Polykun Technical Manual

HDPE- PROFILED PIPES _________________________________________________________________________
SEWERAGE AND STORM WATER PIPING SYSTEMS
TECHNICAL MANUAL (HDPE PROFILED PIPES)
Polykun Piping Systems Sewerage and Drainage Structured Pipe Dr.-Eng. Fathalla QASEM
CONTENTS 1. 1.1. 1.2. 1.3. 2. 2.1. 2.1.1. 2.1.2. 2.2. 2.2.1. 2.2.2. 2.2.3. 2.2.4. 2.3. 2.3.1. 2.3.2. General Specifications of HDPE- Profiled Pipes Material Properties Resistance to Chemical Flexibility and Strength HDPE- Profiled Piping System Series PW Pipes and Field of Applications Wall Structure for Profile Types of Series PW- HDPE Pipes Applications of PW pipes Series DW pipes and field of application Wall Structure of Series DW1-Pipes Wall Structure of Series DW2-pipes with two layers and more Connection Details of Series DW-pipes Applications of DW Series Pipes Series SW solid Pipes and Field of Applications Wall Structure of Series SW solid pipes Connection Details of Series SW - solid pipes
3. HDPE-Fittings 3.1. Bends 3.2. Branches 3.3. Reductions 3.4. Puddle flange 3.5. House connection 3.5.1. House connection fitting components 3.5.2. House connection procedure 3.6. Manholes and Tanks 3.6.1. Manholes 3.6.1.1. Straight passage manholes 3.6.1.2. Tangential manholes 3.6.2. Tanks 4. 4.1 4.1.1. 4.1.2. 4.1.3. 4.2. 4.2.1. 4.2.2. HDPE-Profiled Pipe Connection Methods Welded Connection Electro-fusion Welding Method Butt Welding Method Extrusion Welding Mechanical Connection Rubber Sealing Connection Flange Connection
5. Installation and Application of HDPE/PP Pipes 5.1 Pipe in Trenches and Installation 5.1.1 Choice of Pipe Stiffness 5.1.2 Compaction Degree and Methods 5.1.3. Material of Pipe Zone and Remaining Backfill 5.1.4. Type of Installation 5.1.5. Parallel Piping Systems 5.1.6. Trench width 5.2 Application of HDPE-Profiled Pipes 5.2.1. Sewer and Storm Water Lines 5.2.2. Sea Outfall and Intake Pipes 5.2.3. Relining 5.2.4. Landfill Drainage Systems 5.2.5. Lined Pipes
6. HDPE- Ppie Storage and Transportation 6.1. Storage Methods 6.2. Transportation Methods 7. 8. HDPE- Pipe Manufacturing, Test Methods and Quality Warranty HDPE Pipe Sample Purchase Tender
9. HDPE- Pipes and Manhole Questionaire 9.1. Pipe Questionnaire 9.2. Manhole Questionnaire
1. General Specification of HDPE- Profiled Pipes
Figure 1: HDPE-profiled pipes 1) HDPE- profiled pipes are available in diameters up to inside diameter 4000 mm. they are produced from HDPE or PP in accordance with the field of applications and load conditions. The pipes fulfils the required ring stiffness according to EN 13476, ASTM F 894 and DIN 16961. 2) HDPE- pipes can be delivered with different joint systems. The pipes can be connected with electro-fusion joint for all pipe sizes. In addition to welded connections, socket and spigot can be also incorporated with gasket connections. The pipes with butt-weld or flange joints are also available upon request. 3) Any kind of tanks, manholes or other special applications having ID up to 4000 mm can be produced by HDPE piping system. 4) Transportation and the storage of any kind of foodstuff can be made by HDPE piping system, thanks to HDPE (High Density polyethylene) used in manufacturing of the pipes, which is completely hygienic. 5) The internal wall surfaces of HDPE- pipes are manufactured by co-extrusion technology, if requested all pipes can be delivered either with a bright, inspection friendly color, or an electro-conductive inner surface. 6) No wastage is generated during the transportation and storage of HDPE pipes due to their high impact strength and great deal storage area can be saved by telescopic or stockpiling one onto another. 7) The possibility of using the electro-fusion welding within confined area makes it possible to excavate narrower pipe trenches with less labor and shorter installation times and thus the investment cost can be reduced. 8) Lifetime over 100 years.
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9) High mechanical resistance ( abrasion, impact resistant and secure against fracture). 10) The outer surface of the pipes is back. Black HDPE-pipes are permanently resistance to atmospheric corrosion and UV radiation. UV stabilizers, antioxidants and pigments shall be included pre-compounded by material supplier. 11) Very good hydraulic properties due to inner smooth surface. 12) Good chemical resistance. 13) The absolute tightness and high degree of safety are obtained by HDPE- pipes that are connected with electro-fusion welding. 14) Large range of accessories. 15) Non-polluting, recyclable.
Figure 2: Intake piping system from 1600 mm HDPE-pipe
1.1 Material properties Ploykun piping system (PPS-pipes) are manufactured from high-density polyethylene (HDPE). Polypropylene (PP) pipes are recommended for fluids at elevated temperatures. Properties of HDPE and PP used in manufacturing of PPS- pipes; Ease of transportation due to their low density, High degree of resistance to chemicals, Flexibility that ensures excellent resistance to impact loads, Durability of HDPE against UV, Easily and reliable welding in pipe connection, Resistant to abrasion, Smooth surface preventing precipitation, High degree of fluidity with minimum pressure loss, Suitable for cold weather without effected from frost, Heat resistively up to 60C for HDPE and 95C for PP, No corrosion is ever formed, Resistant to rodents and roots penetration. Table 1: Materials specifications: Properties Standard P Color H DIN 53479 Y Density ISO 1183 S ISO 1133 I Melt Flow Index MFR 190/5 C MFR 190/21, 6 A L MFR 230/5 M Modulus of elasticity ISO 178 Short term DIN 53456 E C Long term (50 years) H Yield strength DIN 53495 A Tensile strength DIN 53495 N Elongation at Break DIN 53495 I Minimum Required Strength ISO 4427 ISO 2039 I Indentation hardness C Impact strength at 23C A (by Charpy method) L DIN 53752 T Coefficient of linear thermal H Expansion DIN 52612 E Thermal Conductivity ISO 306 R VICAT Softening Point M DIN 4120 A Flammability L
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Unit g/cm3 g/10 min
PE 80 Black/ yellow 0,95 0,40 10 -
PE 100 Black/ yellow 0,96 0,45 6,6 1.200 150 25 38 >350 10 46
PP-R Black 0,91 0,50 1,25-1,5 750 160 26 15 >50 45
N/mm2 N/mm2 N/mm2 % N/mm2 1.000 150 23 32 >350 8 42
1/oC W/m. oC o C -
1,8x10-4 0,4 B2
1,8x10-4 0,38 127 B2
1,6x10-4 0,42 B2
1.2 Resistance to Chemical The Polyethylene (PE) and the polypropylene (PP) to chemical aggression are wellknow. The characteristic is considered in EN 13476-1, in which it is stated that the PE and PP materials are resistant to water with a large range of values of pH, as waste water, rain water and ground waters. If the pipes are used for waters contaminated by chemical products originated from industrial discharges, the chemical and thermal resistance has to be considered, as per ISO 10358. 1.3 Flexibility and Strength The flexibility of the materials used for manufacturing of HDPE profiled pipes is very high. Therefore, HDPE pipes are not influenced from the earthquake movements, thanks to their flexibility and impact absorbing properties. Underground piping system is subject to many variable loads and, impact forces in their service life. The pipelines installed by making use of conventional piping materials are worn out eventually under ever-increasing loads induced from road traffic. Especially the pipes that are made from rigid pipe material are in a condition to resist the load induced via concentrated supporting point on their bases. Such pipes are vulnerable to fracture, when they are squeezed by instantaneous impact loads acting along two opposite directions, since their flexibility is inferior. Consequently, the conventional pipes are frequently damaged under such influences and fractured, dented, broken and subjected to the adverse effects of roots penetration and overload. On the other hand, the loads induced on HDPE pipes are uniformly distributed to the sides of the pipe by compacted soil.
Figure 3: Pipe flexibility and Strength

