Wavin PE Pressure Pipe Systems Product and Technical Guide: Intelligent Solutions For

Wavin PE Pressure Product and
Pipe Systems Technical Guide
Intelligent Solutions for Pressure Pipe Projects

1
PE Pressure Pipes
Content
Content
1. Flying the flag in the world page 3
2. Materials for gas and water distribution page 4

2.1 Classification of plastics for piping systems page 4
2.2 Standard Dimension Ratio SDR page 5
3. General material properties page 6

3.1 Polyethylene PE page 6
3.2 Wavin TS page 7
3.3 Technical data PE page 8
3.4 Characteristics & properties page 9
4. Design & Testing page 12
5. Product range page 22
6. Standards & Regulations page 27
7. Installation page 29
7.1 Installation methods page 29
7.2 Jointing page 33
8. Laying instructions page 40
9. Anchorage page 42
10. Handling & Storage page 45
11. Notes page 47
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PE Pressure Pipes
Introduction
1. Flying the flag in the world
Wavin Extensive product range

The Wavin group of companies is one of Wavin’s extensive range of plastic pipe
the largest manufacturers of complete systems is designed and manufactured
plastic pipe systems for the Building, Civil to meet the highest standards set by the
and Utility markets in Europe. In addition building and construction industry world-
to having its own production facilities in wide.
almost every country on the European
continent, Wavin also participates in the Wavin’s products are generally available
equity of plastic pipe companies in ex-stock from one of our numerous
Australia and New Zealand. In the distributors around the world or directly www.wavinoverseas.com
remainder of the world the company is through our export department at Wavin More information about all Wavin
proud of an ever increasing impressive Overseas. products can be found in our extensive
network of licensees, distributors and on-line product catalogue on our website
agents. Wavin has manufactured and The Wavin product range comprises: www.wavinoverseas.com
supplied plastic pipe systems since 1955. Hot & Cold Water Systems (PEX,
The strength of the Wavin Group in terms Metalplastic, PPR and PB) Furthermore this website contains
of manufacturing capability and technical Soil & Waste (DWV) Systems information about Wavin Overseas,
resources places the company at the (PVC, PE and PP) latest news and developments, licensing,
forefront of the industry for product Sanitary Systems machinery and equipment and
quality, innovation, technical support and (traps and siphons) environmental issues.
customer service. Rainwater Management Systems
(collection, re-use and infiltration)
Wavin Overseas Gutter Systems
Wavin Overseas B.V., situated in The Road Drainage Systems / Road
Netherlands, is the central export organi- Gullies
sation of the Wavin Group dedicated to Surface Drainage / Channel Drainage
providing a global service. Wavin Sewer Systems (PVC, PE and
Overseas sells Wavin products, supplies PP/solid and structured wall)
technology (under licence) and equipment Inspection Chambers & Manholes
to manufacture these products locally. Pressure Systems
Wavin Overseas is experienced in setting (U-PVC, O-PVC and PE)
up complete factories, delivering a Cable Duct Systems
comprehensive package of Relining/No-Dig Pipe Renovation
manufacturing equipment, ancillaries and Systems (gas/water/sewer)
services such as production know-how Land Drainage Systems
and technical support. In effect Wavin Irrigation Systems
Overseas can supply all the help you
need to supply your market. Wavin
Overseas operates under a Quality
Management System, which is accredi-
ted to EN ISO 9001:2000 by the Dutch
Council for Accreditation.
Introduction
3
www.wavinoverseas.com
PE Pressure Pipes
Materials for gas and water distribution
2. Materials for water and gas distribution
2.1 Classification of plastics stress is applied over the appropriate load From classification to
for piping systems time. This results in the load duration application
The development of plastics used in gas graph. The MRS value represents the long-term
and water distribution is continuous. In The circumferential stress values for 20˚C circumferential stress in the pipe where
recent years outstanding progress has are extrapolated to 50 years according to the break may occur after 50 years at the
been achieved. ISO/DIS 9080 and lead to earliest. The calculation stress ss is
The creation of new material types with the LTHS anticipated value, 50 years applied for dimensioning of the piping
increased strength, higher property con- (Long Term Hydrostatic Strength), network. This is calculated from:
sistency and at the same time good or the 97.5 % LCL (Lower Confidence
better processability are paramount. Limit). MRS
Moreover, European standardisation σs = ----------
already shows the first conceivable This LCL value is categorised in accor- C
effects in as far as classification systems dance with the Renard series of numbers
come into use today, with subsequent (R10 or R20 in accordance with ISO 3 with C= total operating coefficient.
lasting influences on pipe construction and ISO 497). The calculated LCL value is
with plastics (prEN 1555, prEN 12201, reduced to the next lower Renard num- The total operating coefficient replaces
EN1452). ber. This results in the required MRS the classical "safety coefficient” and
(Minimum Required Strength) considers the facts of application, the
The starting point for the new classifica- This MRS value in MPa is the basis for installation conditions etc.
tion system according to ISO 12162 and the classification. The MRS value
EN 32162 is the long-term behaviour of multiplied by 10 results in the Within the course of harmonisation of
the respective material under internal "classification" of the material. As standards in Europe, uniform guidelines
pressure. For this purpose, values are example, common PE pipe materials. were also created by defining the
obtained with a pipe-type specimen filled They have a MRS of 10 MPa. They are "minimum applied total operating
with water at different temperatures and therefore called PE 100 in accordance coefficient'. For PE materials primarily
evaluated by means of the Standard with the new system. used in the distribution industry, the
Extrapolation Method in accordance with minimum values for C are as follows:
ISO/DIS 9080. Unlike the existing classification methods
based upon the dimensional stress and Material Application C min
Procedure the "safety coefficients" (sometimes PE Water 1.25
At different temperatures, different different in each nation), the new system PE Gas 2
internal pressures (= circumferential refers to a uniformly determined material
stress in the pipe wall) are applied to the parameter. This eliminates earlier The responsibility of selecting the C factor
specimens. The (load) duration until break misunderstandings due to the different to be applied lies with the planning
is determined. The respective breaking starting points. engineer, who can/must also apply higher
values after taking into consideration all
relevant operating and ambient
conditions.
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PE Pressure Pipes
Materials for gas and water distribution
2.2 Standard Dimension The relation between the SDR

Ratio SDR geometrical code and the maximum
In the relevant regulations for plastic permitted internal pressure in the pipes
pipes for distribution, specific pipe important for the user is produced from
dimensions have been fixed based on the the equations:
pipe outer diameter and the pipe wall
thickness in accordance with the respec- σu= p x (da – e) / (20 x e)
tive pipe series. At the same time, each
pipe series is geometrically defined by the and
SDR code = Standard Dimension Ratio,
whereby: σv = σu ≤ σzul.
SDR = d / e The following equation:
or SDR = 20 x (σzul./p) + 1
SDR = 2[s] + 1 If one defines, based on the PE tensile

properties for the life span of 50 years for
to calculate [s]: example,
outside diameter - wall thickness σzul.= MRS/C

[s] =
2 x wall thickness The following relation is produced:
The essential pipe series used for gas SDR = (( 20/p) x (MRS/C)) + 1
and water distribution are described by
the pipe outer diameter d and the pipe As alternate you can use
wall thickness e.
outside diameter
SDR =
wall thickness
or
OD
SDR =
e
Materials for water and

5
www.wavinoverseas.com gas distribution
PE Pressure Pipes
General material properties
3. General material properties
3.1 Polyethylene PE The PE types used by Wavin are suitable Features & Benefits
Polyethylene is the most widely known for drinking water applications and for
mass-produced plastic material. It is the storing foodstuff. The fittings are odour- High reliability and proven service
classical member of the polyolefine fami- less, tasteless and physiologically safe. performance
ly. The chemical formula is: -(CH2-CH2)n, They can therefore be used in all relevant PE is the preferred choice, particularly
so it is an environmentally compatible applications. in buried pipe systems like gas
hydro-carbon product. distribution systems.
PE is a covalent material. The material Resistance to low temperatures
Wavin offers a comprehensive range of can neither swell nor dissolve. Therefore Due to its high ductility, toughness
PE (polyethylene) pressure pipe systems PE pipes cannot be joined with fittings by and elasticity, Wavin PE gives no
designed for potable water and gas means of solvent cement. The problems during installation and
applications (according to EN1555 and appropriate jointing method for the operation at low temperatures.
EN12201), as well as for many other material is fusion jointing. We offer four High impact resistance
pressure and non-pressure applications. jointing methods for pipeline systems in The enormous resistance against
These provide the professionals the our range: electrofusion, compression surge and fatigue eliminates the
option to choose the best system even coupling, heating element butt fusion and necessity of a higher pressure rating
for the most demanding of projects. heating element socket fusion. The first and investments in anti surge
Wavin PE pressure pipes are manufactu- of these jointing methods is favoured for devices.
red from high-density polyethylene, PE 80 pipelines carrying gas, water, Abrasion resistance
and PE 100. PE is especially suitable for compressed air or other less aggressive Comparisons have shown that PE
the transport and distribution of gas and media. pipes have a higher abrasion resistan-
potable water, for industrial applications ce than other materials, therefore PE
and pressure sewers. PE has a high flexi- In buried pipe construction, a high mole- pipes are the most preferred for slurry
bility level and guarantees impact resi- cular type with average to high density is transporting pipe systems.
stance even at low temperatures. accepted. The shortform is: PE80 (PE Excellent flow characteristics
second generation) or PE100 (PE third The smooth bore and resistance
PE has become most widely used in generation). There are hardly any repre- against surge allows higher flow
pipelines systems for the assembly of sentatives of the PE types from the first velocities.
buried gas and water piping together with generation - in accordance with the pre- Excellent chemical resistance
PVC. It has become one of the dominant sent classification PE63 - in the market. To a great number of chemical
piping material in this sphere of agents.
applications in many countries. However, In the past the above mentioned mate- Weldability
this material also offers many advantages rials were named differently. Below you Because of the good weldability and
in domestic installations and industrial can see an overview of the former and elasticity of PE, long lengths can be
piping systems. These include low current material names. assembled outside the (narrow)
weight, excellent flexibility, low pipe fric- trench. The welded joints are strong
tion losses, ductile fracture properties, Old name New name and highly reliable.
toughness even at very low temperatu- LDPE PE 40 Wide variety of installation methods
res, good chemical resistance, fusionable MDPE PE 80 PE pipes offer the installer all possible
and low price. PE has predominantly HDPE PE 63, PE 80, PE 100 solutions for installation, which can
good resistance against acids and caus- provide considerable time and costs
tic substances. It is insoluble in all organic savings. PE pipes are for example
and inorganic solvents at 20 ˚C. PE is preferred in trenchless and “narrow
destroyed by highly oxidized acids over trenching” installation.
the course of time.
The polyethylene we use is stabilised

against the effects of ultraviolet radiation
by the addition of carbon black. The sta-
bilisation also counteracts the heat fati-
gue and thus increases the operating life.
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PE Pressure Pipes
3.2 Wavin TS Features & Benefits

Wavin TS can be installed as easy as
traditional PE pipes. Wavin TS has the Optimum protection
same welding characteristics as PE 100 Against point loads and surface
pipes. The pipes and fittings can be damages.
connected by butt-fusion or electrofusion Ideal for trenchless applications and
as well as other standard jointing installations
techniques applicable for PE pipes. No sand embedding needed.
Wavin TS pipes are compatible with See picture below.
Wavin PE 100 fittings and those from all Suitable for all modern welding tech-
major fitting manufacturers. Wavin TS niques
does not require special embedding All common fusion methods used for
material, which is the most economic PE 100, can be applied.
The increased pressure on Gas- and advantage. Easy and economical installation
Water Boards to reduce installation Similar to traditional PE.
costs, results in new installation No “imported” backfill material is
techniques, like trenchless applications needed.
and installations without sand Very long service life
embedding. With these techniques pipe Even with outside damages.
damage during installation cannot always More cost effective than
be avoided, leading to scoring and point comparable PE multilayer
loads during operation. Therefore a pipe products
is required which service life is not being The possibility of using the native soil
affected by outside damages. To meet for backfill, reduces substantially the
this challenge Wavin developed Wavin installation costs.
Total Security. More benefits
All other benefits of standard PE pipe
Wavin TS is a co-extruded three-layer systems are also applicable for Wavin
pipe with inner and outer protection TS, such as for example cold bending
layers made of the innovative, extremely and resistance against surge and
robust plastic XSC 50, and a middle layer fatigue.
made of PE 100. The three layers are
integrated and cannot be separated
mechanically. The small Wavin TS sizes
25 mm – 75 mm are completely made
out of XSC 50. Due to the material
characteristics of XSC 50 (inner and outer
layers amount to 25% of total wall
thickness each), Wavin TS offers
increased security and a longer service
life compared to traditional PE pipes.
Even when it comes to extreme loads as
a result of notches, grooves and point
loads.
General material
TEL. 7
www.wavinoverseas.com properties
PE Pressure Pipes
3.3 Technical data PE
PE 80 PE 100
Properties Typical Value TypicalValue Unit Test method
Density > 0.93 > 0.95 g/cm3 ISO 1183
Melt flow index MFI 190°C /50N 0.4-1.3 0.4-0.55 g/10 min ISO 1133 cond. 18
Yield stress 22 25 N/mm3 Test rate 125 mm/ min
Elongation at fracture > 800 > 600 %
Bend creep module (1 min. value) 800 840 N/mm2
Crystallite melting range 127-131 127-131 °C
Coefficient of linear expansion 0.20 0.13 mm/m*K
Heat conductivity at 20°C 0.43 0.38 W/m*K
Surface resistance 1013 >1014 Ω
Modulus of elasticity (1 mm/min.) 1200 MPa ISO 527
Linear coefficient of thermal expansion 1.3x10-4 ° K-1 VDE 0304
Specific heat 1.9 J/g ° K Calorimetric at 23 °C
Thermal conductivity 0.38 W/m ° K DIN 52 612 at 23 °C
Min. radius of curvature 25 x dy * at 20°C
*dy = outside diameter of plastic pipe
Environmental technical properties Wavin’s pressure pipes and fittings are tested and approved according to The
Environmental Agency’s demands and found suitable for conducting potable water in
water supply systems.
Pressure rating SDR PE 80 PE 100 Wall thickness

