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1' TOL057A 0000245 O L 5 - E " , -_
', 1 I Civil r
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Stanton Bonna was formed in 1989 as a loint venture beiween the Concrete Division of
Stanton PlC and Bonna, the largest manufacturer of precast concrete products in Europe
The amalgamation has enabled Stanton Bonna and its customers to benefit from over 170
years combined experience in the production of high quality precast concrete products for the
sewerage and drainage markets
The centrally located complex at Stanton-byDale near Noitingham is ideally positioned to
serve UK customers quickly and efficiently and substantial investment has taken Stanton Bonna
to the forefront of concrete pipe and manhole manufacturing technology. The result is the
Vi-KingTM range renowned for the highest standards of vertically cast vibrated products.
Stanton Bonna's expertise in precast concrete products has resulted in diversification into the
power, rail and street lighting markets. The company has subsequently established market
leading positions for its concrete pressure pipe for power stations, twin block railway sleeper
for linht rnil systems, concrete street lighting columns nnrl GRP sewer rpnnvntion units.
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Utilising modern computerised manufacturing equipment, Vi-KingTM pipes uriu iriuiiholes are
vertically cast in steel moulds with a semidry concrete mix which is compacted by
sophisticated vibration patterns. The result is consistently high quality products with sharply
defined joint profiles.
All Stanton Bonna's products are available to meet classes of sulfate attack as defined in
BRE Digest 363 1996 as detailed in the table below.
OPC
OPCIPFA
Products manufactured using ordinary Portlanu ~eiiieiii to BS 12
Products manufactured using a combination of OPC to BS 12 and pulverised fuel ash to BS 3892 Part 1 .
SRC Products manufactured using sulfate resisting Portland cement to BS 4027.
e
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Stanton Bonna offer an extensive range of precast concrete flexible joint pipes from DN 300 to DN 1800 including bends,.junctions (see pages 8 and 9), rocker and butt pipes.
H Vi-KingTM pipes are vertically cast using vibration to compact a semi-dry concrete mix into the mould. Spun pipes are centrifugally spun in a mould to produce a highly compacted product.
H Vi-KingTM pipes employ a unique Delta gasket which,
compared to a circular gasket, requires lower jointing
forces and offers increased resistance to withdrawal after
jointing.
H Gaskets are manufactured in SBR or EPDM and comply
with BS 2494, other types of joint gasket material
(including nitrile compound) can be supplied on request.
w Vi-KingTM pipes will not joint to any other cast or spun
pipes.
w Actual bore sizes available on request
Nominal Maximum Maximum
Size of Pipe Allowable DKW Angular
Deflection DN
300 - 600
675 - 1200
*As defined in BS 591 1 : Part I O U
1350 - 1800
a
a
a
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I Concrete Pipes Data I I I I I
I-WIIIIIIW Pipe Dimensions class n Peiivery uetai ' ig iest Loaas K N / ~ Size of I
Pipe External Diameter
DN J A J ~ ~ 'B' mm 'c' mm ID' mm kg
Effective. length Socket Barrel Th
- 300 2500 48; , 410 55
wu!
I I I I I I I - 25
25 3. 44
25 38 I 48
j8 25
25 50 53
48 53 67
52 I
58 6: 84
60 72 90
1 2500 ! 670 I 578 I 64 I 715 128/33 I 20 450
- -
575 I 2500 I 567 ' '.85 I 5F 1 510 I39/47 ' 20
~~
I 1 " 1 I
6% 525 2500 79:
600 2500 87(
675 2500 968
750 2500 1056
Y -
9q0 1080
13(
241 -
15 1(
91 114
0 138
975* I 2438 310 I 1145 85 - I970 I110/12 1 48 ~
%--+-E- /8 51 64
5 5/6 58 72
4550 4/5 63 79 96 120
5134 ' /4 69 87 10. - 558 /4 75 94 111
1 O!
120
150 I 150
- 1260
1440
1740 I 1680
95( 1800
98( 1920
22 153
1 ,?n
143 160 11600 1 2500 4 183
58 198 124 155 a -
'Spun pipe
Standard bends are available at
angles of 1 1 '/doand 22'/z0. Bends of
45O and 90' are available dependent
on diameter (see table below).