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2. HDPE-Profiled Piping System There are several types of thermoplastics that are used in the manufacture in pipe. There are three principal thermoplastics used to make pipe: polyvinyl chloride (PVC), polypropylene (PP) and high density polyethylene (HDPE). Due to the good flexibility of polyethylene is the polyethylene pipes mostly used. Polyethylene pipes are available in various sizes and wall configurations for varied applications, some of them are listed below: Table 2: Application of Polyethylene Pipes Application Industrial (includes gas) Water (new service) Gravity sewer (lining) Gravity sewer Type Solid wall Solid wall Solid wall/ profile wall Profile wall
Besides the high flexibility of the PolyKun piping system, these profiled pipes have succeeded to meet the German standards DIN 16961or DIN 8074 as well as the standards of other countries like European norm EN 13476, the US norm ASTM F894. HDPE pipes are manufactured in three different shapes according to the field of application and the purpose of use: Series PW : external profiled, internal smooth surface. Series DW : profiled pipe with external and internal smooth surface. Series SW : solid pipe with external and internal smooth surface. Series PF and SW can be produced from HDPE and PP. Series DW pipes are produced from HDPE only.
PW-Pipe
DW-Pipes
SW-Pipe
Figure 4: Different pipe sections
2.1 Series PW Pipes and Field of Applications
Figure 5: HDPE-profiled pipe PW Pipes series in HDPE piping system are the pipes with smooth internal surface, having spiral profiled exterior surfaces. Such pipes are generally used for sanitary sewer systems and the gravity piping systems. 2.1.1 Wall Structure for Profile Types of Series PW HDPE pipes
Figure 6: Sectional and Structural view and of Series PW HDPE pipes a = profile distance [mm] s1 = waterway thickness [mm] s4 = coating thickness [mm] h = profile height [mm]
By using a profiled pipe it is possible to use a light pipe for a high static load. The supportable static load is determined for every profile geometry by the factors elastic modulus [N/mm2] of the respective material and the moment of inertia of the profile geometry [mm4/mm] referring to the pipe diameter. The result is called ring stiffness. 10
Table 3: HDPE Profiled Pipes Classes (E24=380N/mm2) according to ISO 9969
SN2
DN mm 500 600 700 800 900 1000 1200 1400 1600 1800 2000 daPipe mm 555 676 776 892 996 1096 1320 1550 1756 1962 2174 daBell mm 580 680 780 880 980 1080 1280 1480 1680 1880 2080 Profile Type PF 34-0,99 PF 34-0,99 PF 34-0,99 PF 42-1,9 PF 42-2,28 PF 42-2,6 PF 54-4,5 PF 65-7,43 PF 65-10,92 PF 65- 15,31 PF 65-21,36 daPipe mm 576 678 792 920 1020 1148 1348 1560 1774 1990 2178
SN4
daBell mm 580 680 780 880 980 1080 1280 1480 1680 1880 2080 Profile Type PF 34-0,99 PF 34-1,2 PF 42-1,9 PF 54-4,5 PF 54-4,5 PF 65-6.96 PE 65-9.43 PF 65 14.55 PE 65-23.63 PF 65-31.63 DW1 65-45.32 daPipe mm 594 696 820 948 1050 1156 1366 1590 2178
SN8
daBell mm 580 680 780 880 980 1080 1280 1480 1680 Profile Type PF 42-1,7 PF 42-2,28 PF 54-4,5 PF 65-6.96 PF 65-8.30 PF 65-10.92 PF 65-18.83 PF 65-31.63 DW1 65-45.32 -
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2.2 Series DW Pipes and Field of Applications Series DW Pipes or so called closed pipes in HDPE piping system are the pipes that are generally designed for the fabrication of manholes, storage tanks and reservoir for industrial applications. Although Series DW Pipes are similar in major specifications to Series PW Pipes. Series DW Pipes are manufactured in three types according to the field of Applications
DW1-Pipe
DW2-pipe
DW3-Pipe
Figure 7: Sectional and Structural view of Series DW HDPE pipes Series DW pipes in HDPE profiled piping system are the pipes that are generally designed for very high long-term ring stiffness there for it is suitable for extremely high load and big diameter. 2.3 Series SW Pipes and Field of Applications Series SW Pipes in HDPE piping system for industrial applications are the pipes that have smooth internal and external wall surfaces without profiles. These pipes are used within the projects where high degree of strength is requested for fabrication of manholes, tanks and pipes. 2.3.1. Wall Structure of Series SW HDPE- Pipes
Figure 8: Sectional and Structural view of Series SW HDPE pipes
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Table 4: Weight of SW HDPE solid pipes Weight of pipes (kg/m) S 5 10 Di 300 4,6 9,3 400 6,1 14,4 500 7,6 15,4 600 9,1 18,4 700 10,6 21,4 800 12,1 24,4 900 13,6 27,4 1000 15,2 30,5 1100 16,7 33,5 1200 18,2 36,5 1300 18,7 39,5 1400 21,2 42,5 1500 22,7 45,5 1600 24,2 48,6 1700 25,7 51,6 1800 27,2 54,6 1900 28,7 57,6 2000 30,2 60,6 2100 31,7 63,6 2200 32,2 66,7 2300 34,8 69,7 2400 36,3 72,7 2500 37,8 75,7 2600 39,3 78,7 2700 40,8 81,7 2800 42,3 84,8 2900 43,8 87,8 3000 45,3 90,8 15 14,2 18,8 23,3 27,8 32,3 36,9 41,4 45,9 50,4 55 59,5 64 68,5 73,1 77,6 82,1 86,6 91,2 95,7 100,2 104,7 109,2 113,8 118,3 122,8 127,3 131,9 136,4 20 19,3 25,3 31,4 37,4 43,4 49,5 55,5 61,5 67,6 73,6 79,6 85,6 91,7 97,7 103,7 109,8 115,8 121,8 127,9 133,9 139,9 146,0 152 158 164,1 170,1 176,1 182,2 25 24,5 32 39,6 47,1 54,7 62,2 69,7 77,3 84,8 92,4 99,9 107,4 115 122,5 130,1 137,6 145,1 152,2 160,2 167,8 175,3 182,8 190,4 197,9 202,5 213 220,5 228,1 30 29,9 38,9 48 57 66 75,1 84,1 93,2 102,2 111,3 120,3 129,4 138,4 147,5 156,5 165,6 174,6 183,7 192,7 201,8 210,8 219,9 228,9 237,9 247 256 265,1 274,1 35 35,4 45,9 56,5 67 77,6 88,1 98,7 109,2 119,8 130,4 140,9 151,5 162 172,6 183,1 193,7 204,2 214,8 225,4 235,9 246,5 257 267,6 278,1 288,7 299,2 309,8 320,4 40 41 53,1 65,1 77,2 89,3 101,3 113,4 125,5 137,5 149,6 161,6 173,7 185,8 197,8 209,9 222 234 246,1 258,2 270,2 282,3 294,3 306,4 318,5 330,5 342,6 354,7 366,7
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2.3.3. Connection Details of Series SW - Solid pipes (1) Pipe section with bell supplemented by electro-fusion welding at one end and centered spigot at the other. (2) Pipe section with centered spigot at both ends. (3) Pipe section with plain ends/for butt-welding. (4) Pipe section with plain pipe end at one side and plain for butt-welding at the other. (5) Pipe section with centered spigot at one end bell and plain for butt-welding at the other. (6) Pipe section with centered spigot at one end bell and plain for butt-welding at the other. (7) Pipe section with bell supplemented by electro-fusion welding at one end and male centered flange at the other. (8) Pipe section with flange at one end and centered spigot at the other. (9) Pipe section with bell supplemented by electro-fusion welding at one end and flange at the other.
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3. HDPE- Fittings
All fittings are fabricated from pipes of the type SW or DW. Generally the fittings are designed corresponding to the required stiffness and in consideration of the welding factors. Every fitting can have any kind of pipe end and any jointing techniques including the integrated Electro-Fusion socket and spigot. All pipe end dimensions fulfill the requirements of the EN 14376 standard, like minimum lengths and stiffness. The standard spigot length (Ls) is 140 mm and the standard socket length (Lm) is 140mm.
3.1 Bends
Bends can be manufactured and segmented in different angles and the related radius of the bend to pipe diameter can be selected independently.
Table 5:Bend dimensions as per standard DIN 16961

