Installation Guide - Pipes and Fittings2

Installation Guide Water and Sewer Installation Pipes and Fittings

Certificate No. FM12908

A World of Choice Saint-Gobain PAM UK UKisisthe theUK’s UK’sleading leading supplier ductile pipe systems for Saint-Gobain PAM supplier of of ductile ironiron pipe systems for potable water and sewerage applications. potable water and sewerage applications. Saint-Gobain PAM UK is part of the Saint-Gobain Pipe Division, a global company with a Saint-Gobain PAM UK is part ofAmerica the Saint-Gobain global company with presence in Europe, Asia, South and the FarPipe East.Division, The pipeadivision has over 10600 and sells products in 120 different countries of ductile iron aemployees presence in Europe, Asia, South America and the Far with East.over The 40,000km pipe division has over pipesemployees, being installed per in year. 9000 andworldwide sells product 120 different countries with approximately 100,000km of ductile pipes worldwide per year. The Saint-Gobain Pipe iron Division is being part ofinstalled the Saint-Gobain Group, one of the world’s leading multi-nationals, which currently employs over 209,000 people in 59 countries and overSaint-Gobain 1200 consolidated companies. The Pipe Division is part of the Saint-Gobain Group, one of the world’s Everyone at Saint-Gobainwhich PAM UK is dedicated to meeting customer expectations. We leading multi-nationals, currently employs over 180,000 people in 48 countries encourage open communication between staff, customers and related organisations to and over 1200 consolidated companies. make a positive impact on the future of the marketplace and help improve the quality of life for people worldwide. Everyone at Saint-Gobain PAM UK is dedicated to meeting customer expectations. We UK customers benefit from the global network of the Pipe Division through our long termto encourage open communication between staff, customers and related organisations commitment to improve and develop innovative products and processes. We achieve this make a positive impact on the future of the marketplace and help improve the quality through continual investment in Research and Development on a global scale. In excess of for people of life £10million per worldwide. annum is spent on R&D programmes worldwide, meaning an unrivalled product range of next-generation, ductile iron pipe systems being constantly developed andcustomers delivered to the UKfrom market. UK benefit the global network of the Pipe Division through our long term commitment to improve innovative products andculture. processes. We Sustainable development lies atand the develop heart of Saint-Gobain’s corporate achieve this through continual investment in Research and Development on a global Its state-of-the art technologies and focus on research and development have enabled us scale. In excessprovide of £10million per annum spentsustainable, on R&D programmes to consistently our customers with is quality, reliable andworldwide, ergonomic meaning solutions.an unrivalled product range of next-generation, ductile iron pipe systems being developed to thecreated UK market. Water constantly and sewerage pipelinesand aredelivered infrastructures to last for several generations. Sustainable development depends on ‘long lasting’ rather that ‘disposable’ installations. Saint-Gobain PAM UK has taken on board these principles and works to provide effective For further on Saint-Gobain PAM UK visit solutions forinformation the environment .

www.saint-gobain-pam.co.uk

For further information on Saint-Gobain PAM UK visit

www.saint-gobain-pam.co.uk

Contents Introduction Standards and Specifications . . . . . . . . . . . 2

DWI Regulation 31 . . . . . . . . . . . . . . . . . . . . . 2

Section 1 Pre Installation 1.1 Product Identification. . . . . . . . . . . . . . . 4

1.6 Ovality Correction.. . . . . . . . . .. .. .. .. .. .. .. .. 33 Ovality Correction 32

1.2 Handling and Storage . . . . . . . . . . . . . 11

33 1.7 Moving Pipes Pipes and and Fittings Onsite Onsite. .. .. 34

1.3 Pipeline Protection . . . . . . . . . . . . . . . . 20

1.8 Trenching. Trenching . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. .. .. 35 34

1.4 Coating Repairs . . . . . . . . . . . . . . . . . . . 25

35 1.9 Pre-installation. . . . . . . . . . . . .. .. .. .. .. .. .. .. 36

1.5 Cutting Cutting Ductile DuctileIron IronPipes. Pipes.. . . . . .. .. .. .. 29 28

Section 2 Pipe Laying 2.1 Pipe Laying. . . . . . . . . . . . . . . . . . . . . . . . 38

2.8 PAMLOCK . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.2 Rapid Joint . . . . . . . . . . . . . . . . . . . . . . . . 40

2.9 Jointing Methods. . . . . . . . . . . . . . . . . . 56

2.3 Anchor Gaskets . . . . . . . . . . . . . . . . . . . 44

. . . . .. .. .. .. .. 63 64 2.10 Anchor AnchorBead BeadApplication Application.

2.4 PAM Rapid Vi Joint. RapidUniversal Mechanical Anchor . . . . . .. .. .. .. .. 46 46

2.11 Flange FlangeJoints. Joints. .. .. .. . . . . . . . . . . . . .. .. .. .. .. 64 65

Joint 49 2.5 PAM Universal UniversalRapid RapidAnchor Ve Joint .. . . .. .. 47

. . . . . .. .. .. .. .. 67 68 2.12 Couplings Couplingsand andAdaptors Adaptors.

2.6 PAM Universal DirexionalRapid . . . . . . Locked . . . . . . . Joint . . . . . .. .. 48 50

73 2.13 Dismantling DismantlingJoints Joints.. . . . . . . . . . .. .. .. .. .. 69

2.7 Ve Joint (Mechanical). 2.7 Rapid PAM Directional . . . . . . . . . . . . . .. .. .. .. .. .. 51 51

Section 3 Post Installation Cleaning and 76 3.1 Cleaning andTesting Testing.. . . . . . . .. .. .. .. .. .. .. 72

3.4 References 81 References.. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . 77

3.2 Commissioning. Commissioning . . . . . . . . . . . . .. .. .. .. .. .. .. 75 79

Contacts... .. .. .. .. .. .. .. .. . . . . . . . . . . . . . . . . . 78 3.5 Contacts 82

3.3 Service Connections.... . . . . . . .. .. .. .. .. .. .. 75 Service Connections 79

11

Installation Guidelines Installation Guidelines Installation Guidelines Installation Guidelines Introduction Installation Guidelines Introduction Introduction Installation Guidelines Introduction Introduction Installation Guidelines Introduction