Bends having nonstandard angles up to 900can be manufactured on request
dependent upon diameter.
Bends are of polygonal construction
(cut and stuck from two or three pipe
pieces). Dimensions and leg lengths
available on request.
Bends are not designed as
load bearing structures and should be encased in Q
suitably designed in-situ
concrete surround.
TO10598 0000252 255 Bends and Junctions -._._._._._._._._._._._.
Junctions are provided with
DN 100, 150 and 225 Densleeve
clay branches to BS EN 295 or with
concrete socket or spigot branches
for DN 300 and above. Branches
are fitted to full length pipes using
cementitious or resin mortars.
Full dimension details of junctions
and backdrop junctions are
available on request.
Junctions are not designed
as load bearing structures
and should be encased in a
suitably designed in-situ
concrete surround.
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Stanton Bonna offer a range of microtunnelling pipes suitable for
installation by modem microtunnelling techniques.
The joint incorporates the well proven
steel collar and elastomeric sealing
gasket to ensure a watertight joint.
Mild steel collars are provided with a
paint coating. Pipes with stainless steel
collars can be supplied on request.
Pipes are manufactured to produce
accurate joint surfaces with square
faces and a strong high density
concrete with a smooth surface finish to
assist in reducing jacking forces.
w lnterjack stations with integral ’cans’
are available for DN 900 and DN 975 pipes.
Full technical details including pipe
dimensions, packing details and
allowable jacking loads are available
on request.
The diameter range is being extended
to suit market requirements and
enquiries are welcomed for
diameters/lengths not detailed.
7 Internal 1 External r H e c t i \ = T p p r o x i r n a t e
I a 7nn 3 AA E I 0 7 K I
Manhole 8t Soakaway Rings -.-._._._._._._._._.-.-.- m TO10578 000025Y 0 2 8
Vi-KingTM chamber rings are
manufactured with tongue and groove
joints designed to accommodate
cement mortar or 'Tokstrip' flexible
jointing compound (see page 14).
Shaft and chamber sections for all
diameters are supplied with galvanised
malleable iron steps to BS 1247 as
required. ladders can be supplied on
request.
Chamber rings can alternatively be
supplied with single or double plastic
encapsulated mild steel steps which
conform to BS 1247 and Water
Industry Specification 4-330 1
Thickn -t4vailable Depth of
Section in mm 'ind.stem I
Lifting Holes
2400
2700
900
1200
1350
1800
00
2400
2700
3000
4
A __.
6
6 -
8
9 - 4
4
Designed to replace engineering bricks
to seat a cast iron cover and frame.
4 Effective thickness is 67mm i.e. the
thickness of a standard brick course.
w Average compressive strength similar to
Class B engineering bricks.
w Standard access hole is 600mm
square.
w Overall diameter is 1065rnm.
w Each seating ring is reinforced and
weighs 73kg.
.. Cover slabs are heavy duty reinforced.
Supplied with standard 600mm or
675rnm square access hole to suit
chamber rings of DN 900 and above.
w Circular or non-standard access
openings can be made to special
order.
Cover Slabs Data
Cover Slabs & Reducing Slabs _._.-.-._._._._._._._._. W TOL0598 000025b 7 T O
0 - Reducing Slabs
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Reducing slabs are available to suit
chamber rings of DN 1200 and
above.
Reducing slabs are supplied with a
cast-in step iron and have an effective
thickness of 250mm
I Reducing Slabs Data ' Nominal
DiarFter 1 Diameter Overall 1 zT 7 umber 'A' mm
200 1350 + 1500 - 800
J Reinforced landing slabs are available
for use in deep manholes.
Landing slabs have an effective
thickness of 160mm for DN 1500 and 200rnrn for DN 1800 to 3000.
I Landing Slabs Pata
I N o m i n a l vera I meter Diameter
Vi-KingTM manholes are designed and
manufactured to provide accurate joint
profiles with a high quality finish and when
used in conjunction with 'Tokstrip' flexible
jointing compound, will enable the contractor
to construct watertight manholes quickly,
without the need for concrete surround.
