Cladding& Fitting

M.W.
BARVE LECTURE NOTES
FLEXIBLE CLOSED CELL

PIPE COVERING
M.W.BARVE LECTURE NOTES
FIELD AND FACTORY-APPLIED

NON-METAL JACKETING
1 PRE-FORMED PIPE INSULATION

2 VAPOUR BARRIER ADHESIVE
(NOT REQUIRED WITH SELF-SEAL LAP)
3 STAPLES COATES WITH VAPOUR BARRIER COATING
(NOT REQUIRED WITH SELF-SEAL LAP)
4 INSULATION FASTENING
(NOT REQUIRED WITH FACTORY APPLIED JACKET)
5 BUTT STRIP SECURED WITH VAPOUR BARRIER ADHESIVE OR SELF
SEAL
FIELD-APPLIED
METAL JACKET

3 JACKET OVERLAPPED (POSITION TO SHED WATER)
4 JACKET FASTENING OR
5 JACKET FASTENING
STANDARD SPLIT RING

HANGERS

2 INSULATION FACTORY JACKET
3 BUTT STRIP
4 INSULATION NEATLY UT TO ACCOMMODATE
HANGER
5 INSULATION ON HANGER ROD
file:///C|/Documents%20and%20Settings/Administrator/Desktop/INSULATION%20&%20CLADDING%20-figers.pdf
CLEVIS HANGER
HIGH DENSITY INSERTS

2 HINGH DENSITY INSULATION
(EXTEND 50mm BEYOND ENDS OF SHIELD)
3 FACTORY APPLIED VAPOUR BARRIER
4 FINISH JACKET (METAL SHOWN)
5 METAL SHIELD (SUPPLIED BY OTHERS)
PIPE SHOE
ON ROLLER SUPPORT

2 INSULATION FASTENING IF NOT FACTORY
JACKET
4 PIPE SHOE SUPPLIED AND INSTALLED BY
OTHERS
5 INSULATION IN PIPE SHOE CAVITY
TRACED PIPING
1. TUBING TRACER (BY OTHERS)

2. PRE-FORMED PIPE INSULATION (FACTORY JACKET)
3. HEAT TRANSFER COMPOUND (OPTIONAL)
4. HEAT TRANSFER COMPOUND CHANNEL
(OPTIONAL)
5. BANDING SECURING CHANNEL TO PIPE
6. MULTIPLE TUBING TRACER (BY OTHERS)
7. ELECTRIC CABLE OR TAPE TRACER (BY OTHERS)
INSULATION SUPPORT RINGS /

EXPANSION – CONTRACTION JOINTS
1. PRE-FORMED PIPE INSULATION - SINGLE LAYER

2. FACTORY JACKET
3. SLEEVE OR FACTORY JACKET MATERIAL
4. BANDING TO SECURE SLEEVE
5. COLLAR OF FLEXIBLE INSULATION
6. PRE-FORMED PIPE INSULATION DOUBLE LAYER
7. INSULATION SUPPORT RING (BY OTHERS)
8. COLLAR OF FLEXIBLE INSULATION BELOW SUPPORT RINGS
PRE-FORMED ELBOW INSULATION
1. PRE-FORMED PIPE INSULATION (SHOWN WITH METAL

JACKET)
2. PRE-FORMED FITTING COVER
3. BANDING OR SCRES TO SECURE FITTING COVER
MITRED INSULATION ELBOW

OVERSIZE APPLICATION
1. PRE-FORMED INSULATION
2. MITRED SEGMENTS OF PIPE INSULATION
3. FINISH JACKET
4. WIRE OR BANDING
5. FITTING COVER
(METAL CORE TYPE SHOWN)
6. FASTENING (SCREWS OR POP REVETS)
PVC / GLASS FIBRE ELBOW

INSULATION SYSTEM
1 PRE-FORMED PIPE INSULATION WITH FACTORY JACKET

2 COLLAR OF OVER-SIZED PIPE INSULATION
3 FLEXIBLE INSULATION INSERT
4 PVC FITTING COVER SECURED WITH SERRATED
FASTENERS
5 VAPOUR BARRIER END CAP
6 PVC FITTING COVER
7 VAPOUR BARRIER TAPE OR ADHESIVE
FIELD OR FACTORY FABRICATED

VALVE INSULATION
1 PRE-FORMED PIPE INSULATION WITH METAL JACKET

2 COLLAR OF PIPE INSULATION SIZED TO CLEAR
FLANGES
3 COLLAR OF PIPE INSULATION SIZED TO CLEAR
VALVE BODY
4 COLLAR OF PIPE INSULATION SIZED TO COVER
BONNET (OPTIONAL)
5 COVER OF RIGID INSULATION OF BONNET
INSULATED
6 INSULATION ADHESIVE AT JOINTS
7 FLEXIBLE INSULATION FILL (OPTIONAL)
8 CAULKING ON OUTDOOR INSTALLATIONS
9 METAL JACKET MATERIAL COVER
PVC / GLASS FIBRE

VALVE INSULATION

2 OVER-SIZED PIPE INSULATION COLLAR
3 FLEXIBLE INSULATION INSERT
4 PVC COVER (SEAM SECURED WITH SERRATED TACKS,
ADHESIVE OR TAPE)
5 END COVER
6 CAULKING TO SEAL
IN-LINE FLANGE INSULATION