This installation guide is aimed at organisations and individuals responsible for the This installation guide is aimed at organisations and individuals responsible for the installation of ductile pipesat and fittings for the industry. These instructions This installation guideiron is aimed organisations andwater individuals responsible for the This installation guide is organisations and individuals responsible for the installation of ductile iron pipesat and fittings for the industry. These instructions Introduction This installation guide is aimed aimed at organisations andwater individuals responsible forprovide the are based on best practices, which are acknowledged within the industry. They installation of ductile iron pipes and fittings for the water industry. These instructions installation of ductile iron pipes and fittings for the water industry. These instructions are based on best practices, which are acknowledged within the industry. They provide This installation guide is aimed at organisations and individuals responsible for the installation of ductile iron pipes and fittingsand for the water industry. These instructions Introduction clear and concise the handling installation ironThey pipelines, are based on bestguidance practices,for which are acknowledged within of theductile industry. provide are based on best practices, which are acknowledged within the industry. They provide clear and concise guidance for the handling and installation of ductile iron pipelines, This installation guide is aimed at organisations andwater individuals responsible forprovide the installation ductile iron pipes and fittings for industry. These They instructions are based onofbest practices, which are acknowledged within the industry. from delivery through to commissioning, and arethe designed toof ensure clear and concise guidance for the handling and installation ductilethat ironthe pipelines, clear and concise guidance for the handling and installation ductile iron pipelines, from delivery through to commissioning, and arethe designed toof ensure that the installation ofbest ductile iron pipes and fittings for water industry. These instructions are based on practices, which are acknowledged within the industry. They provide clear and concise guidance for the handling and installation of ductile iron pipelines, This installation guide is aimed at organisations and individuals responsible for the performance ductiletoiron pipes and fittings is not compromised during from delivery of through commissioning, and are designed to ensure that installation. the from delivery through to commissioning, and are designed to ensure that the performance of ductile iron pipes and fittings is not compromised during installation. are based on best practices, which are acknowledged within the industry. They provide clear and concise guidance for the handling and installation of ductile iron pipelines, from delivery through to commissioning, and are designed to ensure that the installation of ductile iron pipes and fittings for the water industry. These instructions performance of ductile iron pipes and fittings is not compromised during installation. It is the responsibility ofiron the contractor to ensure thatcompromised competent personnel are employed performance of ductile pipes is during clear and concise guidance for theand handling and installation ductile ironinstallation. pipelines, from delivery through commissioning, and are designed ensure that the performance of ductile pipes and fittings is not not compromised during installation. It is based the responsibility oftoiron the contractor to ensure that competent personnel are employed are on best practices, which are fittings acknowledged withintoof the industry. They provide This for allinstallation site work. guide forms part of the Induct Plus scheme, which has been This installation guide forms part of the Induct Plus scheme, which has been from delivery through to commissioning, and are designed toof ensure that the performance of ductile iron pipes and fittings is not compromised during installation. It is the responsibility of the contractor to ensure that competent personnel are employed for all site work. clear and concise guidance for the handling and installation ductile iron pipelines, developed by Saint-Gobain Pipelines as an installation support initiative which aims to This installation guide forms part of the Induct Plus scheme, which has been This guide forms part of Induct scheme, has been developed by of Saint-Gobain Pipelines asfittings an installation support initiative which aims to performance ductile iron pipes and isPlus not compromised during installation. for allinstallation site work. This installation guide forms partand of the the Induct Plus scheme, which has been from delivery through to commissioning, and are designed towhich ensure that the give confidence to water utilities contractors, assuring that pipes and fittings will developed by Saint-Gobain Pipelines installation support initiative which aims PAM UK asasananinstallation support initiative which aims to to developed by Saint-Gobain Pipelines as an installation support initiative which aims give confidence to water utilities and contractors, assuring that pipes and fittings will This installation guide forms part of the Induct Plus scheme, which has been developed byeffectively Saint-Gobain Pipelines an installation support initiative which aims to PAM UK asasfittings an installation support initiative which aims to to performance of ductile iron pipes and is not compromised during installation. It is the responsibility of the contractor to ensure that competent personnel are employed be installed and in optimum condition. The scheme offers on site training, give confidence to water utilities and contractors, assuring that pipes and fittings will give confidence to water utilities and contractors, assuring that pipes and fittings will be installed effectively and in optimum condition. The scheme offers on site training, This installation guide forms partUK ofas the Induct Plus scheme, which has been developed by Saint-Gobain Pipelines as an installation support initiative which aims to PAM an installation support initiative which aims to give confidence to water utilities and contractors, assuring that pipes and fittings will for all site work. evaluation assessment of optimum the installation of ductile iron pipes and leading be installedand effectively and in condition. The scheme offers onfittings, site training, be installed installed effectively and in optimum condition. The scheme offers on site training, evaluation and assessment ofpart theand installation ofPlus ductile ironthat pipes and fittings, leading developed by Saint-Gobain Pipelines as an installation support initiative which aims to give confidence to water utilities contractors, assuring pipes and fittings will be effectively and in optimum condition. The scheme offers on site training, This installation guide forms of the Induct scheme, which has been to the certification of successful upon completing the scheme. evaluation and assessment of thecontractors installation of ductile iron pipes and fittings, leading evaluation and assessment of the installation of ductile iron pipes and fittings, leading to the certification of successful contractors upon completing the scheme. give confidence to water utilities and contractors, assuring that pipes and fittings will be installed effectively and in optimum condition. The scheme offers on site training, evaluation by andSaint-Gobain assessment Pipelines of the installation of ductile iron pipes andwhich fittings, leading developed installation support initiative which aims PAM UK asasananinstallation support initiative aims to to to the certification of successful contractors upon completing the scheme. to certification of upon completing the scheme. be installed effectively and in condition. The scheme offers on site training, evaluation and assessment of optimum thecontractors installation of ductile ironthat pipes and fittings, leading to the the certification of successful successful contractors upon completing the scheme. give confidence to water utilities and contractors, assuring pipes and fittings will

Standards Standards Standards Standards Standards Standards Standards

DWI DWI DWI DWI DWI DWI DWI

evaluation and assessment of thecontractors installation of ductile iron pipes and fittings, leading to the certification of successful upon completing the scheme.

be installed effectively and in optimum condition. The scheme offers on site training, and Specifications to the certification of successful upon completing the scheme. evaluation and assessment of thecontractors installation of ductile iron pipes and fittings, leading and Specifications and Specifications to the certification of successful contractors upon completing the scheme. and Specifications Saint-Gobain Pipelines are manufactured manufacturedin inaccordance accordance PAM UK’s ductile iron pipes and fittings fittings are Saint-Gobain Pipelines are manufactured manufacturedin inaccordance accordance PAM UK’s ductile iron pipes and fittings fittings are and Specifications with BS EN 545 (1) and BS EN 598 (2) and where applicable they are marked with the Saint-Gobain Pipelines ductile iron pipes and fittings are manufactured in accordance Saint-Gobain Pipelines ductile iron pipes and fittings are manufactured in accordance PAM UK’s fittings are manufactured in accordance with BS EN 545 (1) and BS EN 598 (2) and where applicable they are marked with the Saint-Gobain Pipelines ductile iron pipes and fittings are manufactured in accordance and Specifications BSI Quality Mark (Kitemark). withCertification BS EN 545 (1) and BS EN 598 (2) and where applicable they are marked with the with BS EN 545 (1) and BS EN 598 (2) and where applicable they are marked with BSI Certification Quality Mark (Kitemark). Saint-Gobain Pipelines iron(2) pipes fittings are manufactured in accordance with BS EN 545 (1) and ductile BS EN 598 andand where applicable they are marked with the the and Specifications BSI Certification Quality Mark (Kitemark). BSI Certification Quality Mark (Kitemark).

Saint-Gobain Pipelines ductile iron(2) pipes fittings are manufactured manufactured inaccordance accordance with BS EN 545 (1) andfor BS EN installation 598 andand where applicable they are in marked with the PAM UK’s fittings are in BSI Certification Quality Mark (Kitemark). General requirements the of pipelines are contained the Civil General requirements for the installation of pipelines are contained in the Civil with BS EN 545 (1) and BS EN 598 (2) and where applicable they are marked with the BSI Certification Quality Mark (Kitemark). Saint-Gobain Pipelines ductile iron pipesIndustry and fittings are manufactured in accordance Engineering Specification for the Water (3), Standard Specification for Water General requirements for the installation of pipelines are contained in the Civil General requirements for the installation of pipelines are contained in the Civil Engineering Specification for Water Industry (3), Standard Specification for Water BSI Certification Quality Mark (Kitemark). General requirements the installation of pipelines are contained theBS Civil with BS EN 545 (1) andfor BS ENthe 598 (2) where applicable they are in marked with the and Sewerage Schemes (applicable inand Scotland (4), 8010 and Engineering Specification for the Water Industryand (3),Northern StandardIreland) Specification for Water Engineering Specification for the the Water Industry (3),Northern Standard Specification for Water andCertification Sewerage Schemes (applicable in Scotland and Ireland) (4), BS 8010 and General requirements for the installation of pipelines are contained in the Civil Engineering Specification for Water Industry (3), Standard Specification for Water BSI Quality Mark (Kitemark). and Sewer for Adoption (6th Edition) (6). EN 805 (5) a code of practice for pipeline installation. These publications are used as and Sewerage Schemes (applicable in Scotland and Northern Ireland) (4), BS 8010 and and Sewerage Schemes (applicable in Scotland and Northern Ireland) (4), BS 8010 and and Sewer for Adoption (6th Edition) (6). EN 805 (5) a code of practice for pipeline installation. These publications are used as General requirements for the installation of pipelines are contained in the Civil Engineering Specification for the Water Industry (3), Standard Specification for Water and Sewerage Schemes (applicable in Scotland and Northern Ireland) (4), BS 8010 and the basis for this document, with additional information provided as necessary. These used asfor the basis for this document, additionalare information EN 805publications (5) a code ofare practice pipeline installation. Thesewith publications used as and Sewer for Adoption (6th Edition) (6). EN 805 (5) a code of practice for pipeline installation. These publications are used as the basis for this document, with additional information provided as necessary. These publications used the basis for document, with additional information Engineering Specification forasfor the Water Industry (3),Northern Standard Specification for Water and Sewerage Schemes (applicable in Scotland and Ireland) BS 8010 and EN 805 (5) code ofare practice pipeline installation. These publications are used as General requirements for the installation ofthis pipelines are contained in(4), the Civil provided asanecessary. the basis for this document, with additional information provided as necessary. the basis this document, with additional information provided as These publications used the basis for this document, with additional information provided asanecessary. and Sewerage Schemes (applicable in Scotland and Ireland) (4),are BS 8010 and EN 805 (5)for code ofare practice for pipeline installation. These publications used as the basis for this document, with additional information provided as necessary. necessary. Engineering Specification foras the Water Industry (3),Northern Standard Specification for Water provided as necessary. and Sewer for Adoption (6th Edition) (6). EN 805 (5) a code of practice for pipeline installation. These publications are used as the basis for this document, with additional information provided as necessary. and Sewerage Schemes (applicable in Scotland and Northern Ireland) (4), BS 8010 and

Regulation 31 .4.a the basis this document, with additional information provided as necessary. These publications used as the basis for this document, with additional information EN 805 (5)for a code ofare practice for pipeline installation. These publications are used as Regulation 31 .4.a Regulation 31 provided as necessary. the basis for this document, with additional information provided as necessary. Regulation All materials that31 can .4.a come into contact with potable water, including pipe linings, All materials that31 can come into contact with potable water, including pipe linings, Regulation lining repair material, joints into and contact jointing with lubricants must comply with the All materials that can come potable water, including pipe linings, All materials that can come potable water, including pipe linings, lining repair material, joints into and contact jointing with lubricants must comply with the All materials that can .4.a come into contact with potable water, including pipe linings, Regulation 31 requirements of Regulation 31 of The Water Supply Regulations, England lining repair material, joints and jointing lubricants must comply with theand Wales lining repair material, joints and jointing lubricants must comply with the requirements of Regulation 31 of The Water Supply Regulations, England and Wales All materials that can come into contact with potable water, including pipe lining material, and jointingScotland lubricants comply with the linings, Regulation 31 joints (6), The Water Supply Regulations (7).must (7) or repair (8) requirements of Regulation 31 of Thefor Water Supply Regulations, England and Wales requirements of Regulation 31 of Thefor Water Supply (6), or The Water Supply Regulations Scotland (7).Regulations, England and Wales