'Tokstrip' is approved for such applications by
the Department of the Environment and the
Ministry of Agriculture Fisheries and Food and
TO10578 0000257 837
the use of 'Tokstrip' with precast concrete units
is strongly urged on engineers in the Reports
of the Working Party on the Construction and
Design of Underground Pipe Sewers so that
the high costs of insitu concrete surrounds can
be avoided.
This method of construction meets the
requirements of Building Regulations 1992
Building Standards [Scotland) Regulations
1990, DTp Specification for Highway Works
Kiternarked gullies made to BS 591 1 : Part 230 are available and can be
supplied with adaptors for connection
to clay or plastic pipes.
Gully cover slabs are available with
a DN 450 or DN 375 access.
Slabs are 1 OOmm thick and weigh
approximately 80kg.
1994, DOE Working Pariy on Sewers and
Water Mains Report 1975 and is specifically
endorsed by laxton's General Specification
1996, Scottish Association of Directors of
Water and Sewerage Services and DOE Northern Ireland Standard Specification for
Water and Sewerage Schemes (3rd edition)
1989, Water Services Association Civil
Engineering Specification for the Water
Industry (4th edition) 1993, BS 8005 (Sewerage) 1987 and BS 8301 [Building
Drainage) 1985.
The use of the Vi-KingTM precast concrete
products with 'Tokstrip' flexible jointing
compound also meets the requiremenk of
Water Authorities Association specification
Sewers for Adoption (4th edition) 1995.
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m TOL0578 0000258 773 m Manhole Construction -.-.-.-.-.-.-.-.-.-._._.
Manhole Construction I The in-situ base must be levelled to
provide a vertical manhole chamber.
Install chambers and shaft sections
vertically and in the correct sequence to
ensure proper positioning of the steps
[see notes below).
Sections of 0.75m depth should only
be used:-
a) as a single section manhole
b) as a manhole base section
c) immediately above a landing slab
Sections of 1 .Om and 0.5m depth may
be used in any combination (but not
immediately above a reducing slab).
Sections of 0.25m depth should only
be used:-
a) as the manhole top section
b) immediately below a landing slab
c) immediately above a reducing slab
as a shaft section
d) two sections together at any
position.
Seating ring Cover slab
0.25, 0.50, 1 .OO
d) immediately above a reducing slab a as a shaft section.
0.50, 1 .OO
0.25,0.75
Reducing slab
0.50, 1.00
0.50, 1.00
- Shaft sections (m)
Chamber sections (m)
0.25,0.50
0.75, 1 .OO I I
landing Slab
0.25,0.50, 1 .OO
0.50, 0.75, 1 .OO
In-situ base
- Chamber sections (m)
Volume 1 of Tables for the hydraulic design
of pipes, sewers and channels: 6th
Edition.
Sewers for adoption 4th Edition.
(WRC/WSA).
Civil engineering specification for the
water industry. 4th Edition. (WRC/WSA).
A guide to design loadings for buried rigid
pipes. (TRRL/HMSO 1983).
Simplified tables of external loads on
buried pipelines. (TRRL/HMSO 1986).
BRE Digest 363. Sulfate and acid
resistance of concrete in the ground.
(BRE 1996).
Water Industry Specifications 4484 1 . Imported granular and selected asdug
bedding and side fill materials for buried
pipelines.
Water Industry Specification 4-1 241 . Precast concrete pipes - unreinforced and
reinforced, with flexible joints.
Manual of Contract Documents for
Highway Works. (Department of Transport
HMSO).
H Trench design and preparation has an
important bearing on the strength of the
pipeline and it should be constructed
fully in accordance with the contract
specification and drawings.
H The pipe laying contractor should take
all precautions required by statutory
regulations, or any dictated by actual
circumstances, to ensure the safety of I
the public and the pipe layers when
handling pipes, digging trenches,
jointing pipes and backfilling.
W TO10578 0000259 bOT W ~-
British Standards
BS EN I S 0 9002: 1994. Model for
quality assurance in production, installation
and servicing.