BUILT-UP AND BEVELLED
1 PRE-FORMED PIPE INSULATION WITH FACTORY JACKET

2 PRE-FORMED PIPE INSULATION WITH METAL JACKET
3 COLLAR OF OVER-SIZED PIPE INSULATION
4 SLEEVE OF OVER-SIZED PIPE INSULATION
5 FLEXIBLE INSULATION (OPTIONAL)
6 FABRICATED COVER
7 CAULKING
8 PIPE INSULATION (BEVELLED)
9 BARRIER COATING INDOORS / WEATHER COATING
OUTDOORS
PVC/GLASS FIBRE COUPLING OR

IN-LINE FLANGE INSULATION SYSTEM

2 VAPOUR BARRIER TAPE ON JOINTS
3 FLEXIBLE INSULATION
4 PVC FITTING COVER
FLEXIBLE DUCT INSULATION

ON RECTANGULAR DUCTS INDOORS
1 FLEXIBLE DUCT INSULATION WITH VAPOUR BARRIER

2 JOINTS LAPPED AND STAPLED; SEAL WITH VAPOUR
BARRIER ADHESIVE OR VAPOUR BARRIERE TAPE
3 MECHANICAL FASTENERS
4 VAPOUR BARRIER TAPE ON BREAKS & PENETRATIONS
OF VAPOUR BARRIER
2* & 4* VAPOUR BARRIER TAPE OR SEAL NOT REQUIRED ON

HOT DUCTS
RIGID DUCT INSULATION ON RECTANGULAR

EXPOSED DUCTS INDOORS
1 RIGID DUCT INSULATION

3 VAPOUR BARRIER TAPE ON JOINTS, BREAKS AND
PENETRATIONS
4 CANVAS FINISH JACKET APPLIED WITH LAGGING
ADHESIVE
5 METAL CORNER BEAD
HIGH TEMPERATURE
BLOCK OR BOARD
INSULATION
BREECHINGS,
FLUES AND KITCHEN
EXHAUST DUCTS
1 RIGID BLOCK INSULATION (JOINTS STAGGERED)

2 METAL MESH OVER STIFFENERS (BY OTHERS)
3 STIFFENER OR FLANGED CONNECTION
4 MECHANICAL FASTENERS OR BANDING TO SECURE
INSULATION
5 METAL JACKET FINISH
6 RIGID BOARD INSULATION
7 METAL CORNER BEAD
8 REINFORCEDMESH EMBEDDED IN INSULATION CEMENT
AND CANVAS FINISH JACKET APPLIED WITH LAGGING
ADHESIVE
VESSEL BOTTOM HEAD,

LEG, SKIRT INSULATION
AND SECUREMENT
1 VESSEL, INSULATION AND JACKET

2 FIREPROOFING (BY OTHERS, IF REQUIRED)
4 TIE WIRES
5 REINFORCING WIRE MESH & INSULATING CEMENT
6 INSULATION SUPPORT RING (BY OTHERS)
PIPE AND TUVE EXCHANGERS – ENCASED
1 PIPE INSULATION SECURED WITH BANDING

2 BLOCK INSULATION SECURED WITH BANDING
3 FINISH JACKET (METAL SHOWN SECURED WITH
BANDING)
4 SHEET METAL SCREWS
5 BEVEL INSULATION AND FINISH WITH COATING
6 BLOCK INSULATION AND FINISH WITH COATING
LARGE DIAMETER
VERTICAL VESSELS
BLOCK AND BLANKET
INSULATION
1 SUPPORT RING FOR

HEAD INSULATION
2 BLOCK OR BLANKET
INSULATION
3 MECHANICAL
FASTENERS OR
4 BANDING TO SCURE
INSULATION
5 SUPPORT RING (BY
OTHERS)
6 METAL JACKET
7 SHEET METAL SCREWS
8 BANDING
9 BLOCK INSULATION
MITRED TO FIT
10 FABRICATED HEAD COVER
11 METAL FLASHING
12 BOTTOM HEAD INSULATION
13 VESSEL SKIRT
LARGE DIAMETER HORIZONTAL VESSELS

INSULATION SUPPORT AND SECUREMENT
1 RIGID INSULATION
2 BANDING SUPPORT BARS
3 BANDING
4 FINISH JACKET SECURED WITH BANDING OR
SCREWS
5 HEAD COVER
FLEXIBLE CLOSEDCELL SHEETS
1 INSULATION ADHESIVE (CONTACT TYPE)

2 FLEXIBLE CLOSED CELL INSULATION (CUT TO FIT
TIGHTLY)
3 JOINTS SEALED WITH CONTACT TYPE ADHESIVE
4 LEGS & PROTRUSIONS INSULATED (OPTIONAL)
5 PROTECTIVE COATING WHERE REQUIRED
EXTREME TEMPERATURE VESSELS

BLOCK INSULATION
1 FLEXIBLE INSULATION
2 INSULATION – JOINTS STAGGERED
4 BANDING
5 INSULATION ATTACHMENT FOR HEAD
6 FABRICATED HEAD COVER
7 CLOSED CELL INSULATION FOR FIRST 300mm
SMALL DIAMETER VESSELS / EXHAUST

PIPE COVERING
1 INSULATION SUPPORT RING (BY OTHERS)