All that can come into with potable water, including pipe linings, (7) materials (8)must lining repair material, joints 31 andofcontact jointing lubricants comply with the requirements of Regulation The Water Supply Regulations, England and Wales (6), or The Water Supply Regulations for Scotland (7). (6), or The Water Supply Regulations for Scotland (7). . water, (7) materials (8) lining repair material, joints andofcontact jointing lubricants must comply with the requirements of Regulation 31 The Water Supply Regulations, England and Wales (6), or The Water Supply Regulations for Scotland (7). All that can come into with potable including pipe linings, These instructions include the use of procedures and/or substances that may cause These instructions include the use of procedures and/or substances that may cause requirements of Regulation 31 of The Water Supply Regulations, England and Wales (6), or The Water Supply Regulations for Scotland (7). lining repair material, joints and jointing lubricants must comply withonly the to technical injury affect health if adequate areand/or not taken. It refers These or instructions include the use precautions of procedures substances that may cause These instructions include the use of procedures and/or substances that may cause injury or affect health if adequate precautions are not taken. It refers only to technical (6), or The Water Supply Regulations for Scotland (7). (7) (8)Regulations, These instructions include the ofuser procedures and/or substances thatto may cause requirements Regulation 31 use ofthe The Water Supply England and Wales suitability andof does not from legal obligations relating health and injury or affect health if absolve adequate precautions are not taken. It refers only to technical injury or affect health if adequate precautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligations relating to health and These instructions include the use of procedures and/or substances that may cause injury or affect health if adequate precautions are not taken. It refers only to technical (6), or The Water Supply Regulations for Scotland (7). safety at any suitability andstage. does not absolve the user from legal obligations relating to health and suitability andstage. does not absolve the user from legal legal obligations relating to health and safety at affect any These instructions include the use ofuser procedures substances that may cause injury or health if absolve adequate precautions areand/or not taken. It refers only to technical suitability and does not the from obligations relating to health and safety at any stage. safety at any stage. injury or affect health if adequate precautions are not taken. It refers only to technical suitability and does not absolve the user from legal obligations relating to health and safety instructions at anycontained stage.include These the use of procedures and/or substances that may cause Information in these instructions is given in good faith. The sole Information contained in these instructions is given in good faith. The sole suitability andstage. does not the user from legal obligations relating to to health and safety at affect any injury or health if absolve adequate precautions arefittings not taken. It refers technical responsibility for correct of pipesisand is that ofThe theonly contractor. Information contained ininstallation these instructions given in good faith. sole Information contained in these instructions is given in good faith. responsibility for correct installation of pipes and fittings is that ofThe thesole contractor. safety at any stage. Information contained in these instructions is given in good faith. The sole suitability and does not absolve the user from legal obligations relating to health and Saint-Gobain Pipelines cannot acceptany responsibility actions taken a result. UK cannot accept responsibility forfor actions taken asas a result. responsibility PAM for correct installation ofany pipes and fittings is that of the contractor. responsibility for correct installation of pipes and fittings is that of the contractor. Saint-Gobain Pipelines cannot accept any responsibility for actions taken as a result. PAM UK cannot accept any responsibility for actions taken as a result. Information contained in these instructions is given in good faith. The sole responsibility for correct installation of pipes and fittings is that of the contractor. safety at any specification stage. The contract and drawings prevail if they from these Saint-Gobain Pipelines cannot accept anywill responsibility fordiffer actions taken as a result. Saint-Gobain Pipelines cannot accept any responsibility for actions taken a PAM UK cannot any responsibility for actions taken asas a result. The contract contained specification andaccept drawings will ifinthey differ from these Information in these instructions isprevail given good faith. The sole responsibility for correct installation of pipes and fittings is that of the contractor. Saint-Gobain Pipelines cannot accept any responsibility for actions taken as a result. result. instructions. The contract specification and drawings will prevail if they differ from these The contract specification and drawings will prevail if they differ from these Introduction instructions. responsibility for correct installation ofany pipes and fittings isdiffer that of the contractor. Saint-Gobain Pipelines cannot accept responsibility for actions taken as a result. The contract contained specification and drawings will ifinthey from these Information in these instructions isprevail given good faith. The sole instructions. instructions. Saint-Gobain Pipelines cannot acceptany responsibility actions taken a result. Introduction The contract specification andaccept drawings will prevail if they differ from these PAM UK cannot responsibility forfor actions taken asas a result. instructions. responsibility for correct installation ofany pipes and fittings is that of the contractor. This installation guide is aimed at organisations and individuals responsible the The contract specification and drawings will prevail if they differ from these instructions. Saint-Gobain Pipelines cannot accept any responsibility for actions taken as afor result. installation of ductile iron pipes and fittings for the water industry. These instructions instructions. This contract installation guide is aimed at organisations andifindividuals The specification and drawings will prevail they differ responsible from these for the are based onofbest practices, which are acknowledged within the industry. provide installation ductile iron pipes and fittings for the water industry. These They instructions instructions. clearbased and concise the handling and installation ironThey pipelines, are on bestguidance practices,for which are acknowledged within of theductile industry. provide from delivery through to commissioning, and are designed to ensure that the clear and concise guidance for the handling and installation of ductile iron pipelines, performance ductiletoiron pipes and fittings is not compromised during from delivery of through commissioning, and are designed to ensure that installation. the

Installation Guidelines Installation Guidelines

22 2 2 2 2 2

performance of ductile pipes and fittings is not during installation. It is the responsibility ofiron the contractor to ensure thatcompromised competent personnel are employed This installation guide forms part of the Induct Plus scheme, which has been for all site work. developed by Saint-Gobain Pipelines as an installation support initiative which aims to This installation guide forms part of the Induct Plus scheme, which has been give confidence to water utilities and contractors, assuring that pipes and fittings will developed by Saint-Gobain Pipelines installation support initiative which aims PAM UK asas ananinstallation support initiative which aims to to

Section 1 Pre Installation

3

Section Section 1: 1:PrePre Installation Installation

1.1 Product Identification 1.1 Product Identification

Ductile iron Ductile iron iron is an iron/carbon/silicon alloy. With the addition of magnesium to the Ductile molten iron the graphite forms in spheres rather than flakes. This transformation Ductile iron is an iron/carbon/silicon alloy. With the addition of magnesium to the eliminates brittleness and produces a strong, ductile material. molten iron the graphite forms in spheres rather than flakes. This transformation eliminates brittleness and produces a strong, ductile material.

1.1.1 Pipes & Fittings - for Potable Water 1.1.1 Pipes &fittings Fittings - forbyPotable Pipes and manufactured Saint-GobainWater Pipelines to BS EN 545 for the conveyance of potable water can be identified by the following methods. PAM UK totoBSBS ENEN 545 forfor thethe Pipes and fittings manufactured by Saint-Gobain Pipelines 545 conveyance of potable water can be identified by the following methods.

Section 1: Pre Installation

PAM Natural Pipes – DN80-800 Externally coated with blue epoxy and marked with the nominal diameter (DN) in mm, PAM Natural Pipes – DN80-800

1.1 Product Identification

manufacturing standard, date code, manufacturers’ mark and brand name as shown in Externally coated blue epoxy and marked manufacturing Externally coatedwith withsignal blue epoxy and marked withwith the the nominal diameter standard, (DN) in mm, Fig. 1.1.1. manufacturing standard, date code, range manufacturers’ mark and brand name as shown in pressure class, PAM logo and product as shown in Fig. 1.1.1. The nominal diameter (DN)1.1.1. in mm can be found on the inside of the socket of the pipe (see Fig. 1.1.2). Fig. Internally, the pipes have a cement mortar lining with an epoxy sealcoat, which has a Ductile iron Internally, the pipes(System will either have blast furnace cement, which has a grey appearance green appearance XL). Internally, the pipes have a cement mortar lining sealcoat, with an epoxy sealcoat, which has a (System CL) or cement mortar lining with an With epoxy which has a green appearance Ductile iron is an iron/carbon/silicon alloy. the addition of magnesium to the green appearance (System XL). (System XL). Large diameter pipe DN900-2000 molten iron the graphitewater forms in spheres rather than flakes. This transformation eliminates brittleness and produces a strong, ductile material. Externallydiameter coated with black bitumen and DN900-2000 marked with the nominal diameter, Large water pipe manufacturing standard, date code and manufacturers’ mark. Externally coated and marked with thethe manufacturing standard, Externally coatedwith withblack blackbitumen bitumen and marked with nominal diameter, pressure class, PAM logo and product range as shown in Fig. 1.1.1. The nominal diameter manufacturing standard, date code and manufacturers’ mark. Internally these pipes are supplied with a cement lining only which has a grey (DN) in mm can be found on the inside of the socket of the pipe (see Fig. 1.1.2). appearance, (System CL). Internally these pipes are supplied with a cement lining only which has a grey Internally pipes are suppliedby with blast furnace cement which has545 a grey Pipes andthese fittings manufactured Saint-Gobain Pipelines to BS EN for appearance the appearance, (System CL). Fig. 1.1.1 (System CL). conveyance of potable water can be identified by the following methods. Fig. 1.1.1 Manufacturers’ Date Diameter Fig. 1.1.1 PAM Natural Pipes – DN80-800 Manufacturers’

1.1.1 Pipes & Fittings - for Potable Water Fig. 1.1.2

in mm

Mark Manufacturers’

Standard

Date

Date Manufacturers’ Diameter Externally coated withManufacturers’ bluePAM epoxy and marked with the nominal diameter (DN) in mm, Product range logo Pressure class Manufacturing in mm Mark Standard manufacturing standard, date code, manufacturers’ mark and brand name as shown in standards Fig. 1.1.1.

