HDPE

drainage

[Link]
MARLEY HDPE | 1
Innovation & Expertise Marley HDPE

Marley HDPE is a drainage system which offers an

alternative solution to cast iron. It is particularly suited
for commercial applications or where a product with
high impact or abrasion resistance is required, such as
hospitals, hotels, schools, as well as residential buildings.
HDPE is certified to BS EN 1519. HDPE will also cope with
temperature variations of -40°C to 100°C making it ideal
for external as well as internal installations.

This guide contains product specification Information on the complete range of

details, design and installation information Marley Plumbing and Drainage system
for The Marley HDPE range. solutions is available to download from
[Link] or via the literature
hotline 01622 852585.

FM 30637 EMS 96207 KM 545820

BS EN 1519

Contents
4 Marley Soil & waste systems
6 HDPE drainage

Installation
16 HDPE installation
17 Compatibility
18 HDPE jointing methods
24 HDPE bracketing
27 HDPE handling and storage
28 British and European standards
29 Marley system solutions

MARLEY HDPE | 3
 Marley soil & waste systems
Marley HDPE Marley PVC Soil
The Marley HDPE drainage range is certified to BS EN 1519: 2000 (licence number KM 545820) An 82, 110 and 160mm push-fit and solvent weld soil systems  2, 110 and 160mm pipes and fittings are also suitable for use as
8
extension of the Marley soil & waste portfolio, the HDPE range offers an alternative solution to cast iron. incorporating socketed and plain ended pipe internal and external rainwater pipes to drain flat roofs and metal
The combination of the excellent material properties of HDPE with homogenous welded joints provides  10 and 160mm pipe support components designed specifically
1 gutter systems on commercial and industrial buildings.
greater installation flexibility with a wide range of jointing options. to meet the needs of supporting horizontal or vertical T he range includes the 8-way soil manifold which offers the
suspended PVCu pipework. flexibility of 4 top and 4 side entries, allowing for multiple
inlet connections.

Marley waste
Solvent waste Push-fit waste Overflow Compression waste Traps
PVCu ABS Polypropylene PVCu Polypropylene Polypropylene

Key fitting: Akavent Aerator

The need for secondary venting in high-rise buildings can be eliminated with the Akavent
aerator. An Akavent aerator fitting breaks the discharge fall on each floor and as a
consequence the secondary vent pipe is not required as the pressure difference stays
S uitable for internal Lightweight and cost F or internal use,  complete range of
A  ulti-fit compression
M  range of traps, which
A
well within the limit of 3 mbar.
and external effective for internal ideally suited to fast pipework and fittings socket, for internal enable quick & easy
applications. installation. Easy to installation. Cost for overflow and use. Easy installation installation to any new
The unique shape of the fitting increases the capacity of the stack allowing the soil and cut joint and install. effective solution where boiler condensate to similar sized new or existing plastic or
waste flow from the higher floors to smoothly converge with the flow on the lower floor. systems are being applications. or existing plastic and copper pipework.
installed or modified. copper pipework.

Available in Available in Available in Available in Available in Available in

32, 40 and 50 mm 32, 40 and 50 mm 32, 40 mm 21.5 mm 32, 40 mm 32, 40 and 50 mm
White & Black White, Black & Grey White, Black & Grey White White & Chrome White & Chrome
Marley acoustic system
ABS and polypropylene waste pipes and fittings are designed for internal use and should not be fitted externally as they will be subject to ultraviolet light
degradation. If fitted externally it is recommended that they are protected by the application of a suitable paint or are boxed in.
An acoustic soil and waste range with a layered
pipe providing quick, hygienic removal of
sanitary waste water. The noise generated
KAP2
by the flow of water is dramatically reduced KXT21 WHB

Technical advisory service

2No KR210 B032R

– making it perfect for multi-occupancy WHB

apartment blocks and high specification B032R KT2
SVD4

developments. Technical Services offer a free advisory service, providing KAP2

40
mm
S421150
S411195
WC
SBS40
technical assistance regarding product and installation S201156
S411195
GW059
MKS2

details. Those involved with the building industry may KBA22

KB22 11
0m
m

take advantage of design services provided by the

S241103
company for customers who have made a commitment WC
SBS40
0m
m
4No S411195
MKS2 11
to use or specify Marley products.
UFC1

Technical Hotline: 01622 852695 2No S121145

3No S411195

4 | MARLEY HDPE MARLEY HDPE | 5

 HDPE drainage

PIPE BEND 90° – SHORT

PIPE LENGTH = 5 M d1 Code l1 r Qty d1 Code l1 r Qty

d1 Code e cm 2
Qty d1 Code e cm
2
Qty 160 S 11 16 91 160 160 10 250 S 11 25 91 290 265 1
56 S 10 56 00 3.0 19.60 149 200 S 10 20 00 6.2 276.41 20 200 S 11 20 91 205 200 10 315 S 11 31 91 340 300 1
75 S 10 07 00 3.0 37.40 81 250 S 10 25 00 7.7 431.52 12 Butt-weld only
110 S 10 11 00 4.2 80.70 75 315 S 10 31 00 9.7 685.35 10
160 S 10 16 00 6.2 171.10 39

cm2 = cross sectional area of flow

Pipe = Tempered

PIPE LENGTH = 3M
d1 Code e cm2 Qty

110 S 10 11 03 4.2 80.70 48

BEND 90° – LONG
ELECTROFUSION COUPLER d1 Code l1 l2 r k1 Qty d1 Code l1 l2 r k1 Qty
d1 Code D L System Qty d1 Code D L System Qty
56 S 11 56 92 120 59 56 55 20 110 S 11 11 92 180 113 110 60 20
56 S 41 56 95 68 54 5A/80s 20 200 S 41 20 65 233 175 220V/420s 1 75 S 11 07 92 140 78 75 60 25
75 S 41 07 95 87 54 5A/80s 20 250 S 41 25 65 283 175 220V/420s 1
Electrofusable at one side
110 S 41 11 95 122 58 5A/80s 20 315 S 41 31 65 349 175 220V/420s 1
160 S 41 16 95 172 66 5A/80s 5