2 PIPE INSULATION SECURED WITH BANDS OR WIRE
3 RIGID INSULATION CUT TO FIT
4 FLEXIBLE INSULATION FILLER
6 SHEET METAL SCRES OR POP RIVETS
7 BANDING AS REQUIRED
8 BEVEL INSULATION FOR BOLT REMOVAL AND FINISH
WITH COATING
FIELD APPLIED LINING
1 HOUSING OR SHAFT
2 RIGID DUCT LINER
3 ADHESIVE WHERE NECESSARY
5 JOINTS SEALED WITH INSULATION COATING
EMBEDDED IN REINFORCING MEMBRANE
CURVED SURFACES RIGIDBOARD INSULATION
1 INSULATION SCORED OR BEVELLED TO FIT

CURVATURE
3 BANDING
4 CELLULAR GLASS INSULATION ON BOTTOM 300mm
5 METAL JACKET
6 HEAD FLASHING
7 CAULKING
NOZZLES AND INSULATED MANWAYS
1 VESSEL INSULATION
2 METAL OR REINFORCING MEMBRANE BANDED TO
NOZZLE
3 WEATHER BARRIER COATING OR CAULKING
4 METAL COVER LINED WITH RIGID INSULATION
5 METAL SEAM OR END CAP
6 MECHANICAL FASTENER AS REQUIRED
7 FLASHING
BLOCKS AND PRE-FORMED PIPE INSULATION

AROUND BREECHINGS AND EXHAUST DUCTS
1 AIR SPACE MATERIAL (BY OTHERS)

2 RIGID BLOCK INSULATION
3 WIRE OR BANDING
4 METAL JACKET FINISH
HEAD INSULATION SECUREMENT

AND COVER FABRICATION
1 HEAD INSULATION 6 METAL FINISH JACKET

2 FLOATING RING 7 FLEXIBLE INSULATION
3 BANDING 8 SHEET METAL SCREWS
4 SHELL INSULATION 9 HIGHT COMPRESSIVE
5 HEAD INSULATION STRENGTH RIGID INSULATION
SUPPORT RING 10 REINFORCED MASTING
11 CAULKING / FLASHING
PIPING (0”C THROUGH -40”C)
1 INSULATION INNER LAYER

2 INSULATION OUTER LAYER WITH JOINTS
STAGGERED
3 LONGITUDINAL LAP ON VAPOUR BARRIER SEALED
4 BUTT JOINT VAPOUR BARRIER SEALED
5 BANDING, WIRE OR TAPE AS REQUIRED
FITTINGS (0”C THROUGH -40”C)
1 MULTI-LAYER INSULATION; VAPOUR BARRIER

ON OUTER LAYER
2 PREFORMED INSULATION COVER
3 BANDING, WIRE OR TAPE
4 VAPOUR BARRIER TAPE
5 LONGITUDINAL LAP ON VAPOUR BARRIER
SEALED
6 PREFORMED FITTING COVER
FLEXIBLE INSULATION BLANKETS
1 SHAPED INSULATION BLANKET

2 QUILTER WASHER
3 LACING HOOKS AND WIRE
REMOVABLE AND REUSABLE INSULATION
1 SEAMS STITCHED
2 QUILTING WASHERS
3 LACING HOOKS AND WIRE
REMOVABLE INSULATED
METAL EQUIPMENT COVERS
1 METAL CASING LINED WITH INSULATION

2 SECTIONS OF THE FABRICATED COVER
3 SLIP JOINT OR LAP SEAM WITH SHEET METAL
SCREWS, POP RIVETS OR STANDING SEAM
4 CUT-OUTS FOR PIPES OR SHAFTS
5 CAULKING WHERE REQUIRED
6 SHEET METAL SCREWS OR POP RIVETS
REMOVABLE AND REUSABLE INSULATION
1 FLEXIBLE CLOSED CELL INSULATION

2 METAL FRAME
3 REMOVABLE TOP – FORM FITTED
4 ADHESIVE
ELASTOMERIC REMOVABLE COVERS
1 PERMANENT INSULATION
2 COVERS FROM FLEXIBLE CLOSED CELL
INSULATION
3 ADHESIVE
4 THICKNESS OF INSULATION FILLER EQUAL TO
BOLT HEAD SIZE
TYPICAL FIRE STOP COMPONENTS FOR

FLOOR EXPANSION JOINT
1 COMPRESSION SEAL
2 ULC APPROVED FIRE STOP SEALANT
3 COMPRESSABLE FIRE STOP (MINERAL WOOL)
TYPICAL FIRE STOP COMPONENTS

FOR FLOORS EXPANSION JOINT

2 COMPRESSABLE FIRE STOP (MINERAL WOOL)
3 JOINT COVER (GALVANIZED STEEL)
TYPICAL FIRE STOP

FOR WALL PENETRATIONS
1 STEEL SLEEVE (OPTIONAL)

3 COMPRESSIBLE FIRE STOP (MINERAL WOOL)
TYPICAL FIRE STOP


4 PIPE INSULATION (INSTALLED AFTER FIRE
STOP)
TYPICAL FIRE STOP

1 STEEL SLEEVE
TYPICAL FIRE STOP

1 STEEL SLEEVE
STOP)
TYPICAL FIRE STOP


STOP)
TYPICAL FIRE STOP FOR DEFLECTION

OF METAL STUD WALLS

3 METAL CHANNEL SIZED TO SUIT ALLOWANCE
FOR DEFLECTION & SIZE OF STUDS
4 GYPSYM BOARD FIXED TO STUD AND FREE TO
SLIDE
5 TAPE BREAKER
TYPICAL FIRE STOP COMPONENTS FOR