MDPE (PE80) has a minimum required for d110
strength (MRS) derived from a 50 year (MRS = 8, C = 1.25) (PN) (MRS = 10 C = 1.25) (PN)
extrapolated 97.5% lower confidence SDR 7.5 16 bar (20 bar) 24 bar 15.5 mm
limit of 8 MPa and HDPE (PE100) has a SDR 9 16 bar 20 bar 12.5 mm
MRS of 10 MPa. The Hydrostatic Design SDR 11 10 bar (12.5 bar) 16 bar 10 mm
stress for both materials is determined by SDR 17 6 bar (8bar) 10 bar (9.6 bar with SDR 17.6) 6.5 mm
applying a safety factor of 1.25. The SDR 26 5 bar 6 bar 4.5 mm
design life for the Water Industry requires SDR 33 4 bar 5 bar 3.5 mm
a minimum life of 50 years, therefore the
design stress for PE80 and PE100 is as P = (20*MRS)/(C*(SDR-11)) [bar] = PN
follows:
In other liquids or at medium
PE80 = 5 MPa temperatures above 20°C appropriate
PE100 = 8 MPa reduction factors should be taken into
consideration for the maximum permitted
Polyethylene pipe pressure rating is operating pressure.
generally referred to in bar; 1 bar is
approximately equivalent to 10.2 metre The maximum permitted operating
head. pressure for gas should be in
accordance with the corresponding
The maximum permitted operating pres- national standards.
sure (PN) for water at 20°C and a plan-
ned operating duration of 50 years is:
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PE Pressure Pipes
Durability graph PE 100

The addition of carbon-black and stabili- The harmful chemicals can be grouped
zers (mostly aromatic amines and phe- into 3 main types:
nolic compounds) protects polyethylene
against ageing and alterations caused by Oxidisers, eg very strong acids
UV rays. Cracking agents, eg detergents
Thanks to its paraffinic structure, it has a Solvents, eg hydrocarbons (petrol, oil)
high resistance to chemical agents:
It is insoluble at 20˚C in every organic The degree of resistance to any chemical
and inorganic solvent is dependent on concentration, tempera-
Only at temperatures higher than ture and the working pressure, all of
90˚C it dissolves in aliphatic and aro- which may have an effect on the lifetime
matic hydrocarbons and in their of the pipeline. The effects may be detri-
halogenated compounds mental to the pipes strength or permeate
At room temperature, polyethylene is the pipe wall causing tainting of the pota-
only destroyed, as time goes by, ble water supplies.
from strongly oxidizer substances
(conc. HNO3 , conc. H2SO4 and so Wavin provides extensive technical sup-
To calculate the safety factor and permis- on). port and will be pleased to assist when
sible operating pressure it is necessary to doubt exists over a product's suitability.
know the durability strength of the mate- Polyethylene may be affected by certain
rial. chemicals and care must be exercised Abrasion Resistance
Depending on the desired service life and when considering re-development of old Polyethylene has an extremely low co-
the maximum operating pressure, the industrial brownfield sites. efficient of friction and therefore has sig-
appropriate durability strength can be nificant advantages over other pipe mate-
taken from this diagram. Where soil conditions are unknown or rials for the transportation of abrasive
known to be harmful, a soils analysis slurries and in its resistance to abrasion.
3.4 Characteristics & should be carried out to determine any
Properties likely contaminents or talk directly to Wavin polyethylene pipe has been used
Wavin. extensively for pumped slurry applications
Chemical Resistance over many years and has been used for
Plastic pipe systems are ideal for trans- Polyethylene is in chemical terms a non- power station fly ash, china clay slurry,
porting a wide variety of chemicals and polar high molecular weight paraffin of quarries and sand slurries. Field use and
are widely used in industries where con- the hydrocarbon family. Hence it is very laboratory testing has shown that the
veyance of highly corrosive liquids and resistant to (non oxidising) strong acids, performance of PE exceeds metallic pipe
gases require products with excellent strong bases and salts. It is mildly affec- systems. This coupled with its flexibility,
corrosion resistance. ted by aliphatic solvents although aro- lightweight and ease of installation makes
matic and chlorinated solvents will cause it the ideal choice for abrasive slurry
The exceptional resistance of PE to che- some swelling. applications.
mical attack is well known and generally Polyethylene is attacked by strongly oxi-
there are no naturally occurring ground dising substances such as halogens and The external effects of abrasive backfill
conditions which affect the material. concentrated inorganic acids such as materials have only a negligible effect on
Polyethylene does not corrode, rot, pit or nitric, sulphuric (including oleum), perch- PE. Where pipe has been damaged by a
lose its mechanical strength properties loric, etc. sharp object and the cut or gouge
through electrical or chemical reactions exceeds 10% of the pipe wall thickness,
with backfill soils. PE does not under nor- the damaged section should be cut out
mal operating conditions, support the and replaced.
microbiological growth of algae, bacteria
or fungi, nor is it affected by these condi-
tions.
General material
TEL. 9
PE Pressure Pipes
Low Temperature Usage For design purposes pipe expansion can As a non-conducting material PE should
Site practices do not generally allow pipe be more practically understood if we not be used for the earthing of electrical
laying to continue below 0˚C, however consider the expansion as 1.5mm/10˚C/ equipment nor can it be used as a
there may be instances during installation m. In above ground installations careful conductor for frost protection systems.
or pipeline operation where temperatures consideration should be given to the Similarly PE should not be used where
below 0˚C are encountered. positioning of support brackets and there are high levels of static electricity,
anchor points and the use of fully end eg. in mines.
The mechanical properties of PE, opera- load bearing joints. Where possible
ting pressure and impact resistance are expansion and contraction may be Permeability
maintained at temperatures as low as accommodated at changes of direction. PE pipework for potable water can be
-60˚C and therefore moderate winter Where non-end load bearing fittings are laid in close proximity to PE gas mains.
temperatures do not pose any particular used it is important that such fittings are The presence of naturally occurring gas,
problems to the performance of PE pipe. securely anchored to prevent pipe such as is found in landfill sites, similarly
pullout. has no effect on PE pipework.
Polyethylene is a particularly low thermal
conductor and will delay the freezing of With below ground installations new pipe- Notch sensitivity
water within the pipe. Where the water lines should be allowed to stabilise to Polyethylene is known to be extremely
does become frozen, the flexibility of PE ambient temperatures before making the durable in normal use and it is not
and its ability to expand without rupture final tie-in connections, partial backfilling uncommon for pipes to be scratched and
ensures the security of the pipeline. of the pipe will assist in minimising the scuffed during handling and installation,
effects of direct sunlight. particularly with re-habilitation methods
Expansion & Contraction such as slip lining and mains bursting.
Polyethylene has a co-efficient of linear Electrolytic reaction/ This sort of typical site damage will have
expansion of approximately 1.5 x 10-4˚C-1 Electrical conduction no adverse long-term effect on the pipe
which is approximately 10 times greater Polyethylene is a poor conductor of provided the damage does not exceed
than metallic pipes. Expansion is an electricity and does not suffer from 10% pipe wall thickness. If the damage is
important factor which should therefore electrolytic corrosion when in contact greater than 10% the pipe should not be
be considered in the design of pipelines with metal components (valves etc) or used.
where a significant variation in temperatu- when connected into existing metal
re is expected, particularly above ground pipelines.
pipework.
PIPE EXPANSION/CONTRACTION (mm)

PIPE 5˚c 10˚c 15˚c 20˚c 30˚c 40˚c
LENGTH (M)
1 0.75 1.5 2.25 3.0 4.5 6.0
2 1.50 3.0 4.50 6.0 9.0 12.0
5 3.75 7.5 11.25 15.0 22.5 30.0
8 6.0 12.0 18.0 24.0 36.0 48.0
10 7.50 15.0 22.5 30.0 45.0 60.0
15 11.25 22.50 33.75 45.0 67.5 90.0
20 15.0 30.0 45.0 60.0 90.0 120.0
50 37.5 75.0 112.5 150.0 225.0 300.0
75 56.25 112.5 168.75 225.0 337.5 450.0
100 75.0 150.0 225.0 300.0 450.0 600.0
150 112.50 125.0 337.5 450.0 675.0 900.0
200 150.0 300.0 450.0 600.0 900.0 1200.0
Figure 1. The expansion and contraction of PE pipe in mm for a temperature

variation range over pipe lengths up to 200 metres.
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PE Pressure Pipes
Operational pressures for Hydraulic Properties Fittings formula

elevated temperature use Polyethylene pipe has an extremely Determining the pressure drop in fittings
Polyethylene is a thermoplastic material smooth bore giving exceptionally good is more complex. However, using a
and a loss in strength occurs with flow characteristics. As polyethylene is simple formula to give an equivalent
increasing temperature. The maximum non-corrosive and maintains its smooth increase in pipe length, pressure drop
operating pressure for any specific pipe is bore throughout its lifetime there is no can be carried out using the following
based upon a 50 year design life at 20˚C. deterioration in its hydraulic performance. formula;
Any increase above 20˚C will result in a Polyethylene pipe is classed as hydrauli-
reduction in the maximum allowable cally smooth and the hydraulic frictional L = F x ID
operating pressure or lifetime or possibly co-efficients used for design purposes where L = equivalent pipe length in
both. Polyethylene pipe systems should are as follows: metres
not be operated above 60˚C. The F = Fittings constant
following chart gives the reduction factors Colebrooke - White Ks 0.003 mm ID = Internal diameter of the fitting
to be applied to the maximum operating Hazen Williams C = 150
pressures at 20˚C. BEND FITTING F
All pipelines carrying water or slurries will 90˚ Elbow 0.030
100 see pressure losses due to the friction 45˚ Elbow 0.015
91 between the liquid and pipe wall. These 90˚ Tee (straight through) 0.020
82
are general losses due to fluid flow. In 90˚ Tee (side branch) 0.075
% Rating
73
63
50
55 addition there are point losses caused by 90˚ Long Radius bend 0.020
46
36 fittings in the system. 45˚ Long Radius bend 0.010
20 25 30 35 40 45 50 55 Flow calculations Figure 3. Fittings Constant

Operating T emperature ˚C
Pipe sizing and pressure drop can be

If the temperature falls within this range determined using the Flow Charts
the life expectancy of the pipe can be overleaf. These are based on the
affected. Please contact Wavin for furt- Colebrook - White Formula. Using the
her details. required design flow rate (l/sec) the
following data can be determined:
Figure 2. Pressure Reduction Factors for Pipe Diameter (mm)

PE Pipe at Elevated Frictional Head Loss (m/1000 metres)
Temperatures Flow Velocity (m/sec)
General material
TEL. 11
PE Pressure Pipes
Design & Testing
4. Design & Testing
Although a polyethylene pipeline, like any Design for internal TYPE MRS
other pressure system, is primarily pressure PE80 8.0
designed to take the wall stresses produ- The burst pressure of polyethylene pipe is PE100 10.0
ced by the internal pressure of the sys- time dependent and therefore it is neces-
tem, it is important to consider other sary to define the strength of the material Within the classification system develo-
potential loading conditions. This is parti- at a reference lifetime. ped at ISO/CEN, there has also been
cularly true if full benefit is to be made of considerable discussion of the application
the flexibility of the system in the use of The lifetime chosen for this reference of design factors that should be used to
modern installation techniques. value is 50 years - it should be noted that determine the allowable operating pres-
this does not mean that the pipeline will sures (PFA) of a particular plastic pipe
For example, in close-fit insertion or fail after 50 years, as the various safety system. This design factor is applied to
moleplough operations there is a factors that are incorporated into the account for any ‘unknown’ loading or
tendency to score the outside diameter design mean that the actual lifetime will environmental conditions.
of the pipe. Therefore it is essential to be many times greater. In order to gene-
ensure that the pipe has sufficient rate the burst strength of the material at The classification group has recommen-
resistance to the growth of cracks that 50 years, a number of pipe samples are ded minimum values only, which allow
could arise from these external notches. pressure tested to failure at lifetimes the pipeline engineer to use additional
This and many other potential hazards between 10 and 10,000 hours. The factors if difficult conditions exist (eg
are taken into account in the design and results of these tests are graphically or surge, elevated temperature or poor
performance testing of the Wavin range numerically analysed to obtain the mini- ground conditions). For polyethylene
of polyethylene water systems to ensure mum required strength (MRS) at 50 pipeline systems, the recommended
that they have a long and maintenance years. A graphical representation of this design factor is 1.25, which enables the
free service life under design operating process is shown in Figure 4. allowable operating pressure to be calcu-
conditions. In addition to a sound design lated for each system using Lame’s for-
MPa
philosophy, it is also necessary to work mula for thick walled pipes:

