Contents

INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES .................................................. 4 1.1 Product Benefits ........................................................................................................... 5 1.2 Manufacture .................................................................................................................. 6 1.3 Applications .................................................................................................................. 9 2 MATERIAL PROPERTIES ................................................................................................. 12 2.1 Physical Properties ..................................................................................................... 12 2.1.1 Embodied Energy ................................................................................................ 12 2.1.2 Ring stiffness ....................................................................................................... 13 2.1.3 Abrasion Resistance............................................................................................ 15 2.1.4 Ultraviolet solar radiation resistance.................................................................... 15 2.1.5 Weather Resistance ............................................................................................ 15 2.2 Chemical Properties ................................................................................................... 16 2.2.1 Potable water approvals ...................................................................................... 16 2.2.2 Maximum service conditions ............................................................................... 16 2.2.3 Performance in exceptional chemical environments ........................................... 16 3 SPECIFICATIONS AND TESTING .................................................................................... 17 3.1 Manufacturing Standards............................................................................................ 17 3.2 Standards for Fittings.................................................................................................. 19 3.3 Test requirements for pipes ........................................................................................ 21 3.3.1 Raw Materials ...................................................................................................... 21 3.3.2 Production testing ................................................................................................ 22 3.3.3 Long Term Type Testing ..................................................................................... 27 4 PRODUCT RANGE ........................................................................................................... 29 4.1 Description and classification ..................................................................................... 29 4.2 Dimensions - pipes ..................................................................................................... 30 4.3 Dimensions - fittings ................................................................................................... 35 5 HYDRAULIC DESIGN ....................................................................................................... 55 5.1 Flow and pressure capacity calculations .................................................................... 55 5.2 Economic considerations ............................................................................................ 58 5.3 Air Valves, anti-vacuum valves and scour valves ....................................................... 59 5.4 Surge Capacity ........................................................................................................... 64 5.5 Water hammer surge celerities ................................................................................... 64 5.6 Fatigue under cyclical pressure regimes .................................................................... 65 5.7 Thermal effects on pressure ratings ........................................................................... 65 5.8 Non pressure pipeline design ..................................................................................... 66 6 STRUCTURAL DESIGN .................................................................................................... 69 6.1 Allowable cover heights .............................................................................................. 69 6.2 Thrust block design for pressure pipelines ................................................................. 82 6.3 Angular deflection of Flowtite coupling joint ............................................................ 85 6.4 Design of GRP flanges ............................................................................................... 86 6.5 Above Ground Installation .......................................................................................... 90 7 INSTALLATION ................................................................................................................. 94 7.1 Transportation and Storage ........................................................................................ 94 7.2 Excavation and associated works............................................................................... 95 7.3 Pipe laying .................................................................................................................. 97 7.4 Side support and overlay .......................................................................................... 104 7.5 Trench and embankment fill (i.e. above embedment / overlay) ................................ 105 7.6 Grouting .................................................................................................................... 105 7.7 Joints subject to differential settlement ..................................................................... 106 7.8 Cutting into or repairing installed GRP pipelines ...................................................... 109 1

FIELD TESTING .............................................................................................................. 112 8.1 Leakage testing pressure pipelines ....................................................................... 112 8.2 Leakage testing non-pressure pipelines ................................................................ 114 8.3 Structural assessment on installation ....................................................................... 117 8.4 High pressure water cleaning ................................................................................... 120

INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES

Fibrelogic Pipe Systems Pty Ltd is a company excelling in providing the ultimate in piping solutions to its clients. We are a private, wholly Australian owned company, manufacturing in Australia. We are able to deliver the highest standard of product by incorporating our: World class facilities including Flowtite GRP Pipe continuous winding machines, Extensive QA and testing laboratories Product Engineering and Development service Global knowledge-base through the Flowtite Group (largest GRP Pipe group in the world) Experienced, professional staff ...and strong ethical business principles. Globally, demand for Glass Reinforced Plastic (GRP) Pipe manufacturing is growing dramatically. Due to its high strength, low weight and corrosion resistance, clients are choosing GRP over traditional coated metallic piping. Flowtite GRP Piping has been the leading GRP Pipe manufacturing method for nearly 40 years. The technology is now being used worldwide on all continents with more than forty winding machines located in twenty licensed pipe factories. Fibrelogic Pipe Systems has licensed the Flowtite GRP Pipe manufacturing technology from Flowtite in Norway. Flowtite is a progressive organisation which supports the engineering, production and development of Flowtite GRP Pipe worldwide. Corporately, we are a leading company in Australia in growth and technology, but also in supporting the globally underprivileged through child sponsorship programs. It is a core aspect of why Fibrelogic Pipe Systems exists to help those in need, globally. We have a strong, passionate team of executives, management and staff that, when combined with our world class technology and manufacturing equipment provides a great platform for optimum product and service.

1.1

Product Benefits
Benefits Long, effective service life No need for linings, coatings, cathodic protection, wraps or other forms of corrosion protection Low maintenance costs Hydraulic characteristics essentially constant over time Unaffected by stray (earth) or induced currents. Cathodic protection systems do not need to be considered for either Flowtite pipes or surrounding structures. Low transport costs Eliminates need for expensive pipe handling equipment Standard lengths up to 12 metres with longer lengths available on request Fewer joints reduce installation time Compatible with Hobas GRP, Series 2 PVCU, PVCM and PVCO, ductile iron and most existing AC pipeline applications Fittings are available or can be designed to suit individual requirements Low friction loss means less pumping energy needed and lower operating costs Minimum slime build-up can help lower cleaning costs. Tight, efficient joints designed to eliminate infiltration and exfiltration Ease of joining, reducing installation time Accommodates small changes in line direction without fittings and can accommodate differential settlement Custom diameters can be manufactured to provide maximum flow volumes with ease of installation Lower wave celerity than other piping materials can mean less cost when designing for surge and water hammer pressures High and consistent product quality worldwide which ensures reliable product performance

Features Corrosion-resistant materials

Electrically non-conductive

Light weight(1/4 weight of ductile iron1/10 weight of concrete) Long standard lengths

Dimensions compatible with existing piping products Standard and custom fittings available Extremely smooth bore

Precision Flowtite coupling with elastomeric REKA gaskets

Flexible manufacturing process High technology pipe design High technology pipe manufacturing system

1.2

Manufacture

Fibrelogic Pipe Systems manufactures the Flowtite GRP Pipe at their purpose built facility in Lonsdale, South Australia. Flowtite pipes can be manufactured in a number of standard diameters ranging from DN300 up to DN3000. Flowtite pipe is manufactured using the continuous advancing mandrel process which represents the state of the art in GRP pipe production. This process allows the use of continuous glass fibre reinforcements in the circumferential direction. For a pressure pipe or buried conduit the principle stress is in the circumferential direction. Incorporating continuous reinforcements in this direction and not just chopped discontinuous roving, such as in a centrifugal casting process, yields a higher performing product at lower cost. Using the technology developed by Flowtite, a very dense laminate is created that maximizes the contribution from the three basic raw materials, namely glass fibre, silica sand aggregate and thermosetting resin. Both continuous glass fibre rovings and chopped roving are incorporated for high hoop strength and axial reinforcement. A silica sand aggregate is used to provide increased stiffness with placement near the neutral axis in the core. Thermosetting resin, delivered through a dual resin delivery system gives the equipment the capability of applying a special inner resin liner for severe corrosive applications while utilizing a less costly resin for the structural and outer portion of the laminate.

The raw materials are applied on the continuously advancing mandrel in specific locations to ensure the optimum strength with minimum weight. The materials are applied to produce a series of layers which give both pressure resistance as well as pipe stiffness. The diagram below shows the typical wall construction of a Flowtite pipe and the table explains the layers construction and purpose. Note that all layers contain thermosetting resin.

Layer Interior Liner Barrier Layer Inner Structural Layer Core Outer Structural Layer Exterior Surface

Construction C Glass tissue Chopped glass fibres Continuous glass fibres and Chopped glass fibres Silica sand aggregate and chopped glass fibres Continuous glass fibres and Chopped glass fibres Chopped glass and C glass tissue or polyester veil

Purpose Protection Protection High modulus structural reinforcement Solid separating core High modulus structural reinforcement Protection

After all materials have been applied the laminate is cured completely using a number of strictly controlled mechanisms including heating the mandrel as well as infrared heating of the external surface. The cured laminate is cut to length as required. Standard lengths are 12 metre, 6 metre and 3 metre. Intermediate lengths can also be manufactured at 1 metre increments. Longer lengths are possible but can not be pressure tested.

All pipes are quality inspected after manufacture. Once inspected the pipe spigots are chamfered and calibrated where necessary for fitment of couplings. Each pipe is pressure tested to twice its nominal pressure class to verify performance. Couplings are cut from specially made coupling pipes of an appropriate diameter to allow internal boring to create grooves for the rubber seals and central register. They are also proof tested at 2 x PN pressure on a hydrostatic testing machine.

1.3

Applications

With the aging of the worlds infrastructure there are millions of kilometres of water and sewer pipelines needing rehabilitation. A major concern is that that the deterioration is premature and design lives predicted at the conceptual stage are not being realised. The prime cause of this problem is corrosion, typically for the following reasons: Internal attack on unprotected concrete gravity flow sewer pipes, which deteriorate rapidly in the presence of sulphuric acid as a result of the hydrogen sulphide cycle. In water supply installations, high levels of carbon dioxide in soft water from underground sources can rapidly degrade cementitious liner materials External attack can be caused by aggressive soil / ground water conditions or stray electrical currents affecting ferrous and cementitious materials. Unlike GRP, these pipes are vulnerable when buried in poorly aerated and poorly drained soils of low resistivity. Saline soils, the presence of chlorides, or sulphate-reducing bacteria also accelerate corrosion.

GRP pipes are not subject to any of these problems and with the latest advances in manufacturing technology giving much higher production rates, there has been a widespread increase in their use for both new infrastructure and as replacements for corrosion prone materials. The unique properties of Flowtite pipes with high strength, combined with corrosion resistance and easier laying make them very attractive for use in many of the major infrastructure applications listed below: Water supply transmission and distribution mains Irrigation Gravity and rising main sewers Slip lining Submarine pipelines Hydro-electric power station penstocks Water and sewerage treatment plants Desalination plants Thermal power station supply and cooling systems Chemical and industrial process pipelines Storage tanks

A range of case studies can be found on the international Flowtite website www.flowtite.com

DN 250 Flowtite pipes for a corrosive bore water supply pipeline for Kogan Creek power station in Queensland.

DN1000 PN16 SN 10000 Flowtite pressure pipes and special long length GRP fittings being installed on a major recycled water pipeline near Wivenhoe Dam in SE Queensland.

DN1000 PN16 SN10,000 Flowtite pressure pipe strung out along the alignment near Wivenhoe Dam in SE Queensland

2
2.1

MATERIAL PROPERTIES
Physical Properties

As the wall construction of Flowtite pipes vary according to pipe class and stiffness, only indicative material parameter values have been given below. More specific information for any particular pipe design should be obtained by contacting Fibrelogics engineers. Property Density Thermal coefficient of expansion (axial) Thermal conductivity Tensile Strength - Circumferential (hoop) Tensile Strength - Longitudinal (axial) Elastic Modulus - Circumferential tensile and flexural Elastic Modulus - Longitudinal tensile and flexural Circumferential bending creep / relaxation ratio Minimum ultimate circumferential tensile strain Minimum ultimate circumferential bending strain Poissons ratio Combustibility characteristics (AS 1530.31989) Typical Value 1800 kg/m3 2100 kg/m3 24 - 30 x10-6 m/m.K. 0.14 to 0.22 W/m.K 150 700 MPa 25-60 MPa 17,000 MPa (low pressure pipe) 24,000 MPa (high pressure pipe) 6000 MPa 12,500 MPa 60% retention after 50 years 1.52% initial; 0.65% long term (at 50 years) 2.30% initial; 1.30% long term (at 50 years) 0.22 to 0.29 Ignitability Index (0-20) Spread of flame Index (0-10) Heat evolved Index (0-10) Smoke developed Index (0-10) 10 0 2 6

2.1.1 Embodied Energy The embodied energy of Flowtite GRP pipes is generally lower than that of equivalent nonpolymer pipe materials. For detailed information, contact Fibrelogic Pipe Systems.

2.1.2

Ring stiffness

The stiffness of a pipe indicates the ability of the pipe to resist external soil, hydrostatic and traffic loads together with negative internal pressures. It is a measure of resistance of a pipe to ring deflection determined by testing and is the value obtained by dividing the force per unit length of a specimen by the resulting deflection at 3 percent deflection.

S=

Ff Ld v

Equation 2.1

Where: S= F= dv = Dm = f=

stiffness (Newtons / metre per metre length of pipe) force (N) deflection (m) mean diameter (m) a deflection coefficient including a correction factor for ovality of the deformed specimen obtained as follows:

f = 10 5 (1860 + 2500

dv ) Dm

Equation 2.2

According to the Australian and ISO Standards, stiffness is expressed as follows:

S=

EI Dm
3

Equation 2.3

Where S = the pipe stiffness as determined by testing in N/m per metre length of pipe E = the apparent modulus of elasticity, in Pascals. I = the second moment of area per unit length of the pipe wall section in m4 per m. Dm = mean diameter (m) i.e.

I=

t3 12

Where t

= wall thickness in m.

The initial stiffness is determined using a specific test method and cannot be obtained through calculations using nominal values of E and t as Flowtite is a GRP composite.

There are also other terms in common use internationally describing pipe stiffness. For example according to German DIN Standards and the ATV code the ring stiffness is defined as:

SR =

EI 3 Rm

Equation 2.4

Where Rm = mean radius (m). This stiffness value is 8 times greater than that given by the Australian and ISO Standards, so that in order to avoid mistakes E and SR are expressed as N/mm2 (MPa) when using this formula. According to American ASTM Standards the ring stiffness measured at 5% deflection, is expressed as:

F dv

(Pounds per square inch)

Equation 2.5

Where F = load per unit length (pounds per inch) dv = vertical pipe deflection (inches) GRP pipes are classified by the nominal stiffness value determined from the standard initial stiffness test i.e.:
Table 1 Nominal Stiffness Sp (ISO & Aust.) SR (DIN ATV) F dv (ASTM) Nominal Stiffness / Comparison of Units Unit SN 2500 SN 5000 N/m2 N/mm2 psi 2500 0.02 20 5000 0.04 40

SN 10000 10000 0.08 80

2.1.3

Abrasion Resistance

Flowtite pipes are manufactured with an external layer of reinforced resin to provide scuff resistance during the handling and installation process. The potential for bore abrasion wear can be determined using the Darmstadt method. The test used was developed at the Institute of Hydraulics and Hydrology of Darmstadt, Germany and the procedure involves axially rocking a half section of pipe through 22 degrees, so that a calibrated load of abrasive slurry slides back and forth along the invert of the pipe. When tested a Flowtite pipe specimen showed a wear rate of 0.84mm loss per 100,000 cycles. 2.1.4 Ultraviolet solar radiation resistance

Flowtite pipes have a non-structural external layer of reinforced resin to provide a weathering layer when stored or installed above ground. This layer protects the structural layers from UV radiation but may discolour over time. If this is not acceptable, pipes may be coated with an acrylic (water based) paint. 2.1.5 Weather Resistance

Standard Flowtite pipes can be permanently stored in the open without any detrimental effects on the structure of the pipe due to UV radiation although some superficial roughening and discolouration of the external and internal surfaces may occur. For periods over 6 months in open areas it is recommended that the rubber rings should be stored indoors.

2.2
2.2.1

Chemical Properties
Potable water approvals

Flowtite pipes and fittings meet the requirements of AS 4020. Flowtite pipe has been tested and approved for the conveyance of potable water meeting many of the worlds leading authorities and testing institutes criteria, including: NSF (Standard No. 61) United States DVGW Germany Lyonnaise des Eaux France Water Byelaws Scheme (WBS) United Kingdom Russia (Cert. No. 07700 03515I04521A8) Oficina Tcnia De Estudios Y Controles Spain Pnstwowy Zaklad Higieny (National Institute of Hygiene) Poland OVGW Austria NBN.S. 29001 Belgium Copies of Flowtite Technology qualification test reports are available on the web site www.flowtite.com 2.2.2 Maximum service conditions

Normal Flowtite pipes are intended for use with water, sewage and controlled industrial wastes at temperatures of up to 35C in the pH range 3 to 9. For temperature and chemical conditions in excess of these values Fibrelogics engineers should be consulted for advice on re-rating and chemical suitability. With the exception of chlorinated or aromatic solvents, Flowtite pipes have a high resistance to chemical attack. Furthermore, special resin systems can be used to improve the chemical resistance at elevated temperatures. In the case of some solvents, the use of a vinyl ester resin system may be recommended. 2.2.3 Performance in exceptional chemical environments

Flowtite pipes selected for use in severe environments, such as the processing industry, especially at elevated temperatures, may require special resins systems such as vinyl esters. Because of the range of factors involved, the final determination of the suitability of Flowtite for a given environment becomes the sole responsibility of the specifier. General guidance can be provided by Fibrelogic Pipe Systems as to suitable applications based on information provided by resin suppliuers. However, this advice is not intended to imply approval for any given application, as neither the resin suppliers nor Fibrelogic has any control over the conditions of usage or the means of identifying all environmental conditions that may affect the selected pipes and fittings.

3
3.1

SPECIFICATIONS AND TESTING

Manufacturing Standards

Fibrelogic Pipe Systems complies with the requirements of AS/NZS ISO 9001:2000 Quality Management Systems and has been officially certified by a 3rd party certification body. Standards developed internationally apply to glass reinforced polyester (GRP) pipes, sometimes referred to as fibreglass or fibre reinforced polyester (FRP), when used for infrastructure, including the conveyance of potable water, irrigation water, sewage and industrial waste. Common to all modern pipe product standards is the fact that they are performance-based documents, that is, the required performance and testing of the pipe is specified rather than prescriptive requirements on the manufacturing process. Flowtite pipes have been appraised by the Water Association of Australia refer to Product Appraisal 04/06 Flowtite GRP Pipe System for Fibrelogic Pipe Systems Pty. Ltd. The following list includes standards commonly used for the manufacture and testing of GRP pipes and fittings. ISO Standards The International Standards Organization (ISO) has published a suite of GRP product standards and corresponding test methods. Flowtite Technology in Europe participated in the development of these standards; thereby ensuring performance requirements will result in reliable products. The ISO Standards for GRP pipes and fittings manufacture relevant to infrastructure works include: ISO 10467 Plastics piping systems for pressure and non-pressure drainage and sewerage Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin ISO 10639 Plastics piping systems for pressure and non-pressure water supply -Glassreinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin These Standards are essentially the same except that the sewer pipes must comply with the strain corrosion type test and water supply pipes with the requirements of AS 4020 for potable (drinking quality) water. All Flowtite pipes currently manufactured in Australia meet both standards. Australian Standards Australian practice is to use ISO based standards for GRP pipes and fittings and the following documents are in the process of being revised to meet the latest ISO Standards. Flowtite is already manufactured to the ISO equivalent. Existing standards are: GRP Pipes: Australian Standard AS 3571 Glass Filament (GRP) Pipes Polyester Based Water Supply, Sewerage and Drainage Applications*. Australian Standard AS 3572 1989 Plastics Glass Filament Reinforced Plastics (GRP) Methods of Test*.