THE TOP OF THE MASONRY WALL

3 AIR SPACE
PRE-FORMED PIPE INSULATION

MULTIPLE LAYER CONSTRUCTION
1 PRE-FORMED PIPE INSULATION (AS SPECIFIED)

2 INSULATION WITH STAGGERED JOINTS
4 FINISH JACKET
5 JACKET FASTENING
RECEIVING UNLOADING
When receiving the pipe and/or fittings shipment at the job site, the The means by which pipe and fittings are unloaded in the field is
contractor or purchaser should exercise established precautions. the decision and the responsibility of the receiver.
Each shipment should be inventoried and inspected with care upon The following recommendations should be followed:
arrival. The pipe and fittings are inspected and loaded with due
care at the factory using methods acceptable to the carrier. It is the 1. Remove restraints from the bundles. These may be straps,
carrier's responsibility to deliver the shipment in good condition, ropes, or chains with padding.
and it is the receiver's responsibility to ensure that there has been
no loss or damage. 2. Remove any boards on the top or sides of the load that are not
part of the pipe/fittings packaging.
The following procedures are recommended for acceptance of
delivery: 3. When unloading fittings use industry-accepted means. Use
extreme caution when unloading fittings with any type of
1. Conduct overall examination of the load. If the load is intact, machinery, as fittings may be fiberglass wrapped for added
ordinary inspection while unloading should be sufficient to ensure strength. Damage to wrapping could reduce strength of fabricated
that the pipe has arrived in good condition. fitting. Do not drop or throw fittings into trench. ROYAL is not
responsible for damage to mishandled fittings.
2. If the load has shifted, has broken bundles, or shows rough
treatment, carefully inspect each piece for damage. 4. Using a forklift (or a front-end loader equipped with forks),
remove the top bundles of pipe, one at a time from the truck.
3. Check total quantities and details of each item against shipping
documents. 5. If a forklift is not available, use a spreader bar with fabric straps
capable of carrying the load. Space straps approximately 2.4
4. Note any damaged or missing items on the delivery receipt. metres (8 ft) apart. Loop straps under the load.
5. Notify the carrier immediately and make a claim according to his 6. During the removal and handling, ensure that the bundles do
instructions. not impact anything (especially in cold weather).
6. Do not dispose of any damaged material. The carrier will notify 7. Place pipe bundles on level ground.
you of the procedure to follow.
8. Do not handle bundles with individual chains or single cables,
7. Replacements for shortages and damaged materials are not even if padded.
reshipped without request. If replacement materials are needed,
reorder from your ROYAL distributor or representative. 9. Do not attach lifting cables to bundles or bands.
10. Do not stack bundles more than 2.4 metres (8 ft) high.
11. Protect bundles with packing materials the same way they
were protected while on the truck.
12. To unload lower bundles, repeat the unloading process

described above.
13. Do not unload pipe bundles by hand.
14. If unloading equipment is not available, pipe may be unloaded

by removing individual pieces. Care should be taken to ensure that
pipe is not dropped or damaged.
2 3
STORAGE HANDLING
The following procedures are recommended to prevent damage to The following procedures are recommended:
the pipe:
1. When using mechanical equipment, exercise care to prevent
1. Store the pipe at the site in bundles. damage to the pipe/fittings.
2. Avoid compression, deformation or damage to bell ends of the 2. Lower pipe/fittings carefully from trucks and into trenches. Do
pipe. not drop pipe/fittings. Dropped pipe/fittings can be damaged and
should not be used.
3. When bundles are stacked, ensure that the weight of upper
bundles does not cause deformation to pipe in lower bundles. 3. In sub-zero (freezing) temperatures, use caution to prevent
impact damage. Handling methods considered acceptable for
warm weather are unacceptable during very cold weather.
4. Support pipe bundles at 2.4 metre (8 ft) intervals (1.2 metres (4
ft) from each end) on wood blocking to prevent damage to the 4. When distributing the pipe along a trench (stringing), place pipe
bottom surfaces during storage. on the opposite side of the trench from the excavated earth. Place
pipe with bell ends in the direction of the work progress.
5. Store lubricant in tightly sealed containers under cover.
6. Do not store pipe/fittings where gaskets may be exposed to

ozone, UV radiation, or contamination (ie. grease, oil etc).
7. Protect the interior and sealing surfaces of pipe and fittings from
dirt and foreign material.
8. When the bundles are stacked, ensure that the stack remains
stable.
9. When pipe/fittings are being stored for a prolonged period, the

bundles should be covered with a translucent cover, to protect
against exposure to direct sunlight.
4 5
PIPE INSTALLATION INSTRUCTIONS
Alignment and Grade

