Project: MUARA KARANG

Project number: 5567-X

00 first issue 18/02/2019

rev comments date

NT 216

FOR “BONNA” STEEL CYLINDER

REINFORCED CONCRETE PIPES

LAYING INSTRUCTIONS

version:
V4 02/2016 Change Address

Tour EUROPE, 33 place des Corolles, 92400 COURBEVOIE FRANCE

: +33 1 46 53 24 00
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CONTENTS
1. SCOPE .................................................................................................................. 3
1.1. Laying operations ............................................................................................. 3
1.2. Reference documents ........................................................................................ 3
2. DIFFERENT TYPE OF JOINTS FOR BONNA PIPES ......................................................... 4
2.1. S-L welded joint ............................................................................................... 4
2.2. E-R single rubber gasket joint ............................................................................ 4
2.3. E-RR double rubber gasket joint ......................................................................... 4
3. TRENCH DIGGING AND LEVELLING OF TRENCH BOTTOM ............................................ 5
4. LOWERING AND FITTING OF PIPES AND SPECIALS ..................................................... 8
5. PIPE JOINTING ..................................................................................................... 10
5.1. S-L JOINT WELDING ....................................................................................... 10
5.2. E-R RUBBER GASKET JOINT ............................................................................. 10
5.3. EXTERNAL concrete JOINT ............................................................................... 10
5.4. INTERNAL CONCRETE JOINT ............................................................................ 12
6. THRUST, ANCHORAGE AND SUPPORT BLOCKS ......................................................... 13
7. PIPELINE BACKFILLING ......................................................................................... 13
8. TRENCH TEST ...................................................................................................... 17
9. PARTICULAR MEASURES ....................................................................................... 17
9.1. INTERNAL JOINTING OF SMALL DIAMETERS ....................................................... 17
9.2. LENGTH ADJUSTMENT MEASURES .................................................................... 21
9.3. END-RING MODIFICATIONS ............................................................................. 22
9.4. LAYING OF A CLOSURE PIPE ............................................................................ 23
9.5. FLANGED CONNECTION ................................................................................... 24
9.5.1. General case............................................................................................. 24
9.5.2. Adjustable flanges ..................................................................................... 25
9.6. LIFTING LUGS ................................................................................................ 26
9.7. LAYING ABOVE GROUND ................................................................................. 27
9.8. LABOUR ......................................................................................................... 27
10. Enclosure n°1 S-L welded joint data ..................................................................... 28
10.1. S-L joint typical cross-section ........................................................................... 28
10.2. Deflection angle for S-L joint ............................................................................ 29
11. Enclosure n°2 E-R & E-RR rubber gasket joint data ................................................. 31
11.1. E-R2 joint typical cross-section and deflection angle table .................................... 31
11.2. E-R5 joint typical cross-section ......................................................................... 31
11.3. E-RR joint typical cross-section ......................................................................... 33
11.4. Gasket fitting on R groove procedure and jointing the pipes ................................. 34
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1. SCOPE

The purpose of this document is to describe the operations and conditions necessary for
installing a pipeline made of BONNA steel cylinder reinforced concrete pipe in open trench, in
the most current conditions. Should it be difficult to deal with specific cases, please refer to our
Technical Department for advice.

1.1. Laying operations

The laying of BONNA steel cylinder pipe with double reinforced concrete coating to be
assembled by "slip joint" SL welded joint or rubber gasket E-R or E-RR joints, includes the
following operations:
• digging of trenches and levelling of trench bottom
• digging of niches
• lowering and fitting of pipeline elements (pipes, short pipes and specials)
• Depending on the type of joint fitted on the pipes.
o Joint welding and checking of water tightness for S-L joint types
o Rubber gasket fitting on R groove and pipes jointing for E-R or E-RR joints
The type of joint is mentioned on our layout drawing with a letter code S, L, E, R, RR.
• Internal and external mortar jointing
• Casting of thrust or anchorage blocks, if necessary.
• Pipeline backfilling
• Piping work water pressure test.
These various operations are described hereafter.
Whenever necessary, the pipe to be laid will have previously been coated with the appropriate
protection (paint, plastic wrapping,...).

1.2. Reference documents

One can refer to here under documents if relevant:

• NT 216.1 : WELDING PROCEDURE - Field welding of SL joints
• NT 216.2 : WELDING PROCEDURE - Field welding of S or L end-rings of steel cylinder
short pipes
• NT 171 : ROLE OF PLASTIC WRAPPING SHEET
• NT 416 : WELD TESTING PROCEDURE ON SITE
• NT 238 : Joint-by-joint testing procedure for double gasket E-RR
• NT 239 : TESTING PROCEDURE OF BONNA STEEL CYLINDER PIPELINES
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2. DIFFERENT TYPE OF JOINTS FOR BONNA PIPES

BONNA RCCP pipes are fitted with different type of joints. Type of joint can be identified with a
letter code; S, L, E, R, RR. Our layout drawing, if any, gives the type of joint at spools
connections. Type of joint depends on project specification and /or engineering choices. The
overall piping work can consist of a single type of joint or a mix of different types depending on
engineering choices and discussion.