United States of America Standards Flowtite pipes manufactured in Australia are designed to meet United States Standards in addition to the ISO and AS Standards. Currently, there are several ASTM Product Standards in use that apply to a variety of GRP pipe applications. All product standards apply to pipes with diameter ranges of 200mm to 3600mm and require the flexible joints to withstand hydrostatic testing in configurations (per ASTM D4161) that simulate exaggerated in-use conditions. These standards include various qualification and quality control tests. ASTM D3262 Standard Specification for Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Sewer Pipe ASTM D3517 Standard Specification for Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Pressure Pipe ASTM D3754 Standard Specification for Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Sewer and Industrial Pressure Pipe ANSI/AWWA C950 AWWA Standard for Fibreglass Pressure Pipe is one of the most comprehensive product standards in existence for GRP pipe. This standard for pressure water applications has extensive requirements for pipe and joints, concentrating on quality assurance and prototype qualification testing. Like ASTM standards, this is a product performance standard. Flowtite pipe is designed to meet the performance requirements of this standard. AWWA has recently issued a new Fibreglass Pipe Design manual M-45, which includes chapters on the design of GRP pipelines for buried and aboveground installations. AWWA C950 Fiberglass Pressure Pipe AWWA M-45 Fiberglass Pipe Design Manual Other Standards Standardisation organisations such as BSI and DIN have also published performance specifications for GRP pipes to which Flowtite complies where nominated. DIN 16868 Glass Fibre-Reinforced Polyester Resin Pipes BS 5480 Pipes and Fittings for Water and Sewage Associated fittings Fittings used with Flowtite pipes may be of GRP or metallic materials. The following documents may be relevant:

International Standards ISO 10639 & 10467. Ductile Iron Pressure Fittings Australian Standard 2280 Ductile Iron Pressure Pipes and Fittings. Mild Steel Cement Lined Fittings Australian Standard 1579 Arc Welded Steel Pipes for Water and Gas and Australian Standard 1281 The Cement Mortar Lining of Steel Pipes and Fittings. Flanged joints, specifically drilling patterns in both GRP and metal Australian Standards AS 4087 Metallic flanges for waterworks purposes , AS 2129 Flanges for pipes, valves and fittings and AS 4331.1 (ISO 7005) Metallic flanges - Steel flanges may be applicable. Note that flange thicknesses for GRP will depend on the design but will be greater than for metal flanges.

3.2

Standards for Fittings

For water supply, sewerage rising-mains, and other pressure applications a full range of GRP fittings is available. These fittings can be custom made to specific customer requirements. In addition to GRP pressure fittings, standard ductile iron fittings, valves and hydrants are suitable for use with Flowtite pipe. The outside diameters of Flowtite GRP pipes are compatible with Australian Standard PVC-U, PVC-M, PVC-O, ductile iron, and some AC pipes and fittings of the same nominal diameter. Where pipe tapping Flowtite pipe is a flexible pipe, flexible tapping bands manufactured from gunmetal or stainless steel should be used for service connections. GRP Fittings

Flowtite GRP pressure fittings are manufactured in Classes PN 6, 10, 16, 20, 25 and 32 for use with Flowtite pipes of the corresponding class. These fittings are fabricated from Flowtite pipes using proprietary wrapped laminate designs. Fittings are normally supplied spigot ended suitable for Flowtite couplings. Flanged fittings are available and can be full-faced or, for higher operating pressures, stub flanges with steel backing plates may be the preferred option. Non pressure (i.e. PN 1) fittings are also fabricated from Flowtite pipes and comply with the requirements ISO 10639 and ISO 10467. Fittings are normally supplied spigot ended suitable for Flowtite couplings. Branches for sidelines can be attached to the Flowtite mainline using saddle fittings attached with epoxy adhesive applied in-situ. Adaptor couplings for saddle branches for joining to PVC DWV

Ductile Iron Fittings Ductile iron fittings socket joints can be used on selected Flowtite pipes of the same nominal size. Conventional socketed fittings complying with AS 2280 Ductile Iron Pressure Pipes and Fittings in sizes DN100 to DN750 are suitable. A complete range of bends, tees, reducers and flange-spigot pieces is available with Griptite* or Tyton# rubber ring sockets in sizes DN100 to DN750. Other joint designs may also be acceptable. Fibrelogic should be contacted to confirm the suitability of any particular range of fittings. These fittings may be protected from corrosion using various alternatives. Fusion bonded polymer (polyamide or epoxy) Cement lining and polyethylene wrap. *Registered Trademark of Northern Iron and Brass Foundry. # Registered Trademark of Tyco Water.

Examples of fusion bonded nylon coated ductile iron fittings with Griptite seals suitable for use with Flowtite Steel fittings Fabricated steel (and stainless steel) fittings fabricated from steel plate can be used with Flowtite pressure pipes. Normally, steel fittings are protected from corrosion externally by ultra high build epoxy and internally by cement lining. Where possible these fittings are manufactured with spigots especially sized to match Flowtite outside diameters, including tolerances so that the joint can be made using standard Flowtite GRP couplings. Relevant Standards are AS 1594 Hot-rolled steel flat products AS 3678 Hot-rolled structural steel plates, floor plates and slabs AS 1579 Arc welded steel pipes and fittings for water and waste water AS 1281 Cement mortar lining of steel pipes and fittings AS 4321 Fusion bonded medium density polyethylene coatings and linings for pipes fittings AS 2312 Guide to protection of iron and steel from atmospheric corrosion

and

3.3

Test requirements for pipes

A common element shared by all standards is the need for a pipe manufacturer to demonstrate compliance with the standards minimum performance requirements. In the case of GRP pipe, these minimum performance requirements fall into both short-term and long-term requirements. The short-term tests are conducted at manufacturing sites as part of daily quality control, while the latter have been conducted at Flowtite Technologys laboratory or by a certified third party. Results from quality control tests are part of a Flowtite factorys record and retained by the factory, while the type tests are carried out and archived by Flowtite Technology, which is the international parent organisation. 3.3.1 Raw Materials

Flowtite Purchase Acceptance Standards (PAS) are common to the worldwide organisation and each factory maintains Technical Data Sheets and test reports for the raw material supplied. Raw materials are delivered with vendor certification demonstrating their compliance with Flowtite quality requirements. In addition, all raw materials are sample tested prior to their use. These tests ensure that the pipe materials comply with the stated specifications. Resins Flowtite pipes are normally manufactured using orthophthalic polyester resins. However where unusual environmental conditions exist, isophthalic polyester or vinyl ester can be specified. Aggregate and fillers The quartz sand used in Flowtite pipes is required to meet the specific grading curve particle sizing of the Flowtite Purchase Acceptance Standard. Elastomeric seals The elastomeric sealing rings comply with the requirements of EN 681-1: 1996,Type WA and WC and AS 1646. Unless otherwise requested EPDM rings will be supplied. However in special circumstances rings may be supplied, manufactured from other polymers - see Table 2.
Table 2 Elastomers for Flowtite seals

Polymer Ethylene propylene-diene* Nitrile-butadiene Styrene-butadiene rubber

Abbreviation EPDM NBR SBR

* The standard polymer supplied. Other types are rarely needed and can only obtained as a special order.

3.3.2

Production testing

Every pipe is subjected to the following control checks: Outside diameter Wall thickness Pipe length Visual inspection of all surfaces Hydrostatic leak tightness test (for PN6 or higher) On a sampling basis, the following control checks are performed: Pipe stiffness Deflection without liner cracking or structural failure Axial and circumferential tensile load capacity Barcol hardness Composition Outside diameter Flowtite pipes are externally controlled in accordance with Table 3 External Diameter Series of AS 3571. Normal tolerances are given in Table 3
Table 3 Tolerances on spigot outside diameters

DN

Outside diameter (PN1 to PN16) (mm) Min Max 344.0 425.0 506.0 586.0 666.0 746.0 825.0 922.0 1024.0 1228.0 1432.0 1636.0 1840.0 2044.0 2248.0 2452.0 3064.0 345.0 426.0 507.0 587.0 667.0 747.0 826.0 923.0 1025.0 1229.0 1433.0 1637.0 1841.0 2045.0 2249.0 2453.0 3065.0

Outside diameter (PN20 to PN32) (mm) Min Max 345.0 426.0 507.0 587.0 667.0 747.0 826.0 923.0 1025.0 1229.0 1433.0 1637.0 1841.0 2045.0 2249.0 2453.0 3065.0 345.5 426.5 507.5 587.5 667.5 747.5 826.5 923.5 1025.5 1229.5 1433.5 1637.5 1841.5 2045.5 2249.5 2453.5 3065.5

300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000

Pipe lengths The actual length of each pipe is equal to the nominal length with a tolerance of 25 mm. The effective (i.e. laying) length is equal to the pipe length plus 10 mm (an allowance for the centre register in the coupling). Surface quality The surface of the pipe shall be relatively smooth and free of exposed fibre or sharp projections. Refer to Appendix B of AS 3571 for guidance with respect to surface defects.

Hydrostatic Leak Tightness Testing

Every pipe PN6 or greater is pressure tested to 2 times the nominal pressure class of the pipe. The pipe is held at this pressure for 2 minutes allowing for inspection of the pipe.

Specific ring stiffness

A test specimen from each batch is tested in accordance with ISO 7685 and the calculated initial stiffness shall be not less than the nominal branded stiffness. A 300mm long test piece is taken once per shift of pipes manufactured in a single batch. A diametral load is applied with the pipe bearing top and bottom on flat plates. The load to achieve a 3% deflection is recorded and used to calculate the initial stiffness. Specific ring deflection When tested in accordance with ISO 10466, a test specimen from each production batch of pipes must satisfy the requirements of Table 4 at the nominated deflections. The stiffness test specimen is also used for this test.
Table 4 Minimum test deflections Nominal Stiffness SN No visible damage to inside layer at % deflection of: No structural damage at % deflection of: -

2500 15

5000 12

10000 9

25

20

15

Initial specific longitudinal tensile test When an axially oriented test specimen cut from each pipe batch is tested in accordance with ISO 8513, the longitudinal tensile strength indicated for the pipe shall not be less than the value given in Table 5. The mean elongation at rupture shall not be less than 0.4 percent for pipe Class 6 and above and 0.3 for lower classes and non-pressure pipes (i.e. PN 1).
Table 5 Minimum axial tensile strengths (N/mm) of external circumference Nominal Diameter DN 80 100 150 200 250 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000 Class PN 1* Class PN 6 Class PN 10 Class PN 16 Class PN 20 Class PN 25 Class PN 32

110 133 137 138 146 157 169 182 194 219 245 270 296 321 347 372 449

81 96 112 173 173 192 203 213 233 258 284 309 333 383 434 485 537 587 637 687 838

93 111 129 198 181 210 224 239 263 292 324 352 381 440 498 555 614 672 730 789 962

112 133 155 238 206 245 267 284 314 353 389 427 464 538 612 687 761 837 911 985 1208

230 268 288 311 347 389 433 476 518 603 688

253 305 331 356 402 453 504 558 607 711 815

289 354 384 417 471 536 599 664 726 854 981

Note: Tensile strengths shown are for SN 2500 and comply with AS 3571. Flowtite axial strengths will be greater for higher stiffness pipes.

Apparent initial circumferential tensile strength When a circumferentially oriented test specimen cut from each pipe batch is tested in accordance with ISO8521, the tensile strength it indicates for the pipe shall not be less than the value given in Table 6. These values may be calculated from the equation:

Po =

0.02 cu dm

Where cu = circumferential strength (N/mm) determined from ISO 8521 Po = initial failure test pressure (MPa) determined by regression testing dm = mean diameter (m)
Table 6 DN 80 100 125 150 200 250 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000 Initial (average) circumferential tensile strength Average apparent initial circumferential tensile strength pipes N/mm PN6 PN10 PN16 PN20 PN25 PN32 355 422 488 614 735 1001 1061 1092 1125 1223 1405 1587 1761 1927 2290 2654 3036 3389 3760 4124 4488 5580 367 434 506 644 771 1111 1411 1560 1702 1909 2120 2407 2709 3018 3583 4139 4712 5292 5889 6454 7059 8760 421 542 645 843 1024 1614 2027 2358 2483 2852 3290 3763 4167 4614 5491 6367 7253 8112 9015 9900 10759 13389

1913 2508 2715 3005 3474 3991 4560 5077 5646 6733 7766

2251 2922 3238 3573 4148 4806 5482 6114 6790 8088 9413

2755 3602 3980 4396 5096 5933 6743 7589 8372 10010 11648

Barcol Hardness When tested in general accordance with ASTM Standard D2583 the surface Barcol Hardness of the pipe shall be greater than 35.

3.3.3

Long Term Type Testing

In addition to daily quality control testing, ISO 10467 and ISO 10639 require type testing to determine long term properties such as hydrostatic failure pressures, stiffness creep (or relaxation), and strain corrosion. These tests have duration of at least 10,000 hours to enable extrapolation to establish design values. That is, using the methods of ISO 10928, the physical parameters required can be determined for the specified nominal 50-year design period. A statistically significant number of test specimens, generally a minimum of eighteen in number, are prepared and loaded to various degrees so as to obtain a series of ultimate load (or strain) values spread over the duration of the test period. A log time log load regression line of best fit is established using the method of least squares. The 95% lower confidence limit line can then be constructed based on the 50-year minimum value. In the case of the hydrostatic design this information is needed to set values for the short-term quality control tests. Rigorous joint type tests, which include the combined effect of, draw and shear loading at normal and maximum angular deflections are also requirements of the Standards. Long term pressure testing Flowtite pressure pipe is designed on a strain basis to fulfill the requirements of ISO 10467, ISO 10639, AWWA C950, ASTM D3517 and ASTM D3754. The 50-year strain value for Flowtite pipe as determined in report T-95-101R, 50, is 0,65%. Current product designs comply with this value. For example on particular pipe specimens strain measurements were made and then using regression analysis the long-term strain of 0,0065 at 23.2 bar pressure was determined. That is the 50-year burst pressure, p50, equaled 2.32 MPa. The analysis also provided the corresponding initial value, p0 , of 6.37 MPa. The minimum design pressure can be computed from equation 24 in ISO 10467 and ISO 10639 i.e.:

C 0.1 p0,d =

PN t ,PN ,97.5% LCL RR , p

1 Y 0.01 1.96

The Standards require that the average of the last 20 initial failure pressures during production, p0, mean to be greater than this value for the product in question. With C =

p0 p and RR , p = 50 this equation becomes: p6 p6

p0 , d

p0 0.1 PN t ,PN ,97.5% LCL p50 = 1 Y 0.01 1.96

The coefficient of variation Y, for the Flowtite process has been measured over a period of time and found to be generally within the range of 2.5% to 8%. Assuming a conservative value of 9% the expression for p0,d becomes:

p0 , d =

63.7 0.1 PN t ,PN ,97.5% LCL 1.21 = 3.32 PN t ,PN ,97.5% LCL 23.2

Using the values for safety factors in Table 3.4 of ISO 10467 and ISO 10639 the values for p0,d are shown in the following Table 7:
Table 7 Minimum long-term factors of safety

PN32 t,PN,97,5%LCL
applied to to the long term

PN25 1.3

PN20 1.38

PN16 1.45

PN10 1.55

PN6 1.6

1.3

97.5% LCL

t,Pnmean
applied to to the long term mean

1.6 13.8

1.6 10.8

1.8 9.16

1.83 7.70

1.9 5.15

2.0 3.19

p0,d MPa

Note: As the standards do not provide factors for PN20 this value has been interpolated. Cyclical internal hydrostatic pressure testing In accordance with Clause 5.3 of ISO 10467 and ISO 10639 the resistance of Flowtite pressure pipes to cyclic internal pressure has been verified through testing to ISO. The results are recorded in TV test report TV MP4/3338-90 and Veroc test report 13-T86. In both cases pipes were subjected to one million cycles between 0.75 x PN and 1.25 PN without showing any sign of failure. Resistance to strain corrosion The strain corrosion resistance of Flowtite pipes has been measured to a value of 0.66% (see test report T-99-107). Using the equation in Clause 10.6 of ISO 10952 this value can be converted to deflections and compared with the requirements. By using the thickest of the pipes in each stiffness class the following deflections are obtained: Stiffness class Deflection % SN 2500 14.3 SN 5000 11.3 SN 10000 9.0

These values meet the requirements in Table 17 of ISO 10467. Joint systems Three methods of jointing Flowtite pipes have been tested i.e. both flexible and rigid joints, with or without end load resisting capability to meet the requirements of Clause 7 of ISO 10467 and ISO 10639. The following test reports are available: Flexible non-end-load-bearing joints test report T-93-102 Wrapped non-end-load-bearing joints test report T-2004-127 Bolted non-end-load-bearing joints test report T-2004-129

4
4.1

PRODUCT RANGE
Description and classification

Nominal Sizes (DN) Flowtite pipes are currently manufactured in Australia in the nominal size range 300 mm to 3000 mm. Flowtite pipes are manufactured with the same outside diameters as ductile iron of the same nominal diameter; as a result the internal diameters are approximately 10% larger than nominal size in comparable sizes in the DN300 to DN750 ranges. Nominal Pressure Classes (PN) Pressure pipes are classified according to nominal pressure and nominal stiffness; nonpressure pipes by nominal stiffness only.
Table 8 Nominal pressure rating PN Working Pressure (MPa) Working Pressure (Bar) Working Head (Metres) Max. diameter for specific PN (mm) 1 0.1 1 10 3000 6 0.6 6 61 3000 10 1.0 10 102 3000 16 1.6 16 163 3000 20 2.0 20 204 3000 25 2.5 25 255 2400 32 3.2 32 326 1800

Nominal Stiffness (SN) Standard nominal stiffness is shown in Table 9.

Table 9 Stiffness (SN) 2500 5000 10000

Other pipe pressure or stiffness classes apart from those listed may be manufactured on request. Branding and Marking All pressure pipes are branded to indicate the nominal diameter, pressure class and stiffness as shown by the following example: Couplings for non-pressure pipes are branded to indicate the nominal diameter. Because couplings are common in the non-pressure and pressure range up to Class 6 they will generally be branded Class 6, for example DN900 PN6.