MRS
to a rigorous Quality Assurance testing
scheme if this high level of performance Hoop stress: s = P (D - t)
Log Stress
is to be maintained in day-to-day 2t
production. This is best carried out where:
under a third party certification scheme 10 Log Time Hrs 10,000 50 yrs s = Hoop stress MPa
where an external body regularly checks Figure 4. Hydrostatic Pressure Test Curve P = Max. operating pressure bar
test procedures and product D = Outside Diameter mm
performance. Within the CEN and ISO Standards, it is t = Wall thickness mm
recommended that the MRS value is Therefore:
This provides the end user with complete based upon the 97.5% lower confidence s = P (D - 1)
assurance of quality for the product limit obtained by regression analysis, in 2 t
range. At the present time the Wavin accordance with the method outlined in
range of polyethylene water systems are ISO / DTR 9080.2. Now the Standard Dimensional Ratio
manufactured and tested in accordance (SDR) is related to the diameter and wall
with ISO & CEN Standards. Within the Wavin range of polyethylene thickness of the pipe by the formula:
water systems, one basic polymer is SDR = D
included – High Performance t
Polyethylene (PE100). Therefore:
s= P (SDR - 1)
PE80 has a minimum required strength of 2
8MPa while PE100 has a minimum or
required strength of 10MPa as shown in P= 2s
the following table. (SDR - 1)
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PE Pressure Pipes
Design & Testing
If this equation is applied to polyethylene When operating a pipeline above 20˚C, it This is particularly true when the pipe is
pipe systems it is possible to calculate is important to allow for the reduction in being inserted into an existing main, or
the allowable operating pressure (PFA) as the strength of the material at elevated where trenchless laying methods are
shown below: temperatures. Within the ISO TC 138 being used. In order to ensure that brittle
SC5 committee some work has been failure will not develop in the short or long
PFA = 2 x MRS carried out to establish the relationship term from these surface notches, it is
(SDR - 1) a between the maximum operating pres- usual to carry out elevated temperature
where: sure and the operating temperature of pressure tests on notched pipe samples.
a = minimum design factor the pipeline. It should be noted that this test is only
This equation gives the stress in MPa. used within the UK, although discussions
For conventional use, and to express the Their recommendations are given in are now taking place within ISO/CEN
pressure in bar rating, the value in MPa is Figure 6. committees for a wider adoption of these
multiplyed by 10. For example: tests.
100
91
For PE80: 82 In practice, during installation it is recom-
% Rating
73
PFA 50
63 mended that pipe with notches up to a
55
= 2 x 8 x 10 46 maximum of 10% of the wall thickness
36
(SDR - 1) x 1.25 can be used.
= 128
20 25 30 35 40 45 50 55
(SDR - 1) Operating T emperature ˚C Fast fracture
For virtually all materials it is possible for a
For PE100: If the temperature falls within this dynamic crack to grow along the pipe
PFA = 2 x 10 x 10 range the life expectancy of the pipe length provided that sufficient energy is
(SDR - 1) x 1.25 can be affected. Please contact the available to overcome the material’s resi-
= 160 Wavin Technical Services Helpdesk stance to crack growth. Fractures of this
(SDR - 1) for further details. type have travelled many kilometres in
welded steel pipelines and are only arres-
In calculating the operating pressure, it is Figure 6. Pressure Reduction Factors for ted by a valve or other pipeline fittings.
normal to round up or down the values to Polyethylene Pipe at Elevated
the nearest useful pressure class. Temperatures Over the past 10 years considerable test
work has been carried out to investigate
It should be noted that the above repre- Notch sensitivity the relevance of this mode of fracture to
sent the maximum operating pressures Many materials may be extremely strong polyethylene pressure pipelines.
for the pipeline and additional considera- in laboratory tests but when they are The conclusions of this work may be
tion may cause engineers to reduce the notched or scored in handling they can summarised as follows:
operating pressure to a lower level. For become very brittle. The classic material
example, on large diameter PE80 pipeli- in this category is glass, which is brittle Crack propagation cannot occur if the
nes where rapid crack propagation may enough to snap along a defined line pipeline is full of water. However, if
be of concern (please refer to the section when it is lightly scored. When laying the pipeline contains 10% or more air
on Fast Fracture). pipelines it is common for the pipe sur- then propagation can occur.
face to become lightly scored.
PRESSURE CLASS (BAR)

TYPE SDR 11 SDR 17 SDR 26
PE80 12.5 8.0 5.0 TEST CONDITIONS
PE100 16 10 6 Type Notch Depth Temp˚C Stress (MPa) Life (hrs)
PE80 20% 80 4.0 170
Figure 5. Pressure Class for Polyethylene PE100 20% 80 4.6 170
Systems
Figure 7. Test Conditions for Polyethylene Systems
Design & Testing

TEL. 13
PE Pressure Pipes
Design & Testing
Cracks will not propagate through fit- Additional design details Elevated temperature test
tings including flanges or electrofu- Yield Strength Samples from all production of pipe from
sion couplers. Therefore the crack PE100 23 N/mm2 PE80 material are notched to 20% of wall
will be limited to one pipe length in PE80 18 N/mm2 thickness at four points around the cir-
these cases. Linear Thermal Co-efficient of cumference and subjected to a wall
Crack propagation canno occur in expansion stress of 4.0MPa (8 bar for SDR 11) at
small diameter pipelines and therefo- PE80 1.5 x 10 -4˚C-1 80˚C for a minimum period of 170 hours,
re only large pipelines need be consi- PE100 1.3 x 10 -4˚C-1 to establish comparative performance
dered: trends in relation to the resistance of the
PE80 - pipe diameter This equates to the following more useful system to failure by stress cracking.
250mm or above. terms: For PE100 material, the notched pipe is
PE100 - pipe diameters PE80 0.15mm/m/˚C subjected to a wall stress of 4.6MPa (9.2
above 500mm. PE100 0.13mm/m/˚C bar for SDR 11). The purpose of this test
The critical pressure at which rapid is to monitor the stress crack resistance
crack propagation will occur is (eg for 1 metre of PE80 pipe its length of the system and to ensure that crack
dependent upon the pipe material increases 0.15mm for every 1˚C rise in growth does not occur in less than the
and the pipe diameter. temperature). required test life represented by the test.
(see Figure 8).
Quality assurance
PE100
testing
Continuous performance tests are carried
Pressure
PE80 Crack Propagation

out on Wavin polyethylene pipe systems
during manufacture. These are:
24 BA R
Crack Arrest
250m m Pipe Dia 500m m Tensile tests

Test specimens from pipe production are
Figure 8. Critical Pressure Curve for tensile tested to determine the yield
Polyethylene Pipe strength and elongation at break. Typical
minimum results give elongation at more
than 600%.
If, in a particular scheme, it is important
to design against rapid crack propaga- Delayed burst test
tion, the maximum working pressures For PE80 pipe, samples taken at regular
given in figure 14 should be used. For intervals are subjected to a circumferen-
information on the suitability and maxi- tial wall stress of 12 MPa for a period of
mum operating pressure of Wavin one hour at 20˚C. The pressure is steadily
Polyethylene systems outside increased until the pipe bursts, and it
of the information given, please contact must be at a stress greater than
the Wavin Technical Services Helpdesk. 16MN/m2. For PE100 the same test is
carried out at a wall stress of 12.5 MPa
Other design for 100 hours.
considerations
In designing any pipeline system, it is
necessary to consider other factors that
may influence the performance of the
pipe. In most cases, sufficient data will
have been gathered to provide formal
design recommendations,
but in other situations advice should be
sought from Wavin
14 TEL. FAX E-MAIL

PE Pressure Pipes
Design & Testing
For fewer than 200 housing For a normal single-family house with tour Calculations
units occupants this gives a design water flow
Here the design water flow (qd) is deter- qmax of: Water consumption/house:
mined using DS 439, the DIF (Danish qmax = 167l / hour = 0,046 l/s
Association of Engineers) code of practi- 400 l/24 hours/pe x 4 (pe) x 2.5
ce for water installations. DS 439 states q max
= 24 Water quantity is calculated for each pipe
that the sum of the predicted water flows = 167 l/hour = 0.046 l/s section for instance:
can be set at 1.6 I/s per housing unit,
which gives a (qd) of 0.36 I/s per unit. Example of design of water A - B: (10 + 15 + 8) houses x 0,046 l/s =
supply pipeline 1,52 l/s
For more than 200 housing
units The example is based upon the following Pressure loss is found by means of the
Here the design water flow (qmax) is deter- data: water flow diagram for PE 80 pressure
mined using DS 442, the DIF code of pipes PN 10, diagram on the next page.
practice for public water supply systems. Pressure at station A is measured at
DS 442 states that qmax can be determi- 3.5 bars (35 m Wat.Col.) Using the pipe dimensions below the fol-
ned from the following formula: PE 80 pipes PN 10 are used as lowing pressure will be available at the
pipeline material consumer in station D:
Formula 1 Maximum daily water consumption
(Qmax )= 400 l/24 hours/pe 35 m Wat.Col. – 13 m Wat.Col. = 22 m
Q max
x ft max
Maximum consumption per hour = Wat.Col. > 20 m Wat.Col. OK
qmax
= 2,5 x Q max
24 Necessary pressure at consumer: 2

bars (20 m Wat.Col.)
where Q max
= avarage daily consumption 4 persons per household
[Qm] x 24-hour
factor [fd]
ft max
= hour factor
8
Where normal types of housing are invol- 10 houses
C
ved, Qmax can be set at 200 I/24 hours/pe A houses
Main line
and fd at 2. This gives a Qmax of 200 x 2

50 m
D
= 400 l / 24 hours/pe. For normal types
of housing ft max
is set at 2.5.
15
B houses
500 m 650 m 200 m
Figure 9. Diagram of pipeline in example
Section Quantity of water (l/s) Length (m) Pipe-dimension (mm) Pressure loss Pressure loss of
M Wat.Col./km) section (m Wat.Col.)
A-B 1,52 500 Ø 63 15 7,5
B-C 1,06 650 Ø 63 7 4,6
C-D 0,37 250 Ø 63 3,7 0,9
Sum 13
Table: Example of dimensioning diagram for calculation of pressure loss
Design & Testing

TEL. 15
PE Pressure Pipes
Design & Testing
16 TEL. FAX E-MAIL

PE Pressure Pipes
Design & Testing
Longitudinal expansion and Hydraulic flow: k = frictional resistance [m]

contraction of frictional losses for diameter ≤ 200 mm
plastic pipes k = 0.00001 m
Plastics have a comparatively high coeffi- Formula for diameter > 200 mm
cient of linear heat expansion, which Water flow diagrams are calculated k = 0.00005 m
should be taken into account when laying according to the Colebrook-White
plastic pipes. formula: The curves are designated by trade
Pipe with socket joints do not normally name (external diameter) but calculated
require special measures to be taken Formula 4 according to the internal pipe diameter
regarding expansion caused by tempera- making it possible to read the capacity of
ture changes, as each socket acts as an 0.74 k the pipes direct without having to inter-
expansion piece. Q = -6.95 x log ( + ) x Di 2 x √ Di x I polate between the curves.
Di x √ Di x I x 106 From the diagrams the frictional loss of
However, in the case of a long section of 3.71 x Di the plastic pipe itself appears. Individual
adhesive-jointed PVC pipes, the whole resistances such as bends, valves, redu-
section will behave as a single long pipe. cers, tees, inlet and outlet taps etc. are
Expansion or contraction will thus be Q = water discharge [m3/s ] not taken into account.
concentrated and the whole section will Di = internal pipe diameter [m]
expand or contract. I = frictional loss [m/m] [number]
Formula 2
∆L = ∆t x L x α
where ∆L = longitudinal expansion/con-

traction [m]
∆t = T1 - T1 [°C]
T1 = stable soil temperature

T1 = temperature of pipe when laid
L = length of section [m]
α = coefficient of linear heat expan-
sion
Use of plastic pipes at

temperatures exceeding
20°C
Where circumstances require that the

normal maximum operating temperature
of a pipe be exceeded, the reduction in
pressure necessary to obtain the same
service life as at a 20°C operating tempe-
rature can be calculated from the dia-
gram below.
Formula 3
PNt = PN x Ct
Diagram: Permissible operating pressure at temperatures exceeding 20°C
Design & Testing

TEL. 17
PE Pressure Pipes
Design & Testing
For most water supply projects the diffe- pressure cannot escape. The risk of All known materials show to a varying
rent individual resistances will normally water hammer may necessitate the degree a tendency to suffer fatigue when
not be calculated. In such a case 2 - 5% installation of devices to minimize the subjected to dynamic forces. Incidences
is added to the frictional loss of the pipe- effect of the pressure waves and will of water hammer will therefore reduce the
line. often require special operating service life of the pipes - the extent of
instructions. such reduction depending upon the com-
High water velocity position of the dynamic forces i.e.:
For projects with much higher water velo- There is ample technical literature
city or projects for which a detailed cal- available on the subject. Comprehensive The duration of the pressure rise
culation of different individual resistances guidance is given on calculation methods The maximum value of the above
is desirable the following formula can be but these are both complicated and compared with the level of the static
used: time-consuming. However, data mean stress
programs have been produced which are The time interval between rises in
Formula 5 able to solve even the most complicated pressure (frequency) etc.
problems. In compiling these programs,
v2 information concerning the special The following permissible pressure rises
∆H = ζ x ––– characteristics of the pump, pressure apply for pressure pipes used in water
head and torque, the valve closure, the supply systems:
2g air valves and various designs of the
longitudinal profile etc. has been inclu- Where pressure rises occur infrequently,
where ∆H = pressure head loss(m) ded. As a result there is a risk of pressure e.g. pressure testing, power failure etc.,
ζ = resistance (number) variations, rates of flow, vibration the permissible maximum pressure may
frequencies, volumes of air valve and exceed the nominal pressure by 50%.
v = velocity (m/s) pressure changes along the pipe line
g = gravity = (9.81 m/s2) as a function of time. For plastic pipes it furthermore applies
that where pressure rises occur frequent-
If the ζ -values of our products are Rapid filling of a pressure pipe line and ly (maximum 106 instances in a 50-year
variations between trapped air masses period) the permissible maximum pres-
required please contact Wavin. may also cause sharp rises in pressure. sure may exceed the nominal pressure
Pipe lines should therefore be designed by 25%, but such pressure rises must
Pressure variations to allow bleeding wherever required and not result in a pressure amplitude higher
filling speeds should be kept low. than 30%.
Water Hammer
Each time the rate of flow in a pipe The speed of the pressure wave depends In case of doubt please contact Wavin.
system changes, a pressure wave is on the pipe material, wall thickness and
created. This can result in such large the substance carried by the pipe.
variations in pressure as to cause a
water hammer, which may exceed the The following pressure wave speed
permissible load on the pipes (force values a [m/s] apply for water carrying
acting upon it). (incl. waste water) Wavin pipes:
In pump systems changes in the rate of Pressure class PE

flow can occur in the case of e.g. power PN a [m/s]
cut, sudden blockages, rapid closing of 16 444
valves etc. If this takes place at one end 10 362
of a long pipe line, the pressure waves 8 327
will rebound from the other end and may 6.3 - Figure 10. Example of variation in
cause damage when they return to their 6 288 pressure
point of origin - particularly if this end is 5 263
completely shut off and the increased 4 237
18 TEL. FAX E-MAIL

PE Pressure Pipes
Design & Testing
Flow diagram for Wavin Polyethylene pipe sizes 20 mm to 315 mm
Please note: this diagram is for water at 15˚c. and utilises a roghness factor (ks) of 0.003 mm
Design & Testing