EXPANSION SOCKET
Type A Type B BEND 15°
d1 Code D d L Qty d1 Code D d L I1 Qty d1 Code l1 r k1 Qty d1 Code l1 r k1 Qty

75 S 42 07 20 * 100 76 256 20 56 S 40 56 20 * 74 57 172 135 20 110 S 18 11 15 125 165 65 1 250 S 18 25 15 225 375 135 1
110 S 42 11 20 * 137 112 256 20 200 S 40 20 20 ** 230 202 460 230 1 160 S 18 16 15 175 240 100 1 315 S 18 31 15 250 473 175 1
160 S 42 16 20 * 189 162 256 5 250 S 40 25 20 ** 300 253 480 250 1 200 S 18 20 15 200 300 125 1
75

315 S 40 31 20 ** 370 319 510 270 1 Fabricated

Seals: SBR
35

* Includes protection plug

** Excludes protection plug
See page 26 for details on TYPE A / TYPE B

PLUG-IN SOCKET
d1 Code D d L I1 Qty d1 Code D d L I1 Qty

56 S 42 56 50 72 57 89 54 20 110 S 42 11 50 131 111 111 69 20 BEND 30°

75 S 42 07 50 96 76 109 69 20 160 S 42 16 50 190 162 147 105 10 d1 Code l1 r k1 Qty d1 Code l1 r k1 Qty

Electrofusable spigot ends 110 S 18 11 30 125 165 60 1 250 S 18 25 30 225 255 125 1
Seals: SBR 160 S 18 16 30 175 240 100 1 315 S 18 31 30 250 320 135 1
Includes protection plug
200 S 18 20 30 200 200 115 1
Fabricated

INSPECTION SCREW
d1 Code D L Qty d1 Code D L Qty

56 S 66 56 40 81 74 20 110 S 66 11 40 145 106 10

75 S 66 07 40 111 106 20

6 | MARLEY HDPE To BS EN 1519 as appropriate. Available in black only. Available in black only. MARLEY HDPE | 7
 HDPE drainage

ELBOW 88.5° BRANCH 45º

d1 Code l1 k1 Qty d1 Code l1 k1 Qty

56 S 12 56 88 65 20 20 200 S 12 20 88* 290 60 1

75 S 12 07 88 75 20 20 250 S 12 25 88* 350 60 1
110 S 12 11 88 95 25 20 315 S 12 31 88* 360 60 1
160 S 12 16 88 120 25 10
* Fabricated

d1/ d2 Code L l1/l2 l3 k1 k2 k3 Qty d1/ d2 Code L l1/l2 l3 k1 k2 k3 Qty

56/56 S 30 56 56 180 120 60 25 25 40 20 200/160 S 30 20 16 540 360 180 35 85 115 1

75/56 S 30 07 56 210 140 70 35 25 55 20 200/200 S 30 20 20 700 430 270 160 160 230 1
75/75 S 30 07 07 210 140 70 25 25 40 20 250/110 S 30 25 11 * 660 440 220 150 185 215 1
ELBOW 45° – SHORT 110/56 S 30 11 56 270 180 90 45 40 90 10 250/160 S 30 25 16 * 660 440 220 120 130 180 1
d1 Code l1 k1 Qty d1 Code l1 k1 Qty 110/75 S 30 11 07 270 180 90 35 30 75 10 250/200 S 30 25 20 * 660 440 220 90 50 150 1
56 S 12 56 45 45 20 20 200 S 12 20 45 173 60 5 110/110 S 30 11 11 270 180 90 20 20 55 15 250/250 S 30 25 25 * 900 600 300 160 160 250 1
75 S 12 07 45 50 20 20 250 S 12 25 45 182 60 5 160/56 S 30 16 56 * 375 250 125 120 115 65 5 315/110 S 30 31 11 * 840 560 280 235 260 305 1
110 S 12 11 45 60 25 20 315 S 12 31 45 195 60 5 160/75 S 30 16 07 375 250 125 120 115 65 5 315/160 S 30 31 16 * 840 560 280 200 205 270 1
160 S 12 16 45 69 20 5 160/110 S 30 16 11 375 250 125 50 40 45 5 315/200 S 30 31 20 * 840 560 280 175 125 240 1
160/160 S 30 16 16 375 250 125 10 15 25 5 315/250 S 30 31 25 * 840 560 280 140 130 205 1
200/75 S 30 20 07 540 360 180 95 160 175 1 315/315 S 30 31 31 * 950 610 340 170 170 280 1
200/110 S 30 20 11 540 360 180 65 140 150 1
* Fabricated

ELBOW 45° – LONG

d1 Code l1 l2 Qty BRANCH 88.5°
75 S 12 07 46 145 50 20
110 S 12 11 46 155 60 20
1
25

Elbows 45° with long spigot are applied for making the transition
from stack to building drain acc. to EN 12056 (see drawing).
1 stack
2 x S 12 07 46/
2 building drain
S 12 11 46
120

