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    NAYLOR D E N L O K

    IR T I B S H O T S T D A E I

    N F D

    I

    A T R

    R E D C

    BS En60295

    BSI

    R E

    M

    G R

    II FS T DE ER

    NAYLORDRAINAGE LTD

    Certificate No. FM1420QAS 2489 2/258PSB SingaporePSB Singapore

    MaterialprfungsamtNordrhein-Westfalen

    DENLOK

    Product ManualandSpecification Data

    Vitrified ClayJacking Pipes

    e m a i l : s a l e s @ n a y l o r . c o . u k w e b : w w w . n a y l o r . c o . u k

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    ContentsCompany

    Profile

    Development of TrenchlessTechnology

    Introduction -Pipelines of the Future

    The Need for TrenchlessTechnology

    ProductSpecification

    ProductionProcess

    Product Features andBenefits

    ProductData

    1

    2

    4

    5

    6

    7

    8

    9

    NAYLOR D E N L O K

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    Naylor Industries PLC is a venture capital

    backed fourth generation family business.With its head office in Barnsley UK andfactories in South and West Yorkshire, WestMidlands and Fife the group employs some300 people and sell a wide range of productsacross Britain, Europe, the Middle East,South East Asia, Australasia and North

    America generating a 30 million poundannual turnover.

    The last decade has seen the companychange dramatically. A 18 million capital

    investment programme has been investedover the last 10 years, which has enabledNaylor both to diversify as well as to improvethe productivity of its existing business.

    Naylor's has a unique business approachthat builds on long-term relationships withour customers. This is primarily based onopen collaboration with customers, mutualdependency, professional delivery,sustainable profitable growth and innovation.

    The world of construction and serviceprovision is changing, public and privatesector organisations are working moreclosely together, joint ventures are expected

    Company Profileto deliver end-to-end solutions, new forms of

    contract enable collaborative supply chains.From sustainability and communityengagement to technical innovation andsafety we are proud of the many awards thatrecognise Naylor's commitment to setting thehighest standards.

    Naylor's have established strongrelationships with supply chain partners inorder to minimise risk and to deliver projectsfault-free, on time and to budget.

    Naylor Industries is split into five divisions ofwhich Naylor Drainage Clayware continuesto offer the world's widest range of vitrifiedclay drainage systems.

    I N D U S T R I E S P L C

    NAYLOR

    1

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    Until recently, city administrators and planners believedthat the use of construction techniques involving surfacetrenching was the only option for the construction andrepair of utility services. It was assumed that existingservices were in good condition unless there wasevidence to the contrary. In reality, gradual deteriorationwent unnoticed and failures occurred without warning, in

    many cases requiring an urgent response.Over the last 25 years, it became apparent that little wasknown about existing utility services. Installation drawings,where they existed, gave little information on pipecapacity or materials used. Furthermore, the condition ofthe pipe linings was unknown, leakage and infiltrationwere unmeasured and related health issues were oftennot addressed.

    The two installation options currently available for accessto underground utility services are Open Cut andTrenchless.

    For access by open cut there are four stages:-

    Excavation of the trench, removal of spoil andtemporary support of other services.

    Laying and jointing the product pipe.

    Refilling the trench and compacting the selected spoilor filling material.

    Restoring above ground infrastructure.

    All four stages are characterised by the amount ofphysical work to be undertaken. Typically, 50 times theamount of spoil to be occupied by the product pipe hasto be moved once during excavation and again inrefilling. Much of the work in all four stages is labourintensive, involving different skills that require co-ordination between several companies and authorities. Alarge project can extend over a long period and be verydisruptive in social, economic and environmental terms.

    Access using trenchless techniques also requires surfacework, but not on the scale needed for an open cutapproach.

    Trenchless technology projects require carefulconsideration of the existing condition of theunderground pipes and ground conditions in order toselect the most appropriate technique. The technologyand approach must be determined and the surface workmust be conducted using an existing access or bydigging access pits.

    The determination of the technique, location of theaccess pits and the route for a new pipe requires an initialsurvey. This is often viewed as an additional expense incomparison to open cut techniques. However, the cost ofthe initial survey stage of a trenchless project is usuallyoffset by a shorter time on site.