TEL. 19
PE Pressure Pipes
Design & Testing
Flow diagram for Wavin Polyethylene pipe sizes 90 mm to 1000 mm
Please note: this diagram is for water at 15˚c. and utilises a roghness factor (ks) of 0.003 mm
20 TEL. FAX E-MAIL

PE Pressure Pipes
Design & Testing
Testing & Pipework must not be tested at Take a further reading of pressure P3
commissioning temperatures in excess of 30˚C. at a decay time of not less than 15tL,
Air valves should be placed at all high this is time t3.
Site pressure testing points in the system. t3c = t3 + 0.4tL
The traditional testing procedures used Data loggers with pressure transdu- Calculate Nz = log Pz - log P3
for most pipeline materials are generally cers should be used to provide a log t3c - log t2c
intended for linearly elastic materials, eg precise analysis of the pressure test
ductile iron and steel, and are not data and can provide the engineer The ratio N2 should again be as those
suitable without modification for visco with an early indication of any identified above. The test sensitivity can
elastic materials such as polyethylene. leakage. be increased by extending the value of
Pipe manufactured from such materials For on site calculations a pocket t3.
exhibit creep and stress relaxation. With calculator is sufficient.
a PE pipe sealed under a test pressure, If an unacceptable leak is indicated,
there will be a reduction in pressure Test procedure all mechanical joints should first be
(pressure decay) due to the visco elastic Upon reaching the test pressure, the checked, followed by checks on any
(creep) response of the material. test section is isolated. Butt or Electrofusion joints.
This will occur even in a leak free system. Pressure loading time is used as the If a further test is necessary, a period
This pressure decay is non-linear in an base reference point,(t1). of at least five times the first test
unrestrained pipe. In view of this charac- A correction factor, 0.4tL, is used to period should elapse before re-
teristic a pressure test has been develo- calculate ratios (N), this accounts for testing. This allows the pipeline to
ped which accounts for the effects of the pipeline beginning to relax during recover from the previous pressurisa-
creep and stress relaxation. the pressurisation period. tion.
Take a first reading of pressure P1 at
t1 where t1 is equal to the pressure Commissioning procedure
loading tL. Corrected value = t1c
t1c = t1 + 0.4tL Upon the successful completion of a
Pressure Take a second reading of pressure test, the remaining pressure in the
P2 at a decay time of 7tL this is time pipeline should be released slowly.
t2.
Corrected value = t2c Following successful pressure testing all
Pipe
t2c = t2 + 0.4tL. new mains, lined or re-furbished, should
Calculate N1 = log P1-log P2 be commissioned in the following manner
Figure 11. Test Pressure Curve log t2c-log t1c and in accordance with any local require-
ments:
Test pressures For a pipeline without leaks, N1 should
PE pipe systems could be pressure be: Cleaning and/or swabbing of the
tested up to a maximum of 1.5 times the a) 0.08 to 0.10 for pipes without main
rated pressure of the pipe. However, for constraint (eg sliplined, or not Filling and sterilisation
practical purposes it is usual and may backfilled) Flushing and/or neutralisation
only be necessary to pressure test up to b) 0.04 to 0.05 for pipes with compacted Refilling the main
1.5 times the pipeline working pressure backfill. If the resultant values are Bacteriological sampling
(operating pressure). significantly less than those specified, Acceptance certification
this indicates that there is too great a Introduction of the main into service
Test section preparation volume of air in the pipeline. This air
must be removed before a re-test can
Test in sections of 1000 metres or be satisfactorily carried out.
less.
Pipework should be backfilled, with
joints left exposed at the engineers
discretion.
Design & Testing

TEL. 21
PE Pressure Pipes
Product range
5. Wavin PE pipes product range
Product range Wavin PE pressure pipes
The Wavin PE pressure pipe range consists of a wide assortment of pipes available in many diameters, different pressure classes
and a variety of colours.
Wavin PE pipe systems are available in sizes 20 mm - 630 mm.
The small sizes are available on coils. Larger sizes are available in pipe lengths.
PE pressure pipes for Gas

SDR 11, SDR 17, SDR 17,6
PE 80 PE 80 PE 100 PE 100
Yellow Yellow Orange Orange
SDR 17.6 SDR 11 SDR 17 SDR 11
OD wall/weight wall/weight wall/weight wall/weight
32 2,0 / 0,194 3,0 / 0,277 -/- 3,0 / 0,277
40 2,3 / 0,283 3,7 / 0,427 -/- 3,7 / 0,427
50 2,9 / 0,437 4,6 / 0,661 -/- 4,6 / 0,661
63 3,6 / 0,683 5,8 / 1,043 -/- 5,8 / 1,043
75 -/- 6,8 / 1,455 -/- 6,8 / 1,455
90 5,2 / 1,433 8,2 / 2,106 5,4 / 1,447 8,2 / 2,106
110 6,3 / 2,00 10,0 / 3,121 6,6 / 2,150 10,0 / 3,121
125 7,1 / 2,643 11,4 / 4,074 7,4 / 2, 741 11,4 / 4,047
140 -/- -/- 8,3* / 3,439 -/-
160 9,1 / 4,319 14,6 / 6,616 9,5 / 4,485 14,6 / 6,616
180 10,3 / 5,484 16,4 / 8,360 10,7 / 5,671 16,4 / 8,360
200 -/- -/- 11,9* / 6,995 18,2* / 10,308
225 12,8 / 8,488 20,5 / 13,043 13,4 / 8,868 20,5 / 13,043
250 14,2 / 10,475 -/- 14,8 / 10,865 22,7 / 16,039
280 -/- -/- 16,6 / 13,645 -/-
315 17,9 / 16,579 28,6 / 25,443 18,7 / 17,275 28,6 / 25,443
*Colour Black with yellow stripes
22 TEL. FAX E-MAIL

PE Pressure Pipes
Product range
PE pressure pipes for water

SDR 9, SDR 11, SDR 13,6, SDR 17
Pipe series S
SDR 9 SDR 11 SDR 13,6 SDR 17
S4 S5 S 6,3 S8
Nominal pressure, PN a in bar
PE 80 PN 16 PN 12,5 PN 10 PN 8
PE 100 PN 20 PN 16 PN 12,5 PN 10
Nom. Wall thicknessess b Dimensions in millimetres
size e min e max e min e max e min e max e min e max
16 2,0 c 2,3 x x x x x x
20 2,3 2,7 2,0 c 2,3 x x x x
25 3,0 c 3,4 2,3 2,7 2,0 c 2,3 x x
32 3,6 4,1 3,0 c 3,4 2,4 2,8 2,0 c 2,3
40 4,5 5,1 3,7 4,2 3 3,5 2,4 2,8
50 5,6 6,3 4,6 5,2 3,7 4,2 3 3,4
63 7,1 8 5,8 6,5 4,7 5,3 3,8 4,3
75 8,4 9,4 6,8 7,6 5,6 6,3 4,5 5,1
90 10,1 11,3 8,2 9,2 6,7 7,5 5,4 6,1
110 12,3 13,7 10 11,1 8,1 9,1 6,6 7,4
125 14 15,6 11,4 12,7 9,2 10,3 7,4 8,3
140 15,7 17,4 12,7 14,1 10,3 11,5 8,3 9,3
160 17,9 19,8 14,6 16,2 11,8 13,1 9,5 10,6
180 20,1 22,3 16,4 18,2 13,3 14,8 10,7 11,9
200 22,4 24,8 18,2 20,2 14,7 16,3 11,9 13,2
225 25,2 27,9 20,5 22,7 16,6 18,4 13,4 14,9
250 27,9 30,8 22,7 25,1 18,4 20,4 14,8 16,4
280 31,3 34,6 25,4 28,1 20,6 22,8 16,6 18,4
315 35,2 38,9 28,6 31,6 23,2 25,7 18,7 20,7
355 39,7 43,8 32,2 35,6 26,1 28,9 21,1 23,4
400 44,7 49,3 36,3 40,1 29,4 32,5 23,7 26,2
450 50,3 55,5 40,9 45,1 33,1 36,6 26,7 29,5
500 55,8 61,5 45,4 50,1 36,8 40,6 29,7 32,8
560 x x 50,8 56 41,2 45,5 33,2 36,7
630 x x 57,2 63,1 46,3 51,1 37,4 41,3
a PN values are based on C = 1,25

b Tolerances in accordance with grade V of ISO 11922-1:1997[1]
c The calculated value of emin. (ISO 4065 [2]) is rounded up
to the nearest value of either 2,0, 2,3 or 3,0.
This is to satisfy certain national requirements.
Product range
TEL. 23
PE Pressure Pipes
Product range
PE pressure pipes for water

SDR 17,6, SDR 21, SDR 26, SDR 33
Pipe series S
SDR 17,6 SDR 21 SDR 26 SDR 33
S 8,3 S 10 S 12,5 S 16
Nominal pressure, PN a in bar
PE 80 x PN 6 c PN 5 PN 4
PE 100 x PN 8 PN 6 c PN 5
Nom. Wall thicknessess b Dimensions in millimetres
size e min e max e min e max e min e max e min e max
32 2d 2,3 x x x x x x
40 2,3 2,7 2d 2,3 x x x x
50 2,9 3,3 2,4 2,8 2 2,3 x x
63 3,6 4,1 3 3,4 2,5 2,9 x x
75 4,3 4,9 3,6 4,1 2,9 3,3 x x
90 5,1 5,8 4,3 4,9 3,5 4 x x
110 6,3 7,1 5,3 6 4,2 4,8 x x
125 7,1 8 6 6,7 4,8 5,4 x x
140 8 9 6,7 7,5 5,4 6,1 x x
160 9,1 10,2 7,7 8,6 6,2 7 x x
180 10,2 11,4 8,6 9,6 6,9 7,7 x x
200 11,4 12,7 9,6 10,7 7,7 8,6 x x
225 12,8 14,2 10,8 12 8,6 9,6 x x
250 14,2 15,8 11,9 13,2 9,6 10,7 x x
280 15,9 17,6 13,4 14,9 10,7 11,9 x x
315 17,9 19,8 15 16,6 12,1 13,5 9,7 10,8
355 20,1 22,3 16,9 18,7 13,6 15,1 10,9 12,1
400 22,7 25,1 19,1 21,2 15,3 17 12,3 13,7
450 25,5 28,2 21,5 23,8 17,2 19,1 13,8 15,3
500 28,3 31,3 23,9 26,4 19,1 21,2 15,3 17
560 31,7 35 26,7 29,5 21,4 23,7 17,2 19,1
630 35,7 39,4 30 33,1 24,1 26,7 19,3 21,4
a PN values are based on C = 1,25

b Tolerances in accordance with grade V of ISO 11922-1:1997[1]
c Actual calculated values are 6,4 bar for PE 100 and 6,3 bar for PE 80.
d The calculated value of emin. (ISO 4065 [2]) is rounded up to the nearest value of either 2,0,
2,3 or 3,0. This is to satisfy certain national requirements.
Note: Grade V tolerances are in accordance with ISO 11922-1:1997[1] and calculated
from the following formula: (0,1 emin + 0,1) mm, rounded to the next 0,1 mm higher.
For certain applications for e>30 mm tolerance grade T in accordance with

ISO 11922-1:1997[1] can be used and the tolerance calculated from the following formula:
0,15 emin, rounded to next higher 0,1 mm.
24 TEL. FAX E-MAIL

PE Pressure Pipes
Product range
Coil dimensions
The smaller PE pipe sizes are available on coil.
Please find below a coil dimensions overview.
Coil Dimensions
OD id od width length weight
20 660 840 190 100 16,7
670 950 250 200 33,4
25 660 880 240 100 21,6
660 1060 240 200 43,2
32 880 1060 210 50 14,3
880 1170 240 100 28,5
880 1330 270 200 57,0
880 1440 300 300 85,5
40 880 1100 260 50 17,8
880 1240 300 100 35,6
880 1380 380 200 71,2
880 1510 420 300 106,8
880 1900 420 500 178,0
50 1000 1280 330 50 22,7
1000 1450 330 100 45,3
1000 1790 330 200 90,6
1000 1710 530 300 135,9
1000 1880 530 400 181,2
1000 2050 530 500 226,5
63 1750 1990 350 50 36,1
1750 2090 410 100 72,1
75 1750 2290 410 100 101,5
Product range
TEL. 25
PE Pressure Pipes
Product range
Wavin TS - SDR 17 - in pipe lengths

d / mm s / mm L* / m kg/m Quantity per pallet
225 13,4 12 8,93 14
250 14,8 12 11 11
280 16,6 12 13,7 11
315 18,7 12 17,4 8
355 21,1 12 22,1 8
400 23,7 12 28 5
450 26,7 12 35,4 4
* Special lengths on request
Wavin TS - SDR 11 - in pipe lengths

d / mm s / mm L* / m kg/m Quantity per pallet
32** 3 12 0,28 473
40** 3,7 12 0,43 250
50** 4,6 12 0,67 160
63** 5,8 12 1,05 132
75** 6,8 12 1,47 102
90 8,2 12 2,12 58
110 10 12 3,14 48
125 11,4 12 4,08 34
140 12,7 12 5,08 38
160 14,6 12 6,67 20
180 16,4 12 8,42 17
200 18,2 12 10,4 14
225 20,5 12 13,1 14
250 22,7 12 16,2 11
280 25,4 12 20,3 11
315 28,6 12 25,6 8
355 32,2 12 32,5 8
400 36,3 12 41,3 5
450 40,9 12 52,3 4
** Completely made out of XSC 50
Wavin TS - SDR 11 - in coils

d / mm s / mm L* / m/coil kg/coil A/mm B H / mm
25** 2,3 100 17,1 800 660
32** 3 100 27,9 1170 880 240
40** 3,7 100 43 1240 880 300
50** 4,6 100 66,6 1450 1000 325
63** 5,8 100 105 2090 1750 410
75** 6,8 100 147 2290 1750 413
90 8,2 100 212 2890 2400 495
110 10 100 314 3000 2400 605
125 11,4 100 408 3080 2400 688
140 12,7 100 508 3165 2400 770
160 14,6 100 667 3270 2400 1200
180 16,4 100 842 3384 2400 990
** Completely made out of XSC 50
26 TEL. FAX E-MAIL