2.1. S-L welded joint

Refer to enclosure 1 for technical data

about "S" about "L"

"S" end ring "L" end ring

2.2. E-R single rubber gasket joint

Refer to enclosure 2 for technical data and

for procedure to fit the rubber gasket into
the groove before jointing the pipes.
Procedure to fit the rubber gasket into the
groove must be carefully read before pipe
jointing.
About "R" About "E"
"R" end ring "E" end ring

2.3. E-RR double rubber gasket joint

Refer to enclosure 2 for technical data and

for procedure to fit the rubber gasket into
the groove before jointing the pipes.
Procedure to fit the rubber gasket into the
groove must be carefully read before pipe
jointing.

About "RR" About "E"

"RR" end ring "E" end ring
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3. TRENCH DIGGING AND LEVELLING OF TRENCH BOTTOM

It is necessary to take any suitable measures in order to avoid crumbling and to comply with
the personnel safety rules in force, by bank-sloping, shoring, sheet piling or strengthening the
trench walls by any means suitable to the soil nature (timbering, bracing, sheet piling or
mechanical sheeting,).

Throughout the works, care should be taken not to deposit excavated materials or operate any
vehicle that might cause crumbling.

STABLE TRENCH AND CONTROLLED INFLOW OF WATER

It is also necessary to organize the site works so as to avoid any inflow of water likely to impair
the stability of the trench walls or the reliability of the trench bottom. For this purpose and
according to the needs, current techniques may to be used, such as drainage, dewatering,
watertight sheeting or lowering of ground water surface or even more specific techniques like
injections or freezing, by taking the precautions relevant to each process.

Whenever several pipelines are laid parallel in the same trench, the clear space between them
shall be at least 0.40 m for diameters smaller than 800 mm and 0.50 m for larger diameters
(these values vary according to the backfilling and compacting criteria).

In case laying takes place in an aggressive water table, the water table shall be lowered to 1 m
under the pipe bedding.

Mechanical excavation shall produce a trench width with a minimum 0.40 m clearance on each
side of the pipes at trench bottom. In any case, the trench should be wide enough to allow the
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traffic and compacting operations required for the pipe bedding, but shall not be wider than the
trench width taken into account in the calculation note justifying the pipe characteristics.

0.4 Ø < 800

0.5 Ø > 800

0.40 m 0.40 m

0.40 m 0.40 m

ENOUGH SPACE BUT NOT TOO MUCH

If the soil is homogeneous and can support the loads transmitted by the pipe and backfill
without differential settlements, the pipeline may rest directly on the natural ground even if it
contains stones, provided all the elements likely to damage the pipeline are removed.

If the trench bottom bearing capacity is not sufficient, it shall be necessary to use supporting
devices suitable for the site conditions (pipe bedding made of borrow material or ballast, filter
fabric, piles, ...).

If the ground is rocky, it is excavated 30 cm (0/+5) lower than the theoretical trench bottom in
order to avoid contact between pipe and rock. The trench bottom is raised to the required level
by means of a layer of ungraded materials, sand, ballast or 6/22 gravel, possibly combined with
an anti-contaminant non woven fabric, if the rock is fractured or if the slope is steep, in order
to prevent the fines to be swept away by the infiltration waters.

Any type of bearings or wedges shall be forbidden in order to avoid any damage to the pipe
after backfilling.
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In any case, the pipe bedding (from borrow or natural soil) shall be brought to the level of the
pipe lower longitudinal +0/-5 cm and perfectly compacted so as to match the design
assumptions that determined the pipe characteristics.

0.40 m 0.40 m

0.30 m

IN CASE OF ROCKY GROUND

Furrows perpendicular to the pipeline centreline shall be dug in order to allow the removal of
the laying slings.

A niche for the welder for welded joints

Around the joints, a niche is to be made in order to allow joint welding (in general for pipe
diameters smaller than 800 mm). The niche dimensions shall be such as to get an 0.50 m free
space around the pipe, over a length of 0.50 m on either side of the joint axis.

A niche for rubber gasket E-R or E-RR joints

Rubber gasket joints also calls for a niche but of smaller dimensions. This niche aims to prevent
ingress of laying-bed material into the annular space, when pulling the pipes for joint fitting.
the niche also allows for fitting the coffering for outer grouting purpose.

Protection with plastic sheet if any:

When a plastic wrapping is recommended, it shall be put in place according to NT 171 Technical
Note. Check on layout drawing
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4. LOWERING AND FITTING OF PIPES AND SPECIALS

The pipe or special is held by a sling in a position parallel to its final position. It is lifted by
means of the laying machine such as a crane, for instance, and lowered, into the trench.

If the pipe has "slip joint" S-L steel end-rings are shaped on a special machine that
gives them an accurate diameter and a slightly conical shape. Refer to enclosure 1 for
technical data and procedure
If the pipe has E-R or E-RR rubber gasket joint, the gasket must be fitted on the
groove(s) and end ring lubricated with soap or equivalent suitable grease before fitting
the spools together. Refer to enclosure 2 for technical data and procedure

It is recommended to proceed as follows, i.e.: to fit the spigot of the pipe to be laid into the
socket of the already laid pipe. In this way, the jointing operation is better controlled and it is
easier to check the external aspect of the end of the pipe laid in the trench.

Procedure suitable for pipes with diameters equal to and above 1200 mm

A crossbar is set inside the pipe to be laid. It rests on the internal face of the socket. A cable
fitted with a pulling system such as Tirefor, for instance, links this crossbar to another crossbar
or fixed point installed in a preceding pipe (sketch below).