BS 591 1 : Precast concrete pipes, fittings
and ancillary products.
BS 1 2: 1996. Specification for Portland
cement.
BS 1247 Part 1 : 1990. Specification for
galvanised ferrous or stainless steel
manhole steps.
BS 4027: 1996. Specification for sulfate
resisting Portland cement.
BS 4482: 1985. Specification for cold
reduced steel wire for the reinforcement of
concrete.
BS 882: 1992. Specification for
aggregates from natural sources for
concrete.
BS 2494: 1990. Specification for
elastomeric seclls for joints in pipework and
pipelines.
BS 8005: Part 1 : 1987. Guide to new
sewerage construction.
BS 8010: Part 2. Pipelines on land:
design, construction and installation.
BS 830 1 : 1985. Code of practice for
building drainage.
1 :r --
A,: . . : . _I ,. 1
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Soft areas, local hard spots or boulders
in the bed should be dug out and the
level restored using well-tamped
granular material.
H Disturbance of wet finegrain soils such
as clay, silts and fine sands in the
trench bottom should be avoided.
, I , 1 . .. :
H Drainage of the pipe trench or the
provision of a blanket of coarse
granular material confined within a
trench mat may be needed.
Product Health & Safety Data TO10598 00002b0 3 2 1
0
1. P d u c t s
Precast concrete drainage units
manufactured to various parts of BS 59 1 1 . Pipes and fittings for domestic and
industrial sewerage, highway and
agricultural drainage. Pipes for installation
in trench (or by jacking) together with
manholes, soakaways, slabs and road
gullies.
2. Physical and Chemical characteristics.
0 Concrete unreinforced or reinforced with
steel bars, mesh or steel cylinder. Concrete
manufactured by the compaction of coarse
and fine aggregates, cementitious material
and water which subsequently undergo a
curing process. Elastomeric sealing gaskets
and cast iron steps.
3. Main Hazards
The principal hazards associated with
these products concern handling and
cutting. Concrete has a hard textured finish
which may cause abrasions to the hands
when handled. Excessive handling can
also cause skin irritation and dermatitis.
The cutting and drilling of concrete will
create fine dust and can also project
particles at high velocity with consequent @
risk of impact damage. Such dust if
containing quartz and if inhaled in
excessive quantities over extended periods
can constitute a long-term health hazard.
Products are generally cylindrical and can
roll on uneven or inclined surfaces.
4. Precauiions
Protective gloves should be worn when
handling products. Eye protection and
respiratory masks to the relevant British
Standards must be worn when cutting or
drilling products. Care should be taken to
chock pipes securely to prevent movement,
particularly if products are stacked.
5. Transport and Disposal
The transportation of these products is not
subject to hazardous substance
conveyance regulations and vehicle
labelling is not required. The haulier is
responsible for ensuring loads are secure
to prevent movement in transit.
Precast concrete products are inert, but
should be disposed of in accordance with
local legal requirements. Rubber gaskets
are inflammable and if burned will give off
toxic fumes.
Handling
w Deliveries are usually in 24 tonne
loads. The receiver is responsible for all
off loading.
See pages 19 and 20 for details of
the toc-King lifting and jointing system
for DN 13501 800 Vi-KingTM pipes.
H Use of correct off-loading equipment on
site is essential to ensure a safe
operation and avoid damage to pipes.
w A properly designed "C" beam or
broad banded canvas/fabric slings
with a central lift should be used.
w Pipes should not be lifted by chains
passed through the bore.
w Pipes should not be dropped or
subjected to impact.
w Gaskets should be stored without ties
and protected from sunlight, oil, grease
and heat.
w Pipes should be stacked neatly on level
ground on wooden chocks up to the
height stated in the table below.
DN Max. Number of Layers
no0 - 375
450 - 6 0 ~
675 - 975 2 -
,Le\,, 0 7 K
Laying and hinting
w Before jointing, each pipe should be
examined for damage and the jointing
surfaces and gasket thoroughly
cleaned.
w The Vi-KingTM pipe incorporates a
flexible rolling gasket joint which uses
the unique Delta shaped gasket.
w Care must be taken to ensure the Delta
gasket is positioned on the spigot end
without twists. The flat face of the Delta
gasket is marked with a white line.
w The gasket must be positioned on the
spigot and against the locating step
with the white line facing away from
the spigot (see illustration].