PE Pressure Pipes
Standards & Regulations
6. Standards & Regulations
Wavin products meet the requirements of AII European product standards have a prEN 1452: PVC in water distribution
the relevant international and national uniform structure. They consist of 7 parts prEN 12201: PE in water distribution
standards and regulations with regard to with the following structure: prEN 1555: PE in gas distribution
dimensions, identification, materials and The Wavin range of products is designed
mechanical and physical properties. Part 1: General in such a way that they comply with
Part 2: Pipes these standards. Our commitment to
The relevant standards can primarily be Part 3: Fittings quality and the knowledge that standards
divided into three main groups, as shown Part 4: Valves only include the minimum requirements,
below, Part 5: Fitness for purpose have resulted in internal quality standards
Part 6: Recommended practice for at Wavin, which are more or less above
Norms Committees installation the "Norm level”.
ISO International Organisation for Part 7: Assessment of conformity
Standardisation. Organisation ISO certification
Internationale de Normalisation Plastic products that are used for Wavin Overseas operates under a Quality
underground piping for gas and water Management System, which is accredi-
EN Europäisches Komitee für distribution, are subject to the following ted to EN ISO 9001:2000 by the Dutch
Normung. Comité Européen de standards: Council for Accreditation. We constantly
Normalisation. European strive to enhance this QA-system in order
Committee for Standardisation to improve customer satisfaction.
SN,DS, National Committees for Norms

UNI,
DIN,
BS, NF,
O Norm,
DVGW etc.
European product
standards
The harmonisation of European stan-
dards is one of the key achievements of
the common European market. Technical
regulations and national standards are no
longer allowed to restrict the free exchan-
ge of goods and services.
In the CEN (Comité Européen de

Normalisation) committees, users national
associations/ organisations and manufac-
turers have come together to create uni-
form European standards. These CEN
Standards will become imperative for all
members of the European Community as
well as for the EFTA States who voted in
its favour. They may then not be overru-
led by a national standard.
standards & Regulations

TEL. 27
PE Pressure Pipes
Standards & Regulations
List of relevant standards PE pipe systems
ISO 161-1 Thermoplastic pipes for the transport of fluids

ISO 1183 Polyethylene - measurement of density
ISO 3607 PE pipes - tolerances on o. d. and wall thicknesses
ISO 3663 PE pressure pipes and fittings - dimensions of flange
ISO 4427 Buried PE pipes for the supply of potable water
ISO 4437 Buried PE pipes for the supply of gaseous fuels
ISO 4440 PE pipes and fittings - determination of melt flow rate
ISO 6447 Rubber seals-joint rings used for gas supply pipes and fittings
ISO 8085 PE fittings for the supply of gaseous fuels
PrEN 1555 Plastic piping systems for gas supply - Polyethylene (PE)
PrEN 12201 Plastic piping systems for water supply - Polyethylene
PrEN 13244 Plastic pipe systems for buried and above-ground pressure systems for water for general purpose, drainage end sewerage
DIN 3535 Gaskets for gas supply
DIN 3543 Valves in PE HD for PE-HD-Mass pipes
DIN 3544 Valves in polyethylene of high density (PE-HD) Requirements and test of tapping valves
DIN 8074 Pipes in polyethylene of high density (PE-HD)-Mass
DIN 8075 Pipes in polyethylene of high density (PE-HD) General quality requirements - Test
DIN 16963 Pipe joints and piping components for pressure pipelines in high density polyethylene (PE-HD)
DIN 19533 Pipes in PE-HD and PE-MD for drinking water supply; pipes, pipe joints, piping components
DS 2131.2 Pipes, fittings and joints of PE type PEM and PEH for buried gas pipelines
UNI 8849 Raccorcdi di polietilene (PE5O), saldabili per fusione mediante elementi riscaldanti, per condotte per convogliamento
di gas combustibili. Tipi, dimensioni e requisiti
UNI 8850 Raccordi di polietilene (PE50), saldabili per elettrofusione per condotte interrate per convogliamento di gas combus-
tibili. Tipi, dimensioni e requisiti
O Norm B 5192 Pipes, pipe joints and piping components in PE for buried gas pipelines
DSV 2207 Fusion of thermoplastic plastics, (PE) pipes and Part I piping components for gas and water pipelines
DVGW G 477 Manufacture, quality assurance and testing of pipes in rigid PVC and PE-HD for gas pipelines
DVGW VP 302 Butterfly valves in PE-HD
DVGW VP 304 Gas and tapping valves for PE-HD piping systems
DVGW VP 607 PE-HD fittings for gas and water pipelines
DVGW VP 608 Polyethylene pipes (PE80 and PE100) for gas and drinking water lines; requirements and tests
DVGW VP 609 Plastic clamp joints for connecting PE pipes in the water supply
DVGW VP 610 Temporary test basis for water tapping valve, requirements and tests
DVGW VP 302 PE-HD butterfly valves
DVGW VP 304 Gas butterfly valves for PE-HD piping systems
DVGW VP 610 Temporary test basis for water tapping valve, requirements and tests
DVGW G 472 Laying gas lines
DVGW G 459 Laying gas domestic connections
DVGW G 477 Pipes and piping components for rigid PVC and HDPE gas lines
DVGW W 320 Rigid PVC, HDPE and LDPE water supply pipelines
O Norm B 5192 Pipes, pipe joints and piping components in PE for buried gas lines
prEN 681 Seals (water)
prEN 1555 Plastic piping systems for gas supply - Polyethylene (PE)
prEN 12201 Plastic piping systems for water supply - Polyethylene
UNI 8849 Raccorcdi di polietilene (PE50), saldabili per fusione mediante elementi riscaldanti, per condotte per convogliamento
di gas combustibili. Tipi, dimensioni e requisiti
UNI 8850 Raccordi di polietilene (PE50), saldabili per elettrofusione per condotte interrate per convogliamento di gas combus-
tibili. Tipi, dimensioni e requisiti.
28 TEL. FAX E-MAIL

PE Pressure Pipes
Installation
7. Installation
7.1 Installation methods

Wavin PE80 and PE100 polyethylene Marker T ape
pipe systems provide a cost effective and
Trench Width +300mm
simple to install pipe system. Min As dug
900mm material
Polyethylene is a thermoplastic material 300mm

150mm
resulting in a lightweight, flexible pipe, Min
which is totally corrosion resistant and Less
than
leak free with proven fusion welded and 900mm
mechanical jointing methods.

100mm
Pipe OD +250mm
The following notes give a general
guidance into the use of PE. Imported or selected
bedding & backfill
material
Buried pipework
One of the key strengths of polyethylene Figure 12. Typical Open-Cut Figure 13. Recommended Protection for
is its ability to be fusion welded, either by Trench Detail Shallow Pipes
Butt or Electrofusion. This results in a
continuous, flexible pipe string which can
be easily snaked into pre-dug trenches. The width of the trench should be the Backfilling
Where site conditions permit welding can minimum of pipe O.D. plus 250 mm to Polyethylene is a flexible material and can
be very easily carried out above ground. allow for the correct compaction of side- deform under load without damage. It is
Polyethylene lends itself to a number of fill. The location of cables and pipes from however, important that any deformation
minimum dig and no-dig techniques, other utilities should be identified prior to is minimised and that the placement of
many of which were developed specifi- excavation and generally at least 3 pipe the correct sidefill and initial backfill mate-
cally around PE pipe systems, eg: lengths should be excavated prior to pipe rials is carried out correctly with adequate
installation to allow for obstructions to compaction. A minimum 100 mm cover
Narrow Trenching be avoided. should be placed above the crown of the
Ploughing pipe, with heavy compaction equipment
Moling Polyethylene may in some instances be not being used with less than 300mm
Pipe Bursting laid directly onto the trimmed trench cover. Backfilling can then proceed in
Slip Lining bottom where the soil is uniform, fine 300 mm layers.
Folded PE, lining systems grained and free from large stones and
Directional Drilling flints. Trench backfilling should commence as
soon as possible after pipe laying to give
Conventional open cut In other cases the trench should be the pipe protection from damage from
trenching excavated to a depth to allow for a objects possibly falling into the trench.
Excavation and disposal of waste spoil minimum 100 mm bed of gravel, crushed To protect the pipe from potential future
are major factors in pipe installation. stone or coarse sand. A sand/gravel mix interference damage it is good practice to
Landfill taxes are becoming a significant is also acceptable, provided the gravel is install a marker tape 300 mm above pipe
cost and environmental factors are less than 20 mm insize. crown. Marker tapes can also include
forcing Engineers to look at new a tracer wire to allow future identification
installation methods to minimise the of the pipeline.
disruption and amount of waste spoil
generated.
The current practice is to lay service

pipes at 750 mm cover and mains at 900
mm cover, measured from the
pipe crown.
Installation
TEL. 29
PE Pressure Pipes
Installation
Shallow cover
There may be situations where pipes buckets or chain trenchers, trenches existing pipe is cracked open and the
cannot be laid at the recommended 100mm wider than the pipe being instal- new PE pipe is drawn into the hole cre-
depths of cover. In these situations for led are excavated. Coiled, drummed or ated, and provides either a size for size
highways or traffic areas the pipe should pre-welded pipe strings can be quickly replacement pipe or by use of reamers
be protected by placing a 150mm thick installed. Significant savings can be the original main can be upsized.
reinforced concrete bridging slab above achieved through reductions in less exca-
the pipe. A 150 mm thick granular cus- vated spoil, less imported fill materials The present day hydraulic bursting tools
hion should be placed between the pipe and reduced labour. are capable of cracking out both pipes
crown and concrete, fig. 13 on the pre- and fittings in very demanding situations,
vious page details the typical application. Ploughing techniques and further adaptations are now capable
Developed from agricultural machines of splitting ductile iron and steel mains.
Installation techniques laying land drainage, these machines are
As discussed earlier a number of techni- used for laying cross-country water and With this technique, damage to adjacent
ques have been developed to maximise gas pipelines. utilities plant is possible and therefore
the benefits of using polyethylene, these care is required in the planning and ope-
techniques are briefly discussed below. Pipes are laid with little disruption to the ration of bursting.
land which is quickly reinstated to agricul-
ture. Pipe is installed continuously Moling
through a hollow plough with bed & sur- Moling has become an established no-
round material plus marker tape installed dig method for the installation of small
simultaneously as required. diameter service pipes and mains, and
can give significant cost savings over
Figure 14. Typical Bursting Operation Pipe bursting open-cut trenching. Excavation is limited
This is an ever-increasing method of re- to launch and reception pits and moling
Narrow trenching habilitating an existing pipeline where a is ideally suited for road crossings and
A modification of traditional open-cut non-structural lining method would be installations under expensive paved areas
trenching. Using either narrow backhoe unacceptable. With pipe bursting the and gardens where open-cut trenches
would be very disruptive.
Note: The presence of other services
should be established prior to moling.
The impact mole is an air driven percus-

sion tool, which drives a borehole and
usually pulls a new polyethylene pipe
directly in behind it.
The technique can also be used on car-

riageways in a technique known as "pipe
stitching" where pipe is installed from pit
to pit.
Directional drilling
This technique has also become an esta-
blished installation method for PE pipe
and is used for road, rail and river
crossings where open-cut work would be
usually impracticable and prohibitively
costly.
Figure 15. Typical Directional Drilling Operation
30 TEL. FAX E-MAIL