Internally, the pipes have a cement mortar lining with an epoxy sealcoat, which has a green appearance (System XL).

Large diameter water pipe DN900-2000 Externally coated with black bitumen and marked with the nominal diameter, manufacturing standard, code and manufacturers’ Although not shown here,date uti DN400, the class of pipe ismark. also stencilled onto the pipe Fig. 1.1.3

Fig. 1.1.2 Saint-Gobain

Diameter

Manufacturing

bridge logo in mm Fittingstandard Date Fig. 1.1.2 Diameter in mm Identification Date Diameter Fitting in mm Identification

4 4

(C40, K9). Although not shown here, uti DN400, the class of pipe is also stencilled onto the pipe Internally these pipes are supplied with a cement lining only which has a grey (C40, K9). appearance, (System CL).

Fittings Fig. 1.1.1 fittings externally and internally andand are are marked Fittings All fittingshave haveaablue blueepoxy epoxycoating coatingboth both externally and internally marked with the ofof the socket or or alternatively on the body of the with thediameter, diameter,on onthe theoutside outside the socket alternatively on the body of the Date Manufacturers’ All Diameter fittings have a blueManufacturers’ epoxy coating both externally and internally and are marked fitting. They are also marked with the manufacturing standard number (EN545) either fitting. The body of the fitting may also have the fitting identification and EN 545 Mark mm Standard on the body of the cast withinthe diameter, on the outside of the socket or alternatively on or on a stickerstandard and withnumber the Saint-Gobain bridge Fig.1.1.3) The1.1.2). body of the manufacturing either cast on orlogo on a(see sticker (see Fig. fitting. The body of the fitting may also have the fitting identification and EN 545 fitting may also have the fitting identification. manufacturing standard number either cast on or on a sticker (see Fig. 1.1.2).

Manufacturing Standard Manufacturing Standard

Although not shown here, uti DN400, the class of pipe is also stencilled onto the pipe (C40, K9).

1.1.2 PAM Integral/Integral Plus pipes and fittings for 1.1.2 PAM Integral/Integral Plus pipes and fittings for sewerage sewerage

Fig. Fig. 1.1.3 1.1.5 Fig. Fig. 1.1.3 1.1.5

PAM UK totoBSBS ENEN 598 forfor thethe Pipes and fittings manufactured by Saint-Gobain Pipelines 598 PAM UK to BS EN 598 for Pipes and fittings manufactured by Saint-Gobain Pipelines to BS EN 598 for the conveyance of wastewater and sewage can be identified by the followingthe methods. conveyance of wastewater and sewage can be identified by the following methods.

Pipes Pipes standard, PAM Externally coated with red epoxy and marked with the manufacturing nominal diameter (DN) in mm, manufacturing standard, PAM Externally coated with red epoxyin and with the nominal (DN) in mm, logo and product range as manufacturers’ shown Fig.marked 1.1.4. The nominal diameter in mm can be found manufacturing standard, mark and brand name diameter as(DN) shown in Fig. 1.1.4. logo and product range as shown inaFig. 1.1.4. The nominal diameter inthe mm can beafound manufacturing standard, manufacturers’ mark and brand name as(DN) shown in Fig. 1.1.4. on the inside of the socket of the pipe (see Fig. 1.1.5). PAM Integral Plus pipes also have blue Integral Internally found on have a space on the inside of the socket of pipe (see Fig. PAM Integral Plus pipes also have white cross on the socket face (see Fig. 1.1.3). Integral Internally found on have a space on the inside of the socket of the pipe (see Fig. PAM Integral Plus pipes also have a white cross on the socket face (see Fig. 1.1.3). paint on the Plus socket facealso (seehave Fig. 1.1.6). 1.1.5).section PAM Integral pipes a blue paint section on the socket face (see Fig. 1.1.6). 1.1.5). PAMthe Integral pipes with also have blue paint section on thewhich sockethas facea (see Fig. 1.1.6). Internally pipesPlus are lined high aalumina cement mortar white Internally the pipes are lined with high alumina cement mortar which has a white appearance. appearance. Fig. 1.1.4 Fig.1.1.4 1.1.4 Fig. Product range PAM logo Fig. 1.1.4 Manufacturers’ Diameter Product range PAM logo Diameter in mm in mm

Manufacturers’ Mark Mark

Manufacturing

Product Manufacturers’ Manufacturing standards Product Manufacturers’ Code Standard standards Code Standard

Fig. 1.1.6 Fig. 1.1.6

Fig. 1.1.5 Fig. 1.1.5 Manufacturing Standard Manufacturing Standard

Fittings Fittings Fittings haveaared/brown red/brownepoxy epoxycoating coatingboth both externally and internally marked Fittings have externally and internally andand are are marked Fittings have red/brown epoxycoating both and internally and are marked Fittings red/brown epoxy both externally and internally and arethe marked with thehave sizeaa (DN) onthe theoutside outside ofthe the socket or alternatively on body of the with the diameter on ofcoating socket orexternally alternatively on thethe body of with the size (DN) on the outside ofthe the socket or alternatively body of the cast with the diameter on the outside of socket or alternatively on on thethe body of EN the fitting. The body of the fitting may also have the fitting identification and 598 fitting. They are also marked with the manufacturing standard number (EN598) either fitting. The body of the fitting may also have the fitting identification and EN 598 fitting. They are also marked with the manufacturing standard number (EN598) either cast standard either orlogo on a(see sticker Fig. 1.1.5). on or on anumber sticker and withcast theon PAM Fig.(see 1.1.7). The body of the fitting may also standard number either cast on or on a sticker (see Fig. 1.1.5). on or on a sticker and with the PAM logo (see Fig. 1.1.7). The body of the fitting may also have the fitting identification. have the fitting identification. Fig. 1.1.7 Fig. 1.1.7 Diameter in mm in Diameter mm

Fitting identification Fitting identification

Saint-Gobain bridge logo Saint-Gobain bridge logo

Manufacturing standard Manufacturing standard

Diameter in mm Diameter in mm

5 5

Section Section1:1: Pre PreInstallation Installation

1.1.3 Rapid Rapid Joint 1.1.3 Joint Fig. 1.1.6 Fig. Fig. 1.1.6 1.1.8

Pipes Pipes All Saint-Gobain DN60-2000 areare manufactured with the the PAM UK’spipes with push-fit joints DN80-2000 are All Saint-GobainPipelines Pipelines pipesand andfittings fittings DN60-2000 manufactured with Rapid Joint. Pipes are marked with the DN and ‘STD’ inside the socket (see Fig. 1.1.6). Rapid Joint. Pipes with Pipes the DN ‘STD’with inside (see Fig. 1.1.6). manufactured withare themarked Rapid Joint. areand marked thethe DNsocket and with the letters ‘STD’ (standard push-fit joint) inside the socket (see Fig 1.1.8).

Fittings Fittings Fittings on socket oror sometimes inside thethe socket Fittings are are marked with letters ‘STD’of (standard push-fit joint) on the outside ofsocket the Fittings are marked marked‘STD’ ‘STD’the onthe theoutside outside ofthe the socket sometimes inside (see Fig. 1.1.7). socket or sometimes inside the socket (see Fig. 1.1.9). (see Fig. 1.1.7). Fig. 1.1.7 1.1.9 Fig.

Rapid gaskets The Rapid gasket has a fish tail profile (see Fig. 1.1.8). Gaskets intended for use with Rapid gaskets Fig. 1.1.8 Rapid gaskets Fig. 1.1.8 1.1.10 Fig. potable water are made from EPDM rubber whereas gaskets intended for use with The Rapid gasket (see Fig. 1.1.8). Gaskets intended for for useuse withwith (see Fig. 1.1.10). The Rapid gasket has hasaafish fishtail tailprofile profile (see Fig. 1.1.8). Gaskets intended waste water and sewage are made from Nitrile rubber. potable water are made from EPDM rubber whereas gaskets intended for use with potable water are made from EPDM rubber whereas gaskets intended for use with waste water and are made from Nitrile rubber. waste andsewage sewage are made Nitrile rubber. Gaskets intended for use with potable water arewater embossed with the size and from EPDM. Gaskets uti DN600 can be identified by a double blue circumferential band (see Fig. Gaskets intended intended for use with potable water areare embossed with thethe sizesize andand EPDM. Gaskets water are embossed with the size DN, with the Gaskets intendedfor foruse usewith withpotable potable water embossed with EPDM. 1.1.9). Gaskets uti DN600 can be identified by a double blue circumferential band (see Fig.can letters ‘STD’ push-fit joint) and (seeblue Fig. circumferential 1.1.11). Gaskets uti DN600 Gaskets uti (standard DN600 can be identified by‘EPDM’ a double band (see Fig.be 1.1.9). identified by a double blue circumferential band (see Fig.1.1.12). 1.1.9). Fig. 1.1.9 Fig. 1.1.11

Fig. 1.1.9 Fig. 1.1.12 Fig. 1.1.9

Fig. 1.1.10 1.1.10 Fig.