All pipe should be laid to, and maintained at required lines and
grades established by the pipe system Design Engineer. Fittings,
valves, air vents and hydrants should be installed at the required
locations with valve and hydrant stems plumb.
Trench Width
Trench width at the ground surface may vary with and depend
upon the depth, type of soils, and the position of the surface
structures. The minimum clear width of the trench, measured at
the spring line of the pipe should be 300mm (1ft) greater than the
outside diameter of the pipe. The maximum clear width of the
trench at the top of the pipe should not exceed a width equal to the
pipe diameter plus 600mm (2 ft). If the above defined trench widths
must be exceeded, or if the pipe is installed in a compacted
embankment, the pipe embedment should be compacted to a point
of at least 2.5 pipe diameters from the pipe on both sides of the
pipe or to the trench wall, whichever is less.
Preparation of Trench Bottom

• The trench bottom should be constructed to provide a firm, stable
and uniform support for the full length of the pipe.
• Bell holes should be provided at each joint to permit proper joint

assembly and pipe support. Any part of the trench bottom
excavated below grade should be backfilled to grade and should Laying of Pipe
be compacted as required to provide firm pipe support. Proper implements, tools and equipment should be used for
placement of the pipe in the trench to prevent damage.
• When an unstable sub-grade condition which will provide
inadequate pipe support is encountered, additional trench depth Under no circumstances should the pipe or accessories be
should be excavated and refilled with a suitable foundation material dropped into the trench. All foreign matter or dirt should be
as recommended by the project's Geotechnical Engineer. Ledge removed from the pipe interior. Pipe joints should be assembled
rock, boulders and large stones should be removed to provide with care. When pipe laying is not in progress, open ends of the
100mm (4") of soil cushion on all sides of the pipe and accessories. installed pipe should be closed to prevent entrance of trench water,
dirt and foreign matter into the line.
6 7
Thrust Blocking Mechanical Joint Restraint

Concrete reaction or thrust blocking should be provided at each ROYAL will recognize the use of any restraint device that carries
hydrant, valve, bend, tee and at reducers or fittings where changes third party certification to ASTM F1674 (American Society for
occur in pipe diameter or direction. Concrete thrust blocks shall be Testing and Materials), FM (Factory Mutual) and UL (Underwriters
cast in place, poured against undisturbed soil. Pre-cast blocks are Laboratories). It is the responsibility of the restrainer manufacturer
not permitted. to supply the necessary support data to prove that their product
complies with these requirements and is compatible with the
pipe/fittings.
It is important to note that ROYAL does not assume any liability

1 2 arising from the use of any restrainers on pipe or fittings
manufactured by ROYAL.
1 2
3 4
3
5
6
4
5
6
7 8 8
7
9
9
10
1. Through line connection 6. Vertical direction change
1. Through line connection (tee) 6. Direction change (cross used 2. Through line connection (cross (elbow)
2. Through line connection (cross as elbow) used as tee) 7. Direction change
used as tee) 7. Hydrant Tee 3. Direction change (tee used as 8. Through line connection (wye)
3. Direction change (elbow) 8. Hydrant Boot elbow) 9. Hydrant runout
4. Change line size (reducer) 9. Valve Anchor 4. Direction change (elbow)
5. Direction change (tee used as 10. Vertical direction change 5. Direction change (cross used
elbow) (bend anchor) as elbow)
8 9
Pipe Embedment Assembly of Gasket Joints

PVC pipe should be installed with proper bedding providing The patented "Double-Seal" gaskets are "Locked-In" to the bell at
uniform longitudinal support under the pipe. Backfill material the factory.
should be worked under the sides of the pipe to provide
satisfactory haunching. Initial backfill material should be placed to 1. Clean the gasket, bell interior, and spigot area with a clean rag,
a minimum depth of 300mm (1ft) over the top of the pipe. All pipe brush or paper towel to ensure all debris is removed from bell and
embedment material should be selected and placed carefully. spigot ends of the pipe. Check the gasket position. Inspect the
Stones, frozen lumps and debris are not considered suitable for gasket, pipe spigot bevel and sealing surfaces for damage or
use in the embedment area of the pipe. Proper compaction deformation. Be sure that the gasket is installed properly. Do not
procedures should be exercised to provide soil densities as remove gasket as it is locked in during manufacturing. Once the
specified by the Design Engineer. gasket is removed, it cannot be reinstalled.
Final Backfill
After placement and compaction of pipe embedment materials, the
balance of backfill material may be machine placed. The final
backfill should contain no large stones or large rocks, frozen
material or debris. Proper compaction procedures should be
exercised to provide required soil densities.
2. Use only ROYAL recommended lubricant supplied with the pipe.

Liberally apply lubricant to the spigot up to the reference mark and
to the face of the gasket. Use of non-approved lubricants may
promote bacterial growth and cause damage to the gaskets or
pipe, as well as void the manufacturer's warranty.
3. After lubrication, the pipe is ready to be joined. Good alignment

of the pipe is essential for ease of assembly. Align the spigot and
the bell, and insert the spigot into the bell until it contacts the
gasket uniformly. Do not suspend the pipe and "stab" it onto the
bell. The spigot end of the pipe will be marked by ROYAL to
indicate the proper depth of insertion. The insertion line should be
exposed in front of the face of the bell. Do not over insert the joint.
NOTE: Dual-Durometer gaskets are available upon request for