H The spun pipe joint is a selfaligning
flexible roll ring joint incorporating an
'0 ring gasket.
w The spun pipe gasket must be
positioned on the end of the spigot
w During jointing the pipe should be
supported at its point of balance and
positioned clear of the trench bottom.
Care must be taken not to displace the
gasket as the spigot is entered into the
socket .
w Lubricants must not be used.
w Before pushing the joint home, ensure
pipe ends are square with each other
to allow even gasket roll.
1 All necessary jointing tackle can be
supplied by Stanton Bonna at a
nominal charge which is credited on
return of the tackle.
Alternative methods of joint assembly
may be used, provided the spigot entry
is steady and controlled to line and
level.
1
I Jointed spun pipe cross section I
Loc-King lifting & Jointing Systei -.-.-.-.-.-.-.-.-.-.-.-.-
The Loc-King lifting and jointing system when used in conjunction with %KingTM pipes DN 1350 and above offers these major advantages:
Safe Handling
The Loc-King lifting eyes engage
securely and provide a horizontal lift
every time. Once engaged, the lifting
eyes cannot disengage under load.
Speed
Off loading, site handling and pipe
jointing with Loc-King is much faster than
with traditional tackle and no weight
balancing is required.
Cost Effective
Compared to traditional methods, the
speed, safety and pipe laying efficiency
of the Loc-King system generates savings
in time, plant and labour.
1. The Chain Set
The Loc-King system comprises lifting
anchors cast into the pipe wall and a
special three legged chain set (Fig. 1 J with lifting eyes which connect to the
anchors for lifting and jointing
operations.
2. Engoging the eye
To engage a lifting eye with a lifting
anchor simply place the eye opening
over the anchor head and rotate the
eye tail until it touches the pipe surface.
Correct engagement of the lifting eyes is essential prior to any lifting or jointing operation and the spare lifting eye should be secured to a shortening clutch to avoid accidental damage or injury.
3. Disengaging the eye
To disengage a lifting eye, slacken the
chain set and rotate the eye tail away
from the pipe surface until the eye can
be lifted off the anchor head.
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General Advice
Pipes must be handled, stored and
installed by persons trained in safe
practices for these tasks. Chain sets are
supplied having been tested in
accordance with the Construction (lifting
Operations) Regulations 1961 . Users
should have a current test certificate and
certificate of examination as appropriate
and should check equipment daily for
obvious damage before use. If equipment is subjected to excessive
shock load or abuse it should be taken
out of use, reexamined and tested.
Vi-KingTM junctions, bends, rocker and
butt pipes require jointing by traditional
methods. Rocker and butt pipes may be
lifted using the single cast in anchor.
4 lifring and Handling
Position the crane's top guide pulley
centrally between the lifting anchors and
engage chain A with the socket end
anchor, B with the spigot end anchor
and secure C to its shortening clutch
(Fig.4). During lifting the included angle
between chains must not
exceed 60".
5 Jointing
Lift the pipe, lower it into the trench and
enter the pipe spigot into the socket of
the last laid pipe. Disengage chain A and secure to its shortening clutch.
Position the crane's top guide pulley over
the socket of the last laid pipe and
engage chain C with the spigot end
anchor (Fig.5).
Take up any chain slack and continue
lifting slowly to joint the pipes. Adjust the
pipe to line and level and check for the
recommended joint gap. Disengage the
lifting eyes and repeat the lifting and
jointing operations as necessary to
complete the pipeline.
Anchor Recesses
Before backfilling, clean and make
good anchor recesses flush to the pipe
barrel surface with epoxy or polyester
resin or a 1 :3 cement sand mortar
proportioned by mass.
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Manhole Ring & Slab Handling -.-.-.-.-.-.-.-.-.-._._.