Dimension L in mm (approx.) Number of Segments 2 3 3 4 = 30o = 45o = 60o = 75o 190 230 280 330 210 270 330 410 235 310 390 490 270 350 450 560 300 400 510 550 320 430 560 720 340 470 620 790 380 520 680 870 400 560 750 950 430 600 800 1.020 460 640 860 1.100 490 680 920 1.180 520 720 980 1.260 650 760 1.040 1.340 580 800 1.040 1.420 Special construction as per design dimensions
Di (mm) 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.800 2.000-3.000 15
2 = 15o 100 160 170 180 200 210 220 240 250 270 300 330 360 390 420
4 = 90o 410 510 600 700 820 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800
3.2 Branches
Branches can be manufactured and delivered in every type and form. The angle can be adapted individually from 30 to 90 as well as the ends and the respective segment lengths.
Table 6:Tee dimensions as per standard DIN 16961 DN1 (mm) DN2(mm) Z (mm)
300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.800 2.000-3.000 100/150/200/250 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 100/150/200/250/300 Special construction as per design dimensions 1.100 1.300 1.400 1.650 1.900 1.900 2.000 2.000 2.100 2.100
Z1 (mm)
350 400 400 450 500 500 500 500 500 500
Z2 (mm)
750 900 1.000 1.200 1.400 1.400 1.600 1.600 1.600 1.800
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3.3 Reductions
Reductions can be made both centric and eccentric so that the reduction will always meet the requirements.
Table 7:Reduction dimensions as per standard DIN 16961 Di1 (mm) Di2 (mm) Lt (mm) L1 (mm)
300 400 500 600 700 800 900-4000 400 500 500 600 600 700 700 800 800 900 900 1.000 1.000-3600
L2 (mm)
500 500 500 500 500 500 500 500 500 500 500 500
1.200 500 1.300 500 1.400 500 1.400 500 1..500 500 1.500 500 1.600 500 1.600 500 1.700 500 1700 500 1.800 500 1.800 500 Special construction as per design dimensions
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3.4 Puddle flanges

In order to lead HDPE pipes through walls, e.g. in sewage plants or concrete shafts, we recommend our puddle flanges which can be flush mounted in concrete. The tightness is secured by a ring made of EPDM.
Type 1
Type 2
Type 3
Table 8: Puddle flange dimension

Di (mm) 300 400 500 600 700 800 900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 Type 1 d1 b1 ( mm) ( mm) 770 870 970 1070 1170 1270 1370 1470 1570 1670 1770 1870 1970 2070 160 160 160 160 160 160 160 160 160 160 160 160 160 160 d2 (mm) 336 436 536 636 736 836 936 1036 1136 1236 d3 (mm) 442 542 642 742 842 942 1065 1156 1256 1356 Type 2 and Type 3 d4 b2 (mm) (mm) 517 617 717 817 917 1017 1131 1231 1331 1431 200 200 200 200 200 300 300 300 300 300 b3 (mm) 130 130 130 130 130 130 130 130 130 130 b4 (mm) 140 140 140 140 140 140 140 140 140 140 -
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Table 9: Dimension of wall passes

D (mm) 900 450 400 315 200 s1 (mm) 25 20 20 20 20 s2 (mm) 15 15 15 15 15 h (mm) 150 120 120 100 100 b (mm) 80 80 80 80 80 L (mm) 1000 1000 1000 1000 1000
Figure 9: HDPE- wall passes 3.5 House connection

The house connection fittings are developed to ensure reliable and practical house connection effluent water connections. There is no need to provide connection points on the header pipe to make branch connection or tee. The house connection fitting adapters are completely independent component, which are use for providing connection point at the discharge point of the house connection effluent water. The house connection within HDPEprofiled piping system is provided by the standard fittings having standard sizes of 160 mm and 200 mm.
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3.6. Manhole and Tanks HDPE profiled piping system provides complete solutions for the relevant applications, especially manholes, which are the main problems experienced within sanitary sewer projects, are constructed within HDPE piping system reliably and in a practical manner. 3.6.1. Manholes The manholes are required at several inspection points, ventilation, controlling, and pipe turning points within the sanitary sewer systems. The manholes are completely constructed from HDPE together with relevant top cover and the recesses, with the possibility of concrete tops. The top cover systems of the manholes and the flues completely constructed from this material are telescopic. The covers constructed in this manner have the advantage of elevating the manhole covers at the final level of the road surface, in case of any increase in the elevation of the road surface after coating of the road surfaces.
Figure 11: HDPE-manhole for landfill application The manholes are constructed in accordance with the design project, installed within the piping system together with additional incoming and outgoing branch piping, thus providing convenient application of the pipe installation within the construction site. The design of manholes, together with their nominal diameters, wall thickness, etc., is based on the anticipated loading conditions and the ground water level. Internal surfaces of the manhole piping are made in different colors to ensure ease of inspection, while the auxiliary equipment like access ladder, inspection steps and the canals can also be incorporated into the manholes during fabrication. The problems like corrosion, leakage, etc. on the bottom of manhole and inlet and outlet connections can be prevented, thanks to the properties inherent to HDPE and PP. Two types of manhole design are incorporated within Polkun HDPE- piping system.
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3.6.1.1 Straight Passage Manholes These manholes are designed for use within pipe turning points having several inlet and outlet branch connections. Such manholes are suitable for the pipes having inlet and outlet branch connections with a nominal pipe sized in the range of ID 300 mm to ID 700 mm. The manholes having nominal diameters of ID 1000 mm and ID 1600 mm are suitable for the branch connections with a nominal pipe sizes in the range of ID 300 mm to ID 500 mm and for the branch connections with a nominal pipe sizes in the range of ID 600 mm to ID 900 mm, respectively. The bottoms of the manholes, made from HDPE, are welding construction and therefore, absolute tightness is ensured. The steps and canals on the bottom plate and the access steps can be constructed with the same material, although it is not recommended.
Figure 12 : Straight passage manhole with concrete cover 3.6.1.2. Tangential Manholes The tangential manholes are practical and economic manhole application within Krah HDPE-piping system for the pipes with ID 800 mm and higher. Such applications are possible via standard manufacturing for the pipe size of ID 1000 mm and the manhole is installed tangential to the center of the pipe line. The steps and telescopic HDPE or concrete cover are available within tangential manhole system. Such application is available both on straight pipe runs or turning points.
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Figure 13 : Tangential manhole with telescopic standard cover
Figure 14:
Details of the telescopic cover
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Figure 15: Details of Tangential manhole
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Figure 16: Tangential manholes with 90o and reduced passage
Specifications of HDPE-manholes: Internal surfaces are made in yellow for ease of inspection. Features reduced weight compared with conventional applications. Available up to ID 4000 mm. Internal and external pipe surfaces are smooth. Provides absolute tightness. Not effected from seismic movements and earthquakes. The friction loss is at minimum level. High resistance to chemicals. Minimum service life is 50 years.
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3.6.2
HDPE-Tanks
Polykun HDPE- piping system incorporates the production of cylindrical, vertical and horizontal tanks with diameters ID 300 mm to ID 4000 mm. The tanks are available together with any kind of inlet and outlet nozzle connections, covers, valves, etc. In standard manufacture, HDPE tanks are in the capacities between 2000 to 75000 liters. The material of construction for HDPE tanks allows the resistance to chemicals, suitable to storage of any kind of solid and liquid foodstuff, thanks to the hygienic properties. The internal and external tank surfaces are smooth and the various internal surface colors are also available. The wall thickness of the tanks manufactured from HDPE between 5 mm to 100 mm maximum and with different wall thickness in one pipe to save material. The tanks manufactured from HDPE are resistant to UV by the virtue of the dark material of construction and suitable for outdoor applications. The tanks manufactured from PP are in light colors and suitable only for indoor applications away from the sunlight.
Figure 17: HDPE tank with steps wall tickness The major field of applications of HDPE tanks: Water storage (especially indoor tanks). Storage of liquid foodstuffs. Storage of cereals and beans. Storage of industrial powder chemicals. Storage of waste disposal area. Water treatment plant. Acid tanks and others chemicals Storage of mineral oils.
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4. HDPE PIPE CONNECTION HDPE pipes are available to suit any kind of pipe connections, thank to the properties of HDPE used as material of construction. The connection method of HDPE pipes is mainly determined on the basis of field of application. 4.1 Welded connection 4.1.1. Electro-fusion Welding Method The pipes connected with this method usually incorporate bell (socket) and spigot supplemented by electro-fusion welding over outer end inner circumference of the pipe. Special alloy welding electrodes used for electro-fusion welding are inserted into the bell to prevent deformation and the welding machine welding leads are left free to enable the welding operation under any working conditions. HDPE-profiled pipes suitable for electro-fusion welding range between the pipe sizes from ID 300 mm to ID 4000 mm.
Figure 18: HDPE-profiled pipe section indicating bell (socket) and spigot connection supplemented by electro-fusion welding Pipes Electro-fusion Welding Machine The specification of welding machine used in welding of HDPE-profiled pipes are as follows: Output power Input voltage Output voltage Operating temperatures 3,5kW 380 V 15-48 V Up to 50oC
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The precautions to be observed in welding operations of HDPE profiled pipes with electro-fusion methods are given as below: The welding area needs to be clean , dry, the welding area should be protected against sunlight to prevent the contamination, the welding operation should be performed in the ambient temperatures over 5C. Any package material within the socket and spigot end should be removed in advance of the welding operation. Any failure of the removal of the packaging material in advance the welding operation would result the contamination. The portion of the pipe that will be welded should be completely treated with cleaning agents or industrial type of alcohol prior to welding operation.
Figure19: Required tools for the electro-fusion pipe welding The portion of the spigot that will be inserted into the socket of the adjacent pipe should be measured prior the erection and the insertion of the pipes one into another should be made in accordance with these measurements. The welding point should be axial and vertical to pipe axis and without an angle laying in the bedding. Turn the HDPE-pipe for the welding contacts are up (at 12 o ,clock position) HDPE-profiled pipes, bigger than DN 800 come with a pressing ring, what needs to be installed inside, close to the welding area as indicated in the above drawing. Wall connection will come in all dimensions more than DN 300 with a tightening strap. Put the tightening strap in the for this made groove on the socket, tighten it with the special toll until there is no slit between the socket and the spigot end. If necessary, tighten it during welding. The resistance leads must be carefully inserted into the adapter and tightened by screwing in that way, that there is no tension from the cables weight. It is very important, that there are no forces on the welding wire coming from the connected cables during welding. . The welder should insert the barcode card with the reading pen. Start the welding with the showed instructions on the welding machine.
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After welding, disconnect the welding machine and adapter from welding wire. During cooling down, keep the tightening strap and the pressing ring (bigger as DN 800 mm) in place. Do not move the pipe during this time. It is very important to keep the cooling time. The tightness test of the pipe welding should be performed in advance the removal of the pipe upper welding filling. Important: During the welding and cooling time do not move the pipe at all! Table 10: Electro-fusion welding parameters Welding Preheat Intervals ID mm 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 Welding Voltage 22 25 28 32 35 38 42 45 48 48 48 48 Preheat Interval 800 800 800 800 800 800 800 800 800 860 920 980 Electro-fusion Welding Parameters of HDPE-profiled Pipes (ID 500-1600 mm) ID Welding Welding Period (second) 30 oC 20 oC 15 oC 10 oC 5 oC mm Voltage 500 22 1080 1200 1320 1450 1500 600 25 1080 1200 1320 1450 1500 700 28 1080 1200 1320 1450 1500 800 32 1080 1200 1320 1450 1500 900 35 1080 1200 1320 1450 1500 1000 38 1080 1200 1320 1450 1500 1100 42 1080 1200 1320 1450 1500 1200 45 1080 1200 1320 1450 1500 1300 48 1080 1200 1320 1450 1500 1400 48 1080 1200 1320 1450 1500 1500 48 1080 1200 1320 1450 1500 1600 48 1080 1200 1320 1450 1500
The preheating should be applied on the pipes to be welded, as shown in the table above, in case of the ambient temperature of the welding location is lower than 5 C. Except under extreme conditions, welding operation under the ambient temperature below 5C is not recommended.
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4.1.2. Butt Welding Method The precautions for the welding operations on HDPE solid pipes are as follows: The ambient temperature of the welding location should not be lower than 5 C. The pipes to be connected should have the same wall thickness, or otherwise the difference between the wall thicknesses of two pipes should not be higher than 10%. Prior welding preparation, the surfaces to be welded must be ground to remove any oxidation formed and the full contact of the welded surfaces must be ensured. Prior welding operation, the welding edges should be cleaned with industrial type alcohol. The temperature of the heating element must be in the rage of 200-220 C. upper and lower limits indicated for the thinnest and thickest pipes, respectively. Upon the commencement of the welding operation, the tensioning of the piping during overall quenching period must be kept constant. The welding pressure test of HDPE pipes sanitary sewer piping according to DIN 16961 and pressurized potable water piping should be based on DIN 4279.
Figure 20: Butt welding machine
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The important welding parameters will be calculated as follows:
. Calculation of the welding area:

A pipe = Or di 2 4 = dm s
2
(da
(mm2) (mm2)
A pipe : Pipe welding area (mm) da : Outside diameter (mm) di : Inside diameter (mm) dm : Mean diameter (mm) s : Wall thickness (mm)
. Calculation of welding force

F = p specific A pipe (N) F: Required welding force (N) P specific : Specific welding pressure for PE = 0,15 N/mm2 for PP = 0,10 N/mm2
Figure 21: Butt welding process
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. Calculation of joining pressure

p weld = ( F An ) + p movement
i =1 n
P weld : joining pressure an cooling pressure (N/mm2) An : The Sum of hydraulic cylinder area of the welding machine (mm2) P movement: the movement pressure of the welding machine (N/mm2) Table 11: Optimum welding parameters of HDPE pipes under 20C ambient temperature Wall Thickness (mm) . 4,5 4,57 712 1219 1926 2637 3750 5070 Bead height (mm) By P weld 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 Pre-Heating time by 0.02 N/mm (sec) 45 4570 70120 120190 190260 260370 37500 500700 Adjusting time (sec) 5 56 68 810 1012 1216 1620 2025 Joining pressure Build-up time (sec) .5 56 68 811 1114 1419 1925 2535 Cooling time (minutes) .6 610 1016 1624 2432 3245 4560 6080
4.1.3. Extrusion Welding
Extrusion welding is a manual or semi-mechanized welding process for the joining of thick-walled parts. The pipes having plain connections without a bell/socket can also be the extrusion welding, however, such connection type is exclusively used for HDPE pipes within special project applications for the fabrication of the elbow, tee and the relevant other fittings, including special applications like manhole, tans, etc. The extrusion welding is generally used for the low-pressure gravity pipes. The welding quality depends upon proper weld preparation, cleanliness during handling, heating of filler and faces to be joined. The welding factor according to DVS 2207/4 will be achieved at least: - Short-time welding factor for HDPE : 0,8 - Long-time welding factor for HDPE : 0,40,6
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Figure 22: Extrusion welding The extrusion welding machines, although operating with the same principle, are two types: Hot air spraying welding machines with electrodes Hot air spraying welding machines spraying granular hot extrusion raw material. This is performed (extrusion welding) on the basis of DVS -2207 standard.
Figure 23: Extrusion welding possibilities