Procedure suitable for pipes with diameters up to 1600 mm

Then, the following operations take place:

The pipe is maintained clear of ground so as not to create extra load on the pulling system
used for fitting;
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By means of a Tirfor puller or any other suitable device, the spigot of the pipe to be laid is
drawn close to the already laid pipe until the socket gets in contact with the entrance of the
bell;
The pipe to be laid is then inserted through moderate and successive pulls of the cable;
The fitting depth and the, the laying gap depend on the type of joint S-L, E-R or E-RR. Refer
to relevant enclosure for details.
o Enclosure 1: S-L welded joint data
o Enclosure 2: E-R single rubber gasket joint data
o Enclosure 2: E-RR double rubber gasket data
The position of the pipe in altitude is adjusted by the laying crane and by checking, on the
free side of the pipe, the position of its axis in relation to its theoretical position.

When the pipeline lay-out calls for an angular deflection “alpha” between two successive pipes,
the same procedure in followed, by applying, after partial fitting of the pipe (about 48 mm for
S-L joint), a lateral force designed to obtain the “alpha” deflection, before depositing the pipe
on the ground. This angle shall be checked on the free side of the pipe by comparing the
position of its axis to its theoretical position.

If necessary, the pipe is blocked in altitude with backfill materials. The tension on the pulling
cable is then released, while being careful to maintain the laying gap or angle within the
required limits.
The pipe is then chocked on its sides in order to prevent it from moving during the next fitting
operation.

Important notice:
Piping layout is designed in order to reach the required distances and coordinate with
the nominal laying-gap at every joint. Adjustment sleeves S-S or L-L (welded types) are
located from place to place and, in general case, close to singular points like Bends,
Tees, Wye, etc… in order to allow for position adjustment.
Adjustment sleeves, and associated lap-joints allows for typical 5 to 20 cm length
adjustment, depending on type S-S or L-L and actual gap (refers to layout drawing) and
some centimetre (1 or 2 not more) axle offset. Therefore it is necessary, especially for
long and straight length or for general laying-job accuracy, to check for current position
of pipes from place to place and to undertake every correction as soon as possible in
order to keep-on with adjustment possibilities at S-S or L-L location. Checkpoints
quantity is choose by the contractor, depending on the project layout requirement.
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5. PIPE JOINTING

5.1. S-L JOINT WELDING

The "slip joint" (in short : "SL") welded joint is a joint welded with an electric arc.
(The same process is also relevant for S-S or L-L adjustment sleeves).
The end-rings, integral part of the pipe, consist of two conical rings, a female one and a male
one, respectively called "S" and "L".
After laying and adjustment of pipes, the joint is welded, in accordance with Technical Note NT
216.1 "SL joint field welding - WELDING PROCEDURE -".

The ends of the pipes or specials are not coated with concrete, so as to allow:
External welding only, for diameters up to 800 mm
Internal or external welding for diameters ranging between 800 and 1200 mm
Internal welding only, for diameters larger than 1200 mm.

The welded joint shall withstand longitudinal tensile stresses induced by the pipeline internal
pressure, especially next to tees, elbows or valves. This generally avoids casting thrust blocks
indispensable in the case of a non self-anchored pipeline.

At every joint, a maximum deflection of the two pipes or fittings can be obtained, provided that
the fitting depth is not reduced by less than 20 mm.

After joint welding and testing of this weld according to Technical Note NT 416, the exposed
metal parts shall be protected with a mortar joint cast internally and externally.

5.2. E-R RUBBER GASKET JOINT

For E-R2, E-R5, and E-RR, the rubber gasket must me carefully fitted into the "R" groove before
pipe jointing job. Refer to enclosure 2 for technical data and procedure

5.3. EXTERNAL concrete JOINT

The external concrete joint is cast by pouring mortar into a plastic form to be left on pipe.
If the steel parts are very rusty, they shall have to be brushed energetically
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Generally, the forms delivered with the piping elements are made of semi-rigid plastic. For
diameters larger than 1250 mm, and if the forms are made of jute canvas, a wire mesh shall
strengthen them externally in order to avoid a too important swelling at the joint base.

The external joints of the pipelines laid aboveground shall be smooth. For this purpose, they
shall be cast in a metal form overlapping the two pipe ends, with a gasket, to prevent any
bleeding.
After the form has been placed, a mortar (Sulphate resisting PORTLAND cement, sand and
chloride-free admixtures) shall be grouted into it.

Cement choice: the cement shall be choosing with the following criterions (classified in
preference characters):
• Sulphate resisting cement CEM1 or ASTM class V
• Suitable for sea water works (NF P 15 317)

Ready-mix mortar can be use for this purpose, but as the commercial designation are variable
as well as availability, the choice is to be made locally and in accordance with the here above
stated criterions for cement choice. Contractor can submit is choice to BONNA for advice.
Otherwise use a mortar made up as follows:
Components Nature Weight / Volume
CEMENT Sulphate resisting PORTLAND cement 50 kg
SAND 0/3 or 0/5 sand 165 kg / 110 dm3
(sand equivalent ratio > to 80 %)
ADMIXTURE DOW-LATEX 465 or SIKA LATEX 11 litres
WATER Adjust its quantity in order to get a 10 to 12 litres
sufficient workability
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5.4. INTERNAL CONCRETE JOINT

The internal concrete joint is performed by applying mortar manually or by mechanical

impingement. The mortar lining is then smoothed flush with the inner diameter of pipe in the
following way: with a brush carefully apply a bonding primer solution on all the surfaces - either
of metal or concrete - of the recesses to be filled. This solution is obtained by mixing 1 litre of
water with 0.4 litre of DOW LATEX 465 or SIKA LATEX and 0.7 to 0.9 kg of cement.