d1/ d2 Code L l1/l2 l3 k1 k2 k3 Qty d1/ d2 Code L l1/l2 l3 k1 k2 k3 Qty

2
56/56 S 20 56 56 175 70 105 30 30 65 20 200/160 S 20 20 16 * 360 180 180 45 60 45 1
75/56 S 20 07 56 175 70 105 30 25 65 20 200/200 S 20 20 20 * 360 180 180 25 60 25 1
75/75 S 20 07 07 175 70 105 25 25 55 20 250/110 S 20 25 11 * 440 220 220 110 70 110 1
110/56 S 20 11 56 225 90 135 45 25 90 10 250/160 S 20 25 16 * 440 220 220 85 70 85 1
110/75 S 20 11 07 225 90 135 35 25 85 10 250/200 S 20 25 20 * 480 240 240 65 40 65 1
110/110 S 20 11 11 225 90 135 20 20 65 15 250/250 S 20 25 25 * 480 240 240 40 40 40 1
160/56 S 20 16 56 * 350 140 210 75 30 145 5 315/110 S 20 31 11 * 560 280 280 170 90 170 1
160/75 S 20 16 07 * 350 140 210 80 45 150 5 315/160 S 20 31 16 * 560 280 280 145 90 145 1
160/110 S 20 16 11 350 140 210 60 45 135 5 315/200 S 20 31 20 * 560 280 280 120 65 120 1
160/160 S 20 16 16 350 140 210 30 35 105 5 315/250 S 20 31 25 * 560 280 280 95 65 95 1
200/75 S 20 20 07 * 360 180 180 90 60 90 1 315/315 S 20 31 31 * 560 280 280 70 65 70 1
200/110 S 20 20 11 * 360 180 180 70 60 70 1 * Fabricated

8 | MARLEY HDPE Available in black only. Available in black only. MARLEY HDPE | 9
 HDPE drainage

DOUBLE BRANCH 45° BALL BRANCHES

d1/ d2 Code L l1 l2 k1 k2 k3 Qty

110/110 S 36 11 11 270 180 100 65 20 20 10 1 DOUBLE 2 DOUBLE 3 DOUBLE 4 TRIPLE 5 TRIPLE 6 FOURFOLD
90° 135° 180° 90° 135° 90°
d1/ d2 Code Code Code Code Code Code L l1 l2 D k1 k2 Qty

110/56 S 24 11 15 S 24 11 25 S 24 11 35 S 34 11 15 S 34 11 25 S 44 11 15 240 120 130 170 30 20 1

110/75 S 24 11 17 S 24 11 27 S 24 11 37 S 34 11 17 S 34 11 27 S 44 11 17 240 120 130 170 30 20 1
110/110 S 24 11 01 S 24 11 02 S 24 11 03 S 34 11 01 S 34 11 02 S 44 11 01 240 120 110 170 30 30 1

DOUBLE BRANCH 60°

d1/ d2 Code l1 l2 Qty

110/110 S 37 11 11 90 102 5
GENERAL DIMENSIONS 1 DOUBLE BALL BRANCH 88.5° 2 DOUBLE BALL BRANCH 88.5°
FABRICATED – 90° FABRICATED – 135°

BRANCH 88.5° – SWEPT ENTRY

d1/ d2 Code L l1 l2 k1 k3 Qty

110/110 S 25 11 11 230 140 120 90 20 15

BRANCH 45° – CLEAN OUT 3 DOUBLE BALL BRANCH 88.5° 4 TRIPLE BALL BRANCH 88.5°
d1/ d2 Code D L l1 l2 l3 k1 k3 Qty FABRICATED – 180° FABRICATED – 90°
110/110 S 33 11 00 140 270 180 195 90 20 55 1
160/110 S 33 16 00 140 375 250 220 125 45 45 1

BRANCH 90°– CLEAN OUT

d1/ d2 Code D L l1 l2 l3 k1 k3 Qty

56/56 S 23 56 00 83 175 70 100 105 30 65 1

75/75 S 23 07 00 91 175 70 100 105 25 55 1
110/110 S 23 11 20 140 225 90 115 135 20 65 1 5 TRIPLE BALL BRANCH 88.5° 6 FOURFOLD BALL BRANCH 88.5°
160/110 S 23 16 00 140 350 140 140 210 60 135 1 FABRICATED – 135° FABRICATED – 90°
200/110 S 23 20 00 140 360 180 160 180 90 90 1
250/110 S 23 25 00 140 440 220 185 220 110 110 1
315/110 S 23 31 00 140 560 280 220 280 170 170 1

10 | MARLEY HDPE Available in black only. MARLEY HDPE | 11

 HDPE drainage

FOUR WAY SOIL MANIFOLD REDUCER ECCENTRIC – LONG

d1/ d2 Code L L1 L2 L3 L4 k1 k2 Qty d1 Code L l1 l2 l3 l4 d3 k1 k2 Qty

110/56 S 44 11 56 275 162 134 85 136 30 70 1 200/110 S 14 20 11 * 335 95 36 165 55 160 75 20 1

200/160 S 14 20 16 ** 260 95 95 75 75 1
250/200 S 14 25 20 ** 290 105 95 85 75 1
315/200 S 14 31 20 * 580 115 95 235 190 250 95 75 1
315/250 S 14 31 25 ** 340 115 105 75 85 1
* type A
** type B

AERATOR AKAVENT
Type A Type B
d1 Code L l1 l2 l3 l4 l5 l6 l7 l8 l9 Qty

110 S 60 11 07 * 750 320 170 260 275 90 180 55 130 90 1

160 S 60 16 07 * 715 320 160 235 310 100 200 75 125 110 1 REDUCER ECCENTRIC – SHORT
*1
 /2/3 = max. Ø 110 mm – 4/5/6 = max. Ø 75 mm d1/d2 Code l1 l2 Qty d1/d2 Code l1 l2 Qty
Butt-weld only 75/56 S 16 07 56 35 37 20 110/75 S 16 11 07 31 36 20
20 110/40 S 16 11 04 31 34 10 160/110 S 16 16 11 28 36 5
110/56 S 16 11 56 31 35 10
80