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The precaution of the extrusion welding operation of HDPE pipes or fittings are as follows: The ambient temperature of the welding location should not be lower than 5 C. In no case the extrusion welds are used for gas piping and high pressurized potable water piping. The material to be welded and the welding electrode should be of the same material. The surface of the welding areas should be very clean and any surface oxides should be removed prior the welding operation.
Table 12: DVS 2207 extrusion welding parameters
Welded Part Material HDPE PP
Welding Force (N) 2530 2530
Heat Rating of Hot Air (oC) 300350 280330
Quantity of Hot Air (l/min) 4060 4060
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4.2. Mechanical connection 4.2.1. Rubber sealing connection
The HDPE-profiled pipe consist of integrally formed socket and spigot, the spigot end is designed to accommodate a gasket, which when assembled forms a watertight seal by the radial compression of the gasket between the spigot and the socket ends. Profiled pipes of the connection type of bell and spigot with gaskets are available in accordance with DIN 16961 and astm F 894. The gaskets used within the gasket type connections are produced from EDPM rubber under the specifications of DIN 4060 and EN 681. Standards.
Figure 24: Sectional view of bell and spigot with groove to assembly the gasket
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4.2.2. Flange Connection
HDPE-profiled pipes are also available to incorporate the flange connections in conformity with the specifications given under DIN 16961. This type of connection is preferred for open sea discharge applications, tank connections, for the connections including different materials. The major advantage of the flange connection is the ease of the dismantling. The flanges used for the flange connections are manufactured from galvanized steel or stainless steel in conformity with the specifications given under DIN 2573 and DIN 2576. The flange adapters are manufactured complete with the piping, however, the flanges are also available as independent fitting for welding operations to be performed at the construction site. Flange end of the flanged pipes are manufactured either centered slip-on bell type or plain end. EPDM rubber plain gaskets are used for the connection of the plain end pipes, which are manufactured in conformity with DIN 4060 and EN 681. On the other hand, centered flanged connections can accommodate either the same gasket or the tightness is obtained by the welding operation in accordance with the electro-fusion method applied inside the pipe without using any gasket.
Figure 24: Profiled pipe with flanged connection
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5. Installation of HDPE/ PP Pipes 5.1 Pipe in trenches
Plastics pipes are flexible. When loaded a flexible pipe deflects and presses into the surrounding material. The amount of deflection which occurs is limited by the care exercised in the selection and laying of the bedding and side fill materials. In case of rigid pipes, the load on a pipe is borne primarily by the inherent strength of the pipe material and when this load exceeds a limiting value the pipe breaks. Flexible pipes on the other hand deflect under load and can be deflected to a high degree without fracture. The level of deflection reached by a buried pipe depends on the properties of the surrounding material and to a much less extent on the stiffness of the pipe.
5.1.1 Choice of pipe ring stiffness
The choice of pipe ring stiffness shall made either using the below tables according to EN 1046 or in the basis of static calculation in accordance with ATV A 127 guidelines of German Association for water, wastewater and waste or on the basis of previous experience. If such experience is not available then the minimum stiffness required shall be selected from table and table . These tables are prepared to cover the following conditions: a) Non-trafficked areas with depths cover between 1 m and 6 m. b) Trafficked areas with depths cover between 1 m and 6 m.
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Table 13: Recommended minimum stiffness for non-trafficked areas Backfill CompactionMaterial Class 2) 3) Group Pipe ring stiffness 1) For depth of cover 1 m and 3 m Undisturbed native soil group 3) 1 2 3 4 5 W 1250 1250 2000 2000 4000 1 M 1250 2000 2000 4000 5000 N 2000 2000 2000 4000 8000 W 2000 2000 4000 5000 2 M 2000 4000 5000 6300 N 4000 6300 8000 8000 W 4000 6300 8000 3 M 6300 8000 10000 N *** *** *** W 6300 8000 4 M *** *** N *** *** For depth of cover > 3 m 6 m 1 W 2000 2000 2500 4000 5000 M 2000 4000 4000 5000 6300 2 W 4000 4000 5000 8000 M 5000 5000 8000 1000 3 W 6300 8000 10000 M *** *** *** 4 W *** *** M *** *** 1) Pipe ring stiffness in N/m2 according to ISO 9969 2) See table 3) See table **) Structural design is necessary to calculate the pipe stiffness
6 5000 6300 10000 5000 6300 *** 8000 *** *** 8000 *** *** 6300 8000 8000 *** *** *** *** ***
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Table 14: Recommended minimum stiffness for trafficked areas Backfill CompactionMaterial Class 2) Group 3) Pipe ring stiffness 1)
For depth of cover 1 m and 3 m Undisturbed native soil group 3) 1 2 3 4 5 1 W 4000 4000 6300 8000 10000 2 W 6300 8000 10000 *** 3 W 1000 *** *** 4 W *** *** For depth of cover > 3 m 6 m 1 W 2000 2000 2500 4000 5000 2 W 4000 4000 5000 8000 3 W 6300 8000 1000 4 W *** *** 1) Pipe ring stiffness in N/m2 according to ISO 9969 2) See table 3) See table **) Structural design is necessary to calculate the pipe stiffness
6 *** *** *** *** 6300 8000 *** ***
5.1.2 Compaction degree and Methods
The degree of compaction can be varied by using different type of equipment and by varying the numbers of layers. The table . gives for groups of material classified in conformance with table( soil group) the degree of compaction expressed in Standard Proctor Densities ( SPD) for the three classes of compaction W, M, and N. Table 15: Standard Proctor Densities ( SPD) for compaction classes Compaction class N M W Description Not Moderate Well 4 SPD % 75 to 80 81 to 89 90 to 95 Backfill material group 3 2 SPD SPD % % 79 to 85 84 to 89 86 to 92 90 to 95 93 to 96 96 to 100 1 SPD % 90 to 94 95 to 97 98 to 100
Table 16 Gives the recommended maximum layer thickness and the number of passes required to achieve the compaction classs for the various type of equipment and pie zone materials. Also included the minimum cover thicknesses required above the pipe before the relevant piece of equipment can be used over the pipe.
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Table 16: Recommended layer thickness and number of passes for compaction Equipment Number of passes Maximum layer thickness, Minimum for compaction in meters, after thickness over class compaction for soil group pipe crown before compaction Well Moderate 1 2 3 4 m
Foot or hand tamper min. 15 kg Vibrating tamper min. 70 kg Plate vibrator min. 50 kg min. 100 kg min. 200 kg min. 400 kg min. 600 kg Vibrating roller min. 15 kN/m min. 30 kN/m min. 45 kN/m min. 65 kN/m Twin vibrating roller min. 5 kN/m min. 10 kN/m min. 20 kN/m min. 30 kN/m Triple heavy roller ( no vibration) min. 50 kN/m 3 3 4 4 4 4 4 6 6 6 6 6 6 6 6 6 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 0,15 0,30 0,10 0,15 0,20 0,30 0,40 0,35 0,60 1,00 1,50 0,15 0,25 0,35 0,50 0,25 0,10 0,25 0,10 0,15 0,20 0,25 0,25 0,50 0,75 1,10 0,10 0,20 0,30 0,40 0,20 0,10 0,20 0,10 0,15 0,20 0,20 0,30 0,40 0,60 0,15 0,20 0,30 0,20 0,10 0,15 0,10 0,15 0,20 0,30 0,15 0,15 0,20 0,30 0,50 0,60 1,20 1,80 2,40 0,20 0,45 0,60 0,85 1,00
5.1.3 Material of pipe zone and remaining backfill
The material of the pipe zone dependent upon the pipe stiffness, the depth of cover and the nature of the native soil. Where imported material is used for the pipe zone it is recommended that a well-graded granular material with a maximum particle size in conformance with Table 17 used. Where single-sized material is used it is recommended that the maximum particle size should be one size smaller than that given in Table 17.The native soil may be used for the pipe zone backfill providing it conforms to all of the following criteria:
a) b) c) d) No particles greater than the applicable limit given in Table 32 No soil lumps greater than twice the applicable maximum particle size given in Table32 no frozen material; no debris ( e.g. asphalt, bottles, cans; trees); Where compaction is specified, the material shall be compactable.
e) Table 17: Maximum particle size according to EN 1046 Nominal diameter Maximum size DN mm 100 DN 300 20 300 DN 600 30 600 DN 40
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Table 18: Soil group in accordance with EN 1046

Soil group Symbol (GE) [GU] [GW] (GI) [GP] (SE) [SU] [SW] (SI) [SP] [GM] (GU) [GC] (GT) [SM] (SU) [SC] (ST) [ML] (UL) [CL] (TA) (TL) (TM) [OK]
Soil type Granular
# 1
Typical name Single-sized gravel Well-graded gravels, gravelsand mixtures Poorly graded gravel-sand mixtures Single-sized sands Well-graded sands, sand-gravel mixtures Poorly graded sand-gravel mixtures zones Silty gravels, poorly graded gravel-sand-silt mixtures Clayey gravels, poorly graded gravel-sand-clay mixtures Silty sands, poorly graded sandsilt mixtures Clayey sands, poorly graded sand-clay mixtures Inorganic silts, very fine sands, rock flour, silty or clayey fine sands Inorganic clay, distinctly plastic clay
Example(s) Crushed rock, river and beach gravel, scoria, volcanic ash
To be used as backfill YES
Dune and drift sand, valley sand, basin sand Morainic sand, terrace sand, beach sand Weathered gravel, slope debris, clayey gravel Liquid sand, loam, sand loess Loamy sand, alluvial clay, alluvial marl Loess, loam Alluvial marl, clay
YES
granular
YES
Cohesive
YES
Organic
[OL] Sea chalk, top soil (OU) Organic clay, clay with organic [OH] Mud, loam admixtures (OT) 6 Peat, other highly organic soil [Pt] Peat (HN) (HZ) Muds [F] Muds * The symbols used are taken from two sources. Symbols in square brackets [..] are taken from British Standard BS 5930. Symbols in round brackets (..) are taken from German Standard DIN 18196.
Mixed grained soils with admixtures of humus or chalk Organic silt and organic clay
Top soils, chalky sand, tuff sand
NO
NO
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5.1.4 Type of installation
The two most commonly used practices for the installation of plastics pipes are either to surround the pipe with the same material (see Figure 25) or splitting into two materials (see Figure 26). The use a split embedment is normally only found to be practical with pipes of nominal sizes greater than DN 600.
1 Pipe zone 2 2 Bedding
bs
Figure 25: Trench with full surround pipe zone
1 Split level 2 Secondary pipe zone backfill 3 Primary pipe zone backfill 0,5de height 0,7 de 4 Bedding 5 Invert
4 5
Figure 26: Trench with spilt surround pipe zone