Wait till the primer gets tacky but not completely dry.

Then apply with a spatula at least 3 layers of mortar; Sulphate resisting PORTLAND cement,
sand and chloride-free admixtures).
Cement choice: the cement shall be choosing with the following criterions (classified in
preference characters):
• Sulphate resisting cement CEM1 or ASTM class V
• Suitable for sea water works (NF P 15 317)

Ready-mix mortar can be use for this purpose, but as the commercial designation are variable
as well as availability, the choice is to be made locally and in accordance with the here above
stated criterions for cement choice. Contractor can submit is choice to BONNA fro advice.

Otherwise use a mortar made up as follows :

Components Nature Weight / Volume

CEMENT Sulphate resisting PORTLAND cement 50 kg
SAND 0/3 or 0/5 sand 95 kg / 62 dm3
(sand equivalent ratio > to 80 %)
ADMIXTURE DOW-LATEX 465 or SIKA LATEX 2 litres
WATER Adjust its quantity in order to get a To be adjusted in order to
sufficient workability obtain the required
workability for a satisfactory
placement.

If the mortar cohesion is not satisfactory, it may be enhanced by adding 15 litres of silica
powder (Plenamix/CAB-O-SIL 1013 or equivalent) to the above-mentioned mix.

The mortar shall be placed in 3 stages :

• One application for bonding.
• Then, after waiting for a slight hardening of mortar, application of the filling mortar in one or
several passes.
• After sufficient hardening time, one final application and smoothing of the surface.
The mortar surface shall be smoothed with a small hawk so as to avoid crazing.
Use only pure PORTLAND cements (C.P.A.) otherwise this mortar composition is not suitable. If
special cement has been required, the mortar mix shall have to be adjusted by our Technical
Department.
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24 hours after casting the joint, it shall be sounded with a little hammer, in order to check that
it has not become separated from the steel end-rings. If it sounds hollow, it shall be broken and
re-cast. The internal joint shall be sounded all around but even more carefully in the upper part
where slump risks are higher.

In the event the pipeline would be tested with aggressive water such as sea-water, the internal
concrete joints shall have to be cast prior to the test or a first layer of mortar shall have to be
placed.

6. THRUST, ANCHORAGE AND SUPPORT BLOCKS

Overall pipework drawings point out the efforts to be borne by thrust, anchorage or supporting
blocks, if any.

In the self-anchored pipelines (for a given pressure), the only remaining hydraulic efforts to be
borne are at flexible joints (bellows-joints, non self-anchored Dilatoflex, Gibault joints, ...) or
pipeline elements such as non self-anchored valves, dismantling joints ... that are not self-
resistant.

7. PIPELINE BACKFILLING

Depending on the existing soil conditions (Project soil investigation report) some specific laying
method may be specified by our design department in order to ensure the short term and the
long term stability of the piping works. The here under statements are generics. One has to
refer to BONNA SABLA’s issued project documents (Laying arrangement drawing, calculation
note, technical note…) for specific requirements.

The bedding and backfilling of the pipeline shall be performed so as to meet the design
assumptions.

In general, a compacted backfill shall secure a uniform bedding angle of 90° (see sketch
below).

90° Backfilling
95 % OPN
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A sound bedding of the pipeline is obtained by carefully compacting thin layers of backfill, up to
the pipeline spring line. The material of the first layers shall be pushed and rammed under the
pipeline haunches.

The thickness of each layer generally varies from 0.30 m to 0.60 m depending on the nature of
the material, on the pipe diameter and on the backfilling means. In no case should it exceed
half the outside diameter of the pipe. The sizes of the largest elements shall be less than 1/5 of
the layer thickness to be compacted. The materials shall belong to classes 1 to 3 of the
following table and compacting shall be checked and reach 95 % of the Optimum Proctor
without any results lower than 90 % of OPN.
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Soil classification

Soil Group Brief description

Clean or moderately silty sand and sand-gravel mix (elements to sizes less
1
than 50 mm)
2 Silty or moderately clayish sand and sand-gravel mix
Clay with flint and millstone grit. Hillside debris. Moraines, altered rocks,
3
coarse sediments with high content of fine products
4 [1] Silt, fine sand, shale, more or less flexible marl (Ip < 50)
Very flexible/soft clay and marl (Ip > 50) Organic, soluble and polluting
5a [2]
materials
Evolutive rock such as chalk sandstone, shale…
Compound soils (clay with millstone grit and flint, hillside debris, moraines
5b [3] altered rocks, coarse sediments with elements of sizes beyond 250 mm)
Clean sand-gravel mix, non evolutive rocks with elements of sizes larger
than > 50 mm

[1] These materials may not be used when there is underground water in the area surrounding the pipe.
[2] These materials may neither be used in the pipe surrounding area, nor in the backfill area.
[3] These materials that cannot be used in the pipe surrounding area, may sometimes be used in the
backfill area.

Nota :
If the trench is sheetpiled, it is advisable to partly lift the sheetpiles before carrying out the bedding, so as
not to decompress it afterwards.