    Trenchless technologies present a number of uniqueadvantages. With new installations, engineers can installpipe in the most favourable stratum, irrespective ofdepth. For gravity sewers, significant savings can berealised by retaining gravity flow and avoiding pumpingstations.

    Whichever construction technique is used to installunderground service utilities, the project is greatlyimproved by an understanding of the existingservices and the ground in which they are to beinstalled before work commences. This is particularlyimportant for trenchless projects, where the projectdesign is based on a site investigation report. In opencut projects, the trench itself is often theinvestigation and the plan usually involves solvingproblems as they occur. Advances in the design anduse of CCTV have considerably reduced the cost of

    surveying water and sewage networks, andinformation on conditions below the water level canbe obtained by the use of ground penetrating radar. Atraditional rule for most underground projects is thatcost usually rises in direct relationship to the depth ofwork below the surface. As a result, the firstconsideration has been to make any new installationas shallow as practical, and any access to an existingservice as short and direct as possible.

    For trenchless projects, experience has shown thatthere is little relationship between cost and depth. Forwork on existing services, the access points already

    provided could be used and work can be planned toreduce disruption.

    For new projects, the nature of the ground and depthof the water table can influence the chosentechnology and process to be used. By usingtrenchless technologies, project designers can takeadvantage of the most favourable ground conditions,irrespective of depth, allowing for the installation ofnew services in areas where open cut methods werepreviously impossible. The ability to install pipe atgreat depths can help to simplify designs by allowinglonger pipe runs with shallow gradients, thus avoiding

    the need for pumping stations and sumps. Thisfacilitates pipe installation below already congestedunderground areas close to the surface in towns andcities.

    TheDevelopmentof TrenchlessTechnology

    Systems

    Installation Options Site Assessment

    2

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    In addition to environmental and social factors,financial comparisons can be made betweentrenchless technologies and traditional open cutmethods. However, these comparisons are oftendifficult because there are no universal costcomparison methods. While technically the bestsolution depends upon the ground conditions andthe location of the water table, in practice thefinancial boundaries of a project and the degree ofacceptable financial risk generally play a moresignificant role in the decision-making process.

    The question also arises, cost to whom? The clientis responsible for the direct costs of the contract andpossibly for any compensation for the loss of amenityor trade by local residents and businesses. This oftenmeans that the costs are borne by local citizens andfuture generations. Furthermore, certain governmentfinancial policies can distort the real costs ofinstalling, maintaining and repairing utility services.This can lead to the misconception that open cut ischeaper, when in fact a full accounting of the

    environmental and social costs may indicateotherwise.

    The direct costs of both the trenchless and open cutmethods in the terms of materials, time andequipment can be established relatively easily.Indirect costs such as reinstatement of the surface,long-term repairs to roads and buildings due todelayed settlement, useful life of the service afterwork and a degree of risk for unplanned or additionalemergency work that may arise during the projectcan often exceed direct costs. An advantage of

    trenchless methods is that there are generally lessindirect costs because surface access is lessdisruptive, projects are shorter and hence the socialand environmental costs are considerably reduced.

    Open cut construction work disrupts roads, buildingsand other infrastructure. The duration of thesedisruptions is a major source of frustration for localresidents, business and the general public. This hasresulted in growing opposition to construction work ingeneral, including concern for the natural environment,as well as an increase in claims for compensation.

    Health and safety of workers, equipment operators andthe public is well recognised and has led to theintroduction of legislation requiring the use of safeworking practices. In the case of underground utilities,

    the closer workers and operators are to mechanicaland electrical equipment, to moving traffic, or the morethey have to work in confined spaces the greater therisk of accidents. With trenchless projects, surfaceexcavation is confined to relatively small entry and exitpits or shafts, and it is often possible to locate theseaway from hazardous areas and road traffic.

    In comparison to the use of open cut methods,trenchless projects are characterised by minimalsurface disruption over a much shorter period of time.For a well-managed trenchless project, the public maynot be aware that major construction work is actually

    going on below them.

    Financial Considerations Strategic Considerations

    DN600 x 2min Hungery

    Auger Boring in the UK

    DN700 x 2m in the UK

    3

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    The Need for Trenchless Technology

    For a company with its origins in clay pipes it isnatural that Naylor Drainage Limited is in theforefront of product development and innovation.