4.2

Dimensions - pipes
Table 10 Pipe - available sizes and classifications for SN 2500
Pipe stiffness SN 2500

DN

Spigot OD

375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000

PN 1 t ID (mm) (mm) 426 5.5 415 507 6.6 494 587 7.7 572 667 8.7 650 747 9.6 728 826 10.5 805 923 11.7 900 1025 12.9 999 1229 15.3 1198 1433 17.7 1398 1637 20.1 1597 1841 22.7 1796 2045 25.0 1995 2249 27.5 2194 2453 29.9 2393 3065 37.1 2991

PN 6 Mass t ID (kg/m) (mm) (mm) 14.4 5.5 415 20.8 6.6 494 28.6 7.7 572 36.7 8.7 650 46.0 9.6 728 55.7 10.5 805 69.4 11.7 900 85.6 12.9 999 122.3 15.3 1198 165.7 17.7 1398 215.5 20.1 1597 274.0 22.7 1796 336.8 25.1 1995 406.6 27.5 2194 483.0 29.9 2393 751.7 37.1 2991

PN 10 PN 16 PN 20 PN 25 PN 32 Mass t ID Mass t ID Mass t ID Mass t ID Mass t ID Mass (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) 14.4 20.8 28.6 36.7 46.0 8.6 730 39.9 55.7 9.5 807 48.9 69.4 10.5 902 60.8 85.6 11.5 1002 74.7 122.3 13.6 1202 106.5 165.7 15.8 1401 144.2 215.5 17.9 1601 187.5 274.0 20.0 1801 236.3 336.8 22.1 2001 290.8 406.6 24.2 2201 350.8 483.0 26.3 2400 416.3 751.7

Table 11
DN

Pipe - available sizes and classifications (SN 5000)

PN 6 PN 10 ID Mass t ID (mm) (kg/m) (mm) (mm) See Table for SN 10000 412 18.4 6.6 413 490 26.5 7.8 491 568 35.5 8.9 569 646 45.6 10.0 647 723 57.1 11.1 725 800 69.7 12.2 802 894 86.7 13.6 896 993 106.3 15.0 995 1191 151.9 17.9 1193 1389 207.1 20.7 1392 1587 269.9 23.5 1590 1785 341.3 26.3 1788 1983 419.4 29.2 1987 2180 507.1 32.0 2185 2378 601.6 34.8 2383 2972 937.6 Pipe stiffness SN 5000 PN 16 Mass t ID Mass t (kg/m) (mm) (mm) (kg/m) (mm) 5.1 17.4 6.2 414 15.9 6.2 24.6 7.3 492 22.5 7.2 32.7 8.3 570 29.9 8.1 42.1 9.3 648 38.3 9.1 52.6 10.3 726 47.8 10.1 64.2 11.3 803 58.1 11.1 80.6 12.5 898 72.2 12.3 99.1 13.8 997 88.7 13.5 142.0 16.3 1196 126.3 16.0 191.9 18.9 1395 171.1 18.5 250.2 21.4 1594 222.3 315.5 24.0 1793 280.2 388.8 26.5 1992 345.1 469.4 558.3 PN 20 ID (mm) 335 414 493 571 649 727 804 898 998 1197 1396 PN 25 PN 32 ID Mass t ID Mass (mm) (kg/m) (mm) (mm) (kg/m) 335 10.3 414 15.3 493 21.4 571 28.3 649 36.2 727 45.1 804 54.7 899 67.8 998 83.3 1197 118.7 1396 160.4

300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000

PN 1 Spigot OD t ID Mass t (mm) (mm) (kg/m) (mm) 345 426 6.9 412 18.4 6.9 507 8.3 490 26.5 8.3 587 9.5 568 35.5 9.5 667 10.7 646 45.6 10.7 747 11.9 723 57.1 11.9 826 13.1 800 69.7 13.1 923 14.5 894 86.7 14.5 1025 16.0 993 106.3 16.0 1229 19.0 1191 151.9 19.0 1433 22.1 1389 207.1 22.1 1637 25.2 1587 269.9 25.2 1841 28.2 1785 341.3 28.2 2045 31.2 1983 419.4 31.2 2249 34.3 2180 507.1 34.3 2453 37.2 2379 601.6 37.3 3065 46.3 2972 937.6 46.3

Mass t (kg/m) (mm) 10.4 5.1 15.7 6.1 21.9 7.1 28.9 8.1 37.1 9.1 46.2 10 56.1 11 69.7 12.1 85.5 13.4 121.9 15.8 164.9 18.3

Table 12
DN Spigot OD 345 426 507 587 667 747 826 923 1025 1229 1433 1637 1841 2045 2249 2453 3065

Pipe available sizes and classifications (SN 10000)

PN 1 ID (mm) 328 409 487 564 641 718 794 887 985 1181 1378 1574 1771 1967 2164 2360 PN 6 ID (mm) 328 409 487 564 641 718 794 887 985 1181 1378 1574 1771 1967 2164 2360 PN 10 ID (mm) 328 409 487 564 641 718 794 887 985 1181 1378 1574 1771 1967 2164 2360 g Pipe stiffness SN 10000 PN 16 Mass t ID Mass (kg/m) (mm) (mm) (kg/m) 16.3 8.3 328 16.2 22.2 7.9 410 20.7 32.0 9.2 489 28.9 43.2 10.6 566 39.0 56.0 11.9 643 50.1 70.6 13.2 721 62.5 86.5 14.5 797 76.2 107.3 16.2 891 94.9 132.7 17.8 989 116.6 190.5 21.2 1187 166.9 258.5 24.6 1384 226.1 336.7 27.9 1581 294.3 424.8 31.3 1778 371.7 522.6 631.9 749.8 34.7 1976 g g g 457.5 PN 20 t ID (mm) (mm) 6.3 332 7.7 411 9.0 489 10.2 567 11.5 644 12.8 721 14 798 15.6 892 17.2 991 20.4 1188 23.7 1386 g g g g g g PN 25 Mass t ID (kg/m) (mm) (mm) 13.2 6.3 332 20.0 7.5 411 28.2 8.8 489 37.3 10 567 47.9 11.3 644 59.7 12.5 722 72.8 13.7 799 90.5 15.2 893 111.1 16.8 991 158.8 19.9 1189 215.3 23.1 1387 g g g g g PN 32 Mass t ID (kg/m) (mm) (mm) 12.9 6.2 333 19.4 7.5 411 27.2 8.7 490 36.1 9.9 567 46.2 11.1 645 57.6 12.3 722 70.2 13.5 799 87.2 15 893 107.1 16.5 992 153.0 19.6 1190 207.0 22.7 1388 g g

300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000

t (mm) 8.3 8.3 10.0 11.5 13.1 14.7 16.2 17.9 19.9 23.8 27.6 31.4 35.2 38.9 42.7 46.5 57.9

Mass (kg/m) 16.4 22.2 32.0 43.2 56.0 70.9 86.5 107.3 132.7 190.5 258.5 336.7 424.8 522.6 631.9 749.8

t (mm) 8.3 8.3 10.0 11.5 13.1 14.7 16.2 17.9 19.9 23.8 27.6 31.4 35.2 38.9 42.7 46.5 57.9

Mass (kg/m) 16.4 22.2 32.0 43.2 56.0 70.9 86.5 107.3 132.7 190.5 258.5 336.7 424.8 522.6 631.9 749.8

t (mm) 8.3 8.3 10.0 11.5 13.1 14.7 16.2 17.9 19.9 23.8 27.6 31.4 35.2 38.9 42.7 46.5

Mass (kg/m) 12.6 18.9 26.3 35.0 44.8 55.9 68.0 84.4 103.7 148.0 200.2

2949 1169.7

2949 1169.7

Table 13
DN

Couplings - available sizes and classifications

Coupling dimensions & Masses PN 1 Cplg Cplg OD mass 388 11.5 469 14.0 550 16.6 630 19.1 716 30.8 796 34.1 875 37.6 973 42.8 1076 48.4 1281 59.4 1486 70.5 1691 81.9 1896 93.3 2100 105.2 2305 117.4 2510 129.7 3144 248.4 PN 6 Cplg Cplg OD mass 388 11.5 469 14.0 550 16.6 630 19.1 716 30.8 796 34.1 875 37.6 973 42.8 1076 48.4 1281 59.4 1486 70.5 1691 81.9 1896 93.3 2100 105.2 2305 117.4 2510 129.7 3144 248.4 PN 10 Cplg Cplg OD mass 389 11.7 470 14.5 551 17.3 631 20.0 718 32.2 798 36.3 879 41.2 977 47.1 1080 53.5 1287 66.5 1492 79.4 1698 93.1 1903 107.0 2110 125.3 2317 143.8 2523 162.5 PN 16 Cplg Cplg OD mass 390 12.2 471 15.0 553 17.9 633 21.0 721 34.6 802 38.6 882 43.0 980 49.6 1084 56.6 1291 71.5 1500 89.5 1710 112.5 1918 134.4 2126 156.3 PN 20 Cplg Cplg OD mass 391 12.4 472 15.3 554 18.3 634 21.3 724 36.4 804 40.3 884 44.4 983 51.6 1087 59.4 1300 82.3 1512 107.1 PN 25 Cplg Cplg OD mass 392 12.6 473 15.7 555 18.8 636 22.1 727 38.4 807 42.6 888 48.3 989 57.2 1100 72.7 1315 101.2 1526 128.1 PN 32 Cplg Cplg OD mass 399 14.7 480 18.4 563 22.2 644 26.1 733 43.0 816 50.0 898 57.0 1005 73.4 1116 90.6 1331 121.9 1542 151.0

Length 270 270 270 270 330 330 330 330 330 330 330 330 330 330 330 330 360

(mm)

300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000

Table 14

Pipe spigot ends - dimensional details

Nominal diameter (DN) 300 375 450 -525 600 to 3000

Witness Mark P 130 mm 130mm 130 mm 160 mm

Calibration Length CL 140 mm 140 mm 150mm 190 mm

Chamfer Length N 10 mm 15 mm 20 mm 20 mm

4.3

Dimensions - fittings

(Note that overall dimensions are subject to change without notice) 11.25, 22.5 & 30 BENDS

Table 15

PN 1, PN 10 & PN 16
Nominal Radius 11.25 Length BL (mm) 400 450 450 450 400 400 450 450 450 500 600 650 700 700 700 700
0

22.50 Length BL (mm) 400 450 500 500 400 450 450 500 500 600 650 750 800 800 800 800 Approx Mass (kg) 13 20 32 43 45 64 78 108 133 229 337 506 681 838 1014 1203

300 Length BL (mm) 400 450 500 500 450 450 500 550 550 600 700 800 850 900 900 1000 Approx Mass (kg) 13 20 32 43 51 64 87 119 147 229 363 540 724 943 1140 1503

Diameter of Bend DN R (mm) (mm) 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 450 600 675 750 900 1050 1200 1350 1500 1800 2100 2400 2700 3000 3300 3600

Approx Mass (kg) 10 18 29 39 51 57 70 97 120 191 311 439 554 734 887 1053

45 & 60 BEND

90 BEND

Table 16

PN 1, PN 10 & PN 16
Nominal Radius 45 Length BL (mm) 500 600 600 650 600 650 700 800 850 950 1100 1250 1350 1450 1550 1550
0

600 Length BL (mm) 550 650 700 750 700 800 850 950 1000 1200 1350 1550 1700 1800 1950 2100 Approx Mass (kg) 17 28 43 62 75 107 139 193 250 430 655 979 1353 1755 2296 2932 Length BL (mm) 750 900 1000 1050 1100 1200 1350 1500 1650 1950 2250 2550 2850 3100 3350 3600

900 Approx Mass (kg) 22 35 56 78 104 141 194 266 362 611 953 1404 1977 2631 3423 4349

Diameter of Bend DN R (mm) (mm) 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 450 600 675 750 900 1050 1200 1350 1500 1800 2100 2400 2700 3000 3300 3600

Approx Mass (kg) 16 26 38 55 66 90 118 168 220 352 553 818 1113 1469 1896 2242

TEES sp, sp & sp

Table 17

PN 1

PN 6 & PN 10

PN 16

Nom Dia Nom Dia Body Branch Approx Body Branch Approx Body Branch Approx Body Branch Length Length Mass Length Length Mass Length Length Mass DN DN L H L H L H (mm) (mm) (mm) (mm) (kg) (mm) (mm) (kg) (mm) (mm) (kg) 100 150 300 200 250 300 100 150 375 200 250 300 375 700 700 800 800 900 700 700 800 800 900 1000 400 400 400 400 450 450 450 450 450 500 500 12 13 16 18 21 17 18 21 23 28 33 1000 1200 1300 1300 1400 1100 1200 1500 1500 1600 1700 550 650 650 650 700 650 700 800 800 850 850 18 23 26 29 34 26 30 39 42 49 57 1300 1600 1700 1700 1800 1500 1600 2000 2100 2100 2300 700 850 850 850 900 850 850 1050 1100 1100 1150 23 30 34 37 44 33 37 49 56 61 71

TEES sp, sp & sp PN 1 PN 6 & PN 10 PN 16

Nom Dia Nom Dia Body Branch Approx Body Branch Approx Body Branch Approx Body Branch Length Length Mass Length Length Mass Length Length Mass DN DN L H L H L H (mm) (mm) (mm) (mm) (kg) (mm) (mm) (kg) (mm) (mm) (kg) 100 150 200 450 250 300 375 450 100 150 200 525 250 300 375 450 525 300 375 600 450 525 600 675 300 375 450 525 600 675 750 300 375 450 525 600 675 750 700 700 800 800 900 1000 1100 700 700 800 800 900 1000 1100 1200 900 1100 1100 1200 1300 900 1100 1100 1200 1300 1400 900 1100 1100 1200 1400 1500 1600 450 450 450 450 500 500 550 500 500 500 500 550 550 550 600 600 600 600 600 650 650 650 650 700 700 700 700 700 750 750 750 800 800 24 25 29 31 37 43 53 31 33 38 40 43 55 65 78 60 75 81 93 109 74 92 99 115 131 149 89 111 119 136 163 186 208 1200 1300 1500 1500 1700 1800 1900 1300 1400 1400 1800 1800 1900 1900 2000 1100 1400 1400 1500 1700 1200 1500 1500 1600 1700 1900 1300 1400 1600 1700 1800 1900 2100 700 750 800 800 900 900 1000 800 800 850 950 1000 1000 1000 1000 700 750 750 750 850 750 850 850 850 900 900 850 850 900 950 1000 1000 1050 40 45 54 57 69 78 93 58 64 67 70 93 104 114 130 73 95 102 116 143 97 125 133 150 170 198 126 140 167 188 212 235 272 1600 1700 1900 2000 2200 2400 1500 1700 1800 1900 2400 2500 2600 2600 2700 1400 1700 1700 1800 1900 1500 1800 1800 1900 2000 2100 1600 1700 1900 2000 2100 2200 2300 900 950 1050 1050 1200 1250 1300 1000 1050 1050 1300 1350 1350 1350 1350 800 900 900 900 950 900 1000 1000 1000 1050 1050 1000 1000 1100 1150 1150 1150 1150 48 54 63 70 83 95 81 69 75 82 86 115 129 140 158 83 104 111 125 143 108 133 141 158 178 197 138 150 177 197 218 239 263

TEES sp, sp & sp

PN 1

PN 6 & PN 10

PN 16

Nom Dia Nom Dia Body Branch Approx Body Branch Approx Body Branch Approx Body Branch Length Length Mass Length Length Mass Length Length Mass DN DN L H L H L H (mm) (mm) (mm) (mm) (kg) (mm) (mm) (kg) (mm) (mm) (kg) 300 375 450 900 525 600 675 750 900 300 375 450 525 1000 600 675 750 900 1000 300 375 450 525 1200 600 675 750 900 1000 1200 900 1100 1100 1200 1400 1500 1600 1700 900 1100 1100 1200 1400 1500 1600 1800 1900 1000 1100 1100 1200 1400 1600 1700 1800 1900 2200 750 750 750 800 850 850 850 850 800 800 800 850 900 900 900 950 950 900 950 950 950 1000 1000 1050 1050 1100 1100 109 135 142 163 198 221 245 274 133 164 172 196 236 263 290 341 378 205 231 240 270 323 376 415 456 508 629 1400 1500 1600 1700 1900 2000 2100 2300 1400 1500 1500 1600 1900 2000 2200 2300 2500 1500 1600 1600 1700 1800 2200 2300 2400 2500 2800 950 950 950 1000 1050 1050 1100 1150 1000 1000 1000 1000 1150 1150 1200 1200 1250 1200 1200 1200 1200 1200 1350 1350 1350 1350 1400 166 182 202 226 263 289 321 370 202 221 231 256 317 347 396 434 498 305 331 343 376 410 514 555 602 655 800 1600 1800 2000 2100 2200 2400 2500 2600 1700 1800 1900 2000 2400 2500 2600 2800 2900 1800 2000 2000 2100 2200 2700 2800 2900 3000 3200 1100 1100 1200 1250 1300 1300 1300 1300 1200 1200 1200 1200 1400 1400 1400 1400 1400 1350 1350 1350 1350 1400 1600 1600 1600 1600 1600 170 194 224 248 274 309 336 370 218 235 256 280 350 379 410 459 501 322 362 373 403 437 551 589 636 687 801

TEES sp, sp & sp PN 1

Nom Dia Body DN (mm) Nom Dia Branch DN (mm) 300 375 450 525 600 1400 675 750 900 1000 1200 1400 300 375 450 525 600 1600 675 750 900 1000 1200 1400 1600 300 375 450 525 600 675 1800 750 900 1000 1200 1400 1600 1800 Body Length L (mm) 1000 1100 1200 1300 1400 1500 1700 1900 2000 2200 2500 1000 1200 1200 1300 1400 1600 1700 1800 2000 2300 2500 2800 1000 1200 1200 1300 1400 1600 1700 1800 2100 2300 2600 2800 3100 Branch Length H (mm) 1000 1050 1050 1050 1100 1100 1150 1150 1200 1200 1250 1150 1150 1150 1200 1200 1250 1250 1300 1300 1350 1350 1400 1250 1250 1250 1300 1300 1350 1350 1350 1450 1450 1500 1500 1550 Approx Mass (kg) 275 308 344 381 424 466 539 615 676 797 969 356 430 441 490 539 627 681 746 846 1032 1191 1414 445 538 550 608 668 775 839 910 1085 1253 1492 1695 1975 Body Length L (mm) 1600 1700 1700 1800 2000 2100 2400 2500 2600 2900 3200 1700 1800 1900 2000 2100 2200 2300 2700 2800 3100 3400 3600

PN 6 & PN 10
Branch Length H (mm) 1350 1350 1350 1350 1400 1400 1500 1500 1500 1550 1600 1500 1500 1500 1500 1550 1550 1550 1700 1700 1750 1800 1800 Approx Mass (kg) 436 469 483 524 595 642 750 807 871 1045 1241 597 639 688 738 794 850 908 1092 1168 1377 1610 1818

AIR VALVE TEES sp, sp & fl (Drilling to AS 4087 Class PN 16)

Table 18

PN 1, PN 6 & PN 10
Nom Dia Body DN (mm) 300 375 450 525 Nom Dia Branch DN (mm) 100 100 100 150 100 150 100 600 150 200 100 675 150 200 100 750 150 200 250 100 900 150 200 250 100 1000 150 200 250 100 1200 150 200 250 100 1400 150 200 250 Body Length L (mm) 1000 1100 1200 1200 1300 1400 1100 1100 1100 1200 1200 1200 1300 1300 1300 1300 1400 1400 1400 1400 1400 1400 1400 1400 1500 1500 1500 1500 1600 1600 1600 1600 Branch Length H (mm) 550 650 750 750 800 800 700 700 700 750 750 750 800 800 800 800 800 900 900 900 900 900 900 900 1000 1000 1000 1000 1100 1100 1100 1100 Approx Mass (kg) 21 29 43 48 61 70 66 71 75 90 94 99 117 122 127 135 155 160 165 174 191 196 201 209 291 296 302 310 419 425 430 439 Body Length L (mm) 1300 1500 1600 1600 1700 1800 1400 1400 1400 1500 1500 1500 1600 1600 1600 1600 1600 1600 1600 1600 1700 1700 1700 1700 1800 1800 1800 1800 2100 2100 2100 2100

PN 16
Branch Length H (mm) 550 650 750 750 800 800 700 700 700 750 750 750 800 800 800 800 800 900 900 900 900 900 900 900 1000 1000 1000 1000 1100 1100 1100 1100 Approx Mass (kg) 26 36 51 56 71 80 75 80 85 99 104 109 127 132 137 146 157 163 168 177 204 209 214 224 306 312 317 327 481 487 492 502

AIR VALVE TEES sp, sp & fl

PN 1, PN 6 & PN 10
Nom Dia Body DN (mm) Nom Dia Branch DN (mm) 100 1600 150 200 250 100 1800 150 200 250 100 2000 150 200 250 100 2200 150 200 250 100 2400 150 200 250 Body Length L (mm) 1700 1700 1700 1700 2700 2700 2700 2700 3000 3000 3000 3000 3300 3300 3300 3300 3600 3600 3600 3600 Branch Length H (mm) 1200 1200 1200 1200 1300 1300 1300 1300 1400 1400 1400 1400 1500 1500 1500 1500 1600 1600 1600 1600 Approx Mass L (kg) 578 584 590 599 1153 1159 1165 1175 1574 1580 1587 1597 2092 2098 2105 2116 2706 2713 2720 2731 Body Length H (mm) 2400 2400 2400 2400 2700 2700 2700 2700 3000 3000 3000 3000

PN 16
Branch Length (mm) 1200 1200 1200 1200 1300 1300 1300 1300 1400 1400 1400 1400 Approx Mass (kg) 713 719 725 735 1010 1016 1023 1033 1379 1386 1392 1403

SCOUR TEES sp, sp & fl (Drilling to AS 4087 Class PN 16)

Table 19

PN 1, PN 6 & PN 10
Nom Dia Body DN (mm) 300 375 450 525 Nom Dia Branch DN (mm) 100 100 100 150 100 150 100 600 150 200 100 675 150 200 100 750 150 200 250 100 900 150 200 250 100 1000 150 200 250 Body Length L (mm) 1000 1100 1200 1200 1300 1400 1100 1100 1100 1200 1200 1200 1300 1300 1300 1300 1400 1400 1400 1400 1400 1400 1400 1400 Branch Length H (mm) 550 650 750 750 800 800 700 700 700 750 750 750 800 800 800 800 800 900 900 900 900 900 900 900 Approx Mass (kg) 21 29 43 48 61 70 66 71 75 90 94 99 117 122 127 135 155 160 165 174 191 196 201 209 Body Length L (mm) 1300 1500 1600 1600 1700 1800 1400 1400 1400 1500 1500 1500 1600 1600 1600 1600 1600 1600 1600 1600 1700 1700 1700 1700

PN 16
Branch Length H (mm) 550 650 750 750 800 800 700 700 700 750 750 750 800 800 800 800 800 900 900 900 900 900 900 900 Approx Mass (kg) 26 36 51 56 71 80 75 80 85 99 104 109 127 132 137 146 157 163 168 177 204 209 214 224