Manhole Ring & Slab Handling /
Deliveries are usually in 24 tonne Lifting holes are 40mm diu for
DN 900-1 500 chamber rings,
45mm for DN 1 800.2 100 rings and
50mm for DN 2400-3000 rings.
loads. The receiver is responsible for
all off loading.
w Chamber rings must not be lifted by attaching lifting equipment to steps. Chains should be attached to lifting
eyes on the inside of chamber rings
and the chain angle should not
exceed 45" to the vertical.
Chamber rings should be lifted with
suitable lifting equipment for example
chains and quick release lifting eyes
which are available on request.
O F -
= 2100- -
Chamber rings should be stored
vertically to prevent them from rolling
or toppling.
Slabs are manufactured with three
lifting eyes and should be lifted level
using suitable three legged chains.
Slabs should be stored flat, right side
up on suitable timber bearers at stack
heights not exceeding those detailed
below.
Quick release lifting eyes and chains
are available to enable rapid
handling and jointing of Vi-KingTM
manhole chamber rings.
All lifting equipment is supplied
having been tested in accordance
with the Construction (Lifting
Operations) Regulations 1 96 1 .
Allow a further 5 minutes to elapse
without pumping, the water head
should not drop below 75mm water
Sewers up to DN 750 should be
subjected to air or water tests which
accord with BS 8005 Part 1 . For
sewers above DN 750 special
equipment may be required however
a visual inspection is normally
considered sufficient.
w Where the pipeline is below the
water table the air test is not effective
and an infiltration test should be
used.
H The pipeline should be air tested at
least after every third or fourth pipe
laid, prior to backfilling.
w To air test, seal the pipeline at each
end and any junctions with
inflatable test stoppers. Attach
a U tube (manometer] and pressurise
to slightly above 1 OOmm water
gauge.
Allow 5 minutes for air temperature
stabilisation and adjust the pressure
back to 1 OOmm water gauge. The
air test is temperature sensitive and a
1 "C change in air temperature will
result in a change of approximately
38mm in the water gauge.
gauge.
If the water head drops more than
25mm investigate the possible
causes, for example air temperature
change, dryness of the pipe wall,
faulty stoppers or test equipment. A solution of soap and water may be
used to assist in the detection of
leaks.
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Stockist network
Manholes and gullies are stocked
countrywide by merchants to support
local demand. Pipes are also stocked
by certain stockists at nominated
locations.
Technical support
Technical advice can be provided by
qualified staff either on site or from head
office.
Sales support
Rapid response quotations can be
provided by experienced sales staff.
Special products
Specials can be manufactured to
customers designs.
Loc-King system
Lifting and jointing equipment can be
supplied for DN 1 350 - 1800 Vi-KingTM
pipes (see pages 19/20).
The following literature for concrete drainage products is
also available on request by e-mail, fax or telephone.
Concrete Drainage Products Selector
A wall chart for site and office use.
lac-King User Guide
A five point user guide for site use
Site Information
An information sheet sent to all sites.
Lifting equipment
lifting chains, eye bolts and fabric slings
can be supplied for safe product
handling.
Crane off load
Crane off loading facilities can be
provided.
Jointing compound
'Tokstrip' can be supplied to suit all
manholes (see page 14).
Plastic encapsulated steps
Double width plastic encapsulated steps
(rungs) can be supplied loose or fitted to
manhole rings (see page 1 1 ) .
Manhole scheduling
Manholes can be scheduled and
numbered to customers requirements
Technical literature
Background and technical literature by the Concrete Pipe Association and the
Pipe Jacking Association.
Technical Data Sheets on:
Bends and junctions for flexible joint
pipes;
Sulfate resistance of concrete products
to BRE Digest 363;
Site installation procedure for plastic
encapsulated double steps;
Maximum allowable.iacking loads
and jointing instructions for
microtunnelling pipes. a
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TOL0578 00002b7 78b
Tel: 01 15 944 1448
Fax: 0115 944 1466
E-mail: [email protected]
OFFICE HOURS 8.30am - 5.00pm
Member of the Concrete Pipe Association
Member of the Pipe Jacking Association
Stanton Bonna Concrete ttd littlewell Lane Stanton by Dale II keston Derbyshire DE7 4QW
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