20

END CAP – FLAT REDUCER CONCENTRIC

d1 Code D L l1 Qty
d1 Code l1 l2 Qty d1 Code l1 l2 Qty
56 S 67 56 07 64 16 12 20
75/56 S 15 07 56 30 30 20 200/160 S 15 20 16* 50 40 20
75 S 67 07 07 85 21 16 20
15 110/40 S 15 11 04 30 30 20 250/160 S 15 25 16* 60 40 20
110 S 67 11 07 120 19 19 20
110/56 S 15 11 56 30 30 20 250/200 S 15 25 20* 60 50 20
Butt-weld only 110/75 S 15 11 07 30 30 20 315/200 S 15 31 20* 90 80 20
80
160/110 S 15 16 11 35 30 1 315/250 S 15 31 25* 90 90 20
END CAP – DOMED 15
d1 Code L Qty
*Butt-weld only

160 S 67 16 09 45 1
200 S 67 20 09 55 1
250 S 67 25 09 30 1
315 S 67 31 09 30 1 CONTRACTION SLEEVE
Butt-weld only d1 Code L I1 dx Qty d1 Code L I1 dx Qty
56MM BOSS ADAPTER 50/70 S 55 05 03 210 65 57-64 5 75/90 S 55 07 01 210 75 80-84 5
Ød316 d1 Code Qty 56/75 S 55 56 01 210 70 62-69 5 110/125 S 55 11 02 210 100 102-111 5
32 S 00 56 32 Seal: NBR
40 S 00 56 40
25

Material: TPE

Ø53

STUB FLANGE
d1 Code d1 D L l1 k1 Qty d1 Code d1 D L l1 k1 Qty

56 S 47 56 02 * 70 102 60 14 15 5 200 S 47 20 02 * 232 268 100 18 40 1

75 S 47 07 02 * 89 120 50 16 15 5 250 S 47 25 02 * 285 320 100 20 40 1
110 S 47 11 02 125 158 80 18 30 5 315 S 47 31 02 * 335 370 100 20 40 1
160 S 47 16 02 175 210 80 18 30 1
* Butt-weld only

12 | MARLEY HDPE Available in black only. MARLEY HDPE | 13

 HDPE drainage

WC CONNECTOR SOCKET
WC CONNECTOR 90° d1 Code d D L I1 Qty d1 Code d D L I1 Qty

d1/ d Code l1 l2 l3 l4 l5 k1 Qty 90 S 50 09 51 * 90 113 49 38 10 110 S 50 11 71 *** 110 130 45 28 10

110/90 S 50 11 85 * 225 76 34 95 17 120 10 110 S 50 11 51 ** 90 111 31 20 10
110/110 S 50 11 82 ** 225 75 30 92 19 120 10 * Seal: SBR
** Seal: EPDM
* Seal: SBR *** Seal: NBR
** Seal: NBR
Includes protection plug

WC CONNECTOR PROTECTION PLUG

d1 Code D D1 D2 I1 Qty d1 Code D D1 D2 I1 Qty

90 S 43 09 19 109 90 103 27.0 50 110 S 43 11 19 130 105 119 23.5 50

WC CONNECTOR 90° – HORIZONTAL

98
Left
d1/ d Code I1 I2 I3 k1 Qty

110/90 S 50 10 32 * 350 100 75 170 5

110/110 S 50 11 32 ** 350 100 75 170 5
* Seal: SBR
** Seal: NBR ANCHOR BRACKET
Includes protection plug d1 Code a b s R Qty d1 Code a b s R Qty

56 S 70 56 78 113 30 2.5 “½” 1 200 S 70 20 80 283 40 4 “1” 1

75 S 70 07 78 126 30 2.5 “½” 1 250 S 70 25 80 333 40 4 “1” 1
Right 110 S 70 11 78 161 30 2.5 “½” 1 315 S 70 31 80 398 40 4 “1” 1
d1/ d Code I1 I2 I3 k1 Qty
160 S 70 16 78 215 30 2.5 “½” 1
110/90 S 50 10 33 * 350 100 75 170 5
Galvanised steel
110/110 S 50 11 33 ** 350 100 75 170 5
* Seal: SBR
** Seal: NBR
Includes protection plug GUIDE BRACKET
d1 Code a b s R Qty d1 Code a b s R Qty
DOUBLE WC CONNECTOR 90° – VERTICAL 56 S 70 56 10 113 30 2.5 M10 1 110 S 70 11 10 161 30 2.5 M10 1
d1/ d Code I1 I2 k2 Qty d1/ d Code I1 I2 k2 Qty 75 S 70 07 10 126 30 2.5 M10 1 160 S 70 16 10 215 30 2.5 M10 1
110/90 S 50 09 34 * 225 275 80 5 110/110 S 50 11 34 ** 185 270 60 5
Galvanised steel
* Seal: EPDM
** Seal: NBR
Includes protection plug

MOUNTING PLATE
Code R I1 I2 I3 I4 S C Qty

S 70 94 78 * ½” 145 38 90 25 4 8,5 1
S 70 94 10 ** M10 145 38 90 14 4 8,5 1
S 70 94 80 ** 1” 145 38 90 25 4 8,5 1
Galvanised steel
DOUBLE WC CONNECTOR 90° – HORIZONTAL
d1/ d Code I2 I3 k1 Qty d1/ d Code I1 I2 k2 Qty

110/90 S 50 09 35 * 100 275 200 1 110/110 S 50 11 35 ** 100 270 200 1

* Seal: EPDM
** Seal: NBR
Includes protection plug PIPE SCRAPER
360
Code Qty

S 41 96 00 1

14 | MARLEY HDPE Available in black only, with the exception of protection plug (white) and brackets & mounting plate, which are manufactured from galvanised steel. MARLEY HDPE | 15
 HDPE installation Compatibility
Tempered Pipe