PN 1, PN 6 & PN 10
Nom Dia Body DN (mm) Nom Dia Branch DN (mm) 100 1200 150 200 250 100 1400 150 200 250 100 1600 150 200 250 100 1800 150 200 250 100 2000 150 200 250 100 2200 150 200 250 100 2400 150 200 250 Body Length L (mm) 1500 1500 1500 1500 1600 1600 1600 1600 1700 1700 1700 1700 2700 2700 2700 2700 3000 3000 3000 3000 3300 3300 3300 3300 3300 3300 3300 3300 Branch Length H (mm) 1000 1000 1000 1000 1100 1100 1100 1100 1200 1200 1200 1200 1300 1300 1300 1300 1400 1400 1400 1400 1500 1500 1500 1500 1500 1500 1500 1500 Approx Mass (kg) 291 296 302 310 419 425 430 439 578 584 590 599 1153 1159 1165 1175 1574 1580 1587 1597 2092 2098 2105 2116 2706 2713 2720 2731 Body Length L (mm) 1800 1800 1800 1800 2100 2100 2100 2100 2400 2400 2400 2400 2700 2700 2700 2700 3000 3000 3000 3000

PN 16
Branch Length H (mm) 1000 1000 1000 1000 1100 1100 1100 1100 1200 1200 1200 1200 1300 1300 1300 1300 1400 1400 1400 1400 Approx Mass (kg) 3 0 6 3 1 2 3 1 7 3 2 7 4 8 1 4 8 7 4 9 2 5 0 2 7 1 3 7 1 9 7 2 5 7 3 5 1 0 1 0 1 0 1 6 1 0 2 3 1 0 3 3 1 3 7 9 1 3 8 6 1 3 9 2 1 4 0 3

SLOPE JUNCTIONS

Table 20

Non pressure PN 1 (only)

Nom Dia Body DN (mm) 100 150 200 Nom Dia Branch DN (mm) 100 100 150 100 150 200 100 150 200 250 100 150 200 250 300 100 150 200 250 300 375 100 150 200 250 300 375 450 Body Length L (mm) 600 600 700 600 700 800 600 700 800 900 700 800 900 1000 1100 700 800 900 1000 1100 1300 700 800 900 1000 1100 1300 1400 Branch Length E (mm) 420 420 420 420 500 500 500 500 570 570 500 570 570 640 710 570 640 640 710 780 850 640 710 710 780 850 920 920 Length F (mm) 350 375 425 400 450 500 425 475 525 575 500 550 600 650 700 550 600 650 700 750 850 600 650 700 750 800 900 950 Branch Height H (mm) 300 300 300 300 350 350 350 350 400 400 350 400 400 450 500 400 450 450 500 550 600 200 500 500 550 600 650 650 Approx Mass (kg) 2.6 4.1 5.6 5.6 7.8 9.8 8.2 10.6 13.5 16.9 12.7 15.9 19.3 23.9 29.5 16.9 20.7 24.8 30.2 36.7 47.7 24.0 29.1 34.1 40.6 48.3 61.6 74.3

250

300

375

450

SLOPE JUNCTIONS

Non pressure PN 1 only

Nom Dia Body DN (mm) 525 Nom Dia Branch DN (mm) 100 150 200 250 300 375 450 525 300 375 450 525 600 300 375 450 525 600 675 300 375 450 525 600 675 750 Body Length L (mm) 700 800 900 1000 1100 1300 1400 1500 1100 1300 1400 1500 1600 1100 1300 1400 1500 1700 1900 1100 1300 1400 1500 1700 1900 2100 Branch Length E (mm) 710 710 780 780 850 920 990 990 920 990 990 1060 1130 990 1060 1060 1130 1200 1270 1060 1130 1130 1200 1270 1340 1410 Length F (mm) 600 650 700 750 800 900 950 1000 850 950 1000 1050 1100 900 1000 1050 1100 1200 1300 950 1050 1100 1150 1250 1350 1450 Branch Height H (mm) 500 500 550 550 600 650 700 700 650 700 700 750 800 700 750 750 800 850 900 750 800 800 850 900 950 1000 Approx Mass (kg) 32 38 45 52 61 77 91 108 77 95 112 130 153 94 116 134 155 188 225 113 138 158 182 218 259 304

600

675

750

Table 21 Nominal Diameter DN DN Large Small End End (DL) (DS) (mm) (mm) 150 200 200 250 250 300 300 375 450 525 525 600 600 675 675 750 750 900 900 1000 1000 1200 1400 1600 1800 2000 2200 2400 100 100 150 150 200 200 250 300 375 375 450 450 525 525 600 600 675 675 750 750 900 1000 1200 1400 1600 1800 2000 2200 Taper length (L) (mm) 125 250 125 250 125 250 125 188 188 375 188 375 188 375 188 375 188 563 375 625 250 500 500 500 500 500 500 500 Dimensions Spigot Overall lengths Length (A & B) (mm) 300 300 300 300 300 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 500 500 600 600 600 600 600 (mm) 725 850 725 850 725 1050 925 988 988 1175 988 1175 988 1175 988 1175 988 1363 1175 1425 1050 1500 1500 1700 1700 1700 1700 1700 4 6 6 8 9 15 16 22 29 36 39 50 53 68 67 85 83 106 102 129 125 222 313 473 615 757 927 1108 PN1 Approx. Mass PN6 & PN16 PN10 (kg) 4 6 7 11 12 17 18 29 39 54 55 71 72 100 95 130 121 167 152 206 188 360 557 820 1078 1347 1641 1928 4 7 8 13 14 23 24 44 59 76 75 89 87 120 106 174 155 242 217 298 265 512 740 1166 1495 1821

MANHOLE CONNECTORS

Table 22

Non pressure PN 1 only

Nominal Diameter DN (mm) 100 150 200 250 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 Length L (mm) 600 600 600 600 600 600 600 600 600 750 750 750 1000 1000 1000 1000 1200 1200 1200 1200 OD (Maximum) (mm) 139 162 180 227 282 346 567 667 747 827 906 1013 1115 1319 1523 1737 1941 2155 2359 2563 Approx Mass (kg) 2.4 4.2 6.1 9.3 12.7 17.6 24.3 22.3 42.5 63.1 75.8 94.2 147.9 208.5 279.4 363.2 539.5 663.4 798.1 943.1

FLANGE SPIGOT CONNECTORS

Table 23 PN 10 Nom Diameter DN (mm) 100 150 200 250 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 Flange OD (mm) 230 305 370 430 490 610 675 785 850 935 1015 1185 1275 1530 1750* 1960* 2160* 2395* 2610* 2825* Length L (mm) 350 400 400 400 400 450 450 450 500 550 550 600 600 700 750 800 900 950 1050 1100 Approx Mass (kg) 2.7 5.4 8.4 13.1 16.1 26.4 35.1 43.1 62.0 85.7 113.1 145.1 186.2 303.7 437.6 605.5 844.4 1101.5 1470.8 1799.6 PN 16 Length L (mm) 400 400 400 450 400 450 450 450 500 550 550 600 650 750 800 850 950 1000 Approx Mass (kg) 3.3 6.4 9.3 15.1 17.1 27.8 36.4 46.9 68.1 88.5 117.3 151.1 198.9 326.0 459.1 729.1 892.4 1140.8

CLOSED COUPLINGS

Table 24

Non pressure PN 1
Nom Dia DN (mm) 80 100 125 150 200 250 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000 Coupling OD (mm) 134 157 175 212 278 332 402 483 564 644 732 812 893 993 1098 1307 1516 1725 1934 2144 2353 2562 3208 Length L (mm) 157 157 157 157 182 182 277 277 277 277 338 338 339 340 341 343 345 347 349 352 354 356 392 Approx Mass (kg) 1.4 1.7 2.0 2.4 4.6 6.5 13.3 16.4 19.8 23.2 36.7 41.3 47.1 55.8 66.0 88.6 116.0 149.0 187.0 239.9 293.4 356.3 685.1

Table 25 45 degree Nom Dia Body DN (mm) 300 375 Nom Dia Branch DN (mm) 100 150 100 150 225 300 450 100 150 225 300 525 100 150 225 300 100 600 150 225 300 100 675 150 225 300 100 750 150 225 300 100 900 150 225 300 Branch Length H (mm) 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 Body Body Approx Length Width Mass L W (mm) (mm) (kg) 400 450 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 260 315 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 69 94 62 84 139 195 57 78 129 181 54 73 121 170 37 50 83 116 36 49 80 113 44 59 98 137 47 63 105 147 Body Length L (mm) 260 310 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 90 degree Body Width W (mm) 260 315 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 Approx Mass (kg) 45 64 40 58 97 137 37 54 90 127 35 50 85 119 24 35 58 82 23 34 56 79 28 41 69 96 30 44 73 103

SADDLE JUNCTIONS

Nom Dia Body DN (mm)

Nom Dia Branch DN (mm) 100

Branch Length H (mm) 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400

Body Body Approx Length Width Mass L W (mm) (mm) (kg) 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 400 450 570 670 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 47 63 104 147 54 73 121 170 54 74 122 172 56 76 125 176 57 77 128 179 59 80 132 185 61 83 137 193 64 87 144 202 71 97 160 225

Body Length L (mm) 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470 260 310 400 470

Body Width W (mm) 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490 260 315 410 490

Approx Mass (kg) 30 44 73 103 35 51 85 119 35 51 86 121 36 52 88 123 37 53 90 126 38 55 92 130 40 57 96 135 42 60 101 141 46 67 112 158

1000

150 225 300 100 150 225 300 100 150 225 300 100 150 225 300 100 150 225 300 100 150 225 300 100 150 225 300 100 150 225 300 100 150 225 300

1200

1400

1600

1800

2000

2200

2400

3000

MANHOLE DROP JUNCTIONS

Table 26

Non pressure PN 1
Nom Dia DN (mm) 300 375 450 525 600 675 750 Length L (mm) 1780 1939 1877 2233 2380 2784 3000 Offset B (mm) 890 969 939 1117 1190 1392 1500 Centreline Height F (mm) 890 969 939 1117 1190 1392 1500 Approx Mass (kg) 50 73 103 164 225 333 439

MANHOLE DROP BENDS

Table 27

Non pressure PN 1
Nom Dia DN (mm) 300 375 450 525 600 675 750 Offset B (mm) 890 969 939 1117 1190 1392 1500 Centreline Height B (mm) 890 969 939 1117 1190 1392 1500 Approx Mass (kg) 31 44 61 96 129 185 240

5
5.1

HYDRAULIC DESIGN
Flow and pressure capacity calculations

Flowtite pipelines have exceptionally good hydraulic performance when new, as they fall in the smooth polymer pipe category. However, these may in some instances be affected by various adverse service factors including: Growth of slime (varies with age of the pipeline and available nutrient in the water) Siltation or settlement of suspended particulate matter Fittings types and configurations

The flow resistance chart has been provided see Figures 5.1. It is based on the following parameters. Operating temperature of 20C which corresponds to a kinematic viscosity of water = 1.01 x 10-6 m2/s Equivalent roughness k= 0.020 0.015 mm

An approximate allowance for the effect of variation in water temperature on the chart values an be made by increasing the chart value of the head loss by 1% for each 3C below 20 and by decreasing it by 1% for each 3C in excess of 20 of pressure rating The notation used for the equations in this section follows: d f g HL H i j k m n N Q Qp Qf R Rp Rf S V Vp Vf T y = = = = = = = = = = = = = = = = = = = = = = = = internal diameter (m) Darcy friction co-efficient acceleration due to gravity (m/sec2) friction head loss (m) Total (pumping) head annual interest rate annual interest rate including inflation equivalent hydraulic roughness (m) assumed inflation rate Manning n planned life of system (years) flow or discharge (L/s) most probable peak flow (L/s) flow or discharge - pipe flowing full (L/s) hydraulic mean radius i.e. flow area/perimeter (m) hydraulic mean radius for partly full pipe (m) hydraulic mean radius for full pipe i.e. d/4 (m) hydraulic gradient, also slope of gravity flow sewer (m/m) mean velocity (m/sec) mean velocity in part full pipe (m/s) mean velocity - pipe flowing full (m/s) duration of pump operation (hours/year) depth of flow above pipe invert (m) fluid density (kg/m3)

= = =

kinematic viscosity (m2/sec) angle (radians) subtended at pipe centre by water surface in invert - see Figure 3.4 average boundary shear stress (Pa)

The chart is based on calculations using the Colebrook White Transition Equation see equation 5.1. For pipes flowing full this equation takes into account, liquid viscosity and pipe roughness, and is recognised as being one of the most accurate in general use but requires iterative solutions. The Colebrook-White transition equation is as follows:

k 2.51 2 2 gdS log + 3.7d d 2 gdS

Equation 5.1

When comparing Flowtite with other pipe systems, designers should take into account both the smooth bore and the anticipated pipeline service. Different applications may require a variation of the values of roughness coefficients chosen to conform to accepted practice. In the case of sewerage, it may be considered necessary to allow for slime development. Generally smooth pipe materials have a Colebrook White k value equal to less than one fifth of the value used for the rougher materials such as cement lined, concrete and vitrified clay pipes used for the same purpose. Empirical formulae, exponential in form, have been in engineering use over many years. Being relatively easy to use they are still favoured by some engineers. For water supply applications, Hazen Williams equation is frequently used i.e. Q = 278 C d 2.63 S 0.54 Equation 5.2

Using the Norwegian experimental data the derived value of Hazen Williams Coefficient for Flowtite of C between 152 and 155. The Manning Equation is the most common for non-pressure gravity flow. Q =
4000 d 4 n
8 3

Equation 5.3

For Flowtite n may be taken as 0.01 for a clean pipeline. Again this is conservative compared with Australian Standard AS 2200 that gives the range of n for polymeric materials of 0.008 to 0.009.

Figure 5.1

Design flow velocities The Water Services Association of Australia Code WSA O3 design recommendations may be applied to Flowtite pipe installations. In pumped transmission mains capital cost and discounted running costs should be determined see Section 5.2. However as a guide the Code suggests that the most economic design is likely to have velocities in the range 0.8 to 1.4 m/s. In some circumstances it also suggests that 2.0 m/s may be acceptable or 4.0 m/s for short periods with 6.0 m/s as the maximum. Generally head losses should not exceed 3 m/km (or 5m/km for pipes less than DN 200). Where the water is carrying abrasive material the design velocity should not exceed 4.0 m/s.

5.2

Economic considerations

Since energy consumption is a significant factor in pumped pipelines an economic analysis is necessary of optimize the cost of capital involved in building a pipeline and the present worth of the anticipated energy consumption over the life of the pipeline An example of a typical present worth calculation to determine the optimum pipe diameter for a particular project is shown in Table 28 where 16 km long pipeline is required to carry a flow of 350 L/s. The overall capital cost is combined with the present worth of the annual pumping costs over the 25-year life of the system to determine the least expensive option. The equations needed for these calculations are: Annual pumping cost Y

Y=

0.0098 Q H C T pump efficiency

Equation 5.4

Present value of annuity A can be calculated from:

A=

Y (1 (1 + i ) n ) i

Equation 5.5

Where the rate of inflation is to be included, then

A=

Y (1 (1 + j ) n ) j

Equation 5.6

The adjusted interest rate j is calculated from

j=

(i m) (1 + m)

Equation 5.7

Note that in the special case where i = m then the value of A = n x Y Table 5.1 shows the calculations for optimizing the pipe size for a major transmission main. It can be concluded from the table that for the assumptions made a DN 525 pipeline would be the best option for a minimum present worth cost.

Table 28 Example optimizing pipe size on financial basis Pipe Description: Flowtite Flowtite Flowtite DN450 DN525 DN600 10/5000 10/5000 10/5000

Flowtite DN675 10/5000 350 16000 30 $433.00

Input information
Flow [L/s] Length [metres] Static lift [m] Cost of Pipeline [$/m] Viscosity [m/s2] Internal diameter [m] Roughness "k" [mm] 350 16000 30 $232.00 1.0100E-06 0.487 0.02 350 16000 30 $284.00 350 16000 30 $354.00

1.0100E-06 1.0100E-06 1.0100E-06 0.569 0.647 0.725 0.02 0.02 0.02

Results of calculation
Head loss due to flow resistance [m/m] Total flow resistance head [m] Pump efficiency[%] Power reqd.[kW] Cost per kWh [$/kWh] Op. hours/year Op. cost [$/year] Return on investment [%/yr] Life of scheme [years] Present value pumping cost [w/o inflation]:Total P V [w/o infl.] Annual inflation rate [%] Resulting effective interest rate [%] Present value of pumping cost [including inflation] Total present worth [including inflation] 0.00449 71.82 65.0 537.3 $0.12 7000 $451,347 10.00 25 $4,096,891 $7,808,891 3.00 6.80 $5,357,841 $9,069,841 0.002173 34.77 65.0 341.8 $0.12 7000 $287,092 10.00 25 0.001155 18.48 65.0 255.8 $0.12 7000 $214,893 10.00 25 0.000665 10.64 65.0 214.5 $0.12 7000 $180,141 10.00 25

$2,605,942 $1,950,594 $1,635,152 $7,149,942 $7,614,594 $8,563,152 3.00 3.00 3.00 6.80 6.80 6.80 $3,408,004 $2,550,952 $2,138,422 $7,952,004 $8,214,952 $9,066,422

Table 28 shows that the DN 525 pipeline is likely to be the best option. This may be subject to a sensitivity analysis to cover the effect of varying some of the less certain assumptions made.

5.3

Air Valves, anti-vacuum valves and scour valves

Air must be expelled from a pressure pipeline during the filling operation and also allowed to enter a pipeline if it is being emptied for any reason. Also, because most water is saturated with air, which will leave solution when the water pressure is reduced, air will tend to collect at high point in a pipeline system under normal operating conditions. As air accumulates, it has the effect of lessening the effective pipe diameter leading to reduced discharge or increase friction head. In extreme situations the flow may actually cease (see Fig 5.3). Pressure surges of high magnitude may also result from the unstable flow conditions created.

FIG 5.3 There is no flow in this pipeline due to lack of air valves An automatic air valve is comprised of a float confined in a chamber with an orifice to atmosphere on top and connection to the pipeline at the bottom. When the chamber is full of water the float seals the orifice, but when air from the line enters the chamber or the pressure drops below atmospheric the float drops. It remains open until water refills the chamber and air is bled from the line. Where the hydraulic grade is close to the high point of a pipeline a simple vent tube extended above the grade line may be used as an AV. Location of air valves Air (and gases) periodically released from the liquid in a pipeline due to temperature changes, water movements etc. will accumulate in the more elevated sections or peaks. It is good practice in pressure pipelines to grade evenly between these peaks to ensure that the locations of all potential air traps are known. Air valves are required at peaks or sharp changes in grade in the pipeline to allow the air to escape progressively and avoid any reduction of flow capacity or unnecessary pressure surges. Peaks relative to the hydraulic gradient as well as the horizontal datum should be considered for AV location. Generally the large orifice diameter should be at least 0.1 of the pipe diameter. The volume rate of flow air through an orifice is roughly 40 times that of water under the same pressure differential. The following is the list of typical conditions where air valve may be found necessary. 1. Where a section of pipeline a) Runs parallel to the hydraulic gradient b) Has a long horizontal run. Double air valves are required at the end of a run, and single air valves located at every 500-1000 metres of run. 2. Where pipeline peaks above the operating hydraulic gradient but below the higher (source) level, air can be expelled at this point by installing a manually operated gate valve (not an air valve) which is opened when the lower (outlet) level valve is closed. The operation should be carried out at regular intervals. Where the pipeline peak above the higher (source) level, syphoning will occur and special provision will have to be made to expel air such as a vacuum pump. It is recommended that peaking above the hydraulic gradient, and the source level should be avoided. 3. Where abrupt changes the grade occur on both upward and downward slopes, a small orifice air valve should suffice.

4. During long ascents, large orifice air valves are required at 500-1000 metre intervals. 5. During long descent, double air valves are required at 500-1000 metre intervals. 6. On the downstream side of section valves in trunk mains, or where flow is in both directions, on both sides. In large diameter pipelines (e.g. DN600 or greater) consideration should be given to all likely operating conditions. For example where flow capacities are significantly below the design maximum, hydraulic jumps may develop due to the pipeline being partially full or in a channel flow mode.

