness in line with our

environmental programme – we all share

responsibility for the environmental effects

of our operations.

For more on our environmental commit-

ment, visit us online at www.uponor.fi.

1.1 Uponor and the Environment