Fig. 1.1.11 1.1.11 Fig.

Fig. 1.1.13 Gaskets intended for use with waste water and sewage can be identified, throughout the size range, by twouse yellow circumferential bands and embossed with the DN and Gaskets intended >DN600 doare notnot have thethe blue Gaskets intendedfor for usewith withpotable potablewater water >DN600 do have blue with the letters ‘STD’ (standard push-fit joint) (see Fig.1.1.13). circumferential band. with thethe size STDSTD andand EPDM (see(see (DN), circumferential band.All Allgaskets gasketsare areembossed embossed with size (DN), EPDM Fig. 1.1.10). Fig. 1.1.10).

Gaskets intended water and sewage cancan be be identified, throughout Gaskets intendedfor foruse usewith withwaste waste water and sewage identified, throughout the size range, by two yellow circumferential bands and are embossed with thethe sizesize the size range, by two yellow circumferential bands and are embossed with (DN) and STD (see Fig. 1.1.11). (DN) and STD (see Fig. 1.1.11).

6 6

Rapid anchor Vi Jointjoint (Anchor) Rapid

Fig. Fig. 1.1.12 1.1.14

This system uses standard pipes and fittings with a modified gasket containing Rapid anchor joint moulded-in stainless steel inserts. For use with potable water and sewerage on both pipes and fittings UTI DN600 where are required (see Fig. Fig.1.1.14). 1.1.12). (see This system uses standard pipes andself-restrained fittings with ajoints modified gasket containing

Fig. 1.1.12

moulded-in inserts. For use potable water andbe sewerage These gasketsstainless are only steel available in EPDM andwith therefore they may not suitable on for both Please note that test and working pressures are restricted when using anchor gaskets pipes and fittings UTI DN600 where self-restrained joints are required (see Fig. 1.1.12). some sewerage applications. (see Table 2.3.1). Please note that test and working pressures are restricted when using anchor gaskets Mechanical (see Table 2.3.1). anchor joints Fig. 1.1.14

Section Section 1: 1: Pre Installation Pre Installation

The mechanical anchor joint is used on pipes and fittings, DN600-1200, where selfMechanical joints restrained joints areanchor required, and on pipes and fittings DN80-600 where pressure PAM Universal socket and joints ratings are greater than the anchorDN600-1200, gaskets. The mechanical anchor jointmaximum is used onallowable pipes andfor fittings, where selfThe PAM Universal socket is used on pipes, DN80-1200, where self-restrained joints are restrained joints are required, and on pipes and fittings DN80-600 where pressure Universal Rapid and Universal Rapid Ve joints and on directional required. It is used with the Universal RapidVianchor and Universal Rapid locked joints The jointare utilises thethan same socket and gasket as the Rapid joint. ratings greater the maximum allowable forunanchored anchor gaskets. drilling joints (see Fig. 1.1.15). and on pipe directional drilling pipe joints (see Fig. 1.1.14). Anchorage is provided by the addition of a weld bead on the pipe spigot, a locking ring (single piece uti DN700 andsocket segmented for DN800-1200) which abuts weld bead The joint utilises the same and gasket as the unanchored Rapidthe joint. The joint utilises the same gasket as an unanchored joint, but has an elongated socket and a boltedisgland which against pipe socket using hook bolts and retains Anchorage provided by tightens the addition of athe weld bead on the pipe spigot, a locking ring and does not have the collarette. the locking ring Fig. and 1.1.13). (single piece uti(see DN700 segmented for DN800-1200) which abuts the weld bead Fig. 1.1.15 Fig. 1.1.16 1.1.17 and a bolted gland which tightens against the pipe socket Fig. using hook bolts and retains

Fig. 1.1.15

Gasket Chamber

Chamber for Locking Ring

Fig.locking 1.1.13 the ring (see Fig. 1.1.13). Vi Joint PAM Universal Rapid

Fig. 1.1.15 Fig. 1.1.16 Fig. 1.1.17 The Universal Rapid Vi joint is for use on pipes DN80-600 where self restrained joints are Fig.1.1.19 1.1.13 Fig. Fig. 1.1.20 required.

7

The joint utilises the same gasket as the unanchored Rapid joint. Anchorage is provided by a rubber retaining ring with toothed inserts (see Fig.1.1.16 and Fig.1.1.17). Chamber for Rapid gasket

Chamber for Univ anchor gasket or locking ring

Fig. Fig. 1.1.18 1.1.16

Pipe

Fig. 1.1.18

Pipe

The Universal Rapid Anchor joint is for use on pipes DN80-600 where self restrained PAM Rapid Anchor joint PAMareUniversal Direxional joints required.

STANDARD sealing gasket UNIVERSAL Rapid STANDARD anchoring gasket sealing gasket UNIVERSAL Rapid Fig. Fig. 1.1.19 1.1.18 anchoring gasket Pipe Fig. 1.1.14

Fig. 1.1.19 Fig. 1.1.14

Pipe

STANDARD sealing gasket Weld bead UNIVERSAL RapidSTANDARD locking ring sealing gasket Weld bead UNIVERSAL Rapid Fig. 1.1.23 locking ring

Gasket Chamber Gasket Chamber

There are three types of locking ring dependent upon pipe size:Fig. 1.1.17 1. DN100-200 (see Fig.1.1.15) Fig. 1.1.21 Fig. 1.1.22 DN250-350 Fig. ring 1.1.16) There are2.three types of(see locking dependent upon pipe size:3. 1.1.17) 1. DN400-700 DN100-200 (see Fig. Fig.1.1.15) There are 2. four types of locking ring dependent upon pipe size:DN250-350 (see Fig. 1.1.16) 1. DN100-200 3. DN400-700 (see Fig. 1.1.21) 3. DN400-700(see (seeFig.1.1.19) Fig. 1.1.17) PAM Universal Rapid Anchor joint 4. DN800-1200 (see Fig. 1.1.22) 2. DN250-350 (see Fig. 1.1.20)

Chamber for Locking Ring Chamber for Locking Ring

The jointsystem is for use on pipes DN80-600 drilling where self PAMUniversal DirexionalRapid Pipe isAnchor a pipeline designed for directional (see restrained section 2.6). PAM Universal Rapid Ve Joint The the same the unanchored joint. applications Anchorage isand are joints are utilises required. PAMjoint Direxional drilling pipesgasket can beas used for both waterRapid and sewer The Universal Veretaining joint is forring usewith onby pipes DN80-1200 restrained joints are provided by aRapid rubber toothed inserts where (see Fig. 1.1.18). available from DN100-1000. It is jointed a self-anchored push fitself double chambered required. The joint utilises gasket as the unanchored Rapid joint.of Anchorage is plus 5mm socket and spigotthe withsame a welded bead. External protection consists 200mg Zinc provided by a rubber ring with inserts (see Fig. 1.1.18). cement (ZM-U) coatingretaining for DN100-700 andtoothed thick sprayed polyurethane based (PUX) coating The jointUniversal utilises the same gasket as the unanchored Rapid joint. Anchorage is provided PAM Rapid Locked joint(EN545) for DN800-1000. Internal protection for water pipes is Blast furnace cement and for by the addition of a welded bead onto the pipe spigot and a locking ring which abuts the sewer pipes (EN598) high alumina Thepipes jointDN80-1200 is protected where from abrasive conditions The Universal Rapid aLocked joint is cement. for use on self restrained welded bead (see Fig. 1.1.18) PAM Universal Rapid Locked joint socketcollar and by theare use of a rubber protective andjoints a metal sheet cone (see Fig. 1.1.23). joints required. The Universal Rapidsocket Lockedisjoint forpipes, use on pipes DN80-1200 where self restrained PAM Universal usedison DN80-1200, where self-restrained joints are PAM socket and joints The joint utilises the same as the unanchored Rapid joint. Anchorage is joints Rapid Ve Joint (Mechanical) joints areUniversal required. required. It is used with thegasket Universal Rapid anchor and Universal Rapid locked There are four types of locking ring dependent Fig.on 1.1.19 Fig. provided by the addition ofpipe a1.1.20 welded onto the pipe where spigot self-restrained and a locking ring and directional drilling joints (see Fig. 1.1.14). The PAM Universal socket used on bead pipes, DN80-1200, joints are pipe size:The Rapid Ve joint is used forisDN350-1200 water andupon DN150-1200 sewer pipes, as an which abuts the welded bead (see Fig. 1.1.19). The joint utilises the same gasket as the unanchored Rapid joint. Anchorage is required. IttoisUniversal used with thewhen Universal Rapidjoints anchor and Universal Rapid locked joints alternative joint restrained are required. The joint utilises the same 1. DN100-200 (see Fig.1.1.19) provided by the addition ofgasket a welded bead onto1.1.14). the pipe and a elongated locking ring The joint utilises thedrilling same as an unanchored joint,spigot but has an socket and on directional pipe joints (see Fig. socket and gasket as the unanchored Rapid joint. Anchorage is provided by the addition of 2. DN250-350 (see Fig. 1.1.20) which abuts welded bead (see Fig. 1.1.19). and does notthe have the collarette. a weld bead on the pipe spigot, a locking ring (single3.piece uti DN700 and segmented for DN400-700 (see Fig. 1.1.21) PAM Directional The joint utilises same as anand unanchored joint,which but has an elongated socket DN800-1200) whichthe abuts thegasket weld bead a bolted gland tightens against the pipe 4. DN800-1200 (see Fig. 1.1.22) and does not have the collarette. PAM Directional Pipe is a pipeline system designed for directional drilling (see Fig. socket using hook bolts and retains the locking ring (see Fig. 1.1.24). PAM Directional 3.4.1). PAM Directional drilling pipes can be used for both water and sewer Fig.Directional 1.1.24 andPipe applications are available from DN100-700. It is by a self-anchored push PAM is a pipeline system designed forjointed directional drilling (see Fig. fit double chambered socket and spigot with a welded bead. External protection 3.4.1). PAM Directional drilling pipes can be used for both water and sewer 7 consists of 200mg Zinc plus 5mm (ZM-U)Itcoating. Internal protection for applications and are available fromcement DN100-700. is jointed by a self-anchored push water pipes (EN545) issocket Blast furnace cement for sewer pipes (EN598) a high fit double chambered and spigot withand a welded bead. External protection 7 alumina cement. The joint is protected from abrasive conditions by the use of afor rubber consists of 200mg Zinc plus 5mm cement (ZM-U) coating. Internal protection