100 - 300mm (4 -12 in) diameter DR18 and DR25 pipe.
10 11
Field-Cut Pipe to Pipe Longitudinal Bending of Pipe and Pipe Joint Deflection
To join field-cut pipe, it is necessary to first prepare the pipe There are three common methods used to achieve change in
end. A square cut is essential for proper assembly. The pipe direction for Royal PVC pressure pipe:
can be easily cut with a hacksaw, handsaw or a power saw
with a steel blade or abrasive disc. It is recommended that the (A) Longitudinal Bending of Pipe (ROYAL C900 DR 18 pipe
pipe be marked around its entire circumference prior to cutting only)
to ensure a square cut. The insertion line should be marked ROYAL C900 DR18 Pressure Pipe can be bent to obtain a
on the cut piece of pipe. maximum angle of deflection as shown in the following table:
Max. Angle of
The location of the insertion line is determined by using the Pipe Diameter
Deflection
pipe bell as a guide. Measure the insertion depth of the bell.
150mm (6”) 4.0°
This is the distance from the end of the bell to the start of the
bell taper. Subtract 13mm (½in) from the insertion depth 200mm (8”) 3.0°
distance. The result is the distance from the end of the spigot 250mm (10”) 2.5°
to the insertion line. 300mm (12”) 2.1°
To obtain this result, please follow the guidelines given in the
INSERTION LINE Uni-Bell Handbook of PVC Pipe.
15° BEVEL
NOTE: Do not install service taps of any kind into bent pipe
because it is under stress.
(B) Pipe Joint Deflection (ROYAL C900 DR 18 pipe only)

PIPE ROYAL C900 DR18 Pressure Pipe can be deflected at the joint
DIAMETER by a maximum angle of deflection as shown in the following
table:
Max. Angle of
Pipe Diameter
Deflection
150mm (6”) 3.0°
200mm (8”) 3.0°
Use a factory-finished beveled end as a guide for proper bevel
angle and depth of bevel plus the distance to the insertion 250mm (10”) 3.0°
reference mark. The end may be beveled using a pipe 300mm (12”) 2.5°
beveling tool or a wood rasp which will cut the correct taper. A The close tolerances of ROYAL joints limit the amount of
portable sander or abrasive disc may also be used to bevel the unstressed deflection. The procedure is as follows:
pipe end. Round off any sharp edges on the leading edge of
the bevel with a pocket knife or file. · Make a concentric assembly, but push the spigot into the bell
only to a point about 13mm (1/2 in) short of the insertion line.
This incomplete assembly permits more movement of the end
of the pipe at the bottom of the bell. Do not exceed the
recommended maximum offset and use only manual effort.
NOTE: Do not combine Methods A and B.
ROYAL does not recommend longitudinal bending of pipe or

deflection of joint to achieve change in direction for pipe
diameters larger than 12".
(C) Use of Fittings (All pressure pipe)

Angle fittings or bends are available to obtain change in
direction as required.
12 13
FITTING INSTALLATION INSTRUCTIONS Field-Cut Pipe To Fittings