    With over 100 years of constant production of pipesand fittings throughout the development of water-borne sewerage systems with their associatedimprovements, the Naylor company has developeda product that is a core requirement for thetrenchless construction industry.

    With worldwide operational activities, NaylorDrainage has become the worlds leadinginternational supplier of specialist pipes fortrenchless technology and many prestigiousprojects have been supplied throughout thecompanys UK home base as well as manycontinents overseas.

    Reputation for product reliability and customerservice is part of the Naylor tradition.

    Water and sewerage infrastructures have represented asignificant asset investment on the part of mostmunicipal organisations and water authorities for wellover 100 years. The distribution networks for utilityservices have been located underground in pipes thatare laid, repaired or replaced by trenching from thesurface. In cities and urban areas, these distributionnetworks are located underneath roads. This oftenmakes access difficult, particularly in areas congestedwith traffic and buildings.

    When pipeline infrastructures are not well maintainedthen inefficiencies arise. For example, in waterdistribution systems, leakages occur and watershortages are possible. However, in seweragesystems, cracked and damaged pipes can cause

    wastewater seepage, leading to contamination ofgroundwater. These problems often give rise to relatedhealth and environmental impacts.

    The oldest underground utility services are usuallyfound close to the surface. Services installed later aremost often found below or interwoven with the initialinstallations. Construction and repair carried out fromthe surface inevitably disrupts traffic, business andother services. This disruption has a negative impact onthe local environment in terms of air quality, noise andother pollution, as well as on local vegetation andbuildings. This in turn diminishes the quality of life forlocal residents.

    Trenchless technologies, which minimise therequirements for surface excavation, can significantlyreduce the environmental impacts of undergroundutility service installation, maintenance and repair. Byminimising surface disruption, traffic congestion is

    significantly reduced.

    The companys trenchless technology product -Denlok - is a specially-developed vitrified clay pipesystem to meet the requirements of pipe installation

    by trenchless construction methods which include:- Microtunnelling

    Guided Auger Boring

    Pipe Bursting

    Pipe Eating

    Slip Lining

    The Naylor approach to its development of productsfor the trenchless construction industry has resultedin new manufacturing equipment and productiontechniques. These progressive steps have led to

    reductions in specialist product costs and thesesavings have been passed onto the customer toenable the use of a first-class product at affordableprices.

    Pipelines of the Future

    4

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    Trenchless TechnologyThe trenchless sector is continually being refined and developed. Improvements cover bothlarge and small diameters, longer drives, greater accuracy, faster and curve driving, differentsoil conditions and the ability to work deeper into water tables.

    There are many variants of Pipe jacking, during which the product pipe is forced into theground by hydraulic cylinders mounted horizontal in a launch shaft. The run is completedwhen the pipe string reaches an exit shaft. Both shafts are used later as service accesspoints.

    The various systems for new installations can be broadly categorised into:-

    Pipe Jacking in which the spoil and water is removedby pumping as slurry.

    Guided Auger Boring where the spoil is removed by anauger through a steel casing. Specially designedpipes are then hydraulically jacked in by the machine.

    Pipe Bursting where the existing pipeline is forced intothe pipeline bedding by the means of an expandinghydraulic cone controlled from the surface. The new

    Applicationsfor newinstallations

    pipe pushes the expanding head through the pipelinewhich is being replaced.

    Pipe Eating where the existing pipe line is ground usinga cutting head and the fragments of the pipeline areremoved by augers through the new incoming pipe.

    Slip Lining where pipes are winched through an existingpipe system and the voids between new system and oldsystem are filled with grout.

    Guided AugerBoring

    PipeJacking

    PipeBursting

    5

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    Product SpecificationNaylor Drainage manufactures its products under thecontrol of an approved Quality Assurance Systemcomplying with the requirements of BS EN9002: 2008.Naylor Drainage Ltd is a Registered Firm of AssessedCapability (BSI Certificate No. FM1420).

    Denlok is Third Party Certified by:

    BSI Quality Assurance under Licence No 20173.

    CE07 in accordance with Directive 93/68/EC.

    MPA NRW Germany - Licence No 210001169-01-01

    PSB Singapore - Licence No 02235

    CPRU Brunei - Licence No STD3/003

    All Denlok pipes and assemblies are manufactured inaccordance withBS EN295-7

    Requirements for vitrified clay pipes and joints forpipe jacking.Denlok pipes and joint assemblies aremanufactured in accordance with

    BS EN12889: 2000 Trenchless construction and testing of drains andsewers.