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5.1.5 Parallel piping systems
In case of parallel piping systems laid with a stepped trench (see Figure 27) the pipe zone backfill material shall be granular and shall be compacted to compaction class W.
1 well compacted (class W)
Figure 27: Parallel pipes in a stepped trench
5.1.6 Trench width
The width of the trench at the spring line of the pipe need not be greater than necessary to provide adequate room for jointing the pipe in the trench and compacting the pipe zone backfill at the haunches. Typical values for bs (see table19) are given in table . Table 19: Typical values for bs
Nominal size DN DN 300 300 DN 900 900 DN 1600 1600 DN 2400 2400 DN 3000 bs mm 200 300 400 600 900
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5.2 Application of HDPE-profiled pipes 5.2.1 Sewer and Storm Water Lines
Figure 28: HDPE Storm water pipe line in Kuwait
Bild 29: HDPE Sewer pipe line in Tripoli
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5.2.2 Sea outfall and intake pipes
The effluent waters and the sanitary sewer lines are generally released to open sea discharges. The open sea discharge of he effluent waters and the sanitary sewer lines should be performed upon the treatment of the effluent and sanitary sewer water through specific water treatment process to process them to be discharged to the sea to prevent any further pollution of the sea and endangering the underground sea life. For such critical applications, the practical and reliable solutions are permanently provided by HDPE piping in a most economic way. The effluent water, after being treated within the water treatment plant is discharged to the open sea via the pipe installed on the sea bed after a final manhole installed prior the entry of the water. Being lighter than the sea water, HDPE piping is sunk into the water by concrete blocks fixed onto the piping at specified intervals. The piping sections for the open sea discharge are prefabricated at 250 m to 500 m in lengths at the sea shore, plugged with the blind flanges at the ands, floated on the sea surface and transported at the installation location in the sea. The floating piping sections are connected to each other onto the sea to the interconnection points at the land. The floating pipes with the air entrapped inside are sunk into the seabed by replacing the air with the sea water. In order to prevent the sedimentation of the effluent water towards the end of the piping, the diffuser should be incorporated at the discharge point. The diffuser exits are provided at 120 intervals with respect to the pipe section. Special diffusers are provided for the critical project, which are equipped with filters.
Figure 30: HDPE-sea outfall piping during sinking procedure in Turkey
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Figure 31: Sea intake pipelines in UEA

5.2.3 Relining
The construction of the infrastructure is proved to be difficult and time consuming. There is always the possibility of encountering the unexpected occurrences during the application of the project. In most cases, the installation of the pipe should be performed within narrow and confined areas, where the excavation operations are almost impractical. Such problems are usually encountered during the renovation works performed within the settlement areas, which include the demolishing of the existing building to construct multistory buildings. In some cases, the infrastructure system must be replaced in any event that it is out use due to the collapsing, blockage, or any other similar reasons or becomes insufficient in capacity. In such cases, HDPE-profiled pipes are inserted into the existing piping systems via long pipe or short pipe relining method. Since the friction losses of HDPEpipes are much lower than the conventional concrete pipes, the existing concrete piping system can be utilized via relining of profiled pipes, thus the renewal of the infrastructure can be accomplished without any excavation operation. Consequently, the permanent solution of the infrastructure can be achieved. During relining operation, HDPE-profiled pipes are inserted into the existing piping via excavating down to the beginning of the existing pipe run. The profiled pipes are further driven via continuous driving and welding the pipes one into another. The most important factor to have reliable operation of the system over prolonged service life is to perform suitable lining operation by injecting concrete into the gap between the profiled pipes and the existing concrete pipe, upon completion of the installation of HDPE-profiled pipes.
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Figure 32: Long pipe relining with HDPE-profiled pipe in Istanbul
5.2.4 Landfill drainage systems
The huge mountains of the solid waste garbage of the household disposal is a phenomenon specific to the contemporary industrialized societies undergoing rapid development of industry, together with the high rate of increase of the population. In addition to the danger faced by the society due to the huge garbage wastes for human health, the ground water resources that are eventually diminishing are under the risk of the pollution. The most reliable solution accepted throughout the contemporary societies and in our country is disposing the waste solids within the waste disposal areas, collecting and treating the leaking effluent waters, disposing or recovering the generated methane gases within power plants. The appearance pollution is further eliminated by covering the waste disposal areas with the water tight soil and vegetation to be provided on the soil covered on top of the area thus insulated. The solid wastes include many chemical substances, in addition to formation of many chemical via decomposition. This process continues for years. Therefore, HDPE is ideal for resisting the load imposed on the heavy garbage wastes and the chemicals formed by decomposition.
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HDPE pipes are reliably used under the conditions stipulated by DIN 16961 both in collecting of the leaking effluent waters and the disposal of methane gases. The conditions of the installation and the operation of the pipes to be used for the collection systems are established in conformity with DIN 19677, while the tightness test and inspections are conducted as per DIN 4266.
Figure 33: HDPE-manhole using for landfill drainage in Germany
5.2.5. Lined pipes
Gravity sanitary and storm sewer lines are the most common type of underground infrastructure system installed by micro tunneling or so called pipe jacking operation. The pipes used for jacking is nonpressure applications as most often lined with GRP, UPVC and HDPE-sheets. All these pipe material have a substantial installation history in sewer application. But these methods are prone to failure due to the disbanding of the liners used. By using a HDPE-profiled pipes as a lining instead of HDPE-sheet due to its excellent bonding property to concrete. Furthermore, in case of the concrete pipe wall cracks , the HDPE profiled pipe used as liner will hold. The jacking concrete pipes lined with HDPE- profiled pipes are manufactured according to DIN 4032 or 4035 and with high quality guideline requirements. The jacking pipes are being used for sewage and drainage piping system.
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Figure 34: View of jacking pipes lined with HDPE- profiled pipe
Figure 35: Section of jacking pipe lined with HDPE-profiled pipe
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5.2.5.1. Joint of the pipes
All jacking pipe should have these characteristics: . Gasket-sealed joints are needed to facilitate rapid assembly. . Flush joints are important (joint OD same as OD of pipe barrel) see Fig.52 . Smooth outer surface is needed to reduce jacking force. In Spigot of the HDPE pipes is a groove with a width of 52 mm and depth to insert the rubber seal. The seal is designed primarily for concrete pipes application. The seal is compressed when the pipe spigot is inserted into the socket.
Figure 36: RCC pipe lined HDPE-profiled pipe with inner and outer gasket-seal The special design of the seal gives: . Low assembly force . Excellent sealing capability under loads . Watertight seal connection up to 3 bars (30 m water head) . Good distribution The spigot seal meets and exceeds the requirements of the new standard prEN1961. Material: . EPDM . Hardness 40 . Approved in accordance with EN 681-1 . Protected against ozone
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Figure 37: The outer joint with steel or GRP sleeve
Figure 38: Section of the joint the jacking pipe lined with HDPE-profiled pipe
1) HDPE liner spigot & bell type 2) Internal point in HDPE liner with EPDM sealing rubber ring.. 3) 18mm thick peaking ring (chip wood) in between the concrete surface of two pipes. 4) Reinforcement, 1 or more steel cages according to the requirement of the pipe dia. 5) GRP/steel sleeve for outer joint of pipes. 6) EPDM sealing rubber for outer joint of pipes. 7) Concrete.
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5.2.5.2.
Requirement and Tests
The specification, requirements and test methods for the HDPE lined RCC jacking pipes are contain in the following standard: 1. 2. 3. 4.
Proof load test according to the test method BS 5911 part 120, the result of the test should be no cracks developed in the pipe wall. Ultimate load test according to the test method BS 5911 part 120, the result of the test shall be no separation of the HDPE liner from the wall of the pipe. Cover to reinforcement according to the test method BS 5911 part 120, the concrete cover of the second steel reinforcement should be at least 30 mm. Joint water tightness test according to the test method BS 5911 part 120, the required test pressure should be 3 bars.
5.2.5.3. Advantages of jacking pipes lined with HDPE-profiled pipes
The advantages of jacking pipes lined with HDPE-profiled pipes over the conventional lined materials methods (likes GRP, PVC or HDPE- sheet) as follows: 1) Our lined pipe is one unit, without any weld ( Weak point with a liner in the welding, welding factor from 0,8 by butt welding according to DVS 2207/1), in order to do circular shape by using HDPE or PVC-sheets. 2) HDPE-pipes have bright inner surface as yellow or any required color. This kind of color ensures inspection friendliness. 3) The joint well be gasket rubber sealing, there are no welding. By any welding Methods ( Extrusion welding according to DVS 2209 or warm gas hand welding according to DVS 2207/3 or overlap welding according to DVS 2225/2) are depended on cleanliness and personals skill). The working conditions 30 m under ground are not comfortable to do any of the above mentioned welding methods. 4) By using HDPE-profiled pipe it is possible to do any required ring stiffness in order to resist the under ground water pressure in case of cracks or any damages in the wall of the concrete pipe.
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6. HDPE Pipe Storage and Transportation
HDPE pipes and manholes should be handled carefully during the transportation and storage. Since they are elastic in nature, they are mostly effected from impact loads, rather than falling on the ground or rolling over. To this effect, the following precaution should be observed for the storage, loading and transportation of HDPE profiled pipes.
6.1. Storage Methods
Figure 39: Stockpiling and Telescopic Storage HDPE profiled pipes should be stored away from the direct sunlight, preferably under the shelter or enclosed areas. Prolonged storage within warm and completely enclosed places should be avoided. Maximum period of storage under direct sunshine is half year. The storage area should be free of sharp and hard objects like stones, etc. The relevant measures should be observed within the storage area, since the material of construction of HDPE pipes is combustible. Stockpiling of pipes stored in telescopic method should be avoided. Telescopic pipes should not be stockpiled. Up to 3 crosswise stockpiling is permitted for the pipes up to ID 600 mm. The bells of the pipes should be alternatively placed during stockpiling. Up to 2 crosswise stockpiling is permitted for the pipes between ID 600 mm to ID 1000 mm. The bells of the pipes should be alternatively placed during stockpiling. No stockpiling is permitted for the pipes over ID 1.000 mm.
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6.2. Transportation Methods
HDPE profiled pipe pipes are packed to protect the bell and spigot ends of the pipes. Care should be exercised to prevent the welding edges within the bell and spigot. HDPE profiled pipes are available as standard in 6 mm lengths. The lifting ropes should be used for the loading and installing into pipe trench. They should be simultaneously hanged on both hands with textile ropes. The handling with fork lifts should be performed carefully to extend the forklift legs outwards as much as possible, avoiding hard impacts. The end of the pipes are accurately machined to avoid any problem during the welding operation at site, therefore, care should be observed during the handling of the pipe to prevent damaging of the ends of the pipe, pipe ends should be carefully rested onto the vehicle box during loading. The precaution should be observed to prevent the side stays of the vehicle box to induce any damage on the pipe, textile ropes should be used to clamp the pipe on the box of the vehicle, tied at the middle and end of the pipe. In no case the loads are carried away by pulling the pipe on the ground, they should be roller over on smooth surfaces without inducing any damage to the pipe. Care should be exercised to prevent abrasion of the pipes during the inserting the pipes one into another for telescopic loading. The bell portions should be located at alternate locations. The protection of welding edges at the pipe ends should be exercised. The bells of the pipes should be alternatively located onto the vehicle. The simultaneous installation of the pipes having different pipe sizes at the construction site will allow telescopic loading that greatly contributes to the transportation. This should be taken into consideration during the working scheduling of the site construction.
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7. HDPE Pipe Manufacturing, Test Methods and Quality Control
Profiled pipes manufactured from HDPE and PP feature high quality levels. All tests anticipated within the relevant standards are implemented at every stage of the production starting right from the introduction of the raw materials. The results of the tests are continuously monitored and the relevant documentation regarding the welding operations performed both by us and by the end user is taken into consideration. The service life of HDPE-profiled pipes which are proved to be successful during the tests performed for 1 minute, 24 hours and 2000 hours as per DIN 19537 is 50 years minimum.
Test Methods of HDPE-profiled pipes The following monitoring and tests operations are performed on profiled pipes performed at every stage of the production starting right from the introduction of the raw materials are as follows: a) Raw materials test and relevant standards The raw material and any other new delivery of material is tested before it is stored. Every test is documented and filed. The following tests are required or from raw material supplier submitted for each new HDPE incoming raw material:
Table 20: Characteristic of HDPE raw material