Section Section 1: 1: Pre Installation Pre Installation tallation Installation

Ve®

There are three types of locking ring dependent upon pipe size:1. DN100-200 (see Fig.1.1.15) Fig. 1.1.21 Fig. 1.1.22 DN250-350 Fig. ring 1.1.16) There are2.three types of(see locking dependent upon pipe size:3. DN100-200 DN400-700 (see Fig.1.1.15) Fig. 1.1.17) 1. There are 2. four types of locking ring dependent upon pipe size:DN250-350 (see Fig. 1.1.16) 1. DN100-200 3. DN400-700 (see Fig. 1.1.21) 3. DN400-700(see (seeFig.1.1.19) Fig. 1.1.17) PAM Universal Rapid Anchor joint 2. DN250-350 (see Fig. 1.1.20) 4. DN800-1200 Fig. 1.1.15 Fig. 1.1.16 Fig. 1.1.17(see Fig. 1.1.22)

Fig. 1.1.18 locking ring Pipesealing gasket Weld bead UNIVERSAL Rapid Fig. 1.1.23 locking ringSTANDARD sealing gasket UNIVERSAL Rapid STANDARD anchoring gasket sealing gasket UNIVERSAL Rapid Fig. Fig. 1.1.19 1.1.18 anchoring gasket

ØA ØB

20

20

ØA ØB

ØA

ØB

ØA

ØB

ØA

ØB

ØA

ØB ØA

ØB

ØA

ØB

10

10

lage métallique Masse (kg) Fig. Pipe Fig. 1.1.18 1.1.16 à 200 DN 100 DN à 200 250 à 350 DN 250DN à 350 400 à 700 DN 400DN à 700 800 à 1200 DN 800 à 1200 0,500 DN 100 The Universal Rapid Anchor joint is for use on pipes DN80-600 where self restrained 0,700 PAM Universal Rapid joint Fig. 1.1.18 PAM Direxional Pipe joints are required. Fig. 1.1.15 Fig.Anchor 1.1.16 Fig. 1.1.17 0,900 The jointsystem is for use on pipes DN80-600 drilling where self PAMUniversal DirexionalRapid Pipe isAnchor a pipeline designed for directional (see restrained section 2.6). 1,300 Pas de trou en Pas de trou en the unanchored Rapid joint. Anchorage is The the same gasket as joints are utilises required. PAMjoint Direxional drilling be used for both water and sewer applications and are STANDARD DN600 et 700 pipes can DN600 et 700 1,300 sealing gasket provided by a rubber retaining with inserts push (see Fig. 1.1.18).chambered available from DN100-1000. It is ring jointed bytoothed a self-anchored fit double 1,800 UNIVERSAL Rapid The joint utilises the same gasket as the unanchored Rapid joint. Anchorage is plus 5mm socket and spigot with a welded bead. External protection consists of 200mg Zinc STANDARD anchoring gasket 2,300 sealing gasket provided by a rubber ring with inserts (see Fig. 1.1.18). cement (ZM-U) coatingretaining for DN100-700 andtoothed thick sprayed polyurethane based (PUX) coating There are three types of locking ring dependent upon pipe size:3,600 UNIVERSAL Rapid PAM Universal Rapid Locked joint Fig. 1.1.19 for DN800-1000. Internal protection for water pipes (EN545) is Blast furnace cement and for Fig. 1.1.18 1. DN100-200 (see Fig.1.1.15) anchoring gasket Pipe 4,050 sewer pipes (EN598) a high alumina cement. The joint is protected from abrasive conditions The Universal Rapid joint is for use on pipes DN250-350 Fig. ring 1.1.16) There are2.three typesLocked of(see locking dependent uponDN80-1200 pipe size:- where self restrained 4,600 62 PAM Universal Rapid Locked by theare use of a rubber protective collar and a6metal sheet cone (see Fig. 1.1.23). 2 joint Fig. 1.1.19 joints 3. DN400-700 1.1.17) 1.required. DN100-200 (see Fig. Fig.1.1.15) Pipe 8,600 3 33 L L L L TheLUniversal Rapid joint isavecfor use on pipes DN80-1200 where self restrained L L L Locked 2. DN250-350 Fig. 1.1.16) Élément de liaison broches Élément de liaison avec broches 9,7003 Fig.(see 1.1.21 Fig. 1.1.22 The joint utilises the same gasket as the unanchored Rapid joint. Anchorage is Rapid Ve Joint (see (Mechanical) joints are3.required. DN400-700 Fig. 1.1.17) STANDARD 17,300 provided by the addition of a welded bead onto the pipe spigot and a locking ring PAM Universal Rapid Anchor joint Fig. Pipesealing gasket Fig. 1.1.18 1.1.16 The Rapid Ve joint is used for DN350-1200 water and DN150-1200 sewer pipes, as an 22,600 Weld bead which abuts the welded bead (seeas Fig. 1.1.19). The joint utilises the same gasket the unanchored Rapid joint. Anchorage is The Universal Rapid Anchor for use onjoints pipesare DN80-600 self restrained alternative to Universal joint joint whenisrestrained required. where The joint utilises the same STANDARD 24,800 UNIVERSAL Rapid Joncs de Joncs verrouillage de verrouillage métalliques Universal Universal Ve® Ve® provided bymétalliques the addition of a welded bead onto the pipe spigot and a locking ring

PAM Universal Anchor joint PAM Direxional joints required. socketare and gasket as theRapid unanchored Rapid joint. Anchorage is provided by the addition of