Marley HDPE pipe is tempered. This pipe is produced according Abbreviations The Marley HDPE range can be connected to PVC-c or ABS materials, allowing for easy waste pipe connection to the discharge stack.
to the standards EN 1519 and ISO 8770 and has undergone a
heat treatment after extrusion. The result is less shrinkage when Abbreviation
cooled down from high operational temperature. This gives less D External dimension fitting part Soil stack: Bottle traps:
stress on joints resulting in a longer life for the pipe system. d1, d2 ... External dimension fitting/pipe Connection from a 56mm boss pipe to a 32mm or 40mm pipe, 32mm and 40mm rubber boss pipe connections to bottle traps.
e Wall thickness using a 56m rubber boss adaptor.
Shrinkage according to EN 1519 (3%) k1,k2 ... Maximum length for shortening fittings
L Total length fitting 32mm
PVC-c/ABS waste pipe
Maximum shrinkage tempered Akatherm pipe (1%) l1,l2 ... Lengths of part of fitting
TPE Thermoplastic Elastomer B032R
S005632/S005640 Resealing
SBR Styrol butadiene rubber 32/40mm rubber boss adaptor bottle trap
NBR Acrylnitril-butadiene rubber
EDPM Ethylene propylene copolymer
S005632 rubber boss adaptor
HDPE High density polethylene S201156 56mm Boss pipe
56mm HDPE

Testing the system

Pipe length after production
The system should be inspected for any possible leaks in 40mm
PVC-c/ABS waste pipe
Linear expansion accordance with BS EN 12056. Air should be pumped into the
Marley HDPE material has a linear expansion coefficient of 0.13-0.19 system through a branch of a tee piece until a pressure equal
P040
mm/mK. We calculate with an expansion of 0.2mm per meter to 38mm water gauge is achieved. The inlet valve should then 'P' trap
pipe for every °C temperature difference. The total length be closed and the system should maintain the pressure for a
variation can be calculated as follows: minimum of three minutes.
S005640 rubber boss adaptor
Δl = L x λ x Δt 56mm HDPE
Δl = length change in mm Chemical resistance
L = total length of pipe For all chemical resistance enquiries please contact our technical Alternative connectors:
λ = linear expansion coefficient support team on 01622 852695. Alternative connections from HDPE to PVC-u and PVC-c.
Δt = temperature difference in °C

Example: S415695 S415695

S425650 S405620 S105600 KEC3
10 metres of pipe with a maximum temperature of 60°C and a 50mm PVC 50mm PVC 50mm PVC
minimum temperature of -20°C. This results in an expansion of:

S201156

S201156

S201156
Δl = 10 x 0,2 x 80 = 160 mm
Length changes can be accommodated by the expansion socket S101100 SE405
or 110mm PVC
which can take up the expansion and contraction of a 5 meter 110mm PVC 110mm PVC S101103
length of pipe for temperatures between -20°C and 70°C.

S251111

S251111

S251111
Electrofusion
Marley HDPE products can be welded by electrofusion unless S421150 S411195 S421120 S411195
stated differently in the product table. This is the preferred Butt-weld plugin socket Electrofusion coupling Pvc coupling pushfit to HDPE
method of on-site jointing. with expansion socket

S101100 S101100 S101100

Butt welding and k-dimension or or or
Marley HDPE products can be welded using this jointing method. S101103 S101103 S101103
Fittings can be shortened by up to the k-dimension (indicated in
the product specification section page, 6–15), still allowing butt- Bends at the base of stacks
welding on a standard butt-welding machine. Bends at the base of vertical stacks should be of long radius and
have a minimum centre line of 200mm on a 100mm nominal
size stack. Two 45° bends may also be used as an alternative to
S411195
provide the change of direction. The same design principle should
Electrofusion also be adopted where offsets occur in stacks that have more than
coupling one storey height above the offset.

2No S121146
Long spigot bend 45°

16 | MARLEY HDPE MARLEY HDPE | 17

  

HDPE jointing methods


Electrofusion   Butt-welding

Correct Jointing procedure Incorrect Jointing procedure

1. Cut the pipe square 1. Prevent misalignment
The pipe ends must be cut square to ensure that the heating ✗ 
element in the coupler is completely covered by the pipe or
fitting.   
Butt-welding is a very economical and reliable jointing technique
for making welded joints, requiring only butt-welding equipment.
✔  All pipes and fittings can be joined by this welding method.
  Fittings for which a k-dimension is shown in the product section,
 2. Prevent coupler from sliding down when installed (page 6–15), can be shortened by not more than this amount.
Electrofusion, the most simple and rapid jointing technique, vertical    
Butt-welding is extremely suitable for prefabricating pipe sections
KG and for making special fittings.
for a highly efficient method of assembly for pipes, fittings and ✗
prefabricated sections.   KG KG
2. Mark insertion depth + 10 mm
Preparations
This is to ensure that across the full welding zone the oxidised
Electrofusion couplers 
The HDPE range includes couplers in a range of core diameters
layer will be removed.  The following guidelines are of importance when making
up to 315mm. The couplers are extremely suitable for applications ✔ 10 mm  a proper butt-weld:
in waste water and rainwater drainage, with the following features:  ●● E stablish a work space where the jointing can be done
without being effected by major weather conditions.
1. Injection moulded with excellent dimensional accuracy 10 mm

and stability. 2x  ●●  heck the equipment functions properly. Welding equipment
C
used on site deserves special attention.
2. W
 elding indicators on each welding surface for visual 
T he fittings and or pipes need to be aligned in the welding
 3. Don't weld coupler twice ●●
identification to show that the coupler has been welded. 3. Scrape pipe and mark insertion depth again
 ✗ machine. Mis-alignment can be up to 10% of the wall
3. C
 entre stops easy to remove, in order to use the coupler The outer surface
10 mmof the pipe (approx. 0.2mm deep) must
as a slide- over coupler. be scraped for the full distance that will be covered by
the 2x  thickness.
coupler to remove any surface 'oxidation'.  2x
●●  lean
C  the heating element before each jointing operation
4. R esistance wires fixed to the surface for an optimal heat 10 mm with a lint- free cloth and suitable cleaner (see instructions
transfer and therefore a high quality welding connection. 
The insertion depth should be marked again to safeguard supplied with the welding machine).
5. Y
 ellow edge surrounding the welding indicators of the full insertion. ●●  ut the pipe and/or fitting with a pipe cutter to make the
C
10 mm
diameters 200, 250 and 315mm are provided for better ✔ 4. Prevent load on vertical pipesystem end square.
visibility.  ✗  
 ●●  ake sure that once the pipe and/or fitting ends have been
M
machined, they do not get dirty. Do not touch them with

 KG
your hands. The surface needs to be clear of oil, grease and
dirt.