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 54 Characteristic Density Modulus of elasticity @ 23oC Modulus of elasticity @ 40oC Tensile strength at yield @ 23 oC and 50 mm/min Elongation at break Thermal Stability @ 200oC (OIT) Oxidation Induction Time Vicat Softening temperature under 1 kg Shore hardness type D Melt flow rate Coefficient of linear expansion Coefficient of thermal conductivity Flexural creep modulus Resistance to liquid Chemical Resistance to internal pressure with hoop stress 3.9 Mpa at 165 h at 800C Resistance to internal pressure with hoop stress 2.8 Mpa at 1000h at 800C ESCSR (Environmental Stress Crack Resistance), FNCT (Full Notch Creep Test) U.V. Stabiliser ( Carbon Content) Long Term Chemical resistance for 10000h Test Method ASTM D1505 ISO 1183 EN/ISO 527-2 EN/ISO 527-2 ASTM D638 ISO 6259 ASTM D638 EN 728/ ISO 10837 ASTM D1525 ISO 306 ASTM D2240 ISO 1133 ASTM D1204 DIN 8075 ASTM D790 ISO 527 ISO 4433 EN 921 EN 921 ASTM D1693 ISO 16670 ISO 13477 ASTM D3262 Requirements 941 kg/m3 800 N/mm2 650 N/mm2 21 N/mm2 350 % 20 minutes 120oC 60 0,40,6 g/10min 0,160,2 mm/m. K 0,6 W/m K 758 N/mm2 As per standards No failure No failure 600 hours 2% As per standards Responsibility Raw Material Manufacturer Raw Material Manufacturer Raw Material Manufacturer Q.C. Laboratory Q.C. Laboratory Q.C. Laboratory Raw Material Manufacturer Q.C. Laboratory Q.C. Laboratory Raw Material Manufacturer Raw Material Manufacturer Raw Material Manufacturer Raw Material Manufacturer Q.C. Laboratory Q.C. Laboratory Q.C. Laboratory Raw Material Manufacturer Raw Material Manufacturer
b) Product test and relevant standards
After production, the final product should be tested and compared to the requirements of the customer. The required tests as follows: Table 21: Characteristic of HDPE-profiled pipes:
1 2 3 Characteristic Pipe dimensions Marking and color Appearance and surface finish Test Method EN 13476-1 DIN 16961 EN 13476-1 EN 13476-1 Requirements As per standards As per standards Visually inspected, internal surface shall be smooth and external surface shall be clean and free from grooving or any other surface irregularities Per standard 13476-1 No cracks or deformation No cracks No cracks Sag 5% 4% No leakage No leakage 9% vertical deflection Frequency Every 100 pipes Every pipe Every pipe
4 5 6 7 8 9 10 11 12 13
Pipe stiffness at 23oC for 5% and 10% deflection Ring stiffness Impact resistance Ring flexibility Oven test (resistance to heating) Longitudinal bending test Creep ratio Tightness of electro-fusion joint Tightness of elastomeric sealing ring joint Resistance to combined temperature Cycling & External loading
ASTM D2412 EN/ISO 9969 EN 744 EN 1446 ISO 12091 WIS4-35-1 EN/ISO 9969 DIN 16961 DIN 16961 EN 1277 ISO 1437
Every 1000 pipes Each size every 300 pipes Every 1000 pipes Every 600 pipes Every 600 pipes Every 1000 pipes Once every year Once every year/size Once every year/size Once every year
b) Application test and relevant standards
During the install of the pipes and after finishing the following tests are required: Table 22: Characteristic of HDPE- pipeline
Characteristic 1
Tightness test of sealed or welded joint Deformation test Backfilling compactness test
Test Method DIN 16961 EN 1277 ATV A127
Requirements No leakage at 500 mbar
Frequency Once every day
2 3
3% after 24 hours
Once Once every day
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8. HDPE Pipe Sample Purchase Tender