FIG 5.4 Hydraulic jumps require additional vents

As illustrated in Figure 5.4 a series of unstable hydraulic jumps may cause air to accumulate downstream from the peak. This air may need to be extracted using a series of suitably spaced vents. These may be combined using a series of interconnected tappings to permit air to return to the air space upstream of the jump. Where air valves are require on mains of major importance it is normal practice to install a gate valve directly onto the tee branch prior to connecting the air valve. Alternatively, an air valve incorporated a control valve can be used. This allows maintenance to be carried out on the air valve without dewatering the pipeline. Under operating conditions care should be taken to ensure that this valve is always left in the open position. Types of automatic air valves Single air valves The single air valve, with small orifice (Fig 5.5) is used to release small quantities of air, which may accumulate in charged water main. Although designated by their inlet connection, e.g. 25 mm, this has nothing to do with the orifice size, which may be as small as 3 mm.

Double air valves The double air valve, with small and large orifice in separate chambers (Fig 5.6), performs the dual function of realising small quantity of air as it collects (similar to the single air valve), and admits or releases large volumes of air when a pipeline is emptied or filled. They are designated by their inlet connection, which is usually slightly smaller than the orifice diameter. Sizes range from 50mm to 100mm.

FIG 5.6 Double air valves

Kinetic air valves A difficulty sometimes experienced with large orifice air valves that the ball blows shut when a water main is being filled at the high rate. A pressure differential of 100 kPa could lead to air velocities approaching 300 m/sec i.e. the speed of sound. The kinetic air valve (Fig 5.7) has a float chamber constructed in such a way that air expelled from a rapidly filled main cannot blow the valve shut, however high the emergent air velocity.

FIG 5.7 Double kinetic air valves with control valve

Anti-vacuum valves Anti-vacuum valves have the primary function of preventing the formation of a vacuum in large diameter water mains or hydro-electric penstocks. They are much larger in size than conventional air valves with orifice sizes ranging from DN 200 to DN 500. The corresponding airflows at 50% vacuum will range from 5m3 per second to 50m3 per second respectively.

Scour valves Scouring points located in depressions along a pressure main are essential so that the line can be drained for maintenance purposes and sediment removal. Special flanged scour tees with branches offset to invert level are available. The discharge from a scouring point is usually piped to a nearby stormwater drain unless the effluent will cause pollution. In these cases a detention tank has to be provided so that a tanker can remove foul water.

5.4

Surge Capacity

Flowtite pipes are designed to resist surge pressures in excess of the nominal pressure class. Flowtite pipes are designed in accordance with AWWA M-45 Fiberglass Pipe Design Manual. The maximum surge pressure in accordance with AWWA M-45 is 1.4 times nominal pressure. AS/NZS 2566.1 Buried flexible pipelines Part 1: Structural design recommends a lower value of 1.25 times nominal pressure.

5.5

Water hammer surge celerities

Water hammer effects are considerably reduced in polymeric pipeline materials including GRP when compared with iron steel and concrete due to much lower moduli of elasticity. Typical values for celerities in Flowtite pipes of different diameters, stiffness and classes are given in Table 29.
Table 29 Water hammer celerities (m/s) for Flowtite

Description PN 6 SN 2500 PN 10 SN 2500 PN 16 SN 2500 PN 6 SN 5000 PN 10 SN 5000 PN 16 SN 5000 PN 25 SN 5000 PN 6 SN 10000 PN 10 SN 10000 PN 16 SN 10000 PN 25 SN 10000 PN 32 SN 10000

DN 80 - DN100 570 580 630 -

DN 150 - DN250 520 540 600 -

DN 300 - DN 375 365 435 500 405 435 505 575 -

DN 450 - DN 750 350 420 490 380 420 495 570 415 425 495 570 615

DN 900 - DN 3000 340 405 480 370 410 480 560 410 415 485 560 615

Figure 5.8 illustrates a typical water hammer pressure envelope. These can be determined using computer software such as WATHAM, HYTRAN or an equivalent. In this diagram the maximum surge effect has been generated at the pump shutdown, a situation that is quite common.
MAX. POSITIVE SURGE (ON STOPPING) MAX. POSITIVE SURGE (ON STARTING)

DESIGN HEAD

HYDRAULIC GR ADIENT

(OPERATING )

NO FLOW STATIC HEAD MIN NEGATIVE SURGE (ON STOPPING)

DISCHARGE M/H

SUB ATMOSPHERIC PRESSURE PUMP

Figure 5.8 Typical hydraulic grades and surge envelopes required for design

5.6

Fatigue under cyclical pressure regimes

Flowtite pipes when manufactured in accordance with ISO 10467 and ISO 10639 and used in water, drainage and sewerage applications do not require de-rating for cyclic pressure fatigue. The standards specify that complying pipes shall be type tested in accordance with the methods of ISO15306. In the cyclical pressure test the pipe specimen is subjected to pressure cycles 0.25 times the nominal pressure for at least one million cycles. For example a PN16 pipe would be subjected to a cyclical pressure range from 1200 kPa to 2000 kPa at a nominated frequency. Test reports are available for Flowtite specimens, which show that, after being subjected to a minimum of one million cycles, they had ultimate, burst strengths and pressure proof test performances equivalent to those of untested new pipes. These tests illustrate that there is a considerable difference in the fatigue characteristics between GRP pipes made from reinforced thermoset plastics when compared to un-reinforced thermoplastics pipes.

5.7

Thermal effects on pressure ratings

Flowtite pipe resin is classified as a thermoset and is less affected by elevated temperatures than many thermoplastics. The standard orthophthalic polyester pipe resin has a heat distortion temperature (HDT) of 750 C and is limited to a maximum long term operating temperature of 550C. Refer to Table 5.3 for re-rating factors based on AS 2634 recommendations. Higher operating temperatures are possible where vinyl ester pipe resins are used.
Table 30 Thermal pressure rating for standard polyester resin

Long term operating temperature 0C 35 40 45 50 55

Re-rating factor applied to PN 1.00 0.95 0.90 0.85 0.80

5.8

Non pressure pipeline design

Low head irrigation and stormwater drainage design The design of drainage pipe networks is discussed in Australian Rainfall and Runoff published by the Institution of Engineers. There are differences from other applications owing to the frequency of inlet and junction pits, which significantly affect the hydraulic capacity of the system. Similar effects are sometimes seen in gravity flow irrigation systems. In both cases high head losses occur through pits. Pits may be rectangular, circular, benched and unbenched, with and without sidelines, with and without entries for surface stormwater from gutters on roadways, and often involve changes in flow direction. The value for KL in Figure 5.9 can range from 0.2 to 2.5 or more depending on the pit configuration. Appropriate values can be obtained from ARRB Report No. 34 Stormwater drainage design in small urban catchments by John Argue. Another consideration affecting flow capacity is the debris and sediment load which stormwater flow often carries.

Figure 5.9 Accounting for head losses through low head chambers Sewerage design The design of gravity sewers can be complex owing to the assumptions that must be made to cover wide variations in flows between storm flows and low dry weather sewage flows. Although the pipes must be sized to carry the high wet weather flows, the size and grade must also meet self-cleansing criteria under dry weather conditions. Acceptable design methods will vary between authorities and the whether the system is to be designed for sewage flows only or combined sewage and stormwater flows. In Australia the separated sewage flow is the usual requirement. Even so these systems often carry considerable stormwater flow in wet weather due to incidental inflow and infiltration of storm water. For design purposes the normal average sewage flow of say 0.003 L/s per head of population or equivalent population (EP) is increased by a series of empirical factors to allow for peak dry and peak wet weather flows. The resulting maximum design flow is therefore much higher than the estimated average flow. Sewer pipes are sized to carry the maximum design flow (Qf) flowing full. In addition a check is made to ensure that in dry weather there will be sufficient flow to ensure a self-cleansing flow at least once daily.

Figure 5.10 Self-cleansing flow - angle of repose of sediment Historically, the normal design criterion was that a partial flow with a self-cleansing velocity of 0.6 m/s had to be achieved once a day. Today most design methods are based on fluid boundary layer shear theory. Research on movement of sand particles on submerged pipe perimeters at low flows shows that deposition will occur on the flatter parts of the pipe invert where the slope of the pipe wall is less than = 350 refer to Figure 5.10. Boundary layer design theory builds on this fact. From open channel theory the following expression can be written in terms of average boundary shear stress .

= .g.R.S

Equation 5.8

For a circular sewer flowing part full, since Rf =d/4 Equation 5.8 can be rewritten

= .g . d 4 .

Rp Rf

.S

Equation 5.9

It can be assumed for 1.5 Pa that the pipe invert will be self-cleansing. Therefore taking this as the value for , the minimum self cleansing slope can be determined by rearranging Equation 5.9:

S min =

4. R .g.d . p R f

Equation 5.10

Using geometrical relationships and Mannings equation (Equation 5.3), the hydraulic elements chart Figure 5.11 has been developed to relate the flow, depth and hydraulic mean radius ratios to each other. With the Qp/Qf ratio known, the depth ratio y/d can be found and then from this value the Rp/Rf ratio can be determined for substitution in Equation 5.10

1.0 0.9 0.8

Depth to diameter ratio (y/d)

0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

1.3

Ratio of hydraulic mean radius, velocity and flow

Qp/Qf Vp/Vf Rp/Rf

Figure 5.11 Proportional velocity and discharge in part-full pipes Example Problem: A DN 1000 Flowtite sewer carrier laid at a 0.068% gradient, with an assumed Colebrook White roughness k = 0.02 mm, will carry 800 L/s when flowing full (See Figure 5.2). The probable daily peak dry weather flow is estimated at 320 L/s. Will this sewer be self-cleansing? Solution: From the flow resistance chart Figure 5.2 , it can be seen that a DN 1000 Flowtite pipe has a hydraulic gradient of 0.36 m/m when flowing at 800 L/s. The ratio Qp/Qf = 320 / 800= 0.40 From Figure 5.6; y/D = 0.48 and for this depth ratio Rp/Rf = 0.94 Substituting for Rp/Rf in Equation 5.10 (with 1.5 Pa) = 0.000651 or 0.0.065%. As this required grade of 0.065% is less than the 0.068% proposed, the pipeline will be self-cleansing.

6
6.1

STRUCTURAL DESIGN
Allowable cover heights

In engineering terminology Flowtite pipes are considered to be flexible pipes. This means they are designed to deform or deflect diametrically within specified limits without structural damage. The external soil and live loadings above flexible pipes may cause a decrease in the vertical diameter and an increase in the horizontal diameter of the pipe or cause ring instability. The horizontal movement of the pipe walls in the soil material at the sides develops a passive resistance within the soil to support the external load. That is, the pipeline performance at a given cover height is influenced by the native soil type, its stiffness, the pipe embedment material, its compaction, the height of water table, vacuum conditions, live loading such as vehicular loads, and hydrostatic operating pressures. The higher the effective soil modulus at pipe depth, the less the pipe will deflect and the ring stability will be improved. Initial deflections of up to 3% are permissible and will not affect the pressure rating of the pipe. Contact Fibrelogic for further details or refer to AS/NZS 2566.1 Buried flexible pipelines Part 1 Structural design To properly assess the effect of site conditions on a proposed installation, specific information is needed for design including: Pipe diameter Cover height Properties of native soil Width of embedment Properties of embedment material Height of water table Traffic loading Special requirements, such as concrete encasement or grouting. The appropriate value of the effective soil deformation modulus for a particular installation will depend on the native soil type and condition, the pipe embedment material, its degree of compaction and its geometry (e.g. trench width / embedment width). Geotechnical surveys giving soil types and properties, including soil-bearing capacities, SPT values at pipe depth and embedment compaction, will be relevant to the design. The following notation is used in this Section: a = the radius of loaded circular plate (m) b = embedment width each side of pipe at spring-line (m) B = trench width at pipe spring-line (m) D = overall outside diameter of pipe (m) Ee = embedment soil deformation modulus (MPa) En = native soil deformation modulus (MPa) E/ = combined soil deformation modulus (MPa) H = cover height (m) h = bedding thickness (m) k = overlay thickness (m) p = presumptive (allowable) bearing pressure (kPa) = displacement or settlement (m) = Leonhardt correction factor.

Geotechnical Investigation The conventional approach to a pipeline route investigation has been to assess the soil conditions at pipe depth by carrying out a drilling and soil sampling program along the alignment. While the intention in the past was often to determine the presence of rock and to estimate trench stability for construction purposes, this investigation is now used for more detailed geotechnical reporting with additional information readily obtained from routine surveys. It includes design data such as the Standard Penetration Test (SPT) blow counts (at pipe depth), identification of native soil type and density, and depth of water table. The designer will need to assess the embedment material chosen to surround the pipe and its compaction. Derivation of soil deformation modulus values The correct choice of soil moduli will have significant effects on design decisions. An approximate conversion of SPT blow counts to soil moduli is given in Table 6.1 of AS/NZS 2566.1. However many designers may have more confidence in basing their assessment on the widely available data on foundation design. Often this is contained in records obtained over many years and frequently gives correlations between SPT and allowable soil bearing pressures. If SPT values are not known for the soils in the pipe zone and the soil has already been exposed by excavation, the Clegg impact hammer can be used to obtain Impact Values (CIVs). These are numerically similar to SPT blow counts and can be substituted in Table 6.1 to obtain an estimate of En. The soil deformation moduli stated in AS/NZS 2566.1 were originally derived from European design practice using soil bearing plate tests. These moduli can be nearly half the value of deformation moduli measured using standard laboratory triaxial tests so the two should not be confused. Using allowable foundation bearing pressures it is possible to derive the plate load or pipe design soil moduli from the Boussinesqs plate bearing theory for an elastic, homogenous, isotropic solid. That is for a rigid plate and a soil Poissons ratio of 0.5: -

1 . 18 . p . a . 10 En

Equation 6.1

For the purposes of obtaining a derivation it can be assumed that the plate is a standard 750 mm diameter and the allowable settlement is 15mm. Equation 6.1 then provides a conversion relationship, En = 0.03 x p. Table 6.2 which is partly derived from on data published by Sowers (1979) relating SPT to bearing pressure has been extended to show En values obtained by applying this factor. Values of the soil deformation moduli are needed for both the native and embedment soils within a distance of 2.5 x pipe diameters each side of the pipe centre-line. The modulus for a given pipe embedment soil (Ee) is dependent on the compaction as well as soil type and can be estimated from Table 6.3.

Compaction standard dry density ratio Methods for measurement of compaction are given in AS 1289-E3. The actual dry density ratio (previously known as Proctor ratio) of a soil is defined as a percentage of the maximum dry density determined in the laboratory at the optimum moisture content, which has been determined in the laboratory. Then dry density is derived from the following equation: 100 Equation 6.2 =
d

100 + w

Where = wet field density w = percentage moisture content The dry density ratio is the field dry density divided by the maximum dry density determined in the laboratory for the soil (expressed as a percentage) when compacted at the optimum moisture content.

FIG 6.1 Typical dry densities for different soils Figure 6.1 shows the effect of compacting at different moisture contents on the dry densities of various soil types. It should be noted that the curve for gravel is relatively flat as water content has minimal effect on the achievable compaction. Therefore these materials are preferred for embedment. The curve shown for sand is concave over the intermediate range of moisture contents. With some fine sands at these moisture contents the density can be more than 20% less than for the compaction achievable at higher moisture levels. Because of this property these bulking sands are highly unsuitable as embedment material. The convex curves for cohesive soils such as silt and clay are particularly sensitive with respect to moisture and are difficult to compact adequately in a pipe trench. The dry density may be determined in the laboratory by either the Standard method or the Modified test method each giving significantly different results. The compaction energy for the Modified is 4.5 times higher than for Standard and the resultant maximum dry density ratio will be lower for a given field test sample. For

granular soils the difference is about 5% (less for uniformly graded sand) and about 10% for cohesive soils. AS/NZS 2566.2 refers to standard dry density ratio only.

FIG 6.2 Standard Compaction 2.7 kg rammer is dropped from a height of 300 mm 25 blows per layers Modified Compaction 4.9 kg rammer is dropped from a height of 450 mm 25 blows per 5 layers

Compaction - density index An alternative method of evaluating the degree of compaction, which is faster and less expensive for granular soils, is the density index (or relative density). With this method the loosest and densest densities are determined in the laboratory as follows. A container filled with the soil is vibrated on a vibratory table for 10 minutes or until the settlement ceases to determine a value for the maximum dry density max. The minimum dry density min is determined by gently pouring the soil into the container and measuring the density. Combined with the dry density d, which has been measured on site, the density index ID for site compaction can then be determined from equation 6.3.

( (
max D D max

min min

) )

x100%

Equation 6.3

These two compaction methods give unrelated percentages that are quite different in magnitude and must not be interchanged. For example in broad terms a compacted soil with a density index of 65% may have a standard dry density ratio of 90%.

Table 31

Standard embedment widths (from AS/NZS 2566)

Nominal diameter DN 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000

Outside diameter of pipe D (mm) 345 426 507 587 667 747 826 923 1025 1229 1433 1637 1841 2045 2249 2453 3065

Side clearance b Embedment width B (mm) 200 200 300 300 300 300 300 350 350 350 350 1.5 x D 1.5 x D 1.5 x D 1.5 x D 1.5 x D 1.5 x D 745 826 1107 1187 1267 1347 1426 1623 1725 1929 2133 2456 2762 3068 3374 3680 4598

Note that Tables 31 has been compiled with reference to AS/NZS 2566.1. The side clearances given are conservative to facilitate the compaction of the haunch zone.

Figure 6.3 Critical dimensions for design and installation

Table 32 Typical native soil moduli obtained from SPT or allowable bearing loads

Soil description

Loose sand, dry Firm sand, dry Dense sand, dry Loose sand, inundated Firm sand, inundated Dense sand, inundated Soft clay Firm clay Stiff clay Hard clay Heavily fractured or partially weathered rock *SPT before inundation

Standard Penetration Resistance blow count over 300 mm 5 - 10 11 - 20 31 - 50 5 - 10* 11 - 20* 31 - 50* 2-4 5-8 9 - 15 30+ 50+

Allowable foundation bearing pressures p (kPa) 70 -140 150 - 300 400 - 600 40 - 80 80 - 170 240+ 30 - 60 70 - 120 150 - 200 400+ 500 - 1200

Derived soil deformation moduli En/ (using Eqn. 6.1) (MPa) 2.1 - 4.2 4.5 - 9.0 12 - 18 1.2 - 2.4 2.4 - 5.1 7+ 0.9 - 1.8 2.1 - 3.6 4.5 - 6.0 12+ 15 - 36

The correlation of SPT to bearing pressure given in Table 32 is from George F Sowers Introductory soil mechanics and foundations: Geotechnical Engineering published by Macmillan.
Table 33 Table 6.3 Embedment soil moduli

Soil description

Deformation moduli Ee/ ( MPa) Aggregate single Uncompacted 5 size 50 6 60 7 70 10 3 Aggregate - graded Uncompacted 5 50 7 60 10 70 Crushed rock uncompacted 1 85 3 90 5 95 7 1 Sand and coarse uncompacted 3 grained soil with 85 5 less than 12% fines 90 7 95 Coarse grained soil 85 1 with more than 12% 90 3 fines 95 5 Note: These values are given in AS/NZS 2566.1 Buried flexible pipelines Part 1: Structural design Table 3.2

Standard dry density ratio (%)

Density Index (%)

Effective soil modulus Knowing the proportion of embedment and native soil in the side support zone that is trench (or embedment width) to pipe diameter (B/D) together with the ratio of embedment modulus to native soil modulus (Ee/ En), the Leonhardt factors given in Table 34 enable an overall effective soil modulus E/ to be determined using the equation: E/ = .Ee Equation 6.2

Assuming a density of 20 kN/m3 for the trench fill over the pipe reference to Tables 35 to 37 will then give an estimate of maximum safe cover heights. (See worked example). Normally the embedment widths B should comply with the dimensions in Table 31 and based on these, pre-calculated safe maximum cover heights for a range E values (i.e. many combinations of native and embedment soils) are given in Tables 35 to 37.
Table 34 Leonhardt Correction Factor *

B/D 1.5 2 2.5 3.0 4.0 5.0

Ee/En 0.2 2.4 1.7 1.5 1.2 1.0 1.0

0.4 1.8 1.5 1.3 1.2 1.0 1.0

0.8 1.2 1.2 1.1 1.0 1.0 1.0

1 1.0 1.0 1.0 1.0 1.0 1.0

2 0.6 0.6 0.7 0.8 1.0 1.0

4 0.3 0.4 0.5 0.6 0.9 1.0

6 0.2 0.3 0.4 0.5 0.8 1.0

*Alternatively see Figure 3.2 of AS/NZS 2566.1

Example 6.1 Problem What is the maximum cover height for a DN 900 PN 6 SN 5000 Flowtite pipe laid in a trench 1800mm wide? The native soil is firm clay with a minimum SPT of 7 blows per 300mm. The embedment material is graded aggregate placed with a Density Index of 60. Solution From Table 32 select En = 3 MPa, and from Table 33 select Ee = 7.0 MPa. Since B/D = 1800/900 = 2 and Ee/En = 7/3 = 2.33 from, Table 34 by interpolation, the Leonhardt factor = 0.55. Therefore the combined soil modulus E = 0.55 x 7 = 3.85 MPa. Referring to Table 35; interpolating for a DN900 SN 5000 and an E of 3.85 MPa it appears that the maximum cover height under traffic loading and high water table would be approximately 5.2 metres.