which abuts the welded bead (see Fig. 1.1.19). a weld bead onRapid the pipe spigot, asystem locking ring piece uti DN700 segmented for The Universal joint is for use on(single pipes DN80-600 whereand self restrained PAM Direxional Pipe isAnchor a pipeline designed for directional drilling (see section 2.6). PAM Directional The joint theabuts same gasket thefor unanchored Rapid joint. applications Anchorage isand are DN800-1200) which the weld bead and a bolted which tightens against the pipe joints are utilises required. PAM Direxional drilling pipes can beas used both watergland and sewer PAM Directional Pipe is and a pipeline system for Fig. directional drilling (see Fig. provided by ahook rubber retaining with toothed (see Fig. 1.1.18). socket using bolts the locking ringinserts (see 1.1.24). available from DN100-1000. Itretains is ring jointed by adesigned self-anchored push fit double chambered PAM Directional 3.4.1). PAM Directional pipes can be used for Rapid both water and sewer The joint utilises the gasket as the unanchored joint.of Anchorage is plus 5mm socket and spigot withsame a drilling welded bead. External protection consists 200mg Zinc Fig. 1.1.24 applications and are available from DN100-700. It is jointed by a self-anchored push PAM Directional Piperetaining isfor a pipeline designed forpolyurethane directional drilling provided by a rubber ringsystem with inserts (see Fig. 1.1.18). cement (ZM-U) coating DN100-700 andtoothed thick sprayed based (see (PUX)Fig. coating fit double chambered socket and spigot with a welded bead. External protection PAM Universal Rapid Locked joint 3.4.1). PAM Directional drilling pipes bepipes used for both and sewer for DN800-1000. Internal protection forcan water (EN545) iswater Blast furnace cement and for consists of 200mg Zinc plus 5mm cement (ZM-U) coating. Internal protection for applications and are available from DN100-700. It is jointed by a self-anchored push sewer pipes (EN598) a high alumina cement. The joint protected from abrasive conditions The Universal Rapid Locked joint is for use on pipes DN80-1200 where self restrained water pipes (EN545) is Blast furnace cement and for sewer pipes (EN598) a high fit the double chambered socket and spigot a welded bead.(see External protection PAM Universal Rapid Locked joint by use of a rubber protective collar andwith a metal sheet cone Fig. 1.1.23). joints are required. alumina of cement. joint protected from abrasive conditions by protection the use of afor rubber consists 200mgThe Zinc plusis5mm cement (ZM-U) coating. Internal The Universal Rapid Locked joint is for use on pipes DN80-1200 where self restrained protective collar and is a metal sheet cone (see and Fig. 1.1.20). water pipes (EN545) Blast furnace cement for sewer pipes (EN598) a high The joint the same gasket as the unanchored Rapid joint. Anchorage is Rapid Ve Joint (Mechanical) joints are utilises required. alumina cement. The joint protected from abrasive conditions by athe use ofring a rubber provided by the addition of is a welded bead onto the pipe spigot and locking The Rapid Ve jointand is used for DN350-1200 water and DN150-1200 sewer pipes, as an protective collar a metal sheet cone (see Fig. 1.1.20). 29 29 which abuts the welded bead (seeas Fig. 1.1.19). The joint utilises the same gasket the unanchored Rapid joint. Anchorage is alternative to Universal joint when restrained joints are required. The joint utilises the same PAMLOCK provided by the addition of a welded bead onto the pipe spigot and a locking ring socket and gasket as the unanchored Rapid joint. Anchorage is provided by the addition of The Pamlock joint is used on pipes and1.1.19). fittings, DN1400-2000 where self restrained which abuts the welded bead (see Fig. aPAMLOCK weld bead on the pipe spigot, a locking ring (single piece uti DN700 and segmented for PAM Directional joints are required. DN800-1200) which abuts the weld bead and a bolted gland which tightens against the pipe The Pamlock joint is used on pipessystem and fittings, DN1400-2000 where self(see restrained PAM Directional Pipe is and a pipeline designed for Fig. directional drilling Fig. socket using hook bolts retains the locking ring (see 1.1.24). The joint utilises the same gasket as the unanchored Rapid joint. Anchorage is PAM Directional joints are required. 3.4.1). PAM Directional drilling pipes can be used for both water and sewer provided by the addition of a welded bead onto It the pipe spigot, segmented locking Fig. 1.1.24 applications andPipe are available from DN100-700. by a aself-anchored push PAM Directional is a pipeline system designed is forjointed directional drilling (see Fig. ring which abuts the welded bead, a conformator, which restricts the diameter of the The joint utilises the same gasket as the unanchored Rapid joint. Anchorage is fit double chambered socket and spigot with a welded bead. External protection 3.4.1). PAM Directional drilling pipes can be used for both water and sewer socket mouth and is held in place by two locking clamps and shot (see Fig. 1.1.21). providedofby200mg the of 5mm a welded bead(ZM-U) onto It the spigot, segmented locking consists Zinc plus coating. Internal protection for applications and addition are available fromcement DN100-700. is pipe jointed by a aself-anchored push ring which abuts the welded bead, a conformator, which restricts the diameter water pipes (EN545) issocket Blast furnace cement for sewer pipes (EN598) a high of the fit double chambered and spigot withand a welded bead. External protection socket mouth andThe is held in place by two locking clamps and shot Fig. of 1.1.21). alumina cement. joint is5mm protected from abrasive conditions by (see the use afor rubber 1.1.25 consists of 200mg Zinc plus cement (ZM-U) coating. Internal protection

ges outillages de montage/démontage de montage/démontage Fig. 1.1.19 merciales es commerciales et technico-commerciales et technico-commerciales Pipe

Pipe

STANDARD sealing gasket Mnt-Gobain - DIREXIONAL® PAM - -DIREXIONAL® Edition 2012Weld - Edition bead 2012 UNIVERSAL RapidSTANDARD Fig. 1.1.25 1.1.21 sealing gasket locking Shot ring Rubber Gasket Weld bead Conformator UNIVERSAL Rapid Fig. 1.1.21 locking Shot ring Rubber Gasket Conformator

Locking Ring Locking Ring

Welded Bead

Welded Bead

protective and is a metal sheet cone (see and Fig. 1.1.20). water pipescollar (EN545) Blast furnace cement for sewer pipes (EN598) a high alumina cement. The joint is protected from abrasive conditions by the use of a rubber protective collar and a metal sheet cone (see Fig. 1.1.20).

8 8

PAMLOCK

Fig. 1.1.25 1.1.21 Conformator

Shot

Rubber Gasket

The Pamlock joint is used on pipes and fittings, DN1400-2000 where self restrained PAMLOCK joints are required.

Shot

Rubber Gasket

The Pamlock joint is used on pipes and fittings, DN1400-2000 where self restrained The joint the same gasket as the unanchored Rapid joint. Anchorage is joints are utilises required. provided by the addition of a welded bead onto the pipe spigot, a segmented locking ring which abuts the the same welded bead,asa the conformator, which restricts the diameter The joint utilises gasket unanchored Rapid joint. Anchorage is of the socket mouth and is heldof in aplace by two clamps shot (see Fig. 1.1.21). provided by the addition welded beadlocking onto the pipe and spigot, a segmented locking

Fig. 1.1.21 Conformator

Locking Ring Locking Ring

8 8

Welded Bead

Welded Bead

ring which abuts the welded bead, a conformator, which restricts the diameter of the socket mouth and is held in place by two locking clamps and shot (see Fig. 1.1.25 1.1.21).

Fig. 1.1.22 Fig.1.1.26

Flanged joints Flanged joints are both rigid and self-anchoring and are used primarily for above ground applications, it is not recommended that flange systems are buried. The seal is achieved by axial compression of a flat gasket by clamping two flange faces together with bolts (see Fig. 1.1.22). 26

Fixed flange joints Pipes with welded flanges have the DN and PN rating cast on the rear of the flange (see Fig. 1.1.23). 27 Fig.1.1.27 Fig. 1.1.23

Fittings have the diameter in mm and PN rating of the flange cast behind the flange or on the fitting body (see Fig. 1.1.24). 28 Fig.1.1.28 Fig. 1.1.23

Fig.1.1.29

Adjustable Flanges Adjustable flanges are available on selected fittings DN80-600 and flange on socket tee’s to DN1200 where the branch is DN600 or less. The flange is a moveable flange mounted on the fitting body and provides easy alignment of the flanges (see Fig. 1.1.25). 29 The diameter and PN rating of the flange is cast on the moveable flange (see Fig. 1.1.26). 30

Fig. 1.1.26

Fig.1.1.30

9

Section 1: Pre Installation

Flange gaskets Fixed flanges utilise a flat rubber gasket, 3mm thick and 80 IRHD hardness. These can be supplied as full face gaskets (see Fig. 1.1.27) 31 or with two ‘ears’ which aid alignment (see Fig. 1.1.28). 32

Fig.1.1.31

Fig.1.1.32

Adjustable flanges and fixed flanges DN60, DN125, DN1800 and DN2000 use gaskets which have metal inserts, which, because of the stiffness, help in assembly and reduce the risk of extrusion in service (see 1.1.29and andFig. Fig.1.1.34). 1.1.30). (see Fig. 1.1.33

Fig. 1.1.29 Fig.1.1.33

Fig. 1.1.30 Fig.1.1.34 Metallic insert

Metallic insert

Elastomer

DN≤300

Elastomer

.DN>300

When using will bebe required and a different torque setting When usingthese thesegaskets, gaskets,longer longerbolts bolts will required and a different torque setting Table 2.11.2). 2.11.2). is used used (see (se Table

10

1.2 Handling & Storage It is important to consider that pipes and fittings can be heavy items and can cause injury if mishandled. Particular attention must be paid to all aspects of safety when handling. These instructions are intended for guidance to ensure that the quality of pipes and fittings is not impaired during handling. Proper regard must be paid to all appropriate health and safety regulations in handling pipes and fittings. The contractor should not rely on these instructions for any purpose other than maintaining the quality of pipes and fittings during handling, storage and installation. They should not overrule any site safety procedures. The stock ground area should provide a firm foundation with a suitable approach road for vehicles. It is essential that pipe weights, type of stacking, outreach required and site conditions are taken into account when determining the suitability of lifting equipment. The lifting equipment must be able to cope with the weight of the load and retain the load safely in the event of power failure. Ensure that the machine is operating on hard, level and stable ground. Stacks should be arranged to provide a safe vehicular and pedestrian access. All pipes should be secured to the lorry, trailer or railway wagon during transit to minimise movement. The preferred means of securing will depend upon the coating system on the pipes e.g. straps for standard bitumen/epoxy coatings. The pipes will be loaded on to the vehicle in bundles or singly in a straight-sided formation using timbers and chocks. Ductile iron pipes and fittings are not generally susceptible to damage by impact, under normal use, but adverse handling can result in damaged coatings and linings. Damage to pipes and fittings may be attributable to: ● Insecure load on lorry or wagon. ● Improper use of handling equipment. ● Use of unsuitable handling equipment. ● Incorrect stacking methods. ● Unloading on uneven or sloping ground. ● Impact between pipes. On receipt, all pipes and fittings should be inspected for damage to: The pipe or fitting itself. ● Cement mortar linings. ● Factory applied wrapping. ● Jointing surfaces. ●

All damaged pipes or fittings should be set aside for repair and the supplier should be contacted.