8.1. SUBJECT This technical specification defines the technical and physical properties of sanitary sewer piping manufactured from HDPE piping to be used gravity piping within sanitary sewer pipeline. We recommend the following tender texts.
8.2. GENERAL PROVISIONS
1. The diameters specified for profiled HDPE piping shall refer to internal pipe diameter. The pipe sectional view and the relevant definitions are as follows. 2. The pipes with ID 300 mm to ID 4000 mm shall be manufactured in 6.0 m in lengths, excluding the length of the bell, in accordance with DIN 16961 Part 1 and Part 2 and ASTMF-894 standards. 3. The material of construction to be used in manufacturing of piping shall be black PE 4. The internal surfaces of the pipe shall be in light colors via co-extrusion technology to facilitate ease of inspection. 5. During extrusion the spiral band is curled on a winding tool and melted together by overlapping. At the same time the reinforcement profile is extruded and exactly laid over the lap joint of the band so that together with the bad the profile forms a homogeneous pipe wall. 6. The specified material specifications shall be complied during the test and inspection to be conducted upon the completion of the manufacturing. In addition to the relevant standard for the tests, the equivalent international standards for the raw material and the final products shall be also referred. In such case, the manufacturing shall be performed in conformity with the standard referred. 7. The square ness of the pipe edges shall be within the specified tolerances, pipe surfaces shall be free of any swelling and gaps, the texture shall be homogenous. The minimum tolerances shall be complied during the test performed on the pipe walls for the wall thickness. The pipes shall be free of any kind of defects like sharp edges, burrs, etc. 8. The bell and spigot wall thickness shall be in conformity with the specified dimensional tolerances, the wall thickness shall be homogenous. The allowance between the outer diameter of the spigot and the inner diameter of the bell shall be 2 mm maximum. In order to ensure the smooth joining of the pipes, the end of the bell and the spigot shall be cut at 45 in opposite directions, respectively. 9. The pipes shall be manufactured suitable for the electro-fusion welding, via inserting the welding wire or by sealing joint by inserting EPDM gasket into the groove of the spigot end without any damage induced onto the bell or spigot of the pipe. The manufacturer shall supply the parameters for the welding operation.
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8.3. MATERIAL TESTS
The following test shall be conducted during the inspection and the acceptance test of HDPE pipes. These tests shall be performed in the manufacturers laboratory. Any other tests that cannot be performed by the manufacturer shall be made by the independent party to be approved by the client. If required, the client shall be entitled to have the test performed by an independent testing party.
1. Raw Material Tests HDPE Pipe Specifications Material Pipe Outside Color Pipe Inside Color Density of Raw Material Melt flow rate (190/5) Tensile Strength Elongation Amount of Carbon Black Required Test Method
HDPE PE 80 or 100 Black Light color 0.94 grams/cm 3 0.15 0.40 gram/10min 21 MPa 350% 2 3%
ISO 1183 & ASTM D1505 ISO 1133 ASTM D 638 ASTM D 638 ISO 6964
2. Product Tests Tests Dimension & Tolerance a) Internal diameter of pipe b) Length of pipe c) Profile height d) Pitch of profile e) Waterway wall thickness Ring Stiffness Impact Test Ring Flexibility Tightness Test a) Electro fusion joint b) Electrometric sealing ring joint Required As per standard Test Method DIN 16961
2 125 kN/m2 No Cracking 30% No leakage
DIN 16961 EN 744 EN 1446 EN 1277
57
9. HDPE-profiled pipe and manhole questionnaire
58
9.1. Questionnaire for buried pipes Technical questionnaire for design calculations of the pipes as per ATV 127 standard 1. PROJECT Date Site address Contractor Person in charge of the project Phone 2. PROFILED PIPE Profile pipe (PR) SQ- pipe (SQ) Solid wall pipe (VW) 3. PIPE LOADS Fluid Density of fluid Average temperature Operating pressure Service life Traffic load
Fax ......Pipe ID:.....mm ......Pipe OD:.....mm ......Wall thickness (s):.....mm ................................................ ... g/cm3 Maximum working Temperature (Tmax)...... oC .....bar (gravity pipe, if not given) 50 years No ,HLC 60,.HLC 30, HGV 12 .....kN Yes/ No ......m from invert of the pipe
Other loads ground water Level of ground water
59
4. INSTALLATION DATA
Pipe trench: Trench width (b):mm Trench inclination mm Cover height (h)..mm
Height above the pipe (h)

Pipe installation conditions
Bedding conditions A1 A2 A3 A4
B1 B2 B3 B4 180o others:....
Laying angle 2 ......... 120o Note: Recommended figure 180 Bedding form: loose firm
5. Soil Conditions E1 Group E2 E3 E4
G1 loose (sand, gravel) G2- lightly bonded (sand, gravel) G3 mixed land bonding, muddy G4- clay, wet clay Degree of compacting 90% - 100%, Dpr% ..%
G1 G2 G3 G4
G1 G2 G3 G4
G1 G2 G3 G4
G1 G2 G3 G4
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9.2. Manhole Questionnaire

Technical questionnaire for design calculations of HDPE manholes 1. PROJECT
Date Site address Contractor Person in charge of the project Phone Fax
2. FABRICATION DATA
: : : : : :
Manhole ID Installation depth (h1) Manhole pipe length (h2) Level of ground water (hw) Working width (bA) Density of bedding material Manhole material HDPE /PP
3. SOIL CONDITIONS
: .mm : mm
Bedding Soil class Degree of compactness (Proctor density)

4. TRAFFIC LOADS On the lid
Existing Soil G1, G2, G3, G4
G1, G2 .%
Near manhole lid
No traffic load HLC 30 HLC 60 HGV 12
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5- MANHOLE LID
6- FUNDATION
7- CONNECTION /INLET AND OUTLET PIPES Diameter Wall Thickness 1. pipe mm ..mm 2. pipe mm ..mm 3. pipe mm ..mm 4. pipe mm ..mm 8- Details on construction Thickness of concrete foundation plate Diameter of Concrete foundation Plate Concrete Filling Height
Position o o o o
..mm .mm .mm
62
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HDPE- PROFILED PIPES _________________________________________________________________________

SEWERAGE AND STORM WATER PIPING SYSTEMS

TECHNICAL MANUAL (HDPE PROFILED PIPES)

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

1. General Specification of HDPE- Profiled Pipes

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 2: Intake piping system from 1600 mm HDPE-pipe

HDPE- PROFILED PIPES _________________________________________________________________________

Unit g/cm3 g/10 min

PE 80 Black/ yellow 0,95 0,40 10 -

PE 100 Black/ yellow 0,96 0,45 6,6 1.200 150 25 38 >350 10 46

PP-R Black 0,91 0,50 1,25-1,5 750 160 26 15 >50 45

N/mm2 N/mm2 N/mm2 % N/mm2 1.000 150 23 32 >350 8 42

1,8x10-4 0,38 127 B2

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 3: Pipe flexibility and Strength

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 4: Different pipe sections

HDPE- PROFILED PIPES _________________________________________________________________________

2.1 Series PW Pipes and Field of Applications

HDPE- PROFILED PIPES _________________________________________________________________________

Table 3: HDPE Profiled Pipes Classes (E24=380N/mm2) according to ISO 9969

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 8: Sectional and Structural view of Series SW HDPE pipes

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

Table 5:Bend dimensions as per standard DIN 16961

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

3.4 Puddle flanges

Table 8: Puddle flange dimension

HDPE- PROFILED PIPES _________________________________________________________________________

Table 9: Dimension of wall passes

Figure 9: HDPE- wall passes 3.5 House connection

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 13 : Tangential manhole with telescopic standard cover

Details of the telescopic cover

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 15: Details of Tangential manhole

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 16: Tangential manholes with 90o and reduced passage

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

HDPE- PROFILED PIPES _________________________________________________________________________

Figure 20: Butt welding machine

HDPE- PROFILED PIPES _________________________________________________________________________

The important welding parameters will be calculated as follows:

. Calculation of the welding area:

. Calculation of welding force

Figure 21: Butt welding process

HDPE- PROFILED PIPES _________________________________________________________________________

. Calculation of joining pressure

4.1.3. Extrusion Welding

HDPE- PROFILED PIPES _________________________________________________________________________

6 * * * * 6300 8000 * *