4. Clean coupler
 ●● P ut the pipe parts into the welding machine to facilitate
a firm hold during the jointing process.
Before assembling the pipes into the coupler ensure that ●●  digital thermometer can be used to check the temperature
A
all surfaces are clean and dry.

 42
of the heating plate. The temperature should be checked
at several points around the plate and should be between
✔ 200ºC and 220ºC. Maximum deviation between points is
 given in the table.

 Used surface of heating element

After connecting the cables of the control box the welding process for welding diameter (d1)
Δt max
can commence by pushing the start button. The control box

 adapts the welding time to the ambient temperature.
2x  When it d1 = 40-160 8ºC
5. Insert pipe and/or fitting up to pipe stop is colder than 20°C the welding time is extended and when the d1 = 200-315 10ºC
ambient temperature exceeds 20°C the welding time is shortened.
the fitting.

Ensure that the pipe is pushed as straight as possible into
For welding times and cooling down time see table below. Maximum temperature variation heating element

The joint assembly should not be disturbed during the fusion cycle
✔  and for the specified cooling time afterwards.

weld
 dimension d1
42
system
time
cooling time

mm sec min
42
 40-160 Constant current 5A 80 20
200-315 Constant voltage 220V 420 30

18 | MARLEY HDPE MARLEY HDPE | 19

 HDPE jointing methods
Welding process

The butt-welding of Marley HDPE operates according

to the following steps: pressure N/mm2

Machining the surface Heating up with less pressure (PE)

HDPE
preheating pressure (F o) welding pressure (F L)
Both sides should be machined until they run parallel. When the HDPE is a good insulator, therefore at this stage it is necessary 0,15
machining is finished, open the carriages (the plastic shavings that the correct heating depth of the pipe ends is obtained. Only
must be continuous and uniform in both sides to weld). Take off a small amount of pressure 0.01 N/mm2 is required to maintain
the milling cutter. the contact of the pipe ends with the heating element. The heat
Verify the alignment between the machined surfaces. Remove will gradually spread through the pipe/fitting end. The size of the
the plastic shaving. Do not touch or get any dirt on the machined bead will increase a little. The time and pressure needed for this
surfaces. phase can be found in the table on the next page.

heating pressure (F d)
0,01
time

pressure time
changeover

building-up
time
preheating time heating time cooling time

total welding time

Preheating under pressure Change over
height welding bead
Press the two ends to be jointed gradually on to the heating Remove the heating element from the jointing areas and
element until a bead is created. The size of the bead is a good immediately make those areas touch each other. Do not push
indication that the appropriate pressure and time is used. For the pipe ends abruptly onto each other. total time welding process
pressure and bead size see the table on the next page.
The removal of the heating element needs to be done quickly
to prevent the pipe ends from cooling down. The times for
changing over can be found in the table on the next page. Preheating
pressure /
welding Heating
Diameter Wall thickness pressure pressure Height Changeover Building-up
Welding and cooling d1 e (0,15 N/mm2) (0,01 N/mm2) welding bead Heating time time pressure time Cooling time
After the jointing areas have made contact they should be joined mm mm FO/FL N Fd N mm sec sec sec min
with a gradual increase in pressure up to the specified value.
*40 3.0 55 4 0.2 29 4 4 4
Keep the specified welding pressure at a constant level during
*50 3.0 70 5 0.5 30 4 4 4
the cooling period. Do not cool artificially.
56 3.0 75 5 0.5 30 4 4 4
*63 3.0 85 6 0.5 31 4 4 4
75 3.0 105 7 0.5 32 5 5 4
*90 3.5 145 10 0.5 35 5 5 4
110 4.2 210 14 0.5 42 5 5 6
*125 4.8 275 18 1.0 48 5 5 6
*125 3.9 225 15 0.5 39 5 5 5
160 6.2 450 30 1.0 62 6 6 9
110 3.4 175 12 0.5 35 5 5 4
160 4.9 370 25 1.0 49 5 5 7
200 6.2 570 38 1.0 62 6 6 9
250 7.8 900 60 1.5 77 6 6 11
The welded components can be removed from the machine 315 9.7 1400 93 1.5 77 6 6 11
when 50% of the cooling period has elapsed, providing that this 200 7.7 700 47 1.5 77 6 6 11
is done carefully, with no load or strain being placed on the joint. 250 9.6 1090 73 1.5 97 7 7 13
The joint must then be left undisturbed for the remainder of the 315 12.1 1730 115 2.0 121 6 8 16
cooling period.
Marley HDPE – Welding parameters *Please note these sizes are made to order and require a 28 day lead time.

In this table the welding parameters can be found for Marley HDPE. The exact regulation of the welding machine depends on its
mechanical resistance. The tables provided with the machine are to be used for regulating the machine.