    Quality Assurance

    Component Specification

    LoknSlip 4.5 Bar Seal

    Third Party Assurance

    CE Conformity

    1

    2

    3

    MAX

    NORM

    MIN

    29

    35

    41

    11.31

    18.33

    38.07

    0.85

    1.20

    1.87

    13.3

    15.3

    20.4

    LoknSlip is available in either EPDM or Nitrile certified toEN681- 1

    Root InfestationDue to the high contact pressure LoknSlip reduces therisk of root infestation through the joint allowing for pipeinstallation under mature trees

    Naylor Drainage Vitrified Clay Pipe conforms toEuropean Standard: EN 295-10.

    Denlok and Revit pipes above diameters DN300 in corporate the new LoknSlip NS pipe seal.

    Seal Design and FunctionLoknSlip is designed as a sliding seal that is located in the pipe endrebate. No lubricant is required on either the seal or stainless steel

    sleeve as lubricant is enclosed within the sliding mantel. As the malespigot is inserted into the female sleeve the seal is compressedcreating a positive 4.5 bar internal and external pressure.

    The mantel rolls over the seal during jointing reducing friction to aminimum and acts as a cushion between the spigot and sleevelimiting differential movement under transverse shear loads once thejoint is completed. The design optimises joint performance andprovides an exceptionally high level of operational reliability.

    Item Gap Compression%Deformation Force

    N/mmContact Pressure

    MPAContact Width

    mm

    6

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    Locally-quarried raw materialsare accurately blended beforebeing ground to a fine form toenable subsequent extrusion.

    Clay raw material is mixed withwater to give plasticity for extrusion.

    High-pressure extrusion ensures thata strong dense pipe body is produced.

    Close attention to drying to removemoisture is undertaken prior to firing underaccurate temperature control.

    2 4

    3

    6

    5

    Use of special highly-insulated kilns isemployed for attaining accurate firing.The special qualities of vitrification of thepipe body are attained at a firingtemperature in excess of 1050C.

    After the firing and subsequentgrading processes the pipe ends areaccurately machined with computer-

    controlled diamond profile cutters. Accurate production of parallel ends is

    also achieved.

    Intermediate inspection takes placeas well as pipe ends being pressure

    tested to ensure integrity of pipematerial. The joint components are

    then applied and materials arepacked for shipment.

    Naylor Denlok Pipes readyfor despatch.

    1

    Production Process

    7

    Delivery of pipes is to the customersrequest, consignee to be responsible foroffloading all packs, which are designedto be offloaded by forklifts.

    If there is no forklift available on site amoffat off-load vehicle can be arrangedat the time of order placement.

    Close attention to packing fortransportation and overseas shipment is

    part of the Naylor delivery service.

    It is a major recommendation that allunit packs must be kept assembledwith all protection intact until the pipe isready for use.

    All Denlok pipes and elastomercomponents are resistant to heat, ozone

    and ultra violet light.

    Delivery and Site Handling

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    Product Features and Benefits

    Denlok is covered by and fully certified to EN295,the international standard for clay jacking pipes.

    High-axial strength for jacking force assurance.

    High crushing strength for load bearingcapabilities.

    Smooth wall surface with very minimal frictionalresistance.

    Excellent chemical resistance, Denlok handles

    domestic, industrial and chemical effluents.

    Accurately machined pipe ends for easy loadtransference of jacking force.

    EPDM elastomer sealing components and particleboard thrust rings factory fitted. Particle boardcomponents tested as best material for loadtransference.

    Wide range of diameters available.

    Worldwide international project-supply references.

    International Technical and Commercial support.

    Major advantages of Denlok Vitrified Clay Jacking Pipes are:

    Pipe underresearchat a UK materiallaboratory

    Pipe beingtype tested

    in accordancewith EN295-7

    Clause 4.8Strength

    Installedpipeline

    8

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    DN150 jacking pipe with EPDM seals and aninjection moulded polypropylene sleeve and integralthrust ring, all elastomer conforms to therequirements of EN681 1.

    A vitrified clay jacking pipe which is suitable for theconstruction of house connection installed bytrenchless technology.