PE Pressure Pipes
Installation
The hole is bored by either high-pressure PERMISSIBLE GROUTING PRESSURES FOR PE PIPES
liquid jets or with drill bits, and fully Deformation 0% 1% 3% 6%
steerable systems are available by SDR Permissible Grouting Pressure (KN/M2)
monitoring transmitters in the cutting 33 13 12 10 7
head.The operation involves drilling a 26 27 25 20 15
small diameter ‘pilot’ hole beneath the 17 96 88 73 59
obstacle and the final hole size is achie- 11 417 383 317 242
ved by progressively back reaming up to
the diameter required. Figure 16. Permissible Grouting Pressures
The PE pipe (coil or pre-welded string) is
finally pulled through on the last pass.
Experienced contractors are necessary
with this technique to ensure the PE
string is not over stressed on the final pull
through.
Slip lining
The insertion of a smaller diameter PE
pipe, slip-lining, into an existing pipeline is
one of many no-dig techniques for Figure 17. Typical Slip Lining Operation
re-habilitation of ageing pipelines.
With slip-lining there is inevitably a reduc- Two methods rely on physically reducing to reduce its diameter for ease of installa-
tion in pipe bore, although this can be the outside diameter of the liner pipe to tion into the existing main.
minimised by thorough cleaning of the provide a clearance gap for insertion. Lengths of up to 700m can be pulled in,
old main and choosing the largest possi- Both work by either passing the pre- in one operation, and when in place the
ble pipe size for insertion. welded pipe through rollers or a reducing folded pipe is reverted with mains water,
die. The pipe is either re-expanded using to form a close-fitting liner.
The smaller bore is also compensated for water pressure or allowed to recover The technique is particularly effective on
by the greatly improved flow characteris- naturally when the winch load has been small diameter mains, 3 - 12" diameter,
tics of polyethylene and in many cases removed. with the full system comprising termina-
the higher operating pressure capability tion fittings and ferrule connections.
of the new pipe. Wavin have developed and patented their
Pressure grouting of the annular gap own re-habilitation method based on Pipe bending
provides structural rehabilitation of the reducing the liner pipe O.D. by physically One of the major benefits of PE is its
existing pipe and reinforces the overall deforming the pipe into a ‘C’ shape. This flexibility and this can be utilised to full
strength of the new pipe. Grouting may product which is factory formed is known advantage for buried pipework. Gradual
also offer a more economical total instal- as ‘Compact Pipe’ and is available in a changes of direction up to 11.5˚ can
lation by allowing the use of a thinner range of diameters and SDR’s . normally be accommodated by the pipe
walled PE pipe. Consideration should be itself, without the need for additional
given to the resistance of the pipeline to For further details on Compact Pipe fittings and the costs of jointing.
grouting pressures and this will be please contact Wavin.
dependent on pipe SDR and ovality The accepted rule of thumb for Wavin PE
(especially coiled or drummed pipe). Thin wall polyethylene liners pipe systems (warm conditions for SDR
For pipelines, which are still structurally 11 pipe) is, Bend radius = 15 x pipe O.D.
Close Fit insertion methods sound and require rehabilitation for For colder weather and SDR 17 pipe a
A number of methods are available for leakage or water quality problems, thin safe bending radius is 25 x pipe O.D.
the structural lining ofexisting pipes, wall PE liners can provide the solution. In very cold winter temperatures this
maximising the overall cost savings of With SDR’s of 33 - 61 the pipe is either increases to 35 x pipe O.D. Where
using the existing ‘hole in the ground’. factory or site formed into a folded profile thinner walled SDR 26 and SDR 33 pipes
Installation
TEL. 31
PE Pressure Pipes
Installation
are being used these values should be Pipe entry into structures Contaminated Ground
increased by 50%. Fittings and pipe Pipe entry into rigid concrete or brick- Polyethylene is resistant to most naturally
joints should not be included in bent pipe work structures needs to take account of occurring ground contaminants.
sections; formed bends and elbows a number of design factors and should However, the greater use of previously
should be used instead to prevent undue include: developed land (brownfield sites) is resul-
stresses in the pipeline. ting in a greater potential exposure to
Differential settlement harmful contaminants.
Pipe detection This can usually be accommodated
For future location of PE pipelines and in by the flexibility of the pipe itself and The main concern for potable water
line with good pipe laying practice, the by incorporating a flexible annular pipework is the risk of long term mecha-
simplest and most economical method is seal to the pipe sleeve through the nical damage to the material and of more
to lay a marker tape/ mesh which incor- structure. importance, the contamination may
porates a tracer wire. This should be cause water quality problems, taste and
installed 300mm above the pipe crown Watertight seal odour, due to permeation through the
and also provides protection from any The protective sleeve should provide pipe wall. Former industrial sites pose
future third party damage. both a watertight seal to the structure the greatest problem. Development of the
and to the PE pipe passing through following sites should be carefully
Pipe anchorage & thrust the sleeve. assessed:
blocks
A key feature of a welded PE pipeline is In some situations PE pipe may be Coal workings, including coking and
that it is a fully end load resistant system connected to the structure by a rigid town gas production.
and thrust blocks are not required at flanged joint. To prevent undue Chemical works
changes of direction/diameter or stresses through movement and Gas works
branches, providing significant time and settlement, support can be provided Paint and varnish works
cost benefits to the total installed cost of by a reinforced concrete plinth. The Wood plants (preservatives)
the system. It should be remembered plinth should extend one pipe diame- Landfill sites
that any connection to a non-end load- ter or 300mm (min) from the flange Garages/petrol stations
bearing fitting will require anchorage to face, with pipe straps bolted to the
prevent pipe pull-out. plinth. Where there is a known risk of contami-
nation, professional guidance should be
Where heavy ancillary plant is installed on sought on soils analysis to identify the
a PE pipeline, provision should be consi- range and degree of contaminants. The
dered for concrete support. This should analysis can then be used to determine
provide support both for the dead weight the suitability for polyethylene potable
and resist any turning movements under mains and services and whether suitable
operating conditions, eg. valves and hyd- protection can be provided.
rants.
In some instances where contamination
is negligible protection can be given with
a clean sand/granular surround and a
heavy gauge polyethylene membrane
lining to the trench. If conditions are such
that the use of polyethylene would not be
suitable, the ‘Trigon’ barrier pipe has
been developed specifically for carrying
potable water through contaminated
land. Further guidance is available from
Wavin.
32 TEL. FAX E-MAIL

PE Pressure Pipes
Installation
7.2 Jointing SDR 11 – SDR 11 a Trim the pipe ends until a continuous
Polyethylene pipe systems are relatively SDR 11 – SDR 17 r shaving is seen from each pipe end.
simple to joint and install. Two jointing Site fusion welding methods cover the Remove loose shavings and impor-
methods are available to cater for the single and dual pressure methods. Dual tantly, do not touch the prepared pipe
components that are used to build an pressure welding was introduced as a ends.
operational system. result of investigations into joint quality Close the clamps and check for good
and this procedure should be used for all alignment of the pipe ends, the
Fusion Welded Joints pipes with a wall thickness greater than allowable mismatch is; 90mm-
20mm. Due to the low pressures invol-
a) Butt Fusion 315mm pipe, 1 mm 355mm-630mm
ved in the dual pressure procedure, only
b) Electrofusion pipe, 2 mm Re-trim if mismatch is
fully automatic machines should be used;
Mechanical fittings greater than these values.
manual machines may still be used for
a) Compression fittings Open and close the clamps, noting
single pressure Butt Fusion jointing. The
b) Flanged Joints butt fusion process can be used for join- the gauge pressure to close the
ting PE pipes and fittings in sizes of 90 clamps - This is the drag pressure.
Fusion welding mm and above. In general this jointing The fusion (jointing) pressure is obtai-
Both Butt Fusion and Electrofusion use operation will be carried out to the side of ned by adding the drag pressure to
specialist equipment to carry out field the trench and the complete pipeline then the hydraulic ram pressure given on
jointing. Modern machine developments lowered in. All “in trench” jointing will usu- the machine data plate.
now provide totally automatic jointing, ally be carried out using electrofusion fit- Place the heater plate in the machine,
eliminating the risk of operator error and tings. checking it is clean and undamaged
providing a full record of joint history for and up to temperature, 225˚C -
Quality Assurance of site welding. Equipment required 240˚C.
Butt Fusion machine, inclusive of Close the clamps and apply the pre-
Machinery can be either purchased or trimmer, heater plate and hydraulic viously determined pressure until a
hired from manufacturers and detailed pump. bead of 2-3mm is formed.
product literature is available together 110v Generator, fuel Reduce the pressure in the system to
with familiarisation courses to ensure Welding Tent/Base board between 0 and drag, the heat soak
correct use of the machinery. Pipe support rollers time commences. Ensure the pipes
Operatives should however receive full Clean water, lint free cloths maintain contact with the heater
training. Training is available from Wavin External de-beading tool plate.
either at its Customer Training facility or Bead gauge Upon completion of the heat soak
at the customers premises. For more Pipe end covers time, remove the heater plate and
information, please contact Wavin. Indelible marker pen close the clamps immediately, (within
Pipe cutting tools 10 seconds).
Butt fusion Maintain the required fusion (jointing)
Butt Fusion jointing involves the fusing Note: Wavin Overseas can supply the pressure for the specified cooling
together of two pipe ends in a specialist necessary equipment. period.
machine which prepares the pipe ends, Remove the joint & allow to cool for a
heats them and brings them together Procedures of manual similar period.
under pressure to form a homogeneous butt fusion Clearly mark the joint and bead for
weld. The joint is fully end load resistant identification with an indelible pen.
and is at least as strong as the parent Ensure the pipe ends are clean and if Check the joint is free from any con-
pipe. necessary, wash with clean water tamination, and check the bead
and dry. widths meet the specified limits and
With Butt Fusion it is essential only similar Cut the pipe ends square and clamp are uniform.
grades of PE are welded, eg: securely in the B/F machine. Remove the external bead and twist
PE 100 – PE 100 a Align and level the pipes with pipe in several positions. If the bead splits
PE 100 – PE 80 r support rollers. at any position the joint should be cut
To prevent cooling of the heater plate out and re-made.
and similar SDR’s are used, eg: blank off the free pipe ends.
Installation
TEL. 33
PE Pressure Pipes
Installation
Additional notes for butt and over the full fusion area. The melt Equipment required
fusion must be adequately controlled within the A number of manufacturers produce E/F
If the heater plate requires cleaning hot and cold zones to ensure a fully wel- control boxes and the ancillary tooling
this should be done when the plate is ded, homogeneous joint. The different required. The correct tooling must be
cold. The plate can be washed with zones of an E/F fitting are shown in used to ensure consistently reliable joints
clean water and lint free cloth and Figure 18. and this may be either purchased or
dried thoroughly. Isopropanol may be hired from the tooling manufacturer or
used to remove any oil or grease. their agents. The site equipment should
Washing the heater plate may not include:
Fusion
remove very fine dusty particles, Indicator E/F control unit
therefore at the start of each welding 110 volt generator
session a dummy weld should be 3 - 3.5 KVA for 39.5 volt fittings
carried out for pipes up to 180mm in 6 - 7 KVA for 80 volt fittings
Fusion
diameter. For pipe sizes greater than Zone Jointing shelter
180mm, two dummy welds should be Pipe scraping tool, including mecha-
made. An actual joint need not be nical scrapers for pipe end prepara-
Cold
made, the dummy weld can be abor- Zones tion and hand scrapers for saddle
ted at the end of the heat soak Figure 18. Cross section through an joints
period. Pipe offcuts may be used. Electrofusion Coupler Pipe cutting tool
In very cold conditions, below 5˚C, Marker pen, solvent wipes, lint free
additional space heating must be Automatic & manual fittings cloths/paper towels
provided in the fusion welding tent to Many manufacturers now offer Automatic
maintain the required minimum and Manual fittings and it is important to Note: Wavin Overseas can supply the
ambient temperature for welding. ensure the E/F control unit is compatible necessary equipment.
Electrofusion "wet wipes" should not with the fittings being used. Most control
be used after the pipe ends have units can be operated in both Automatic Principles of EF Jointing
been trimmed, if any contamination and Manual mode. Pipe ends must be cut
does occur the pipe ends should be square and de-burred.
re-trimmed. Saddle Fittings (Tapping If necessary clean the pipe ends with
Tees) clean water and dry.
Electrofusion The style of saddle fittings available; Clearly mark the depth of entry, plus
Electrofusion fittings incorporate an elec- clamp saddles 25 mm, around the pipe circumferen-
trical heating element which is energised ce. Use the fitting as a guide, without
via an E/F control box to heat the These provide a service connection to removing from its sealed bag at this
elements. polyethylene mains. stage.
Using the mechanical pipe-scraping
When the fitting is energised the material With clamp saddles the jointing force is tool, remove the entire pipe surface
next to it becomes molten and in turn provided by a clamp device, located over the marked area in a continuous
causes the pipe surface to melt, resulting beneath the fitting and pulls the fitting ribbon of material if possible.
in a molten pool of material fusing the down onto the pipe.
materials of fitting and pipe. NOTE: Do not touch the cleaned scraped
Once cooled this produces a fully fused surface.
and leak free joint.
Mechanical scrapers are preferred over
Electrofusion fitting design hand scrapers as skill and practice is
The design of an E/F fitting is crucial to required with hand scraping and can be
its performance and is dependent on the quite time consuming for larger diameter
position and pitch of the heating coil. pipes.
The heat distribution should Remove the fitting from its bag,
be consistent throughout the fusion cycle check it is clean and undamaged,
34 TEL. FAX E-MAIL

PE Pressure Pipes
Installation
and assemble onto the pipe ends Mechanical joints

clearly marking the depth of entry Compression fittings “o” Ring Replacement Pipe
with a marker pen. Compression joints may be dismantled. It

Securely clamp the joint assembly is used as a connection element in plastic
with the appropriate clamps. piping systems and is distinguished by its Pipe Stiffeners
Attach the control unit leads, check low installation costs owing to simple and
the generator has sufficient fuel and quick assembly. Compression jointing
commence the fusion cycle following can be loaded immediately after assem- Figure 19. Cross Section through an
the control unit instructions for the bly. It is sealed with elastomeric ele- Elastomeric Ring Seal
type of fitting being used. ments. Typical applications are domestic
Check the melt indicators have risen, lines in drinking water supply, irrigation a polyethylene stub flange.
these indicate the fitting has been systems, telecommunication applications, Stub flanges are supplied pre-fabricated
energised and has completed a water supply at construction sites and with either spigot or pupped pipe lengths
fusion cycle. sprinkler systems. There are numerous and steel backing ring, drilled to suit
Allow the joint to cool for the required manufacturers of compression fittings metric PN16 flanges. Other flange dril-
time, full fusion details are given on suitable for use with polyethylene pipe, lings are available upon request.
each fitting. they are all based on the same design As polyethylene pipe is sized on the O.D.
principle where an elastomeric ring seal is and Ductile Iron, for example, is sized by
Additional notes for compressed between pipe and fitting. its internal bore, allowances must be
electrofusion Some fittings require the use of pipe bore made for differences in pipe bore and
Jointing must always be carried out in inserts to provide sufficient rigidity for the discrepancies in corresponding mating
dry and dust free conditions. compression seal to be effective. flanges. This occurs more with larger dia-
Do not use rasps/files or abrasive Wavin offers polypropylene compression meter pipes and a flange converter will
sheets to prepare pipe ends. fittings, which offer exceptional joint secu- be required in these instances to ensure
Always use the correct clamps for rity for metric OD PE pipes and form a compatibility of pipe bores.
jointing. seal without distorting the pipe or restric-
When jointing coiled pipe, additional ting the pipe bore. Flange convertor
re-rounding and pipe straightening Where a change in pipe bore is not
tooling should be used to assist in the Flanged joints acceptable, a steel flange converter can
process. One of the simplest and earliest methods be used to maintain a clear bore, the dia-
Do not extend control unit leads to for connecting PE pipe to valves, hyd- gram below shows a typical flange confi-
the fittings and ensure the lead rants and existing pipe materials is to use guration for a 450mm PE stub flange to a
between generator and control unit is 400mm D.I. flange.
not excessive as an unacceptable
power drop can be created. TYPICAL BOLTING TORQUES (PE TO PE)
If the fusion cycle stops in mid-cycle Pipe Nominal Bolts Torque (nm)
first check for any control unit faults. Diameter Flange ± 10%
Check for fuel. If the fault can be 63 (mm) 50 (mm) M16 x 4 35
rectified, welding can recommence 90 (mm) 80 (mm) M16 x 8 35
providing the joint has cooled to 125 (mm) 100 (mm) M16 x 8 35
ambient temperature and the fusion 180 (mm) 150 (mm) M20 x 8 60
time is re-set for a further full cycle. 225 (mm) 200 (mm) M20 x 12 80
For live connections, tapping into the 250 (mm) 250 (mm) M24 x 12 100
water main should be carried out 315 (mm) 300 (mm) M24 x 12 120
after all joints have cooled for a 355 (mm) 350 (mm) M24 x 16 150
minimum of 30 minutes. 400 (mm) 400 (mm) M27 x 16 200
Where E/F couplers are to be used 450 (mm) 450 (mm) M27 x 20 250
for repair situations the existing main 500 (mm) 500 (mm) M35 x 20 300
should be completely dry with no
running water. Figure 20. Typical Bolting Torques
Installation
TEL. 35
PE Pressure Pipes
Installation
Stub flange jointing Connection of flange ring