Table 35 Permissible maximum cover height (metres) for PN 10 pressure pipe operating at 80 metres head

Nominal Stiffness / DN (all PNs) 1.0 MPa

Effective (combined) soil modulus E (Derived from En, Ee, and embedment width B) 2.0 MPa 3.0 MPa 4.0 MPa 5.0 MPa 6.0 MPa 7.0 MPa 8.0 MPa

SN 2500 DN300 DN600 DN1200 DN2400 SN 5000 DN300 DN600 DN1200 DN2400 SN 10000 DN300 DN600 DN1200 DN2400

ns ns ns 2.00 ns ns 2.74 2.92 2.57 1.52

2.90 2.57 1.52 3.96 3.65 2.90 4.41 4.85 4.80 4.20

4.17 3.84 3.09 5.50 5.18 4.47 5.88 7.23 6.85 6.18

5.52 4.90 4.23 6.88 6.55 5.81 7.36 8.90 8.60 7.90

6.29 5.90 5.22 8.17 7.84 7.15 8.70 10.82 10.20 9.43

7.21 6.85 6.19 9.30 9.02 8.30 10.00 12.00 11.60 10.90

8.12 7.77 7.09 10.43 10.12 9.40 11.20 13.35 13.05 12.37

8.92 8.50 7.90 11.45 11.10 10.40 12.40 14.65 14.30 13.60

Note: Table 35 is based on the following design parameters 1. Class PN 10 pipes operating at a head of 80 metres 2. No negative pressure (i.e. vacuum) 3. Allowable design deflections 6%, 4. Circumferential flexural strain 0.65% 5. Buckling factors of safety 2.5 6. No water table 7. AUSTROADS dual lane T44 highway loading 8. Fill density of 20 kN/m3 Minimum Cover Height Cover heights shown in Table 35 may be insufficient to prevent flotation should the trench become flooded when the pipes are empty. A minimum cover of at least 1.5 x diameter is necessary to avoid this possibility.

Table 36 Permissible maximum cover height (metres) for PN 10 pressure pipe operating at 100 metre head

Nominal Stiffness / DN 1.0 MPa SN 2500 DN150 DN300 DN600 DN1200 DN2400 SN 5000 DN150 DN300 DN600 DN1200 DN2400 SN 10000 DN150 DN300 DN600 DN1200 DN2400

Effective (combined) soil modulus E (Derived from En, Ee, and embedment width B) 2.0 MPa 3.0 MPa 4.0 MPa 5.0 MPa 6.0 MPa 7.0 MPa 8.0 MPa

ns ns ns 1.63 1.42 ns ns ns 1.80 1.83 1.54

2.91 2.57 1.54 3.44 3.55 2.90 1.50 2.50 3.25 3.30 3.40

4.17 3.83 3.08 4.77 4.93 4.47 2.56 3.48 4.43 4.50 4.61

5.25 4.90 4.20 6.05 6.25 5.80 3.28 4.40 5.52 5.62 5.75

6.29 5.90 5.20 7.20 7.40 7.15 4.00 5.25 6.59 6.70 6.85

7.23 6.87 6.18 8.22 8.50 8.30 4.60 6.10 7.60 7.72 7.90

8.12 7.77 7.08 9.25 9.50 9.70 5.22 6.82 8.55 8.65 8.85

8.92 8.60 7.90 10.20 10.50 10.45 5.77 7.60 9.45 9.60 9.80

Note: Table 36 is based on the following design parameters 1. Class PN 10 pipes operating at a head of 80 metres 2. No negative pressure (i.e. vacuum) 3. Allowable design deflections 6%, 4. Circumferential flexural strain 0.65% 5. Buckling factors of safety 2.5 6. No water table 7. AUSTROADS dual lane T44 highway loading 8. Fill density of 20 kN/m3 Minimum Cover Height Cover heights shown in Table 36 may be insufficient to prevent flotation should the trench become flooded when the pipes are empty. A minimum cover of at least 1.5 x diameter is necessary to avoid this possibility.

Table 37 Permissible maximum cover height (metres) for PN 1 non pressure applications only

Nominal Stiffness / DN 1.0 MPa SN 2500 DN150 DN300 DN600 DN1200 DN2400 SN 5000 DN150 DN300 DN600 DN1200 DN2400 SN 10000 DN150 DN300 DN600 DN1200 DN2400

Effective (combined) soil modulus E (Derived from En, Ee, and embedment width B) 2.0 MPa 3.0 MPa 4.0 MPa 5.0 MPa 6.0 MPa 7.0 MPa 8.0 MPa

n/s n/s n/s 1.65 n/s n/s 2.85 2.77 2.62 2.29 1.50

2.62 2.31 1.50 3.55 3.27 2.70 4.85 4.85 4.69 4.45 3.87

3.73 3.47 2.88 4.90 4.65 4.10 6.67 6.60 6.45 6.20 5.60

4.69 4.45 3.88 6.19 5.85 5.30 8.20 8.15 8.00 7.70 7.19

5.60 5.33 4.75 7.30 7.05 6.45 9.57 9.50 9.35 9.10 8.55

6.45 6.20 5.60 8.35 8.10 7.50 10.92 10.80 10.70 10.40 9.86

7.25 7.00 6.40 9.30 9.05 8.50 11.20 12.10 12.00 11.66 11.10

8.00 7.70 7.18 10.28 10.00 9.45 12.47 13.30 13.10 12.85 12.35

Note: Table 37 is based on the following design parameters 1. Pipes are Class PN 1 i.e. non pressure 2. No negative pressure (i.e. vacuum) 3. Allowable design deflections 6%, 4. Circumferential flexural strain 0.65% 5. Buckling factors of safety 2.5 6. Water table at surface 7. AUSTROADS dual lane T44 highway loading 8. Fill density of 20 kN/m3 Minimum Cover Height Cover heights shown in Table 37 may be insufficient to prevent flotation should the trench become flooded when the pipes are empty. A minimum cover of at least 1.5 x diameter is necessary to avoid this possibility.

Table 38

Minimum cover heights

Location Not subject to vehicular loading Subject to vehicular loading - not in roadways - in sealed roadways - in unsealed roadways Pipes in embankment conditions or subject to construction equipment loading

Minimum height of cover H (m)* 0.30 0.45 0.60 0.75 0.75

Minimum value of E/ (MPa) Not applicable 2.0 2.0 1.5 2.0

* Note these covers may be applied where there is no risk of flotation. Calculations using the methods of AS/NZS 2566 Part 1 show that these values can be used for stiffnesses of SN 5000 or greater and diameters up to DN 1400 for the minimum E shown. The same criteria as for Table 6.5 have been used except for the live load which is AUSROADS TL 44 dual lane Under roadways the only pipe embedment material should be used above the pipes and have a minimum compaction Density Index of 65%. After pipes are laid and centred in the trench, the embedment material should be compacted in 80-100mm layers to the specified density. The embedment should continue above the pipe to provide protection from the back fill. That is a height above the pipe of 100-300 mm may be required depending on pipe size and site conditions.

External hydrostatic pressures As can be seen when applying buried flexible pipe design principles, soil support significantly enhances the buckling resistance of pipes under external hydrostatic pressure which may occur due to a high water table and/or negative internal pressures. However where Flowtite pipes are subjected to external hydrostatic pressures without any significant external soil support, the possibility of buckling due to reduced structural stability of the pipe wall must be considered. Negative heads such as in suction delivery pipelines to pumps or as the result of negative water hammer surge waves may require a minimum stiffness of SN 10000 if the pipes are above ground. If during installation, pipes are to be grouted externally inside another conduit, the allowable liquid grout pressure will be limited by the pipe stiffness - see Table 6.6. Table 6.7 Allowable negative / external fluid pressures on unsupported pipes (factor of safety = 2.5) Stiffness SN 2500 5000 10000 External pressure, kPa For intermittent & short For continuous long term term duration (<6 hours) duration (i.e. 50 years) 22 15 44 31 88 61

Where pipes are encased in concrete, which in turn is subjected to high external hydrostatic pressures, a further long term buckling possibility exists owing to the permeability of concrete. This mode of collapse should be checked for pipes serving as liners in the structural concrete of tunnels at considerable depths below the standing water table see Table 6.8.

Table 6.8 Allowable external fluid pressures on pipes in a rigid encasement( i.e. concrete encased with a factor of safety 2.5) Radial gap as percentage of radius 0.001% 0.01% 0.1% 1.0% 10.0% Stiffness (SN) N/m.m Enhancement Factor applied to unsupported buckling pressure of Table 6.7 17.3 14.9 13.0 16.8 14.8 12.9 16.2 14.0 12.0 9.5 8 7.7 3.5 3.5 3.5 External hydrostatic pressure (kPa) for continuous long term operation 266 458 799 258 455 793 249 430 737 146 246 473 54 108 215

2500 5000 10000 2500 5000 10000 2500 5000 10000 2500 5000 10000 2500 5000 10000

Values in Table 6.8 have been calculated using the method given by Lo, King and Zhang Jane Collapse Resistance Modelling of Encased Pipes published in Buried Plastic Pipe Technology STP 1222 ASTM Philadelphia 1990.

DN250 SN 10000 Flowtite being inserted into host pipe. The allowable grouting pressure can be obtained from Table 6.7 i.e. 88 kPa

6.2

Thrust block design for pressure pipelines

Where the pipeline system is rubber ring jointed there will be unbalanced force at changes of size or direction of the pipeline. That is, at bends tees, reducers, valves and closed ends. In buried installations, concrete blocks sized according to soil conditions usually restrain fittings. Where bends are in the vertical plane, convex and close to surface, the mass of a concrete anchor block alone may have to be used.

Figure 6.4 Typical concrete thrust block arrangement for ductile iron fittings

Table 6.9 Hydrostatic forces in kilonewtons on rubber ring jointed fittings per 10 metres hydrostatic head Pipe DN 300 375 450 525 600 675 750 900 1000 1200 1400 1600 1800 2000 2200 2400 3000 Pipe OD 345 426 507 587 667 747 826 923 1025 1229 1433 1637 1841 2045 2249 2453 3065 Bend 90 0 13.22 20.16 28.55 38.27 49.41 61.98 75.78 94.63 116.70 167.77 228.09 297.65 376.46 464.51 561.81 668.35 1043 Bend 45 0 7.15 10.91 15.45 20.71 26.74 33.54 41.01 51.21 63.16 90.80 123.44 161.09 203.74 251.39 304.05 361.71 564.71 Bend 22.5 0 3.65 5.56 7.88 10.56 13.63 17.10 20.91 26.11 32.20 46.29 62.93 82.12 103.86 128.16 155.00 184.40 287.88 Bend 11.25 0 1.83 2.79 3.96 5.31 6.85 8.59 10.50 13.12 16.18 23.26 31.62 41.26 52.18 64.39 77.88 92.64 144.64 Tee / Closed end & Valve 9.35 14.25 20.19 27.06 34.94 43.83 53.59 66.91 82.52 118.63 161.28 210.47 266.19 328.46 397.26 472.59 737.82

Note: For concentric reducers the resultant thrust will be the difference between the closed end forces for the two pipe sizes. Table 6.10 Estimated horizontal soil-bearing capacities (kPa) apply minimum factor of safety of 1.1 for thrust block design Soil group description as per AS 1786 GW, SW GP, SP GM, SM GC, SC CL ML OH Minimum soil cover above fitting supported by thrust block 0.75 metre 57 48 48 79 74 69 0 1.0 metre 76 64 64 92 85 81 0 1.25 metre 95 80 80 105 95 93 0 1.5 metre 114 97 96 119 106 106 0

Thrust blocks must be formed so as to distribute the hydrostatic force to a plane surface of undisturbed soil, which is approximately perpendicular to the imposed load. The equation for this calculation is: A = T/ b x f Where A = area perpendicular to force (m2) T = hydrostatic thrust (kN) b = soil bearing capacity (kPa) f = factor of safety Equation 6.3

Example 6.1 Problem A DN 750 PN10 SN 5000 pipe laid at a cover height of 1000 mm will be subjected to 1100 kPa during the field testing of the pipeline. A design check is required for a thrust block for 90-degree bend that has been constructed against undisturbed soil estimated to have a safe horizontal bearing capacity of 100 kPa. Solution From Table 6.9; the thrust from a 90-degree bend under 100 kPa pressure equals 75.78 kN. Therefore the outwards thrust along the axis symmetry of the bend at a test pressure of 1100 kPa will be T = 11 x 75.78 = 833.6 kN. Using Equation 6.3 to check the area of concrete/soil interface that is perpendicular to the line of thrust. A = 833.6/100 x 1.1 = 7.17 square metres Example 6.2 Problem A DN1200 x 1000 PN16 SN 10000 taper is to be installed in a pipeline. What is required for resisting the unbalanced thrusts on this fitting assuming the maximum test / operating pressure is 1500 kPa? The fitting will have a cover height of 1200 mm in native soil with an estimated horizontal bearing capacity of 75 kPa. Solution For a pressure of 1500 kPa i.e.150 m head from Table 6.9; the axial thrust on the DN1200 (closed) end of the fitting will be 118.63 x 15 kN and on the DN1000 end it will be 82.52 x15 kN. The difference will be the thrust to be supported by a thrust block i.e. 541.6 kN. Therefore the area of the thrust block at the concrete / native undisturbed soil interface which is perpendicular to the line of thrust (i.e. parallel to the axis of the fitting - refer to Figure 6.2) can be calculated using Equation 6.3. A = 542/75 x 1.1 = 7.95 square metres

6.3

Angular deflection of Flowtite coupling joint

The maximum angular deflection at each coupling joint must not exceed the values given in Tables 7.2 and 7.3. It will be noted from Table 7.3 that pipe lengths shorter than standard may be useful were the pipe alignment needs to be curved without the use of bend fittings.

6.4

Design of GRP flanges

GRP flanges may be required for joining to other materials or where external thrust restraints are not practicable. The unique fabrication methods possible with GRP frequently provide economic solutions for complicated fitting assemblies. Flange compatibility For bolting compatibility flange drillings for GRP fittings manufactured to ISO 10639 and ISO 10467, the bolt PCD, outside diameter, number and diameter of bolt holes can be determined from the purchasers order, or if not specified, then Class 16 of AS 4087 Metallic flanges for waterworks purposes would be the default configuration as given in Table 6.11. This coincides with Tables C & D of AS 2129 Flanges for pipes, valves and fittings. Note that for rated pressures from 1600 to 3500 kPa the Class 35 configuration of AS 4087 should be used which coincides with Tables F & H of AS 2129. Table 6.11 Compatible bolting configuration for Class 14 & 16 metallic flanges DN Outside Dia 185 215 280 335 370 405 455 525 550 580 640 705 825 910 995 1060 1175 1255 Pitch circle diameter 146 178 235 292 324 356 406 470 495 521 584 641 756 845 927 984 1092 1175 Bolting Details No. of holes 4 4 8 8 8 8 12 12 12 12 12 16 16 20 20 20 24 24 Dia. of holes 18 18 18 18 18 22 22 26 26 26 26 26 30 30 33 36 36 36 Fastener size and thread M16 M16 M16 M16 M16 M20 M20 M24 M24 M24 M24 M24 M27 M27 M27 M33 M33 M33

80 100 150 200 225 250 300 350 375 400 450 500 600 700 750 800 900 1000

Bolt and gasket materials shall comply with AS 4087 Table 3.2 and WSA 109 Industry standard for flange gaskets and O rings respectively.

GRP flange characteristics The jointing procedures for flanged connections including one or more GRP flanges as compared with all metal-flanged joints are not significantly different. However the following points unique to GRP should be observed. These are: a) Because GRP flanges are pressure rated (e.g. PN 6, PN 12, etc) in the same way as GRP pipes, the required rating shall be specified by the purchaser. The flange thicknesses will vary accordingly and typically will be substantially thicker than metallic flanges of similar pressure rating. b) GRP flanges may be either flat face and full gasket (includes flanges with concentric ribbing on flange or gasket surface), flat face and O ring seal or stub flange and matching flat gasket (with metal backing plate) see Figure 1. O ring seals and groove dimensions shall comply with AS 4087 Appendix B. c) At higher pressure/torque values, flat face flanges may require a full metal backing plate to avoid risk of crushing GRP under washers. Alternatively O ring seals may be used to reduce torques required at high pressures. i.e. greater than PN 12 for larger than DN 500. For the maximum allowable torque values see PN6 and PN12 of Table 6.12. d) Flat face GRP flanges to be mated with raised face flanges require an insertion plate to support the GRP flange with minimum thicknesses shown in Table 6.14. A second gasket and longer bolts will be required. (The nominated bolt torques are unaffected) e) GRP stub flanges (with steel backing plate) can be used with raised face flanges without an insertion plate. The torque values of Table 6.12 apply. f) Metal washers of similar material to the fasteners shall be used with all GRP flanges. g) Fastener bearing surfaces on GRP flanges are machined all over or spot faced depending on size. h) Appropriate bolt torques for GRP flange fasteners are listed in Table 6.12. These vary depending on the operating and rated pressure of the flange system and values for intermediate pressures may be interpolated. i) Flat gaskets 3 mm thick complying with WSA 109 for flanges rated up to PN 16 shall be used with hardness within the range 56 to 75 IRHD. j) If the flange requires an O ring seals it shall comply with WSA 109 with hardness in the range 36 to 55 IRHD. k) Grade 4.6 galvanised steel or Grade 316 property Class 50 stainless steel fasteners are recommended for GRP flanges. Higher strength bolts are acceptable i.e. Grade 8.8 galvanised steel and Grade 316 Class 80 stainless steel.