Above the pipe bedding, backfilling and compacting are continued symmetrically, by successive
layers with the excavated materials deprived of the elements of sizes larger than 100 mm, or
with any material making it possible to obtain a backfill cover of the quality required by the
owner of the works.

The backfill height shall not exceed the one anticipated on the drawings. Likewise, no machines
should be operated on top of this backfill, if their load has not been taken into account in the
calculations for the considered height. Pay particular attention to the use of road-works
compactors above the piping works. Should heavy compactor be use, one has to inform BONNA
SABLA design department for advice.
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It is very important that backfilling be carried out immediately after laying. The trenches may
be flooded following storms or heavy rains; the pipeline might then be floating as a result of its
buoyancy. If Specifications demand to leave the joints exposed for tests, backfilling materials
shall be placed in heaps over the pipes up to the edge of trench over the greatest possible
length. The backfilling materials shall be placed in successive layers and compacted as specified
above.

Important note :
The piping system generally includes apparatuses or branchings that are most of the
time placed inside the manholes, so as to allow their operation and maintenance. In
case bare or painted metal parts without concrete cover would not be inside these
structures but would be designed to be in contact with backfill, they shall be
protected by a 1 cm thick bituminous sealing compound and then wrapped into a
polyethylene sheet or similar, in order to prevent the protection from being damaged
during backfilling.
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8. TRENCH TEST

This section is relevant only if the contract include this test. "Contract" addresses, the contract
between the supplier at the buyer, or the contract between the buyer and the owner.

The pipelines to be submitted to the trench testing pressure specified in the designing note,
shall be plugged at each end by steel dished ends welded to the end-rings or by blank flanges if
the pipelines extremities are flanged.

The dished ends shall be fitted with the tapings necessary for filling and emptying the pipeline,
for expelling air and measuring pressure.

The hydraulic tests shall be performed in accordance with Technical Note "NT 239" Testing
Procedure of BONNA Steel Cylinder reinforced concrete pipes.
Perform the hydrostatic test with backfill (partial or total thickness) is to be checked according
to technical specifications mentioned on layout drawings. Otherwise, one has to inform BONNA
SABLA design department for advice.

9. PARTICULAR MEASURES

9.1. INTERNAL JOINTING OF SMALL DIAMETERS

It is not possible to enter pipelines with diameters less than or equal to 500 mm for grouting
the concrete joint.
It is however indispensable to cast this joint whenever there is a risk of steel corrosion by the
carried fluid.
For this purpose we have developed the technique that consists in placing mortar on the inside
shoulder of the socket before fitting one pipe into another, in smoothing it and in expelling any
possible excess mortar.
The last two operations are carried out by means of very simple equipment described hereafter.

Operating mode

• Apply with a brush, on the metal and concrete parts of the S and L ends market “a” on the
sketch hereunder, the solution specified in § 4.2..

S and L ends

• Insert the smoothing machine about 20 to 30 cm back from the end of the pipe or special
already laid. The afore-mentioned extremity should be a socket “S” according to the designed
laying method.
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• Prepare a mortar specified in § 4.3.

• Place this mortar on the “S” end against the lining forming a 45° angle.

S end

• Lower the pipe or special to be next laid to the bottom of the trench and introduce the
machine operating rod in it.
• Fasten the operating rod to the machine.
• Proceed to the fitting of the element to be laid and to its definitive laying.
• Manoeuvre the operating rod in such a way that the circular brush n° 1 passes twice or
three times over the inner joint. During the operation, brush n° 2 always remains on the
same side with respect to the joint.
• Withdraw the machine from the element that has just been laid in order to remove the
possible excess mortar with the two brushes.
• Reset the machine - without its operating rod - in the last element laid about 20 cm
back from the pipe end.
• Cast the outer concrete joint according to the instructions of § 4.2.

Description of the smoothing machine

This machine includes:

• Two successive circular brushes, the former one designed for smoothing the mortar, the
latter one designed for driving out any possible excess mortar.
• A support for these brushes that may either be a system on 3 rollers or a steel reducer
slit lengthwise.
• A rod to draw the machine near the joint and the previously laid pipe.
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Sketch of one type of machine

Machine placed in the pipeline before smoothing.

Verification

After removal of the machine, a rear-view mirror shall be introduced into the pipe by means of
a rod and with adequate lighting, one shall check that mortar has been applied all around the
joint.

Special arrangement when the smoothing machine cannot be used

When the pipeline design does not allow the use of the machine preceding described the joint
shall be cast in a different way (see sketch below) : a small tube is fitted on the lap-joint to
enable access for manual internal jointing.
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Compressive seal included in the internal coating

Another solution, witch requires preliminary statement and agreement for each contract,
consists in including an elastomeric joint during the manufacturing of the pipe.
This solution:
• requires no specific intervention during the installation of the pipe,
• replaces joint with mortar;
• resists to the heat produced during the outside weld (end rings SL),
• resists to the pressures and the depressions undergone by the pipes in service.

The protection seal is anchored in the concrete of the female end ring during the moulding of
the pipe.
During the fitting, the edge of the male end ring comes to compress the joint.

This compression is without incidence on the effort of fitting.

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9.2. LENGTH ADJUSTMENT MEASURES

The piping systems include straight sections of different lengths consisting of pipes and specials
(tees, elbows, short pipes...).

The combination of the laying (fitting) and the manufacturing tolerances results in a
discrepancy between the designed theoretical lengths and the length actually obtained on site.