procedure to PE stub flanges
Jointing is straight forward and the Flanged joints should always be tightened
following guidelines can be used. with a torque wrench, using the tighte-
ning forces shown in table 9. “Making the
Ensure the mating flange faces are joint as tight as possible” is inadvisable as
clean and free from damage. this is likely to overload the joint.
Select the appropriate size and grade
of gasket for the application. Deviations may occur in practice if, for
Align both flange faces before bolting instance, the pipes resist tightening or
up. Ensure the pipes/components are there is great friction in the bolt threads.
aligned and do not impose any Where such situations occur, the problem
bending stresses on the joint. should not be solved by increasing the
Jointing compounds are not tightening force. If Wavin standard gas-
necessary. kets are not employed, a different shore
Use only clean undamaged nuts, of the gasket may alter the tightening
bolts and washers of the correct size. force.
Ensure the gasket is aligned and
centred before bolting . Connection procedure
Assemble the joint and finger tighten It is recommended that flat gaskets are
all nuts / bolts and progressively used for flanged joints. Flat butyl rubber
tighten all bolts in a diagonally gaskets for pipe dimensions over 90 mm
opposing sequence as follows, should be reinforced on account of the
using a torque wrench: internal pressure in the pipeline. The
• 5% of final torque shore of the gasket should be approxi-
• 20% of final torque mately 65ºC.
• 50% of final torque
• 75% of final torque
• 100% of final torque Figure 21. Diagram showing connection
For evenness of tightening it is of blue glass-fibre flange ring
advisable to use two operators for to polyethylene fitting
flanged joints larger than 180mm
diameter. 1) Place the flange ring on the PE pipe.
If practical, final torquing up should be
repeated after the joint has relaxed for 2) Butt-fuse the stub flange to the pipe
1 hour. end outlined in the fusion instructions.
It is important the joint is tightened The electro-socket fusion method can
evenly and in sequence to ensure a also be employed - in such case
leak free joint, this is as important as remember to locate the flange ring by
the use of recommended final torque the fitting before fusing.
values.
3) Locate the flange gasket.
4) Bolt the flange, using a torque wrench

as outlined in the instructions.
Employ the approximate tightening forces

shown in table 9:
36 TEL. FAX E-MAIL

PE Pressure Pipes
Installation
Outside pipe-diameter dy mm 25 32 40 50 63 75 90 110 125 140 160 200 225

NW mm 20 25 32 40 50 65 80 100 110 125 150 175 200
Tightening force Nm 9 10 20 25 30 35 40 45 50 50 60 75 75
Table 9
A torque wrench should also be used to tighten a flanged joint with flat gaskets. Bolts should always be cross-tightened.
Dim Number Thread A B C D E

of bolts M S L Lfix Bmin L Lfix Bmin L Bmin L Bmin L Bmin
63 4 16 24 80 110 38 70 110 46 70 38 90 38 80 38
75 4 16 24 80 110 38 70 110 46 70 38 100 38 80 38
90 8 16 24 90 120 38 70 110 46 80 38 100 38 80 38
110 8 16 24 90 120 38 80 110 46 80 38 100 38 80 38
125 8 16 24 90 120 38 80 110 46 80 38 120 38 90 38
160 8 20 30 110 150 46 90 120 46 80 46 120 46 100 46
180 8 20 30 110 150 46 90 120 46 80 46 130 52 100 46
200 8 20 30 120 160 46 100 150 60 90 46 140 52 110 46
225 8 20 30 120 160 46 100 150 60 90 46 140 52 110 46
250 12 20 30 150 190 60 110 150 60 90 46 150 52 120 46
280 12 20 30 150 190 60 110 150 60 90 60 150 52 130 46
315 12 20 30 170 220 73 130 190 80 100 60 160 52 130 46
355 16 20 30 190 260 100 130 190 80 100 60 190 52 150 52
400 16 24 36 220 280 100 160 220 80 120 60 220 60 160 60
500 20 24 36 250 330 100 170 220 80 130 73
A = Combi flange, tensile resistant combi flange connected to the same

B = Combi flange, tensile resistant combi flange connected to flange valve, flange fittings
C = Flange valve, flange fittings connected to the same
D = MDPE flange adapter connected to the same
E = MDPE flange adapter connected to flange valve, flange fittings
Lfix = 4 auxiliary bolts used for connection
A = 500 mm cast iron L= 330

B = 500 mm cast iron L = 220
Table 9a. Overview of bolt lengths and dimensions
Installation
TEL. 37
PE Pressure Pipes
Installation
Connection of Combiflange Figure 22 - Diagram showing connection

- Tensile resistant for PE of tensile resistant flange for PE
(with use of bush)
Tensile resistant Combiflanges are used 1) Cut the PE pipe at right angles using
to connect PE pipes to valves and fittings a fine-toothed saw.
with flanges drilled to take PN 10 (or PN 2) Remove swarf, soil and other impurities
16). from both the outer and the inner sur-
face of the pipe end. Do not chamfer.
The Combiflange consists of three parts: 3) Slightly compress the bush and insert
a cast-iron flange, a red brass grip ring in the pipe as far as its collar.
and a rubber gasket. The stainless circu- 4) Insert the wedge in the bush groove
lar bush is used together with a wedge. by hand and gently knock into place
with a hammer.
Its area of application is water and neutral 5) If the end of the wedge is not com-
liquids at temperatures pletely flush with the pipe end, remo-
not exceeding 70ºC. The Combiflange ve the protruding piece with a hack-
tolerance is ±1 mm. saw.
6) Place the cast-iron flange on the pipe
with the smaller end facing away from
the pipe end.
7) Place the red brass grip ring on the
pipe with the small end facing away
from the pipe end.
8) Locate the rubber gasket on the pipe
so that the large end projects 20 mm
from the PE pipe end, i.e. with small
end of rubber gasket facing inwards.
9) Slide the red brass grip ring back until
it connects with the rubber gasket.
10) Apply a thin layer of lubricant to the
outer surface of the rubber gasket.
Place the pipe end with the flange,
grip ring and rubber gasket and bush
in position against the valve or fitting
flange.
11) Push the cast-iron flange by hand
over the grip ring and rubber gasket
as tar as it will go.
12) Locate the bolts and tighten by hand
until the parts connect.
13) Ensure that the assembly is correctly
aligned.
14) Tighten the bolts using a spanner.
Cross-tighten to ensure that the bolts
are evenly tightened.
NB: The same procedure should be follo-

wed when connecting two tensile-resi-
stant Combiflanges. When tightening, two
extra-Iong "auxiliary bolts" will be needed.
38 TEL. FAX E-MAIL

PE Pressure Pipes
Installation
Flange dimensions
DN D k d1 Bolts Number of Holes

n n
PN 10 PN 16 PN 10 PN 16 PN 10 PN 16 PN 10 PN 16 PN 10 PN 16
25 115 - 85 - 14 - M 12 - 4 -
32 140 - 100 - 18 - M 16 - 4 -
40 150 - 110 - 18 - M 16 - 4 -
50 165 - 125 - 18 - M 16 - 4 -
65 185 - 145 - 18 - M 16 - 4 -
80 200 200 160 160 18 18 M 16 M 16 8 8
100 220 220 180 180 18 18 M 16 M 16 8 8
125 250 250 210 210 18 18 M 16 M 16 8 8
150 285 285 240 285 22 22 M 20 M 20 8 8
200 340 340 295 295 22 22 M 20 M 20 8 12
250 395 400 350 355 22 26 M 20 M 24 12 12
300 445 455 400 410 22 26 M 20 M 24 12 12
400 565 580 515 525 26 30 M 24 M 27 16 16
500 670 715 620 650 26 33 M 24 M 30 20 20
600 780 840 725 770 30 36 M 27 M 33 20 20
Table of standard flange dimensions
Figure 23. Flange design
Installation
TEL. 39
PE Pressure Pipes
Laying Instructions
8. Laying instructions
European standard EN 1452-6 “Plastic Sharp flints or other crushed material 1) The longitudinal profile should be
piping systems for water supply” guidan- must not be employed projected with a slight upward incline
ce for installation applies for the laying of for ventilation purposes.
pressure pipes. The back fill must conform with the requi- 2) A form of ventilation (manual -
rements placed upon it by the type of automatic) should be installed in all
The standard lays down that a pipeline construction (road, pavement or the like) summits - correct installation of
should be located at such a distance above the pipeline. ventilation: In the direction of flow a
from other pipelines and installations that little below exact summit.
it causes no damage to these and allows The standard states that the soil covering 3) Barring procedures should be
the repair of other installations. Reference (hd) must not be less than 0.6 m where established enabling pressure testing
should be made to the standard for the the pipeline will be exposed to traffic of the line by stages.
distances in question. load, unless special measures are taken. 4) It should be possible to connect a fil-
In view of the requirement that pipelines ter socket in the lowest point and
Requirements are also attached to the are laid in frost-free soil, pipelines ventilation (air escape) in the summit
design of the pipe trench. carrying, e.g. potable water, are normally to the starting and end points of the
laid with a 1.1 m soil cover. line respectively.
The levelling layer must be laid or 5) Bends, tees, reducers, valves, end
loosened and subsequently levelled so Pressure testing caps etc. should be anchored for the
that the pipes are evenly supported. increased testing pressure.
Pressure testing of PE 6) The demands placed by the owner on
The side fill layer must provide adequate pressure lines possible pressure testing should
side support for the pipes and it is It is possible to pressure test a PE appear from the project description
therefore important that this layer is pressure line, before it is put into service enabling the contractor to take the
compacted, e.g. by stamping with the (taken over by the client). necessary measures for pressure
foot. testing.
Pressure testing is carried out according 7) Choice of pipe and fitting material
The materials employed for the levelling to DS 455. If pressure testing is reques- should be made under reference to
layer and the side tilt must meet the ted, it should form part of the project, EN1555/12201/1452
following criteria: and here the following conditions should
be observed: When the above conditions have been
The particle size must not exceed fulfilled the next step is the practical
16 mm accomplishment of the job, and here the
The content of particles of between following points may contribute to pro-
8 and 16 mm must not exceed 10% blem-free pressure testing:
The material must not be frozen
Correct transport, storage and hand-
ling of pipes and fittings
Correct excavation, laying, filling and
compaction
Correctly used jointing components
and methods
It is highly important that above mentio-

ned rules are observed as they will
influence the final result of the project.
Figure 24. Diagram of trench design
40 TEL. FAX E-MAIL

PE Pressure Pipes
Laying Instructions
Procedure for pressure 5) After 60 minutes the pressure is meas- Formula 6

testing of pipe systems ured and water is added until the pres-
Below is the procedure for pressure tes- sure is again 1.3 x the nominal pres- a) pressure drop in percentage of initial
ting of pipe systems. The procedure is in sure class (testing pressure). pressure = 2%
accordance with the standard of the 6) The fall in pressure and the amount of b) water quantity in litres/metres = 0.02di
Danish Engineers Union: 'Tightness of water added must not exceed the fol- - 0.001 + ∆V
underground sewer systems" DS 455, lowing limits:
1st edition, January 1985. ∆V = 0.05 x d2 for PVC pipes
∆V = 0.08 X d2 for PE pipes
Before pressure testing the following di = inside diameter
must be observed:
1) End caps are mounted on all ends of After pressure testing the end caps are
the system. The end cap can be an demounted.
end socket or a blank flange. A 90˚C
bend, a ball valve and a 32 mm tensile
resistant coupler are mounted on the
end cap, for mounting of a 32 mm PE
pipe.
2) AII end caps must be anchored.
3) The system must be filled with water at
least 24 hours prior to the start of the
pressure test. Ensure that the system
is entirely ventilated.
4) During the first 6 hours the pressure in
the system must be 1.3 x the nominal
pressure class. This is very important
in order that the result of the test is not
misleading. This part of the test must Figure 25. Diagram of pressure testing of pipeline.
be documentable to the inspection
authorities.
5) There must be access to water on the
testing site.
6) Pressure testing against a valve is at
your own risk.
During pressure testing the following is to

be observed:
1) The actual pressure is measured and
water is added to the system if
required.
2) The system is exposed to a pressure
corresponding to 1.3 x the nominal
pressure class (testing pressure).
3) This pressure is maintained for 2
hours. Supplementary filling of water is
allowed.
4) During the following 60 minutes water
must not be added.
Laying Instructions
TEL. 41
PE Pressure Pipes
Anchorage
9. Anchorage
All examples shown in this chapter are Formula 8 Anchorage of bends

based on PVC, but are also applicable for The resulting force for bends can be cal-
PE pipes. The size of the axial force N = p x N1 culated as follows:
depends on the dimension and working
pressure (testing pressure) of the pipe where N1 = axial force at 1 bar [kN] Formula 9:
line and is calculated as follows: α
p = max. pressure occurring in R = 2 x N1 x p x sin —
Formula 7 pipeline [bar] possibly testing 2
pressure
π x dy x p
2
where N1 = axial force at 1 bar [kN]
N = ——————— (table 7)
104 x 4
p = max. pressure occurring in
where N = axial force [kN] pipeline [bar] possibly testing
dy = external pipe diameter [mm] pressure
PE
p = max. pressure occurring in
pipeline [bar] possibly testing α = angle of bend [degrees]
pressure
R = resulting force [kN]
Anchorage of tees, end
caps and valves Figure 26. Diagram showing anchorage
of tee Angle α 11˚ 22˚ 30˚ 45˚ 60˚ 90˚
Fittings exposed to shearing forces k 0.19 0.38 0.52 0.77 1.00 1.41
caused by internal water pressure, e.g.
bands, tees, end caps, reducers and Table of angle constants
valves must be anchored.
The resulting shearing force which the
The shearing force which the anchorage is anchorage is intended to withstand can
intended to withstand can be easily calcu- be easily calculated by using the figures
lated by using the figures in the table in the tables in the following simplified
below in the following simplified formula: formula:
Figure 27. Diagram showing anchorage
Outside Axial force at 1 of tee Formula 10
diameter [mm] bar N1 [kN]
40 0.13 R = k x p x N1
50 0.20
63 0.32 Where k = constant for resulting force
75 0.45 (see table of angle constants)
90 0.64
110 0.95 p = max. pressure occurring in
125 1.23 pipeline [bar] possibly testing
140 1.54 pressure
160 2.00
200 3.15 N1 = axial force at 1 bar [kN]
225 4.00
250 4.90
280 6.16
315 7.80
400 12.60
500 19.60
630 31.20
42 TEL. FAX E-MAIL