Table 6.12 Bolt tightening torques for flat face and stub flanges
PN 6 Torque N.m 25 80 35 100 35 150 50 200 50 225 50 250 70 300 70 350 70 375 70 400 75 450 75 500 80 600 100 700 120 750 150 800 190 900 200 1000 DN PN 10 Torque N.m 35 80 40 100 50 150 60 200 70 225 80 250 90 300 120 350 120 375 120 400 150 450* 150 500* 210 600* 210 700* 200 750* 300 800* 300 900* 400 1000* DN PN 16 Torque N.m 50 80* 75 100* 60 150* 80 200* 90 225* 100 250* 100 300* 150 350* 150 375* 200 400* 250 450* 250 500* 300 600* 350 700* 400 750* 450 800* 475 900* 500 1000* DN

* NB Full metal backing plate required with flat face flange & gasket. Alternatively use O ring or ribbed reinforced seals that allow reduced torques. Table 6.13 Dimensions of washers to AS 1237-1973 required for flange nuts and bolts
Size of bolt Galvanised steel Outside washer Nominal diameter (mm) thickness (mm) 30 3 37 3 44 4 50 3 60 3 Stainless steel Outside washer Nominal diameter (mm) thickness (mm) 30 1.5 37 2.0 44 3 50 3 60 3

M16 M20 M22 M27 M33

Table 6.14 Backing plates (for full face and stub flanges) and insertion/spacer flanges for raised face installations (Based on AS 4087 Table PN 16 steel flange thicknesses & drilling patterns)
Nominal diameter 80 100 150 200 225 250 300 375 400 450 500 600 700 750 800 900 1000 Galvanised steel Thickness (mm) 8 10 10 16 16 16 19 26 26 26 34 43 51 51 51 61 61 Outside dia. 185 215 280 335 370 405 455 550 580 640 705 825 910 995 1060 1175 1255 Stainless steel Thickness (mm) 10 10 13 13 16 16 19 22 22 25 29 32 Outside dia. 185 215 280 335 370 405 455 550 580 640 705 825

6.5

Above Ground Installation

Standard Flowtite pipes with rubber ring couplings or butt strap joints can be used for permanent above ground pipelines. However when standard Flowtite pipes with rubber ring jointed couplings are used above ground or in situations without soil support there is a need for careful consideration to be given to the design and location of the supporting structures. Exposure to sunlight and ultra violet radiation does not affect unprotected Flowtite structurally although the exterior will become weathered, that is roughened and discoloured with time. If this is not acceptable pipes can be coated with water based acrylic paint finishes. Should there be unusually high tensile axial loadings exceeding those allowable for standard pipe, special biaxial Flowtite can be specified which has enhanced axial strength up to three times that of standard pipe. Pressure pipes must be installed on a straight alignment to ensure there are no unanticipated lateral reaction forces due to the hydrostatic pressure in the pipeline. Fittings will need special anchorage to withstand thrusts caused by hydrostatic pressures within the pipe system. In the case of pressure pipes supports are required each side of the coupling at a centreline distance not exceeding the greater of 250 mm and 0.5 X DN, to ensure its complete stability - see Fig 6.3. This limitation can be increased up to 1/6 of the pipe length from the end for low-pressure applications - see Fig 6.4. When a pipe length is supported on more than two supports, the alignment should be kept straight to within a tolerance of 0.1% of the span length. A typical detail for support cradles and hold-down/ anchor straps is shown in Fig 6.5. Compressible material such as 5 mm thick insertion rubber should be placed between the pipe wall, the cradle and/or strap. The cradle should extend to 150 degrees of the circumference and have a radius that allows for the protection. Any misalignment of the supports across the joints should be limited to the lesser of 0.5% x DN and 3 mm. Although a hold down straps is not usually required at every support there should be at least one per pipe, uniformly spaced along the pipeline. Calculations of the safe span lengths in Table 6.15 have been made on the basis of applying a factor of safety of 6 to the axial strength of the pipe and limiting the deflection to span / 500.

Figure 6.5: Recommended support locations for pressure pipes

Figure 6.6: Alternative support locations for low pressure pipes

Figure 6.7 Typical support details

Table 6.15 Permissible spans for standard Flowtite pipes simply supported and full of water Nominal diameter DN
80 100 125 150 200 250 300 375

Pressure class PN
16 16 16 16 16 16 16 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0

SN 2500
4.06 4.47 4.47 4.64 4.81 4.96 5.14 4.12 5.02 5.04 5.17 5.37 5.55 5.73 4.14 5.14 5.45 5.69 5.89 6.08 6.28 4.26 5.38 5.71 6.18 6.39 6.61 6.81 4.41 5.66 6.02 6.64 6.88 7.11 7.33

Nominal Stiffness SN 5000

4.06 4.47 4.47 4.64 4.81 4.96 5.14 4.12 5.04 5.04 5.17 5.37 5.55 5.73 4.14 5.54 5.54 5.69 5.89 6.08 6.28 4.26 5.97 6.04 6.18 6.39 6.61 6.81 4.41 6.22 6.40 6.64 6.88 7.11 7.33

SN 10000
2.07 2.25 2.46 2.83 3.24 3.81 4.35 4.06 4.47 4.47 4.64 4.81 4.96 5.14 4.12 5.04 5.04 5.17 5.37 5.55 5.73 4.14 5.54 5.54 5.69 5.89 6.08 6.28 4.26 6.04 6.04 6.18 6.39 6.61 6.81 4.41 6.52 6.52 6.64 6.88 7.11 7.33

450

525

600

675

750

1.0 6.0 10.0 16.0 20.0 25.0 32.0

4.58 5.94 6.34 6.98 7.34 7.58 7.82

4.58 6.46 6.64 7.09 7.34 7.58 7.82

4.58 6.96 6.96 7.09 7.34 7.58 7.82

Table 6.15 - continued Nominal diameter DN

900

Pressure class PN SN 2500

1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 20.0 25.0 32.0 1.0 6.0 10.0 16.0 1.0 6.0 10.0 16.0 1.0 6.0 10.0 16.0 1.0 6.0 10.0 1.0 6.0 10.0 1.0 6.0 4.73 6.20 6.61 7.32 7.74 8.15 8.40 4.91 6.43 6.88 7.63 8.07 8.72 8.99 5.22 6.90 7.39 8.22 8.71 9.47 10.11 5.52 7.35 7.87 8.77 9.31 10.14 11.13 5.80 7.77 8.31 9.29 6.07 8.17 8.74 9.78 6.32 8.55 9.15 10.26 6.57 8.91 9.53 6.81 9.25 9.91 7.48 10.22

Nominal Stiffness SN 5000

4.73 6.76 6.95 7.55 7.90 8.15 8.40 4.91 7.03 7.24 7.89 8.29 8.72 8.99 5.22 7.57 7.80 8.52 8.96 9.47 10.11 5.52 7.54 8.31 9.09 9.31 10.14 11.13 5.80 8.57 8.80 9.64 6.07 9.01 9.26 10.16 6.32 9.44 9.70 10.64 6.57 9.85 10.12 6.81 10.25 10.52 7.48 11.34

SN 10000
4.73 7.39 7.39 7.64 7.90 8.15 8.40 4.91 7.73 7.73 8.16 8.45 8.72 8.99 5.22 8.35 8.35 8.90 9.30 9.75 10.11 5.52 8.91 8.91 9.51 9.94 10.45 11.13 5.80 9.46 9.46 10.09 6.07 9.96 9.96 10.64 6.32 10.45 10.45 11.16 6.57 10.92 10.92 6.81 11.36 11.36 7.48 12.60

1000

1200

1400

1600

1800

2000

2200 2400 3000

7 INSTALLATION
7.1 Transportation and Storage

Although Flowtite pipes are light and robust, they should not be rolled, dropped, thrown, or allowed to come into contact with sharp objects likely to cause damage. Where Flowtite pipes are unloaded to storage they should be kept in their packs if possible. The storage site should be smooth and level. If pipes are not crated they should be placed on horizontal supporting timbers (at approximately 2 metre centres), and these should also be used to separate layers if pipes are stacked. Stack heights should be limited to prevent excessive ovalisation, The socket and spigot ends should be placed at alternate ends with sockets protruding so they will not be subject to load during storage. Table 7.1 Packing specifications Nominal pipe size (DN) 300 375 450 525 600 675 750 900 1000 1200 1400 - 2400 Quantity of pipes on table-top truck Across 6 5 4 4 3 3 2 2 2 2 1 High 5 5 4 4 3 3 3 2 2 2 1 Number of 12 m lengths per semi-trailer 30 25 16 16 9 9 6 4 4 4 1 Number of metres per semi-trailer 360 300 192 192 108 108 72 48 48 48 12

FLOWTITE pipes are packed for road freight on shaped timber bearers with couplings already fitted unless otherwise specified

7.2

Excavation and associated works

Flowtite is a flexible pipe and is designed to deflect under vertical soil loads, which are then transferred to the soil in the side support zone. Australian Standard AS/NZS 2566.2 Buried Flexible Pipelines Part 2 Installation provides extensive guidance on installation requirements.

Fig 7.1 Buried pipeline terminology

Trench excavation Excavate the trench to the line and grade specified. The trench width must be sufficient to permit compaction of the pipe embedment materials with suitable equipment. The minimum pipe trench width required is typically equal to pipe OD + 300 to OD + 0.OD/2 mm depending on pipe diameter see Table 6.2 for widths as per AS/NZS 2566.2. The trench bottom should be even and free of large clods and stones. Foundation The native soil in the foundation zone should be carefully excavated to grade to permit the pipeline to be correctly aligned, allowing for bedding material of a minimum thickness of 75 to 150 mm beneath the pipe, depending on the diameter. Unstable and wet ground conditions When wet and/or unstable soil conditions are encountered, precautions must be taken to maintain firm and permanent side support for the pipes once installed. Where groundwater is present and there will be a risk of the fine soil particles migrating across the interface between the native and embedment soils, it is recommended that the embedment material should be fully enveloped with geotextile material. Details of soil gradings where this can occur are given in AS/NZS 2566.2. Pipe installation should be carried out in a trench free of water. Where there is a possibility of a continuing high rate of ground water inflow it may be necessary to facilitate drainage of the trench by the use of a porous layer of bedding material in the foundation zone. Generally this will be a coarse granular material which will need to be fully encapsulated in a geotextile fabric and is sometimes described as a drainage mattress. Trench shields Where trench shields or soil boxes are required, it is desirable for them to be a close fit against the excavated trench walls and for the bottom edge to be kept above the top of the pipe. If for safety reasons they must extend to the bottom of the trench, compaction of the embedment after the shields are lifted is necessary to eliminate any voids that may otherwise develop (see Figures 4.2 a and 4.2 b). Soil boxes used in open excavations are prone to accumulate loose debris between the box and the trench wall. As this poor quality material can adversely affect the available side support, it is good practice to place high quality embedment material in this part of the side support zone as soon as possible to exclude any debris or material which may slough from the trench wall (see Figure 7.3)

Figure 7.2(a) Shields kept above side zone

Figure 7.2(b) Shields in side support support zone

Figure 7.3 Shields in wide trench

7.3

Pipe laying

Bedding The pipe bedding should be comprised of embedment material used to provide uniform support and load distribution along the pipe barrel as well as supporting the side support embedment material. A layer of granular material with a maximum particle size of 20mm placed and compacted to least 100mm clear thickness is recommended. A slight depression should be formed under each socket to ensure that the complete length of the pipe barrel is evenly supported. When aligned as specified the pipes should be on the centreline of the trench. If groundwater is present, the trench should be de-watered so that the pipes can be installed in a relatively dry trench. In unstable soils additional bedding may be required to provide a sound foundation where unsatisfactory native material has been removed from the foundation zone. Once the trench and bedding has been prepared, pipes can be lowered into the trench with suitable lifting equipment (chains should not be used). Generally an excavator/backhoe can be used with a nylon sling at the midpoint of a pipe. The following procedure is recommended when installing Flowtite rubber ring jointed pipes and fittings.

Jointing of pipes and fittings (rubber ring types) Flowtite pipes are delivered to site with a coupling already fitted on each length. It is normal practice to string pipes so that they can be laid by starting from the downstream end with the coupling or socket end facing in the up-stream direction. Thoroughly clean the coupling grooves for the rubber seal and central register stoppers.

Inspecting and cleaning coupling grooves and ring before joining DN750 FLOWTITE pressure pipes

Applying an approved jointing fluid to pipe spigot prior to insertion into coupling

Although pipes may show some out-of-roundness due to storage loads, this is usually quite minimal. Where it is present, it is advantageous to orientate the larger pipe diameter vertically. This will ease the jointing process and helps to offset any deflection after backfilling. If the joint is to be made using a cut pipe length the pipe spigot diameter must first be checked to ensure it is within tolerance. Cutting with a portable circular saw fitted with a diamond tipped or abrasive masonry blade can be used. As Flowtite pipes contain significant amounts of silica precautions against the inhaling the dust produced are essential. A field lathe could be used to machine pipe spigots but is generally not required as at least 40% of pipe lengths supplied on a project will be suitable for cutting and joining without any machining. If the pipe has been cut the spigot should be chamfered and a new witness mark made with a black marker pen at a distance from the spigot end equal to the socket depth. Ensure each pipe is progressively placed on the bedding material at the correct line and grade. Insert the REKA ring seal in the groove with the tapered side facing outwards and ribbing exposed. It will help if the ring is allowed to form two loops on opposite each other while the ring is progressively pushed into the recess as the ring is being compressed circumferentially during this process. Ensure the ring is uniformly seated. Only at this stage should a thin layer of jointing fluid be applied to the exposed rubber seal surface. Also apply jointing fluid liberally to the spigot in the area where the seal will slide. (Under no circumstances should mineral oils or greases be used, as these compounds will cause long-term degradation of the rubber seal. In an emergency common soap can be used).

Joining force being applied to DI fitting with an excavator bucket (protected from possible damage using a timber bolster) Petrol powered disk cutter used to cut back pipe spigot

The jointing force must be applied in an axial direction without jerking. If mechanical plant such as an excavator bucket is being used, timber packing must be provided to protect the GRP surfaces. Alternatively one or two cum-along-winches attached to nylon slings wrapped around each pipe can be used. Push (or pull) the joint home using the witness mark on the spigot to determine when it is fully inserted. Where a change in alignment is to be made at a joint the offset should be made after pushing the pipe fully home without any misalignment. The pipe can then be moved to achieve the required angular deflection limited to the maximum allowable offsets shown in Table Angular deflection limits for Flowtite couplings The normal angular deflection permitted for Flowtite coupling joints is shown in Table 7.2. However for diameters larger than DN525 where both sides of the coupling are mobilised the permissible overall joint deflection can be as much as TWICE that tabulated. Note that where these deflections result in a convex vertical curve in the pipeline alignment, the depth of cover should be increased to at least 1.2 m for pipeline if the operating pressure is more than 1500 kPa. Table 7.2 Angular deflection (rotation) at a Flowtite coupling joint (for pipe pressure rating shown) Nominal pipe diameter DN < DN525 DN525 - DN900 > DN900 - DN1800 > DN1800 - DN3000 PN16 3.00 2.00 1.00 0.50 Pipe rating (bar) PN 20 2.50 1.50 0.80 NA PN 25 2.00 1.30 0.50 NA PN32 1.50 1.00 0.50 NA

Figure 7.4 Joint geometry - angular deflection includes both sides of coupling

Table 7.3 Offset in millimetres for angular joint deflection (for pipe length shown) Deflection angle Y (degrees) 6.00 5.00 3.00 2.50 2.00 1.50 1.30 1.00 0.80 0.50 Offset (mm) 3m 6m 12 m Nominal radius of curvature R (Metres) 3m 6m 12 m

157 136 105 78 65 52 39 26

314 261 209 157 120 105 78 52

628 523 419 313 240 209 156 104

57 69 86 114 132 172 215 344

115 137 172 228 265 344 430 688

230 274 344 456 532 688 860 1376

Cut pipe spigot-end preparation It is important to select an Adjustment pipe (branded ADJ or ADJUST) for cutting as this will meet the required spigot tolerances and allow the use of the standard Flowtite coupling without any machining required. The cut end should be chamfered at a 20-degree angle (to the pipe axis) for the distance given in Table 4.4(b). Joint misalignment The maximum sideways or vertical shear displacement (i.e. misalignment) between pipe spigots joined with Flowtite couplings is limited to 5 millimetres. Therefore attention must be given to the possibility of differential settlement between the pipeline components or associated structures to avoid exceeding this limit over time. Field closures

(i)

Flowtite couplings can be used as slip collars if the central rubber stops are removed and the pipe ends to be joined are within the tolerances for adjustment pipes. This can be checked in the field by removing the rubber rings and ensuring that the coupling will slide over pipe for the required distance. Proprietary mechanical joints such as Teekay, Straub, Norma or in the smaller diameters (< DN900) gibault joints will be required for cut-ins if the pipe ODs are too large for the Flowtite slip collar procedure of (i) above. In the larger diameters at higher pressures Klamflex and Viking Johnson couplings may be necessary. The coupling manufacturers recommendations with respect to assembly and bolt tightening must be followed.

(ii)

Tapped connections As with most pipe materials Flowtite pipes cannot be direct tapped but will require either tapping band or flanged branch sleeve, depending on the diameter of the branch required. Specialist contractors with equipment for live (under pressure) tapping should be used when tapping mains under pressure. No tapping should be closer than 2 x main diameter to the end of a pipe and should be limited to pipes not subject to significant axial stresses. For small off-takes for service connections, approved tapping bands such as Taptite nylon coated ductile iron or Milnes gunmetal full-circle types are available. Holes should be drilled using tungsten tipped masonry drill or similarly faced hole trepanning cutter. Where larger off-takes are required, they should not exceed the following nozzle diameter to main diameter percentage ratio for different stiffnesses: SN 2500 SN 5000 SN 10000 20% 25% 30%

Only approved tapped sleeves should be used, that is proprietary types which have been tested on GRP pipes. The manufacturers instructions must be followed with particular attention paid to applying the correct bolt torques. Flanged joints The procedure for assembling flanged joints is as follows: 1. The mating flanges and gasket must be clean, smooth and properly aligned at the start of the assembly process. Should an O ring seal be used in lieu of a full face gasket, it should be correctly seated in the prescribed groove. The mating flange shall not be grooved. 2. Insert lubricated fasteners (with washers for GRP surfaces) molybdenum disulphide grease or equivalent nickel based anti-seize compound is recommended. Ensure that no traces of petroleum oil or grease contaminate the flange faces or rubber gasket. 3. Tighten fasteners using the usual star sequence pattern See Figure 7.6, with torque increments per cycle not exceeding the lesser of 25 N.m or 20% of the final torque requirement. 4. On achieving the recommended torque value given in Table 6.12 allow a onehour rest period and re-check torques. Do not over tighten as this may damage the joint components, e.g. localised crushing of the GRP under the washers or of the gasket, leading to potential leakage in service. 5. Where possible leave access to flanged connection for inspection purposes until after acceptance testing is complete. 6. Should leakage be observed under test it is preferable to eliminate the hydrostatic pressure before relaxing and retightening the fasteners.

Figure 7.5 Flange types

Full Face Flange with O ring gasket

Figure 7.6 Fastener tightening using star sequence

7.4

Side support and overlay

Embedment haunching and side support Generally material used in the embedment zone should be uniform selected cohesionless soil. Information regarding selection is given in Appendices G and H of AS/NZS 2566.2. The most important aspect for the successful installation of Flowtite pipe is the selection and compaction of the embedment, i.e. the material in around the pipe. Embedment material should be of a granular nature, which is readily compactable. Crushed rock, aggregate and graded sand are commonly used but occasionally native soils, (eg. beach and mallee sand) may also be suitable, provided they are free flowing and readily compacted. The embedment must be evenly compacted between the pipe and the surrounding native soil given that the side support zone extends beyond the pipe horizontally for a distance of twice the pipe diameter in the pipe zone. Care must be taken not to move the pipe from its alignment when compacting the embedment material. Where trench shields or boxes are used special care must be taken to ensure any voids resulting from their use are completely filled with compacted embedment material as described in Clause 5.4.4 of AS/NZS 2566.2 If there is a possibility of migration of fines between the embedment and native soil geotextile fabric should be used at the interface to envelope the embedment including the bedding completely (See Section 4 of AS/NZS 2566.2 and Appendix J for further information) Attention to the quality and degree of compaction of embedment material placed each side of a Flowtite pipeline is fundamental to its structural integrity. The following, Table 7.4, shows the default values given in AS/NZS 2566.2 for the appropriate degrees of relative compaction of the embedment bedding and side support zone. Table 7.4 Minimum relative compactions (extract from AS/NZS 2566.2 Table 5.5)
Soil type Cohesionless Cohesive Test method Density Index Standard Dry Density Ratio, or Half Density Ratio Trafficable areas Embedment Trench / material % embankment fill material % 70 70 95 95 Non trafficable areas Embedment Trench / material % embankment fill material % 60 Compaction to suit site requirements 90

Overlay The embedment material should extend to a cover height of 100 to 300mm above the pipe (depending on the diameter) to provide protection from placement of fill material and the operation of compaction equipment.