Therefore, when a straight section runs over more than 30 meters typically, an adjustment ring
is included in the pipe work design (see sketch here under) before any change of direction or
special (Tees, ...) whose position is imperative. The piping elements adjacent to the adjustment
ring are generally designed with SL type end-rings that shall be welded. The external coating
shall consist of the concrete mix mentioned in § 4.2 in which half the quantity of sand shall be
replaced by gravel 5/10 or 5/15.
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• Our layout drawings are representing the effective gap. For S-S adjt. sleeve, the real
laying adjustable gap is the effective gap reduced by 2x78mm. Pay attention at position
of the quotation in case of S end rings.
• Lap joint/Adjustment ring. Width to be adjusts if necessary for welding on L ring. Length
to be adjusted on site after the laying of the elements (can be re-cut in two halves cut
lengthwise).
Note:
The laying clearance is reduced when some length is gained after fitting and increased, in the
opposite case.

Example of wire mesh inside adjustment sleeve

9.3. END-RING MODIFICATIONS

It is sometimes necessary on site, either to change an S or L end-ring, or to shorten one

pipeline unit, originally designed with a minimum 3 mm thick steel cylinder.

For this purpose, the following operations are performed:

• With a mechanical or hand chipping hammer, the inside and outside concrete is broken
right where the end-ring should be ;
• The steel cylinder is cut at the given length, if necessary;
• The end-ring is welded at the desired place, in accordance with the instructions of
Technical Note "NT 216.2".
• The following parts are then restored:
- the external reinforcement.
- the inside concrete placed by hand.
- the outside concrete placed by hand or during the grouting of the external
concrete joint.
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9.4. LAYING OF A CLOSURE PIPE

It may be possible, upon request, to connect two already laid sections, by means of :
• a precast element ;
• Or a short-pipe cut from a pipe designed for that purpose, on site.
The connection of this element is carried out as shown on these drawings depending on
whether the overlapping joints are inside or outside, according to the pipe diameters. The
external concrete joint shall consist of the mix mentioned in § 4.2 in which half of the sand shall
be replaced by gravel 5/10 or 5/15..

Type 1: Pose en clé entre 2 abouts S avec un élément S-L

Closure between two S with S-L element

Tel que représenté sur le plan d'appareillage

S S Presented as follow on layout drawing L S

4
1

5 6
2 3 5

Type 2: Pose en clé entre 2 abouts L avec un élément S-L

Closure between two L with S-L element

Tel que représenté sur le plan d'appareillage

L L Presented as follow on layout drawing S L
4 1

6 5 6

Element with "S" and "L" end-rings.

Overlapping joints, each of them in two parts.
Concrete reinforcement.
Clearance enabling the lowering of the pipe.
"S" female end-rings.
"L" male end-rings.
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9.5. FLANGED CONNECTION

9.5.1. General case

B B

In general cases, as show on this example, the S S

flanges are fitted on End Adaptors. An End Adaptor is S S

a short spool with, at one side, an “S” or “L” (“E” or

“R”) end ring, and at the other side, the flange. This
L
spool is in general cases, fitted to the BONNA’s L
S
piping arrangement by the mean of an adjustment S S
S

sleeve S-S or L-L in order to allow some

misalignments. The overall misalignment
compensation for S-S or L-L could not exceed
several centimetres. Should the foreseen
misalignment exceed this range then, specific
solutions are more appropriates.

When connecting to others apparatus and at the limits of supply, the flanged connection are
generally electrically insulated in order to deal with effects of stray currents.
Position of insulating tubes and washers:

Bonna flange other

Insulating tube and washer

rondelle acier
steel washer Tube isolant
rondelle acier Ecrou
Insulating tube
Vis steel washer Nut
Screw

Rondelle isolante
Insulating washer
Joint élastomère
Rubber gasket

The connection with flanges shall be carried out as follows:

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• The gasket shall be placed flush with the interior all around;

• The internal diameters of the two flanges shall be equal and in the same alignment;

• The internal shape of the flanges shall be angular (i.e. with no rounded edges) to allow
the tightening of the elastomer gasket down to the internal diameter;

• Bolts shall be tightened gradually two by two, the first two shall be diametrically opposite and
the following ones shall form a perpendicular with the preceding ones.

9.5.2. Adjustable flanges

When required, or upon request, the flange connection can be adjusted and/or postponed by
using the following principle sketch:

BEFORE CONNECTION AFTER CONNECTION

Allowable adjustments:
transversal, axle offset: ±20mm <-/->
Longitudinal: up to -55mm
BONNA Flange and steel sleeve
CUTBACK NECESSARY TO ALLOW

for adjustment on site

B B
FOR REMOVAL OF BOLTS
Effective Length

Internal lining to be make good

after welding and testing.

Overlap with painting If necessary, for ensuring at least 20mm

˜ 95

system once concrete

extra length is cured concrete cover, the adjustment ring can
adjustment be re-cut on inner side.
C1 C1
˜ 55mm

CR CR
External reinforced
Adaptor End

12

Inner diameter
Factory cutback ˜ 20

concrete made on site

45° to 60° bevel when vertical
risers above ground for
rain-water drainage
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9.6. LIFTING LUGS

Some large diameter elements are

delivered with lifting lugs used for
handling them.

After the pipe installation but

before backfilling, these lugs
shall be cut off with a gas-cutting
torch down to 25 mm at least
into the concrete coating; the
concrete coating shall then be re-
made above to prevent metal
corrosion.