PE Pressure
Anchorage
Anchorage block Formula 11

R The resulting force will then be:
b= R = 0.77 x 9 x 3.15 = 21.83 kN
h/ σ earth
Now the size of the concrete block can
be calculated by using formula 11:
where b = width of anchorage [m] R
b=
h = height of anchorage [m] hx σ earth
R = resulting force [kN]

σ earth is estimated at [kN/m ] 2
Figure 28. Diagram of anchorage of bend σ earth = permissible earth pres-
sure [200 kN/m2] The height is estimated at:

h = 0.2 (height of pipe)
It is a condition for the strength of the The minimum width must then be:
anchorage that the concrete is cast
against a solid wall of the pipe trench. It 21.83
may, however, sometimes be necessary b= = 0.55 m
to cast against carefully compacted fill. In 0.2 x 200
such case account should be taken in
the calculations of the lower strength of Anchorage of reducer
the fill.
Figure 29. Diagram of anchorage of bend The axial force for reducer is found by
The fitting in question must be protected means of formula 12:
When calculating the area necessary for from the damage by the concrete by an
the determination of the size of the intermediate layer of e.g. plastic film Formula 12
anchorage, due consideration has to be before casting takes place. π x (dy21 x dy22) x p
paid to the permissible earth pressure, N=
which in each individual case has to be Example of anchorage of 104 x 4
determined by geotechnical surveys. In bend
most cases it is sufficient to use the
following formula: Conditions: where dy21 = the outside diameter [mm]
of the largest pipe
σ earth = 200 (kN/m2) - Ø 200 x 45º pressure pipe bend
- Testing pressure (maximum pressure) dy22 = the outside diameter [mm]
9 bar of the smallest pipe
The person in charge of the project
should always make an appraisal of the Formula 10 is applied as follows:
relevance of this value.
R = k x p x N1
This width of an anchorage can then be
calculated by means of the following for- where k = 0.77 according to table of
mula: angle constants
p = 9 bar
Figure 30. Diagram of anchorage of
N1 = 3.15 according to table of reducer
the previous page
Anchorage
TEL. 43
PE Pressure Pipes
Anchorage
Example of anchorage of
reducer
Conditions:
- Ø 200/110 reducer
- Testing pressure (maximum pressure) 9
bar
which is inserted in formula 12:
π x (2002 - 1102) x 9
N=
104 x 4
N = 19.72 kN
The anchorage (concrete block) is

calculated as follows:
h = (is estimated at) 0.2m
σ earth = (is estimated at) 200kN/m2
N
b=
hx σ earth
19.72
b=
0.2 x 200
b = 0.49 m
Figure 31. Diagram of anchorage of

reducer
44 TEL. FAX E-MAIL

PE Pressure Pipes
Handling & Storage
10. Handling & Storage
Handling plastic piping Figure 33

systems Bearers must be placed on the truck
body.
Wavin pressure pipes are supplied in pre- Support the full length of the load.
packed bundles to ensure adequate pro- Always load and unload properly.
tection during transport and storage. The Do not tip or throw the pipes from the
pipes are supplied with end caps protec- carrier.
ting the pipes effectively from dirt entering
the pipes.
Handling on site
Figure 34
Small-diameter pipes can easily be
carried without the use of auxiliary
equipment.
Figure 35
Figure 32. Pipes should be handled and Do not drag the pipes across the ground
stored in bundles as delivered and avoid sharp edges.
from Wavin for as long as
possible.
Transport
Vehicles for transporting pipes should be
selected in such a way that the pipes lie Figure 36
completely on the floor of the vehicle, Small-diameter pipes can be manually
without jutting out of the vehicle. Sagging placed in the trench.
is to be prevented. Impacts are to be
avoided under all circumstances,
particularly at temperatures near the
freezing point. To protect the pipes and
fittings from damage, they should not
grind against the load area of the vehicle Figure 37
or against the floor of the vehicle during Pipes in larger diameter may necessitate
transportation. Pipes and fittings should slings. Always use at least 2 slings.
be loaded and unloaded with extreme
caution and care. If hoists are used, then
pipe components may not be thrown
from the vehicle into the storage area.
Figure 38
Larger diameters may necessitate a
special lifting bar.
Handling & Storage

TEL. 45
PE Pressure Pipes
Handling & Storage
Storage with sheeting or cardboard (including the

Storage areas for pipes should be side supports) in order to avoid damage
without gravel and plain. Storage and caused by protruding rivets and nails.
stock heights should be selected in such
a way, as to avoid damages or perma- The influence of weather on stored pipe
nent deformations. Pipes with large dia- components should be kept to a mini-
meters and small wall thickness should mum, i.e. the pipe components should
be equipped with circular stiffeners. Point be kept in a warehouse. If the pipes are
and line supports for the pipes should be stored in the open (construction sites),
avoided. then they should be covered with colou-
red or black sheeting to protect them
The recommendation for the permitted from the influence of weather (for exam-
stacking height for PE pipes not stored ple, UV rays). Wavin PE fittings and val-
on pallets is 1 m. Pipes should be ves are packed in PE plastic bags to pro-
stacked in layers with sockets placed at tect them from ultraviolet radiation and
alternate ends of the stack to ensure their dust. We recommend removing the pipes
support along the entire length. from the packing only shortly before
installation.
Moreover, one-sided heat exposure

caused by sunshine can lead to
deformations in the pipes.
Maximum permitted storage periods

should be adhered to (for example,
DVGW). The pipe components should be
used in the order of their manufacture
and delivery to ensure appropriate stock
turnover.
If the pipes are stacked on pallets and

are secured against lateral movements,
the stacking height can be increased to
1.5 m. When spacing the pipes the
bearing width of the supports and tim-
bers respectively must be at least 7.5
cm. The distance between the supports
and timbers respectively should be 1-2
m. The outer supports and timbers
respectively are to be arranged 0.5-1.0 m
from the stack end.
The area where pipe components are

stored should provide as much protection
as possible. Pipes should be completely
protected from the effects of oil, solvents
1,50 m
and other chemical substances during

the storage period. The area where the
pipes are to be placed should be covered
46 TEL. FAX E-MAIL

PE Pressure Pipes
Notes
11. Notes
This document gives units of the interna- Dimensions and units

tional system (SI), e.g. the unit for force Dimensions are indicated in mm and/or
Newton (N) instead of pond (p) and the inches and are specified as nominal or
unit of power Watt (W) instead of kcal/h. standard sizes.
Conversion: d, d1, d2, d3, d4 Diameter
1 kp = 9.80665 N DN Nominal diameter
or 1 kp ≈ 10 N SC Size of hexagonal bolts
1 Mp = 9806.65 N AL Number of screw holes
or 1 Mp ≈ 10 kN s Width across flats of hexagonal bolts
and 1 Mp/m = 10 kN/m g Weight in grams
1 kp/cm2 = 9.80665 N/cm2 = SP Quantity per standard pack
0.0980665 N/mm2 = GP Quantity per large pack
0.0980665 Mpa or e Pipe wall thickness
1 kp/cm ≈ 0.1 N/mm
2 2
PN Nominal pressure
1 m of water column Rp Parallel internal pipe thread to
= 0.0980665 bar or 1 m of ISO 7-1
water column ≈ 0.1 bar R Conical external pipe thread to
1 kcal/m h degree ISO 7-1
= 1.16 W/mK (Thermal ppm Parts per million
conductivity) or 1 kcal/m h 1 bar = 0.1 N/mm2
degree ≈ 1.2 W/mK = 0.1 Mpa (Megapascal)
= 14.504 psi
The thermal conductivity is given in C Design factor
W/mK. One gets here identical figures for S Pipe series
K and °C respectively as it is a matter of SDR Standard Dimension Ratio
temperature differences. In this sense, MFR Melt Flow Rate
1 W/m °C is identical to 1 W/mK. According to ISO 4440
K (Kelvin) is the SI unit for the
temperature. The Celsius temperature (t) SDR
differs from the Kelvin temperature (T) by
273.15 K. SDR Standard Dimension Ratio:
OD / SDR = WT
t (°C) = T – To = T – 273.15 K. OD / WT = SDR
In this document, g is supposed to be 10 OD = Outside Diameter

m/s, the fault of approximately 2% being WT = Wall Thickness
neglected. DN means nominal diameter,
PN is nominal pressure.
Notes
TEL. 47
PE Pressure Pipes
Notes
Pressure system dimensions Explanations of

DN = Nominal Diameter abbreviations
OD = Outside Diameter
PB Polybutylene
DIN DIN/ISO/EN PE Polyethylene
DN versus OD versus Inch PE-X Cross-linked polyethylene
4 6 PP Polypropylene
5 8 PVC Polyvinylchloride
6 10 PVC-C Rechlorinated polyvinylchloride
8 12 1/4’’ (increased chloride content)
10 16 3/8” PVC-U Unplasticised polyvinylchloride
15 20 1/2” PVC-O Oriented polyvinylchloride
20 25 3/4”
25 32 1”
32 40 1 1/4”
40 50 1 1/2”
50 63 2”
65 75 2 1/2”
80 90 3”
100 110 4”
125 125 5”
125 140 DIN 5”
150 160 6”
150 180 6”
GAS
200 200 8”
200 225 DIN 8”
250 250 10”
250 280 DIN 10”
300 315 12”
350 355 14”
400 400 16”
400 450 DIN 18”
500 500 20”
500 560 DIN 22”
600 630 24”
PSI BAR (PN) Mpa Kpa

87,08 6 0,6 600
91,44 6,3 0,63 630
108,85 7,5 0,75 750
116,11 8 0,8 800
145,14 10 1 1000
181,42 12,5 1,25 1250
232,22 16 1,6 1600
290,28 20 2 2000
48 TEL. FAX E-MAIL

PE Pressure Pipes
Notes
Notes
TEL. 49
Wavin PE Pressure Product and
Pipe Systems Technical Guide
Meeting your needs

Wavin PE Pressure Pipe Systems form part of a comprehensive
range of plastic pipe systems to provide intelligent solutions for
all building, construction and utilities projects
These include:
Above Ground Projects
Wavin Soil & Waste Systems
Wavin Rainwater Systems
Wavin Electrical Conduit Systems
Plumbing & Heating Projects
Wavin Hot & Cold Water Systems
Wavin Underfloor Heating Systems
Below Ground Projects
Wavin Sewer Systems
Wavin Inspection Chambers & Manholes
Wavin Road Gullies
Wavin Stormwater Infiltration Systems
Wavin Cable Duct Systems
Wavin Land Drainage
Pressure Pipe Projects
Wavin PE Pressure Systems
Wavin operates a programme of continual product development, and therefore reserves the right to modify or amend
Wavin PVC Pressure Systems the specification of their products without notice. All information in this publication is given in good faith, and believed to
be correct at the time of going to press. However, no responsibility can be accepted for any errors, omissions or incor-
Wavin Pipe Relining Systems rect assumptions. Users should satisfy themselves that products are suitable for the purpose and application intended.
05/2006
Wavin Overseas B.V. www.wavinoverseas.com

Rollepaal 19, 7701 BR,
P.O. Box 158, 7700 AD,
Dedemsvaart, The Netherlands
Phone: +31/523-624911
Fax: +31/523-624600
Email: wavin.overseas@wavin.com

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Wavin PE Pressure Product and

Pipe Systems Technical Guide

Intelligent Solutions for Pressure Pipe Projects

1. Flying the flag in the world page 3

2. Materials for gas and water distribution page 4

3. General material properties page 6

4. Design & Testing page 12

5. Product range page 22

6. Standards & Regulations page 27

8. Laying instructions page 40

10. Handling & Storage page 45

11. Notes page 47

2 TEL. FAX E-MAIL

1. Flying the flag in the world

Wavin Extensive product range

2. Materials for water and gas distribution

4 TEL. FAX E-MAIL

2.2 Standard Dimension The relation between the SDR

SDR = d / e The following equation:

SDR = 2[s] + 1 If one defines, based on the PE tensile

outside diameter - wall thickness σzul.= MRS/C

Materials for water and

3. General material properties

The polyethylene we use is stabilised

6 TEL. FAX E-MAIL

3.2 Wavin TS Features & Benefits

3.3 Technical data PE

Pressure rating SDR PE 80 PE 100 Wall thickness

8 TEL. FAX E-MAIL

Durability graph PE 100

PIPE EXPANSION/CONTRACTION (mm)

Figure 1. The expansion and contraction of PE pipe in mm for a temperature

10 TEL. FAX E-MAIL

Operational pressures for Hydraulic Properties Fittings formula

20 25 30 35 40 45 50 55 Flow calculations Figure 3. Fittings Constant

Pipe sizing and pressure drop can be

Figure 2. Pressure Reduction Factors for Pipe Diameter (mm)

4. Design & Testing

philosophy, it is also necessary to work mula for thick walled pipes:

12 TEL. FAX E-MAIL

PRESSURE CLASS (BAR)

Design & Testing

PE80 Crack Propagation

250m m Pipe Dia 500m m Tensile tests

14 TEL. FAX E-MAIL

24 Necessary pressure at consumer: 2

and fd at 2. This gives a Qmax of 200 x 2

500 m 650 m 200 m

Figure 9. Diagram of pipeline in example

Table: Example of dimensioning diagram for calculation of pressure loss

Design & Testing

16 TEL. FAX E-MAIL

Longitudinal expansion and Hydraulic flow: k = frictional resistance [m]

where ∆L = longitudinal expansion/con-

T1 = stable soil temperature

Use of plastic pipes at

Where circumstances require that the

Diagram: Permissible operating pressure at temperatures exceeding 20°C

Design & Testing