7.5

Trench and embankment fill (i.e. above embedment / overlay)

Backfill over Flowtite pipelines may involve the use of excavated material providing the thickness of overlay is adequate. Care must be taken to avoid the inclusion of large stones, rocks or hard clumps that may cause point loading on the pipeline. Compaction of the final backfill by large vibrating power compactors should be used until there is an adequate height of fill over the pipes. This will vary depending on the capacity of the machine but generally a minimum of 0.5 metres is desirable. Monitoring embedment compaction After the filling operation is complete, the adequacy of embedment compaction and the use of correct backfilling techniques may be assessed either by soil stiffness/density testing during placement or by the measuring the diametral deflection of the pipe after backfilling is complete. The deflection check described in Section 8.3 is particularly useful in the early stages of construction for pipes with more than 2 metres cover. Acceptable deflection values will vary depending on the elapsed time after installation. AS/NZS 2566.2 gives factors which can be applied depending on the time intervals after completion of the backfilling e.g. the maximum recommended allowable deflection at 24 hours is 3% for Flowtite and at 30 days, 3.5%. Refer to Table 6.2 of AS/NZS 2566.2 for allowable deflections at other time periods. Note: During compaction of backfill in the pipe embedment zone, an increase in the vertical diameter and decrease in the horizontal diameter may occur. This is not detrimental providing the magnitude of the horizontal diametral deformation does not exceed the prescribed allowable deflections. See Section 9 for test procedure.

7.6

Grouting

In situations where it is necessary to pressure grout the annulus between Flowtite pipes and an enveloping conduit, e.g. when using Flowtite to reline a deteriorated pipeline, it is important to ensure the grout is introduced into the annulus evenly. The pipe must be adequately chocked to resist flotation and bending. The allowable hydrostatic grout pressure will depend on its setting time but typically must not exceed Pallow of Equation 7.1 to ensure an adequate factor of safety (of 2.5) against buckling instability which may lead to pipe collapse. See also Table 6.8 for more accurate detail. Pallow = 24 x SN / 2500 kPa Equation 7.1

If necessary the effect of grout pressures can be substantially reduced by filling the pipeline with water. Alternatively it may be possible to stage the grouting process in two or even three lifts, i.e. to allow grout to solidify in the annulus below the spring line before the top section is filled.

7.7

Joints subject to differential settlement

Relative settlement Where Flowtite pipes are connected to significant concrete structures it is recommended that short pipe lengths or rocker pipes be used adjacent to the structure as described in AS/NZS 2566.2. This will allow the pipes to accommodate differential settlement through a small amount of rotation of the rocker pipe together with joint deflection without damage. Pipe / concrete interface Flowtite pipes can be directly embedded directly into concrete. However it is recommended that at the entry and exit points, i.e. at the face of the concrete, the pipe should be wrapped in a compressible material. Alternatively a Flowtite coupling should be located and cast into the concrete face so that the rubber ring joint can accommodate any movement.

Flanged off-takes for air valves and scours.

Auxiliary pipe connections Scour and air valve structures are often associated with flanged pipe work which in turn must be connected to small diameter flanged off-takes on the mainline. As there is potential for differential settlement or movement between these assemblies provision must be made for this. The usual method is to provide a rocker pipe of between 2 x DN and 3 x DN in length which is designed to articulate between two introduced rubber ring joints as illustrated in Figure 7.7. Alternatively a similar length of a small diameter polyethylene pipe spool with stub flanges and backing plates can be inserted between the two assemblies. Any relative movement is then absorbed by the flexibility of the polyethylene. Figure 7.8 shows a scour arrangement using PE pipes and fittings.

Figure 7.7 Use of a rocker pipe

Side view of scour valve pit with rocker pipe

Plan view of scour valve pit with rocker pipe

Figure 7.8 Use of flexible PE spool pipe

Side view of a PE pipe being used to provide flexibility between the mainline and scour structure

Plan view of a PE pipe being used to provide flexibility between the FLOWTITE mainline and scour structure

7.8

Cutting into or repairing installed GRP pipelines

If it is necessary to remove a section of an installed Flowtite pipeline to insert a fitting or replace a damaged pipe the following procedure is a guide. Repair kits In addition to the replacement item which is assumed to have ends to Flowtite pipe tolerances (of which at least one is a spigot), the materials required for its insertion into the pipeline will depend on whether there is an in situ adjustment pipe in the vicinity of the intended replacement: (i) If this were the case, the repair kit would comprise of three Flowtite couplings and a short closure length (say 3m minimum in length) of adjustment pipe. (ii) a: If it is not the case the repair kit could comprise of two Flowtite couplings, a mechanical coupling and a short closure length (say 3m minimum in length) of adjustment pipe, or (ii) b: Alternatively, if a larger excavation is possible so as to expose another joint then a full length adjustment pipe (usually 12m) for the closure should be used. This will enable all joints to be on correctly toleranced ends suitable Flowtite slip collars Note that jointing lubricant is required for both Flowtite and mechanical couplings. Procedure 1) Dewater the pipeline. 2) If a pipe, fitting or coupling has to be removed from the installed pipeline select a position at about 1.5 metres away on one of the GRP pipes located adjacent to the item to be removed. This will be the location of the initial two rough cuts. If there is an option of these cuts being made in an adjustment pipe this should be selected for cutting. 3) This initial opening in the line should be made by making two parallel rough cuts at least 450mm apart i.e. more than the 330mm coupling width. After clearing debris from the gap it should be possible to pull the item to be removed in an axial direction into this gap. Once free it should be possible to lift it out of the trench. 4) The in-situ rough-cut pipe end must then be prepared for a new joint by cutting back to allow for the insertion of the replacement plus closure pipe. The distance from the newly prepared spigot to the spigot end replacement piece should be calculated so as to allow for 20mm clearance allowance at between spigots 5) Care must be taken to achieve the required squareness tolerances and it will need to be sanded smooth and chamfered to the same dimensions as factory made pipe spigots. If this spigot is an adjustment pipe OR a pipe to adjustment pipe dimensions, it will be possible to plan for slipping a Flowtite coupling over the pipe-to-pipe joint.

FIG 7.9 shows the sequence for inserting the closure pipe using slip couplings and/or mechanical couplings on each end

6) If the spigot is not to the required jointing tolerances for a Flowtite coupling then a mechanical coupling will be required for the pipe-to-pipe joint. 7) Because the closure pipe is an adjustment pipe, it will be possible to use a Flowtite coupling on the pipe-to-replacement joint as a slip collar. If the insitu pipe is also to acceptable tolerances (even if not an adjustment pipe), a slip joint using a Flowtite coupling will also be possible for the pipe-to-pipe joint. 8) Note that the central stops are removed when using Flowtite couplings as slip collars. 9) Ensure that new rubber rings for used for any reused couplings. 10) If not already socketed, make up the replacement piece with a single Flowtite coupling (only) pre-fitted. Prepare bedding material in the trench to the correct level and lower the replacement into the trench. Once aligned this replacement-to-pipe joint should be made in the normal way. 11) Where both ends of the closure pipe can be slip jointed with Flowtite couplings, lubricate each in turn for a distance of 340mm (i.e. double the normal distance). Place slip couplings on both ends. They must be pushed clear of the pipe ends. Refer to Figure 7.9. Special attention is needed during this operation to ensure that the second ring is eased into position because it is being slid in the opposite direction to normal. Ensure witness marks are made on the in-situ replacement and pipe spigots and carefully align the short length in the trench. Push each slip coupling over the lubricated in-situ spigots as far as the witness marks. An observer inside the pipeline must monitor this operation. 12) Where a mechanical coupling has to be used for the closure pipe follow the separate General Assembly Guide specifically for this joint. Typically bolt torques for PN 16 joints should typically be in the range of 80 to 120 N.m. Note that mechanical couplings also require lubrication. 13) IMPORTANT: Use the information in the Technical Note to check the distortion Figure 7.12 of the pipe under the mechanical gasket to ensure the allowable bending strain in the pipe in the axial direction wall has not been exceeded. Adjust bolt tensions where necessary. 14) It is desirable to leave mechanical joints exposed until the completion of hydrostatic testing, as bolts may need to be re-tightened.

Figure 7.10 Gibault, Viking Johnson and Klamflex couplings

Figure 7.11 Teekay, Norma and Straub couplings

Figure 7.12 Note: The magnitude of any distortion under the gasket of large diameter mechanical couplings should be monitored internally during installation - see separate technical note.

8
8.1

FIELD TESTING
Leakage testing pressure pipelines

The test procedures of Clause 6.3.4 of AS/NZS 2566.2 Buried flexible pipelines, Part 2: Installation are recommended for Flowtite. The recommended test pressure should be not less than the maximum design pressure and at the same time not exceed 1.25 times the pipe rating at any point along the pipeline that is not exceeding 2000 kPa. Before carrying out, the test pipes should be substantially backfilled to ensure they cannot move. Where joints are exposed some movement of the witness mark away from the socket may be apparent due to the Poisson effect that is the shortening of the pipes under circumferential working stress. If no make-up water is required to maintain pressure after one hour at test pressure or after the time needed to inspect the whole pipeline, it can be considered that the test has been passed. The need for make up water may not indicate a leak if it is within certain limits. The following equation for calculating the allowable make-up to maintain the test pressure is given in the Standard. That is: Q 0.14xLxDxH Equation 8.1

Where Q = allowable make-up water, litres per hour D = nominal diameter, in metres L = test length, in kilometres H = average test head over length of pipeline under test, in metres This allowance is intended to compensate for the apparent loss due to entrapped air being forced into solution. Prior to carrying out a hydrostatic test it is normal to complete the pipe installation including the backfilling and allow sufficient time to elapse to allow for curing of concrete thrust and anchor blocks. It is recommended that mechanical joints and flanged connections remain exposed so that they can be visually checked for leaks. Where testing against closed valves, arrangements should be made for checking these for leaks. Appendix M4 of AS/NZS 2566.2 describes the test procedure and Figure 10.1 illustrates the usual test equipment arrangement.

Mains supply

Air bleed valve Stop cock to protect gauge during pump - up period Calibrated test gauge(s) (150 mm min.
dia . preferred)

Make -up water reservoir

Reference Sight level gauge glass -for Pressure volume relief valve check Test Pump Supply pipe Pressure control valve End closure

Pump isolation valve

Return pipe

End closure (possible swab insertion point) Pipeline under test (at lowest point)

Temporary thrust supports

Temporary tee

Figure 8.1 Typical arrangement of pipeline testing equipment

WARNING: High pressure (i.e. >30kPa) air testing is not recommended for safety reasons as the energy stored by a significant volume compressed air or other gas in a pipeline can be both extremely destructive and life threatening if released accidentally.

Individual joint testing For large (man entry) diameter pipelines in situations where it is impractical to charge the pipeline with water for hydrostatic testing purposes, individual joints can be proof tested using portable equipment inside the pipe as shown in Figure 8.2. This purpose built equipment is comprised of segmented circular moulds, which support twin sealing gaskets. These rubber gaskets are hollow and designed to be inflated with water under pressure to create a seal against the inside surface of the pipe. When the equipment placed across a joint it is possible to pressurise the annular joint space using a hand operated hydrostatic test pump. Water can be obtained from a small water cart not shown in Figure 8.2. Typically this equipment is limited to about 60 kPa but for higher-pressure mains this may still be sufficient for a proof test. Note that pipes must be backfilled before attempting this test to stop the joint separating. In some situations it may be possible substitute air for water but the test pressure must be limited to a safe level See the warning above.

Figure 8.2 Typical arrangement of joint testing equipment

8.2

Leakage testing non-pressure pipelines

Field testing is used for revealing damaged pipes, unsatisfactory embedment, joints incorrectly installed, or other laying deficiencies. Where watertight pipelines are required as in the case of sewers, a leakage testing is usually required before acceptance A leakage check on a buried non-pressure pipeline can be done using any one of the following methods: Hydrostatic pressure test , Vacuum test Low pressure air test, Infiltration test. The air and vacuum tests are usually more convenient as they do not require water. An infiltration observation/ test measurement is a further option where a pipeline is been laid well below the water table. Hydrostatic (exfiltration) testing The pipeline should be filled with water to a height of not less than 1m above the natural ground level at the highest point of the test length but not exceeding 6m at the lowest point of the test length. A minimum of 2 hours should elapse to allow temperature changes to stabilise. Then during a minimum time of 30 minutes any fall in water level in the test vessel must not exceed the hourly allowance amount shown in Table 8.1

Table 8.1 Hydrostatic - leakage limits for non pressure pipes Make- up allowance* DN Make- up allowance* (Litres / m / hour) (Litres / m / hour) 0.14 0.60 300 1200 0.19 0.70 375 1400 0.23 0.8 450 1600 0.26 0.9 525 1800 0.30 1.00 600 2000 0.34 1.10 675 2200 0.37 1.20 750 2400 0.45 1.50 900 3000 0.50 1000 * Based on an allowance of 0.5 litres per hour per mm diameter per km (Ref. AS/NZS 2566.2) If this is not achieved the pipeline should be carefully examined visually for leaks, and any defects repaired. The pipeline should then be retested. Low pressure air (exfiltration) testing The test length of pipeline should be generally restricted to lengths between access chambers (the most convenient places for fixing temporary bulkheads). The procedure for low-pressure air testing of large diameter pipelines is potentially hazardous at higher pressures because of the very large forces to be resisted by temporary bulkheads and the serious consequences of accidental bulkhead blow-out. The procedure should be as follows: Pump in air slowly until a pressure of 28 kPa above any external ground water pressure is reached (but do not exceed 50 kPa gauge). Maintain the pressure for at least 3 minutes. If no leaks are detected, shut off the air supply. DN

The low pressure air test for a test length of pipeline is satisfactory if the test pressure does not drop more than 7 kPa, within the time period shown in Table 5.2 after the shut-off of the air supply. Note that if there is no discernible pressure loss after 1 hour has elapsed, the test can be considered satisfactory and terminated. If the pipeline fails the test, re-pressurise to 28 kPa and check for leaks. This may be assisted by the use of leak detecting equipment. Establish the source of any leak. Leaks in small installations with joints exposed may be detected by pouring a concentrated solution of soft soap and water over joints and fittings. Repair and then repeat the test.

Table 8.2 Minimum allowable times for test (for 7 kPa pressure drop) Minimum allowable time* (minutes) for different test lengths DN 50 m 100 m 150 m 6 9 14 300 7 14 22 375 10 21 31 450 14 28 42 525 18 37 55 600 23 46 70 675 29 57 86 750 41 83 124 900 51 102 153 1000 73 147 220 1200 * These times may be halved where a pressure drop of 3.5 kPa is used. Refer to AS/NZS 2566.2 for calculation basis. Infiltration testing Where a freestanding water table exists at a level of at least 1.5m above the pipeline and 150mm above any sideline connections the absence infiltration can remove the need for either of the previous pressure tests. In all cases where infiltration is observed the source should be investigated and the leak plugged. Where the size of the catchment and number of side connections precludes this approach then the inflow should be measured over a 24-hour period and the principal informed for determination of the acceptable allowable inflow. Generally this should not exceed 5 litres / mm diameter / km length / day.

8.3

Structural assessment on installation

Compaction testing A method of monitoring the compaction of bedding and side support zones of the embedment material around all flexible pipelines is desirable for proper quality control of a buried flexible pipeline at the time of installation. Some soil compaction tests used for civil earthworks may be inappropriate for pipeline work as they are more suited to the higher levels of compaction control needed, for example, with pavement construction. There also may be some delay while samples are being checked at an offsite laboratory. However, methods employing Clegg Impact Hammers are readily adaptable for pipeline work and have the added advantage that the impact figures obtained can be read as an approximation to the soil deformation modulus. Deflection testing Deflection measurements are a useful means of checking that installation requirements have been met and should be done as soon as possible after the completion of the installation. These measurements are frequently used as a quality control device for indirectly assessing the relative embedment compactions achieved during installation. Typical deflections that might be expected in a normal installation would be about half of the values given in Table 8.3. For non-man entry pipes AS/NZS 2566.2 gives a deflection test method using pullthrough go / no go provers. Prover design Suitable types of provers are described in AS/NZS 2566.2. A lightweight vaned type with a minimum of eight vanes between 1.0 and 1.3 pipe diameters in length may be used. The acceptable prover diameter should be determined after giving consideration to the effect of different time periods after completion of construction. Table 8.3 shows the outside diameter of provers required for the maximum allowable deflections (less a further clearance of 2.5mm) at various times after the completion of the installation. The prover should be pulled through the pipeline by hand or means of a hand-operated winch. A tail rope should be attached to ensure it could be retrieved if pipes are found to be over-deflected.

Table 8.3 Max. prover ODs for PN 1 SN 10000 at various times after backfill completion. (These values would be different for other stiffness pipes)
24 hours Adjustment Factor Deflection (%) DN 100 150 200 250 300 375 450 525 600 675 750 Pipe ID 114 166 220 270 328 409 487 564 641 718 794 108 158 210 258 314 392 467 542 616 690 764 107 157 209 257 313 391 466 540 614 689 762 107 156 208 256 312 389 464 538 611 685 758 0.7 3.5 3 days 0.75 3.8 7 days 0.85 4.3 14 days 0.95 4.8 Prover OD 106 156 207 255 310 387 461 535 608 681 754 106 155 207 254 309 386 460 533 606 680 752 105 154 205 253 307 384 458 530 603 676 748 105 154 204 251 306 382 455 528 600 672 744 30 days 3 months 1 5 1.1 5.5 1 year 1.2 6

Where a prover cannot pass along the test length the cause of the obstruction should be determined, generally by a CCTV investigation and appropriate remedial construction undertaken. In extreme situations this may require the exposure of the affected section of the pipeline and proper compaction of the side support zone material carried out. Flowtite pipes are rarely damaged by greater than normal deflections. A visual inspection of any pipe that has been over-deflected is usually sufficient to determine if further embedment compaction or a pipe relay is required. In larger size pipes a visual line-of-site inspection will usually indicate any abnormal deflections. Measured deflections should be based on the following calculations: Deflection (%) = (Actual ID installed vertical ID) x 100 Actual ID

The actual ID or internal diameter is determined by measuring accessible loose pipes of the same class and stiffness, which have not been installed (and with no pipes stacked above them). That is: Actual ID = (Vertical ID + Horizontal ID) 2

Correcting over-deflected pipes For pipes deflected up to 10% of diameter: 1) Excavate to a level about 40% below the crown of the pipe using hand tools to avoid damaging the pipe. 2) Check the exposed pipes for damage. If pipes are damaged they must be repaired or replaced. 3) Re-compact the embedment material to the specified degree in the side support zone. 4) Replace the overlay and backfill to the final level. 5) Check that the deflection complies with the specification or Table 8.3. For pipes deflected more than 10% there is a possibility that the pipes will need to be replaced. Check with Fibrelogic for advice.

8.4

High pressure water cleaning

There are several methods used to clean pipes, depending on diameter and the degree and nature of blockage, which may use either mechanical means or water jets. Whenever mechanical means are employed, use plastic scrapers to avoid damage to the pipes inner surface. The use of high-pressure water emitted through jet nozzles is a practice used to clean pipe internal surfaces. If not properly controlled, water emitted under highpressure through a jet nozzle can cause damage or delamination of most pipeline materials. Based on experience gained with water jet cleaning of Flowtite sewer pipes, the following guidelines must be followed to avoid damage to pipes. Cleaning of Flowtite pressure pipes 1. Limit maximum pressure to 8,300 kPa (1,200 psi / 83 bar). Due to the smooth interior surface of GRP pipe, adequate cleaning and removal of blockages can be achieved below this pressure. 2. Nozzles with jet holes around the circumference are preferred. Nozzles with cleaning chains, wires, or rotating, aggressive damaging nozzles must not be used. 3. The water discharge angle must be between 6 and 15 relative to the pipe axis. See Figure 8.4. 4. The number of jet holes should be 6 to 8 or more and holes size must be at least 2.4 mm. 5. The external surface of the nozzle shall be smooth and the maximum weight 2.5kg. See Figure 8.5. 6. The forward and backward moving speed of the nozzle shall be limited to 30m/min. Uncontrolled movement of the nozzle is not allowed. When inserting the nozzle into Flowtite pipe, care should be taken to prevent it from hitting the pipe wall. 7. Jetting/swabbing sleds with several runners give a greater distance between nozzle and pipe wall are required. See Figure 8.4. 8. The use of equipment or pressures that do not meet the above criteria could cause damage to the installed pipe.

Figure 8.4 Water jet discharge angle.

Figure 8.5 Nozzle weight 2.5 kg.