Procédure pour enlever les oreilles de levage

Procedure for cutting-off the lifting lugs
Phase 1: Etat initial / Initial state

Oreille de levage
Lifting lug

Phase 2:
Couper l'oreiile de levage au chalumeau Oxy/acetylène
Cutting off the Lifting Lug with Gas-cut device

>=25mm

Phase 3: Bétonnage / Concreting

Voir NT216 §4.2 pour le béton de remplissage identique aux joints extérieurs
Refers to NT216 §4.2 for concrete mixture, same as external grouting
Utiliser du latex pour accrochage
Use Latex for bonding

Lifting Lugs#00.dwg
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9.7. LAYING ABOVE GROUND

When a pipeline is laid above-ground on cradles or on cradles resting on piles, a capillary rise of
the ground water may occur through the concrete of the cradles and possibly of the piles.

To prevent this water from reaching the concrete of the pipes, since it is likely to deteriorate
the concrete and the steel as a result of a concentration phenomenon created by successive
rises and evaporations, if the water is aggressive, it shall be necessary to place between the
cradles and the pipes:

• Two one-piece polyethylene sheets, at least 200 microns thick, each. These sheets shall
overlap the cradle by 5 cm all around it.
• Otherwise, reinforced Neoprene bearings (that will also take the shifts due to thermal
expansion).

The phasing of the operations shall be dealt with in a special study.

9.8. LABOUR

The qualification level of the personnel guarantees the successful installation of the pipelines
and compliance with the site works procedures is one of the requirements for obtaining the
specified quality standard.
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10.Enclosure n°1 S-L welded joint data

10.1. S-L joint typical cross-section

Joint S-L coupe type Procédure d'emboîtement: voir NT 216 §3

Deviation angulaire admissible: voir NT 216 §3
Typical S-L joint section Procédure de soudage: voir NT 216 §4.1 et NT216-1
Procédure de contrôle des soudures: voir NT416
Procédure de rejointoiement: voir NT216 §4.2 et §4.3

Fitting instructions: refers to NT 216 §3

Allowable angular deflection: refers to NT 216 §3
Welding instructions: refers to NT 216 §4.1 and NT216-1
Welding testing procedure: refers to NT416
Coffrage
Coffering
Grouting instruction: refers to NT 216 §4.2 and §4.3

Soudure extérieure pour diamètres:

external welding for diameters:
250 ≤ Ø ≤ 1200

Soudure extérieure ou intérieure pour diamètres:

External or internal welding for diameters:
800 ≤ Ø ≤ 1200
About End ring "S"
Soudure intérieure pour diamètres:
internal welding for diameters:
Ø ≥ 800

About End ring "L"

Emboîtement théorique
Theoretical fitting depth
78 +0/-10 mm (-20 possible)
(sauf pour, except for Ø300 and Ø250; voir, see NT216 §3)

Longueur utile Effective length

S-L#03.dwg
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10.2. Deflection angle for S-L joint

The table below gives an indication of the allowable deflection angle with standard end-rings,
according to the pipe diameters. End-of-pipe deflection and curve radius are given for the
mentioned effective length.
Allowable Pipe Corresponding
Inside deflection effective deflection at the Corresponding
end of a pipe
diameter angle length (*) curve radius
(mm)
(mm) (°) (m) (m)
250 Please consult us 6.07 - -

300 Please consult us 6.07 - -

400 Please consult us 6.15 - -

500 Please consult us 6.15 - -

600 2.00 6.15 215 176

700 1.80 6.15 193 196

800 1.70 6.15 182 207

900 1.60 6.15 172 220

1000 1.50 6.15 161 235

1100 1.40 6.15 150 252

1200 1.35 6.15 145 261

1250 1.30 5.03 114 222

1250 1.30 6.15 140 271

1400 1.20 5.03 105 240

1400 1.20 6.15 129 294

1500 1.15 5.03 101 251

1500 1.15 6.15 123 306

1600 1.10 5.03 97 262

1600 1.10 6.15 118 320

1700 1.05 5.03 92 274

1800 1.00 5.03 88 288

1800 1.00 6.15 107 352

2000 0.95 4.50 75 271

2000 0.95 6.00 99 362

2100 0.90 4.50 71 286

2200 0.85 4.50 67 303

2200 0.85 5.03 75 339

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Allowable Pipe Corresponding

Inside deflection effective deflection at the end Corresponding
of a pipe
diameter angle length (*) rayon
(mm)
(mm) (°) (m) (m)

2350 0.80 3.50 49 251

2350 0.80 4.00 56 286

2400 0.75 4.50 59 344

2400 0.75 5.03 66 384

2500 0.75 2.97 39 227

2500 0.75 4.00 52 306

2600 0.70 2.91 36 238

2800 0.65 2.91 33 257

2800 0.65 3.50 40 309

3000 0.60 2.91 30 278

3200 0.55 2.91 28 303

3500 0.50 2.41 21 276

4000 0.45 2.01 16 256

(*) Effective length can varies depending on the factory source. Refer to layout drawing or project documents.
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11.Enclosure n°2 E-R & E-RR rubber gasket joint data

11.1. E-R2 joint typical cross-section and deflection angle table

For inner diameter from 400 to 1600 the R profile groove is called R2 and present the following
typical cross-section
rejointoiement au mortier
jointing with mortar Coffrage perdu
formwork left on pipe