    Naylor DN150 Denlok can be connected directly to

    Naylor DN150 Densleeve using the factory fittedDenlok coupling removing the need for any specialconnections.

    Jacking Strengths1. F1 = permissible jacking force for manual recorded safety factors 2/2 (for standard dimensioning)2. F2 = permissible jacking force for automatic and control, recorded safety factors 2/1.6)

    ProductData

    Pipe Dimensions Strength

    NominalSize

    DN

    mm

    InternalDiameter

    d1

    mm

    ExternalDiameter

    d2

    mm

    Pipe EndDiameter

    d3

    0.5mm

    EffectiveLength

    L

    0.5mm

    ManualSteering

    F1(2)

    sf=2.0kN

    CrushingStrength

    kN/mFN

    AutomaticSteering

    F2(3)

    sf=1.6kN

    ApproxWeight

    kg/m

    45183 228150 9961493.0 2083.0 186

    d2 d1 d3

    L

    64

    NC RangeDN150

    Naylor Denlok

    9

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    Pipe Dimensions Strength

    NominalSize

    DN

    mm

    InternalDiameter

    d1

    mm

    200

    225

    250

    300

    2003.0

    2254.0

    2534.0

    3055.0

    ExternalDiameter

    d2

    mm

    2713.0

    2934.0

    3574.0

    4125.0

    Pipe EndDiameter

    d3

    0.5mm

    246

    272

    332

    388

    EffectiveLength

    L

    0.5mm

    996

    996

    996

    996

    ManualSteering

    F1(2)

    sf=2.0kN

    CrushingStrength

    kN/mFN

    AutomaticSteering

    F2(3)

    sf=1.6kN

    ApproxWeight

    kg/m

    350

    358

    815

    938

    438

    447

    1019

    1172

    60

    80

    100

    120

    Pipes up to and including DN300 are generally supplied in 1.0m lengths. DN300 are available in 2.0m lengths.

    Other lengths available as special requirements.

    d2 d1 d3

    L

    Naylor Denlok NC range of jacking pipes consists of avitrified clay pipe with parallel end faces and a squareaccurate machined seal interface.

    All pipes have a factory fitted 316 stainless steelcoupling which incorporates a moulded EPDMelastomer seal, each seal has an integral EPDM thrustring, which transmits the jacking forces during pipeinstallation, all elastomer conforms to the requirementsof EN681 1.

    By precision machining of the seal interface thecoupling will with stand a 2.4 bar internal and externalpressure allowing installation below the water table andprotection from lubrication systems during pipeinstallation.

    Naylor Denlok

    80

    80

    100

    120

    From DN200 to DN300NC Range

    10

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    Pipe Dimensions

    NominalSize

    DN

    mm

    InternalDiameter

    d1

    mm

    400

    450

    500

    525

    600

    700800

    900

    1000

    1100

    1200

    4065.0

    4505.0

    5045.0

    5245.0

    6097.0

    7159.07909.0

    8909.0

    9919.0

    108512.0

    118312.0

    ExternalDiameter

    d2

    mm

    5525.0

    5855.0

    6395.0

    6605.0

    7587.0

    8559.09649.0

    10809.0

    11939.0

    130712.0

    143012.0

    PipeEnd

    d3

    0.5mm

    526.5

    564.0

    612.5

    633.0

    730.5

    819.0964.0

    1051.0

    1164.0

    1276.0

    1393.0

    EffectiveLength

    L

    0.5mm

    9841984

    9841984

    9841984

    9841984

    9841984

    9841984984

    1984

    9841984

    9841984

    9841984

    9841984

    ManualSteeringStrength

    F1(2)

    sf=2.0kN

    CrushingStrength

    kN/mFN

    AutomaticSteeringStrength

    F2(3)

    sf=1.6kN

    Strength

    ApproxWeight

    kg/m

    1575

    1625

    1700

    1780

    2260

    25003077

    4350

    5210

    6237

    7527

    1969

    2031

    2125

    2225

    2825

    31263846

    5437

    6512

    7797

    9408

    240

    250

    260

    280

    338

    430508

    680

    800

    967

    1170

    Jacking Strengths1. F1 = permissible jacking force for manual recorded safety factors 2/2 (for standard dimensioning)2. F2 = permissible jacking force for automatic and control, recorded safety factors 2/1.6)

    From DN400 to DN1200

    d2 d1 d3

    L

    Naylor Denlok NS range of jacking pipes consists a

    vitrified clay jacking pipe with parallel ends and arebated accurate joint interface.