20 | MARLEY HDPE MARLEY HDPE | 21

 HDPE jointing methods
Evaluating the butt-weld joint Plug-in joint Expansion joint

The butt-weld can be evaluated using destructive and non destructive When there is either insufficient heating up or too low welding
evaluation methods. For these evaluations special equipment has to pressure there are hardly any beads. In cases like this thick walled
be used. Butt-welds can easily be judged by a visual inspection making pipes often form shrinking cavities. The weld must be classified as
this the recommended method for a first evaluation. "not acceptable".
The shape of the welding bead is an indication for the proper
operation of the welding process. Both welding beads should Butt-weld (not acceptable)
have the same shape and size. The width of the welding bead A plug-in joint is an easy to make, detachable and non pull-tight Expansion sockets can absorb length changes of pipes with a
should approximately be 0.5 x the height. Differences between ✗ jointing method. maximum length of 5 m.
the beads can be caused by the difference in HDPE material used
in the welded components. Despite the differences in welding
bead the butt can be of sufficient strength. Jointing process:
Jointing process:
In the next illustration a good weld is shown with a uniform
welding bead. At a visual inspection this would be classified Cut pipe square and remove burr
as an "acceptable" weld. Cut pipe square and remove burr
✔ ✔
Butt-weld with even welding beads (acceptable)
In the next illustration a cross-section of a regular, round fusion
✔ bead, free of notches or sagging is shown. Special attention
e*
should be paid to the fact that the collar value 'K' is greater than 0.

Cross section of a good butt-weld

✔ Mark insertion depth Mark insertion depth

✔ ✔
Plug in socket: An expansion socket counteracts
Mis-alignment between fittings and pipe can occur for several
reasons. Oval pipe ends or irregular necking of the pipe can cause the variation in length caused
The pipe needs to be inserted in
an incomplete fit. If this is less than 10% of the wall thickness the by the thermal expansion and
the plug in socket using the full
weld can still be classified as "acceptable" (see next illustration). shrinkage of the pipe.
insertion depth.
Depending on the ambient
Butt-weld with mis-alignment of pipe (acceptable) A plug-in joint is not to be used to
temperature the insertion depth
accommodate the expansion and
varies. The right insertion depth
✔ contraction of a pipe system.
for both 0°C and 20°C is indicated
max 0.1 e*
on the expansion socket.

Chamfer pipe end Chamfer pipe end

✔ ✔
The pipe-end needs to be The pipe-end needs to be
chamfered at an angle of 15°. To chamfered at an angle of 15°. To
The next illustration shows a joint with beads that are too big.
obtain an even cut and chamfer a obtain an even cut and chamfer a
The uniformity indicates a good joint preparation. Heat supply
chamfering tool should be used. chamfering tool should be used.
and jointing pressure settings, however, are too high. A purely
visual assessment would still classify the weld as "acceptable".

Butt-weld with big welding beads (acceptable)

✔
Make joint Make joint
Lubricate the pipe end and insert the pipe up to the marked Lubricate the pipe end and insert the pipe up to the marked
insertion depth.
insertion depth.

* For the value of 'e' please refer to the table on page 21

22 | MARLEY HDPE MARLEY HDPE | 23

 HDPE bracketing
Bracketing system Bracket distance

For the installation of Marley HDPE pipe systems several bracketing systems can be used: The bracket distances for Marley HDPE pipes are largely dependent on the
working temperature of the pipe system. Also the filling rate of the pipe
Anchor point bracket plays a role. A fully filled pipe has a different bracket distance.
This method of bracketing is used for rigid installations. The expansion forces are transferred to the building structure.

Support bracket fixed to building Electrofusion coupler either side of

structure- brackets must be of support bracket
sufficient strength to resist forces
generated by thermal movement
of the pipes

Anchor bracket with expansion socket

This method of installation is used for flexible installations where the expansion force is not transferred to the building structure.
Only the force caused by the internal resistance of the expansion socket is transferred.

Bracket distances for vertical and horizontal PE pipe systems with standard filling

Support bracket fixed to building Thermal movement of PE pipework

structure-brackets to be of sufficient
strength to resist forces caused by Horizontal installation with expansion sockets
the internal resistance of the The bracket directly in front of the expansion socket has a shorter
expansion socket
bracket distance (LA*) This makes a better guidance into the
expansion socket possible (see image). The bracketing distances d1 LA LA*
for this application can be found in table below. The maximum
distance between 2 expansion sockets is 5 m. 75 0.8 m 0.4 m
*90 0.9 m 0.5 m
Guide bracket 110 1.1 m 0.6 m
The guide bracket is used to support the pipe and to prevent the pipe from buckling sideways when in a rigid installation. *125 1.3 m 0.7 m
The pipe can freely move in the bracket. 160 1.6 m 0.8 m
200 2.0 m 1.0 m
250 2.0 m 1.0 m
315 2.0 m 1.0 m

Bracket distances horizontal installation with expansion sockets

*Please note these sizes are made to order and require a 28 day lead time.

24 | MARLEY HDPE MARLEY HDPE | 25

 HDPE handling and storage
Bracket distance

Vertical installation: to the wall Fittings Storage of loose pipes

For the vertical installation the The fittings and electrofusion couplers need to be stored
bracketing distance is in general 1,5 in a dry place. To prevent oxidation and contamination, it is
times the distance of the horizontal recommended to leave the fittings in their original packaging as
bracketing. There is no separate long as possible.
bracketing distance for immediately in
front of the expansion socket because Pipes
there is no sagging of the pipe and
The high impact strength of Marley HDPE provides some
the insertion is always in line.
protection against damage but care should be taken at all stages
of handling, transportation and storage.
Pipe must be transported by a suitable vehicle and properly
loaded and unloaded, e.g. wherever possible moved by hand Tools
or mechanical lifting equipment. It must not be dragged across Tools need to be protected against moisture.
the ground. The storage should be flat, level and free from sharp
Vertical installation
stones.
Health and safety at work act and COSHH regulations
GB = guide bracket FP = fixed point Bundles Attention is drawn to the requirement in the UK of this act
LV = vertical support distance and to the 1988 Control of Substances Hazardous to Health
Bundled packs of pipe should be stored on clear, level ground
(COSHH) Regulations. Marley cannot accept responsibility for
with the battens supported from the outside by timber or
accidents arising from the misuse of its products because of bad
concrete blocks. For safety, bundled packs should not be stacked
installation or incorrect application.
d1 LV more than three high.
Handling of HDPE has no detrimental health impact. It is
*50 1.0 m Smaller pipes may be nested inside larger pipes. Side bracing
recommended, however, that HDPE is not ingested or dust
56 1.0 m should be provided to prevent stack collapse.
inhaled.
*63 1.0 m
Similar precautions should be taken with fittings and these should
75 1.2 m be kept packaged until required for use.
*90 1.4 m Personal Protective Equipment (PPE)
110 1.7 m When welding HDPE, molten material is formed, which can cause
*125 1.9 m burns to skin. Appropriated PPE should be worn.
160 2.4 m
200 3.0 m
Physical contact
250 3.0 m
HDPE is not considered to be a skin irritant. Where HDPE dust
315 3.0 m
is generated by cutting of machining pipe of fittings, powder
Bracket distances vertical installation with expansion sockets particles of HDPE dust may cause eye irritation by abrasion.
*Please note these sizes are made to order and require a 28 day lead time.