Z Joint élastomère
Elastomer gasket

About "R2" emboîtement =85 About "E"

"R2" end ring fitting = 85 "E" end ring

jeu de pose=5
laying gap = 5
Rejointoiement ou joint protecteur
Internal jointing or sealant

E-R2 deflection angle table

Nominal/Internal Effective length Z Allowable angulation
diameter mm (Lu) m (*) mm with Z=10mm (**)

400 6,15 28,3 1°48’

500 6,15 28,3 1°24’
600 6,15 28,3 1°06’
700 6,15 28,3 54’
800 6,15 28,3 42’
900 6,15 28,3 36’
1000 6,15 28,3 30’
1100 6,15 28,3 24’
1200 6,15 28,3 21’
1250 6,15 – 5,03 28,3 18‘
1400 6,15 – 5,03 28,3 15’
1500 6,15 – 5,03 28,3 12’
1600 6,08 – 4,96 28,3 09’

(*) Effective length can varies depending on the factory source. Refer to layout drawing or project documents.
(**) Z = 10mm ensure the fitting watertightness for the given angulations. Larger value can lead to leakage.

11.2. E-R5 joint typical cross-section

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For inner diameter from 1500 to 3200 the R profile groove is called R5 and present the
following typical cross-section.

Coffrage perdu
rejointoiement au mortier formwork left on pipe Joint élastomère
jointing with mortar Elastomer gasket
Z 37.5

About "E"
About "R5"
"E" end ring
"R5" end ring
jeu de pose=10
Rejointoiement ou joint protecteur
laying gap = 10
Internal jointing or sealant

E-R5 deflection angle table

Allowable
Nominal/Internal Effective length Z
angulation
diameter mm (Lu) m (*) mm
with Z=10mm (**)

1500 6,15 – 5,03 50 54’

1600 6,08 – 4,96 50 51’
1700 6,08 – 4,96 50 48’
1800 6,08 – 4,96 50 42’
2000 5,93 – 4,43 50 36’
2100 4,41 72 1°06’
2350 3,99 72 57’
2400 4,41 72 54’
2500 3,91 72 51‘
2800 3,41 72 42’
3000 2,82 72 39’
3200 2,82 72 36’

(*) Effective length can varies depending on the factory source. Refer to layout drawing or project documents.
(**) Z = 10mm ensure the fitting watertightness for the given angulations. Larger value can lead to leakage.
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11.3. E-RR joint typical cross-section

Double gasket E-RR joint can be suggested for diameter from 700mm to 3200mm.
The RR profile can be fitted with optional threaded hole for testing each joint during laying job.
Coffrage perdu
rejointoiement au mortier formwork left on pipe
Joint élastomère
jointing with mortar Elastomer gasket
Z 68.0

About "RR" About "E"

"RR" end ring Test nipple; refer to NT238 "E" end ring
Rejointoiement ou joint protecteur jeu de pose=5
Internal jointing or sealant laying gap = 5

E-RR deflection angle table

Allowable
Nominal/Internal Effective length Z
angulation
diameter mm (Lu) m (*) mm
with Z=10mm (**)

700 6,15 87 1°20’

800 6,15 57 1°20’
900 6,15 57 1°20’
1000 6,15 57 1°20’
1100 6,15 57 1°20’
1200 6,15 57 1°20’
1250 6,15 – 5,03 57 1°20’
1400 6,15 – 5,03 57 1°20’
1500 6,15 – 5,03 72 1°20’
1600 6,08 – 4,96 72 1°20’
1700 6,08 – 4,96 72 1°20’
1800 6,08 – 4,96 72 1°20’
2000 5,93 – 4,43 72 1°11’
2100 4,41 72 1°06’
2350 3,99 72 56’
2400 4,94 – 4,41 72 54’
2500 3,91 72 51‘
2800 3,41 72 42’
3000 2,82 72 38’
3200 2,82 72 34’

(*) Effective length can varies depending on the factory source. Refer to layout drawing or project documents.
(**) Z = 10mm ensure the fitting watertightness for the given angulations. Larger value can lead to leakage.
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11.4. Gasket fitting on R groove procedure and jointing the pipes

If necessary, clean the rubber

gasket by removing all the dust,
sand, gravel or others things.

Lubricate abundantly the “O” ring rubber seal.

BONNA SABLA, depending on the contract, an
supply the soap or suitable grease for this
purpose. Every lubricant suitable for O-Ring
joint can be use for this purpose

Install the “O” ring rubber seal into the R groove.

In case of double groove RR install the two
gaskets.
When fitting the "O"ring on the groove,
the gasket is tensioned at typically 20% of
elongation. This tension is an important part of
the "O"ring design and must be equally
spread all around the spigot diameter. Spread
the tension on the installed “O” ring rubber seal
by stretching it with small rod at least 2 rounds.
(See photos).

Spread lubricant abundantly on "E" end ring.

Lack of lubricant will harden the fitting and
might damage the rubber O-ring, check that
both E ring and rubber O-ring has been
properly lubricated.

Slowly approach the R pipe until the

rubber joint touches the E Ring.
Adjust both E and R pipe in same axis to
insure proper fitting. (ER design axis
tolerance : +/-0,5deg).
Pull for fitting.
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BONNA reserves the right to make alterations to this publication without notice.
It shall be the responsibility of the user of this publication to make sure that it is still valid.
Reproduction of full text only is authorized.