    All NS range of pipes consists of a couplingmanufactured from 316 stainless steel a LoknSlip seal

    160

    144

    120

    126

    120

    96128

    108

    120

    132

    114

    and MDF load transferee ring.

    Each pipe supplied will have all seals and a stainlesssteel sleeve factory fitted with the thrust ring suppliedseparate in a cover to protect the material from theweather elements.

    NS Range

    Naylor Denlok

    11

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    All information correct at time of print.

    d2 d1 d3

    Naylor Revit the special designed pipe for use by the '3'Pass Guided Auger Boring Installation Technique.

    Naylor Denlok NS range of jacking pipes consists avitrified clay jacking pipe with parallel ends and arebated accurate joint interface.

    All Revit NS range of pipes consists of a couplingmanufactured from 316 stainless steel a LoknSlip sealand MDF load transferee ring.

    Each pipe supplied will have all seals and a stainlesssteel sleeve factory fitted with the thrust ring suppliedseparate in a cover to protect the material from theweather elements.

    Naylor

    From DN225 to DN500Revit Range

    Pipe Dimensions Strength

    NominalSize

    DN

    mm

    InternalDiameter

    d1

    mm

    ExternalDiameter

    d2

    mm

    Pipe EndDiameter

    d3

    mm

    CrushingStrength

    kN/mFN

    JackingStrength

    kN

    ApproxWeight

    kg/m

    225

    300

    375

    400

    450

    500

    225 +/-3

    300 +/-3

    375 +/-5

    400 +/-5

    450 +/-5

    500 +/-5

    277 +/-3

    380 +/-5

    455 +/-5

    482 +/-5

    548 +/-5

    610 +/-5

    260

    360

    445

    468

    534

    586

    54

    60

    45

    64

    54

    60

    360

    580

    610

    650

    745

    815

    40

    80

    125

    150

    200

    235

    12

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    For pipelines needing to operate at hightemperatures - up to 130C - the DenChemrange is ideally suitable. Special ceramic pipescapable of withstanding higher temperaturesand full resistance to Alkaline and Acid attackcan now be offered for microtunnelling.

    Applications within the chemical,pharmaceutical, food and dairy processing aswell as brewing industries can beaccommodated. High temperature chemicaleffluents resulting from process or cleaningoperations can be handled with confidence.

    d2 d1 d3 c1

    L

    Naylor

    From DN150 to DN300DenChem Range

    150

    200

    225

    300

    400

    450

    150+/-3

    200+/-3

    225 +/-3

    300 +/-3

    400 +/-5

    450 +/-5

    208+/-3

    271+/-3

    277 +/-3

    380 +/-5

    482 +/-5

    548 +/-5

    186

    246

    260

    360

    468

    534

    64

    80

    54

    60

    64

    54

    183

    350

    360

    580

    650

    745

    45

    45

    50

    85

    160

    210

    Pipe Dimensions Strength

    NominalSize

    DN

    mm

    InternalDiameter

    d1

    mm

    ExternalDiameter

    d2

    mm

    Pipe EndDiameter

    d3

    mm

    CrushingStrength

    kN/mFN

    JackingStrength

    kN/mFN

    ApproxWeight

    kg/m

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    Vitrified clay pipe systems for trench andtrenchless installation

    Hathernware Thermachem - ChemicalDrainage and Industrial Ceramics

    Band-Seal couplings for the repair of andconnections into existing pipelines

    Plastic Land Drainage, Twinwall DuctingSystems and Access Boxes

    Lintels - Prestressed Concrete Lintels

    Yorkshire Flowerpots, a range of frostproofplant pots

    Naylor Industries plc - morethan 100 years of productionand supply to theConstruction Industry

    K 0 4 1 1

    CLOUGH GREENCAWTHORNEBARNSLEY, SOUTH YORKSHIRES75 4AD

    NAYLOR DRAINAGELIMITEDNAYLOR

    D E N L O K

    TELEPHONE: 01226 790591FACSIMILE: 01226 790531EMAIL: [email protected]: WWW.NAYLOR.CO.UK

    ?