Field cutting pipe to fittings should follow the procedure on page
1. Make sure both the bell and spigot are clean. 12. Along with those instructions, the following procedure should
be used. Cut pipe to required length. Measure the insertion length
2. Cut the pipe square to the required length and bevel the pipe to on the fitting as described in the "Field-Cut Pipe to Pipe" section
match that of a factory bevel. Use a piece of pipe with a factory and transfer that measurement to the pipe end, after the pipe end
made bevel as a guide when making field bevels. Remove any is beveled. Mark the measured length on the pipe with a marker,
burrs or other sharp pieces that may harm the gasket when the ensuring the mark is easily visible. Once the pipe is beveled and
pipe is inserted into the bell. the insertion line is marked, insert the pipe into the fitting as
suggested in previous sections.
3. Measure the insertion depth of the bell and mark the spigot with
this dimension. Mark the spigot with a line 360° around the pipe. NOTE: Do not insert the pipe past the measured insertion line.
The insertion depth is from the lip of the bell to the beginning of the Over insertion of the pipe into the fitting can cause failure of the
taper inside the bell. Over insertion of PVC pipe is one of the fitting.
primary causes of failure for both PVC pipe and fittings. Over
insertion of the spigot is characterized by a crushing of the spigot Cast iron fittings have shallower bells than PVC fittings. For M-J
in the bell, which causes the bell to crack at the taper of the fitting. cast iron fittings, the edge of the PVC pipe should be square cut.
The crack will then move in both directions until it splits the bell, For push-fit cast iron fittings, a small chamfer is required. For more
releasing the stress on the bell and causing a failure of the fitting. detailed information about assembly to cast iron fittings, please
contact the fitting manufacturer.
4. Lubricate both the bell and the spigot with the lubricant supplied
by the manufacturer. The lubricant shall be applied in a 1 mm
thickness to the bell lip and gasket area and to 76mm (3in) from the Deflecting the Joint at Fittings
end of the spigot. This distance on the spigot includes the chamfer PVC pressure fitting joints by nature of their gasket design and
of the pipe. insertion depth cannot accommodate large deflection angles. The
maximum deflection should be 1° for all sizes of PVC pressure
5. Check again that the bell and spigot are still free of debris, and fittings. This is equivalent to 100mm (4in) of deflection over a 6.1
then place the spigot at the bell lip positioning the spigot such that metres (20 ft) length of pipe. If the deflection exceeds 1°, failure is
the chamfer is resting against the edge of the gasket. Then, push characterized by a crack in the lip of the bell of the fitting which
the spigot into the bell until the assembly line on the spigot is even propagates back towards the gasket causing a failure of the fitting.
with the lip of the bell. See notes below. When deflecting the pipe/fitting joint, use the following procedure.
NOTES 1. When assembling the pipe/fitting joint, push the spigot into the
· For small diameters the assembly effort should be able to be bell until the assembly line on the spigot is 13mm (1/2in) short of
delivered by hand using a block and bar. Never push directly the lip of the bell. The 13mm gap allows for more movement at the
against the pipe. end of the pipe being inserted.
· Always keep a piece of wood between the face of the pipe bell 2. Shift the end of the pipe being inserted by 100mm (4in) for a 6.1
and the bar used for pushing. This protects the pipe as well as metre (20 ft) length. This is equal to 1° of deflection.
ensures even distribution of the force pushing the pipe into the
bell. 3. If a large resistance force to the insertion of the spigot is felt by
the installer, it could mean that the gasket has become dislodged.
· For larger diameters, mechanical assembly methods may be In this case, disassemble the joint and re-assemble as per the
required such as a come-along, jacks, pulleys and even the instructions above.
backhoe bucket. Of all the methods the backhoe bucket is the
least preferred. A backhoe bucket cannot feel the resistance to ROYAL has the production capacity to make any degree bend
the spigot entering the bell and therefore cannot tell if the joint is required (from 5 to 89 degrees) in addition to our standard 11.25°,
going together correctly. Over insertion by the backhoe will 22.5°, 45° and 90° bends. Please contact your ROYAL
damage the fitting joint and may also damage other joints representative for more details.
previously installed.
14 15
INSPECTION AND TESTING SERVICE CONNECTIONS AND TAPPING
Good practice dictates pressure testing portions of lines as they Service lines can be connected to ROYAL PVC Pressure Pipe by
are completed in advance of the entire system. Before testing, the the following methods:
pipeline must be backfilled and braced sufficiently to prevent
movement under pressure. Direct Tapping
· Up to 25mm (1in) corporation stops can be used.
The following three points should be considered when testing: · Only 150 - 300mm (6 - 12in) diameter AWWA C900 Pressure
Class 150 (DR 18) and Pressure Class 200 (DR 14) pipe. Do not
1. The pipe to be tested must be sufficiently backfilled to prevent direct tap Pressure Class 100 (DR 25) pipe.
movement while under test pressure. · "Wet" (under-pressure) or "dry" (no-pressure) taps are permitted.
2. Thrust restraint at fittings should be permanent and constructed Approved Service Saddles for PVC Pressure Pipe
to withstand test pressure. If concrete thrust blocks are used, · Can be used with any size or class of pipe.
sufficient time must be allowed before testing to permit the · Maximum outlet permitted is 50mm (2in).
concrete to cure. · Saddles must be sized to provide even support around the full
circumference of the pipe.
3. Test ends should be capped and braced to withstand the thrusts · The strapping must provide a minimum of bearing width of 50mm
that are developed under test pressure. (2in) along the axis of the pipe.
· The design of the saddle should not have lugs that will indent the
Pressure and Leakage Test pipe when the saddle is tightened.
A combined pressure and leakage test is recommended. The test · Can be used with wet or dry taps.
pressure and duration shall be as specified by the Design
Engineer. The test pressure should never exceed the pressure
rating of the pipe being tested.
Relieving Air From Pipe Line

The pipeline should be filled as slowly as possible (not more than
1 ft/sec) to avoid any unnecessary surges. Venting air from the line
is of utmost importance.
Pressure pipe is seldom laid to grade, so there are high and low
sections along the line. If the high section elevation is considerably
above the low part of the line, a larger amount of air will be trapped.
Corporation stops or automatic air relief valves should be installed Tapping Sleeves and Valves
at these points. Air can be blown from hydrants in pipe sizes up to · Should be used for services requiring larger than 50mm (2in)
200mm (8in). In larger diameter pipes, air will not enter the hydrant taps.
branch, therefore it will be necessary to install air release valves at · Should be supported independently of the pipe.
high points. · Thrust restraints are required.
· Can be used with wet or dry taps.
The line should then be filled with water to static pressure, and all
air vents opened to allow air to escape. It is recommended practice
to let the line remain under static pressure for at least 15 minutes.
All air vents should then be opened again to allow any remaining
air to be released from the line, after which the line may be brought
up to full test pressure. The leakage shall not exceed that specified
by the Design Engineer. Test pressure should never exceed the
pressure rating on the pipe being tested.
Air pressure testing of installed PVC pressure pipe is expressly

prohibited for safety reasons.
16 17
General Tapping Recommendations 9. When making more than one tap on a length of pipe the tap
1. AWWA C800 (Mueller) threads are required. locations should be staggered at least 600mm (2ft) apart,
longitudinally.
2. Shell cutters (with or without slots) are necessary to retain and
remove the coupon. The throat depth should be sufficient to handle 10. Taps should not be made in areas of the pipe that have
heavier DR 14 pipe. Do not use single slot cutters. become discoloured.
Do not use twist drill bits for tapping PVC. It is required that a sharp 11. NEVER DIRECT TAP IN AN AREA OF THE PIPE THAT HAS
tapping tool and tapping lubricant be used in the tapping process. BEEN BENT.
12. Do not tap closer than 600mm (2 ft) from the ends of the pipe.
Basic Safety Precautions