Behaviour in Fire
HDPE is a flammable material. It has, however, been installed
HDPE expansion socket insertion depth throughout Europe for over 35 years and presents no greater
risk of fire propogation than similar plastic based systems when
HDPE Expansion Details installed in accordance with local regulations. Marley offer
Type A Type B a range of firecollars suitable for HDPE. Please speak to our
Min. Insertion
Diameter Total Length Max. Expansion (No White Retaining Ring) (With White Retaining Ring) Technical Department on 01622 852695 for further information.
Depth @ 20°C
*40mm 132mm 76mm 56mm Type B
*50mm 132mm 76mm 56mm Type B Storage of bundles
56mm 132mm 76mm 56mm Type B
*63mm 132mm 76mm 56mm Type B
Lengths
*75mm – On Fitting On Fitting Type A
Pipe lengths stored individually should be stacked in a pyramid
*90mm – On Fitting On Fitting Type A
not more that one metre high, with the bottom layer fully
110mm – On Fitting On Fitting Type A
restrained by wedges. Where possible, the bottom layer of pipes
125mm – On Fitting On Fitting Type A
should be laid on timber battens at one-metre centres. On site,
160mm – On Fitting On Fitting Type A pipes may be laid out individually in strings (where appropriate,
200mm 230mm 120mm 110mm Type A protective barriers should be placed with adequate warning signs
250mm 250mm 125mm 125mm Type A and lamps).
315mm 270mm 126mm 144mm Type A

*Please note these sizes are made to order and require a 28 day lead time.

26 | MARLEY HDPE MARLEY HDPE | 27

 Standards Marley system solutions
British & European Standards

BS EN 1519-1: 2000
Plastics piping systems for soil and waste discharge (low and high
temperature) within the building structure – polyethylene.

BS EN ISO 9001: 2008

Quality systems. Model for Quality Assurance in Design,
Development, Production, Installation and Servicing. Marley PVCu Soil Marley waste systems Marley acoustic
Standard PVCu soil systems to A wide range of PVC-u, ABS and An acoustic soil and waste range with
BS EN ISO 14001: 2004 BS EN 1329: 2000. Ideal for domestic and polypropylene waste ranges from a layered pipe providing quick, hygienic
commercial applications, including branch 32mm to 50mm and in a variety of removal of sanitary waste water.
Environmental management systems. Requirements with guidance
connections to other materials. Available colours. Available in solvent weld The noise generated by the flow of water
for use.
in 82mm, 110mm and 160mm, ring seal and push fit jointing. is dramatically reduced – making it perfect
and solvent weld jointing variants. for multi-occupancy apartment blocks
and high specification developments.
Accreditations

FM 30637 EMS 96207 KM 545820

BS EN 1519

Marley rainwater Marley underground systems Alutec

Five gutter profiles and three downpipe The Marley Plumbing & Drainage range Alutec offer modern and traditional
options provide a rainwater solution of underground systems include the aluminium rainwater profiles, providing
for any application. Advanced Life4 solid wall range, predominately for solutions for any type of building.
technology on four of the key profiles, round the house drainage and Quantum Aluminium has high visual appeal and
coupled with the benefits of the Easyclip structured wall range for sewer and durability, lasting for 50 years or more.
and notching capability combine to make highway drainage applications. The product portfolio includes Evolve;
the Marley rainwater range the most easy to install, low cost gutter systems
comprehensive available. in four profiles. The rainwater ranges are
complemented by aluminium soffit and
fascia systems and roof & floor outlets.

NOTE:
Marley Plumbing & Drainage products are manufactured to a constant high standard. The Company will not therefore accept responsibility for failure of any installation
which includes components not supplied by us.
Customer attention is drawn to the Company’s official Terms and Conditions of Sale. Goods are supplied strictly in accordance with these terms and conditions, copies of which are freely available
on request and on [Link]. Product illustrations may vary slightly depending on the type and size. Product images are for illustrative purposes only. Qty, refers to the pack quantity. Products can
be purchased individually e & o e.

28 | MARLEY HDPE MARLEY HDPE | 29

 Underground

[Link]
For general enquiries and details of your
nearest stockist please call the customer
services department:
Tel: 01622 852585
Email: marketing@[Link]

To place an order
For delivery to England & Wales
Email: [Link]@[Link]
Fax: 01622 851111
For delivery to Scotland
Email: [Link]@[Link]
Fax: 01698 810307

For all estimate requests

Email: estimates@[Link]

For Technical advice please call

01622 852695

Head Office
Lenham, Maidstone
Kent ME17 2DE
Tel: 01622 858888
Fax: 01622 858725

Email: marketing@[Link]

Scotland
Birkenshaw Industrial Estate
Uddingston, Glasgow G71 5PA
Tel: 01698 815231
Fax: 01698 810307

Export Division
Lenham, Maidstone
Kent ME17 2DE England
Tel: +44 (0)1622 858888
Fax: +44 (0)1622 850778

Email: export@[Link]

@marleyplumbing

April 2015

30 | MARLEY HDPE