When drilling or tapping any pressurized water pipe, basic safety
precautions are advised to assure personal safety of the workmen
3. The tapping machine shall have an independent boring bar feed in the event of a sudden and unexpected pipe failure. Although
mechanism. Manufacturers instructions for operating the tapping such failures are extremely infrequent, the following safety
machine should be followed. practices are recommended.
· A second workman or supervisor should always be present in the

immediate vicinity when making "wet" taps.
· Normal protective clothing: including hard hat, safety shoes,
goggles or face mask, should be worn.
· A heavy protective blanket, 1.2 metres x 1.8 metres (4ft x 6ft)
should be used to cover the exposed pipe in the area of the tap.
The blanket should have a hole in the center permitting access
This is a sample of a proper tapping coupon. and operation of the drilling and tapping machine.
4. The tapered thread of the corporation stop shall be spirally

wound with 2-3 layers of Teflon® tape. This procedure is also
required when installing corporation stops in tap couplings.
5. A torque wrench should be used to tighten the corporation stop

using 36.6N•m (27ft•lb), 2-3 threads should be showing after
removal of the tapping machine. If leakage is apparent after final
torque tightening of 47.5N•m (35ft•lb), the corporation stop will
have to be reinstalled. The line pressure should be relieved; the
corporation stop removed; new Teflon® tape wrapped on the
threads and the corporation stop reinstalled to a torque of 36.6N•m
(27ft•lb).
6. Taps should be made at 10 o'clock or 2 o'clock on the pipe.
7. Horizontal goose-necks of the service line are suggested to

allow the expansion and contraction of the service line.
This is a sample of a proper tapping coupon.
8. Pipe temperature should be between 0 - 40°C (32 - 104°F)

when direct tapping under pressure. Be extremely cautious when
tapping in very cold weather.
18 19

Cladding& Fitting

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M.W.

BARVE LECTURE NOTES

FLEXIBLE CLOSED CELL

FIELD AND FACTORY-APPLIED

1 PRE-FORMED PIPE INSULATION

1 PRE-FORMED PIPE INSULATION

STANDARD SPLIT RING

1 PRE-FORMED PIPE INSULATION

1 PRE-FORMED PIPE INSULATION

1 PRE-FORMED PIPE INSULATION

1. TUBING TRACER (BY OTHERS)

INSULATION SUPPORT RINGS /

1. PRE-FORMED PIPE INSULATION - SINGLE LAYER

PRE-FORMED ELBOW INSULATION

1. PRE-FORMED PIPE INSULATION (SHOWN WITH METAL

MITRED INSULATION ELBOW

PVC / GLASS FIBRE ELBOW

1 PRE-FORMED PIPE INSULATION WITH FACTORY JACKET

FIELD OR FACTORY FABRICATED

1 PRE-FORMED PIPE INSULATION WITH METAL JACKET

PVC / GLASS FIBRE

1 PRE-FORMED PIPE INSULATION

IN-LINE FLANGE INSULATION

1 PRE-FORMED PIPE INSULATION WITH FACTORY JACKET

PVC/GLASS FIBRE COUPLING OR

1 PRE-FORMED PIPE INSULATION

FLEXIBLE DUCT INSULATION

1 FLEXIBLE DUCT INSULATION WITH VAPOUR BARRIER

2* & 4* VAPOUR BARRIER TAPE OR SEAL NOT REQUIRED ON

RIGID DUCT INSULATION ON RECTANGULAR

1 RIGID DUCT INSULATION

1 RIGID BLOCK INSULATION (JOINTS STAGGERED)

VESSEL BOTTOM HEAD,

1 VESSEL, INSULATION AND JACKET

PIPE AND TUVE EXCHANGERS – ENCASED

1 PIPE INSULATION SECURED WITH BANDING

1 SUPPORT RING FOR

LARGE DIAMETER HORIZONTAL VESSELS

FLEXIBLE CLOSEDCELL SHEETS

1 INSULATION ADHESIVE (CONTACT TYPE)

EXTREME TEMPERATURE VESSELS

SMALL DIAMETER VESSELS / EXHAUST

1 INSULATION SUPPORT RING (BY OTHERS)

FIELD APPLIED LINING

CURVED SURFACES RIGIDBOARD INSULATION

1 INSULATION SCORED OR BEVELLED TO FIT

NOZZLES AND INSULATED MANWAYS

BLOCKS AND PRE-FORMED PIPE INSULATION

1 AIR SPACE MATERIAL (BY OTHERS)

HEAD INSULATION SECUREMENT

1 HEAD INSULATION 6 METAL FINISH JACKET

PIPING (0”C THROUGH -40”C)

1 INSULATION INNER LAYER

FITTINGS (0”C THROUGH -40”C)

1 MULTI-LAYER INSULATION; VAPOUR BARRIER

FLEXIBLE INSULATION BLANKETS

1 SHAPED INSULATION BLANKET

REMOVABLE AND REUSABLE INSULATION

1 METAL CASING LINED WITH INSULATION

REMOVABLE AND REUSABLE INSULATION

1 FLEXIBLE CLOSED CELL INSULATION

ELASTOMERIC REMOVABLE COVERS