11

Section 1: 1:PrePre Installation Section Installation Section 1: Pre Installation

Bundled Pipes Bundled Pipes Bundled Pipes Pipes DN60-400 are supplied in bundles. Larger diameter pipes will be supplied as singles. Delivering in provides a number of pipes advantages PipesPipes DN60-400 in bundles bundles. Larger diameter pipes will be as as DN60-400 arepipes supplied in bundles. Larger diameter willsupplied beduring supplied 80 are supplied transportation andpipes for pipe laying contractors, stock personnel and site singles. Delivering pipes in bundles provides a number ofground advantages during singles. Delivering in bundles provides a number of advantages during operatives:and for transportation laying contractors, stockstock ground personnel and site transportation andpipe for pipe laying contractors, ground personnel and site ● Ease of transportation operatives: operatives: ● Time and effort minimised in handling ● Ease ● of transportation Ease of transportation ● Improved on-site safety ● Time ● and effort minimised in handling Time and effort minimised in handling ● Effective utilisation of stock ground space ● Improved ● on-site safety Improved on-site safety ● Risk of damage to the protection systems is reduced ● Effective ● utilisation of stock ground space Effective utilisation of stock ground space ● Risk Risk of damage to the systems is reduced of damage toprotection the protection systems is reduced Water pipes DN80-300 are fitted with protective plastic end caps on both the socket and spigot ends. Water pipes DN80-300 are fitted withwith protective plastic end caps on both the socket Water pipes DN80-300 are fitted protective plastic end caps on both the socket

●

and spigot ends.ends. and spigot Standard pipe bundles comprise of two base timbers, with raggle boards between each pipe row pipe of pipes. The bundle secured by steel retaining straps, which incorporate Standard bundles comprise ofistwo basebase timbers, withwith raggle boards between Standard bundles comprise of two timbers, raggle boards between the base timbers. eacheach row of pipes. The bundle is secured by steel retaining straps, which incorporate row of pipes. The bundle is secured by steel retaining straps, which incorporate the base timbers. the base timbers. N.B. Bundles should never be lifted by their retaining straps. N.B. N.B. Bundles should nevernever be lifted by their retaining straps. Bundles should be lifted by their retaining straps.

Off-loading Pipes Off-loading Pipes Pipes Off-loading The lifting equipment must be able to support the weight of the bundle and retain the load safely in the event of power (see Table 1.2.1). Ifof itbundle can bundle not,and refer toretain Section The lifting equipment mustmust be able tofailure support the weight of the retain the the The lifting equipment be able to support the 1.2.2 weight the and ‘Dismantling bundles’ on how to dismantle pipe bundles and remove the pipes load load safely in the of power failure (see (see TableTable 1.2.1). If2it can referrefer to Section safely inevent the event of power failure 1.2.1). If it not, can not, to Section individually. ‘Dismantling bundles’ on how to dismantle pipe pipe bundles and remove the pipes ‘Dismantling bundles’ on how to dismantle bundles and remove the pipes

individually. individually. Table 1.2.1: Pipe bundles dimensions and weights for 5.5m pipes Table 1.2.1: Pipe bundles dimensions and weights Approx. Number of TableTable 1.2.1:1.2.1: Pipe Pipe bundles dimensions and weights bundles dimensions and weights Overall Overall Width Overall Weight Approx. of DN Size Number pipes per Overall Width Overall Nominal (m) Height (m) Overall Length (m) of Bundle Weight of Pipes bundle Number of inof Number Approx. (tonne) (m)WidthOverall Height (m) Overall Length (m) Approx. DN Size Overall Width Nominal Size Nominal Overall Overall Overall Bundle (tonne) Bundle Weight of of PipesPipes in in Weight 80 30 0.5Length 5.8 2.6 (m) (m)1.1 Height (m) (m) (m) (m) DN DN Height Length (tonne) Bundle Bundle Bundle (tonne) 60 24 0.54 0.49 6.3 Bundle 1.6 100 27 1.1 0.6 5.8 2.8 60 60 24 24 0.54 0.54 0.49 0.49 6.3 6.3 1.6 1.6 80 30 1.33 0.54 5.8 2.6 150 18 1.1 0.7 5.8 2.8 200 80 100 80 250 100 100 125 300 125 125 350 150

10 30 30 27 8 27 27 12 8 12 12 186

1.2 1.33 1.33 1.42

400 150 150 200

6 18 18 10

1.4 1.24 1.24 1.34

1.1 1.42 1.42 0.65 1.3 0.65 0.65 1.241.2

0.6 0.54 0.54 0.60

2.6 2.6 2.8

0.8 0.58 0.58 0.760.9

5.8 5.8 5.8 5.8 5.8 5.8 5.8 6.3 5.8 6.3 6.3 5.8 5.8

1.7 1.7 2.8

2.5

1.0 0.76 0.76 0.62

5.8 5.8 5.8 5.8

2.8 2.8 2.1

2.9

0.60 0.60 0.58

0.7

200 200 10 10 1.34 1.34 0.62for 0.62 Table 1.2.2: Pipe bundles and weights 6m pipes5.8 5.8 250 8 dimensions 1.26 0.73 5.8 250 250 300 DN 300 300 350

350 350 400 80 400 400 100

12 12 12

8 8 8 Number of pipes per 8 8 6 bundle 6 6 615 6 615

1.26 1.26 0.73 0.73 5.8 1.47 0.84 Overall Width Overall 1.47 1.47 0.84 0.84 (m) Height (m)5.8 1.31 0.95 1.31 1.31 1.400.6 1.40 1.400.6

0.95 0.95 1.05

2.1 2.7

2.1 2.1 2.1

2.1 5.8 5.8 Overall 2.7 5.8 Length (m) 5.8

1.05 1.050.5

5.8 5.8 5.8 6.3 5.8 5.8 6.3

0.4

2.8 2.8 1.7

2.1

2.1 2.7 Approx. Weight 2.7 2.5of Bundle (tonne) 2.5 2.5 2.9 1.3

2.9 2.9

1.6

150

9

0.6

0.6

6.3

1.4

200

6

0.7

0.5

6.3

1.3

250

4

0.6

0.6

6.3

1.1

300

4

0.7

0.8

6.3

1.4

350

6

0.8

0.8

6.3

2.7

400

5

1.0

0.9

6.3

2.7

Weights are provided for estimation purposes only and actual values may vary from those provided in this table

Fig. 1.2.1 Fig. 1.2.1

By Excavator/Crane By Excavator/Crane When lifting with slings, use two broad webbing slings made of Terylene, nylon or other synthetic material withstanding the required loads. The slings When lifting with slings, capable use twoof broad webbing slings made of Terylene, nylonshould or be of a length adequate to make an acute angle between the slings at the hook so as other synthetic material capable of withstanding the required loads. The slings should to reduce the risk of pipe slippage. be of a length adequate to make an acute angle between the slings at the hook so as to reduce the risk of pipe slippage. Never attempt to utilise chains or wire ropes as slings, these may cause slippage and/or damage to the to pipes external system and/orthese bundle assembly. Never attempt utilise chainsprotection or wire ropes as slings, may cause slippage and/or damage to the pipes external protection system and/or bundle assembly. Only lift complete bundles (See Fig. 1.2.1). Do not attempt to lift multiple loose pipes with slings. Only lift complete bundles (See Fig. 1.2.1). Do not attempt to lift multiple loose pipes with slings. When the excavator/crane operator does not have a clear view of the load, a competent person must guide the operator position. When the excavator/crane operator does notfrom havea asafe clear view of the load, a competent person must guide the operator from a safe position. It is preferable to use guide ropes to steady the load and the bundle should be lifted smoothly without sudden movements. It is preferable to use guidejerking ropes to steady the load and the bundle should be lifted smoothly without sudden jerking movements. Take care when lifting, using and removing slings from around the pipes, to avoid damage the pipes external protection system. Take caretowhen lifting, using and removing slings from around the pipes, to avoid The excavator/crane operator’s attention is drawn damage to the pipes external protection system. to Health and Safety Guidance Note PM.42 (8) Certificate No: CON (LO) (9). Excavator/crane (10). 9 and to Exemption The excavator/crane operator’s attention is drawn to 1981/2 Health and Safety Guidance Note operators should refer to the Health and Safety Executive Code Practice L113, Lifting The excavator/crane operator’s attention No: is drawn the1981/2 latest Health and Safety Guidance PM.42 (8) Certificate CONto (LO) (9).ofExcavator/crane (10). 9 and to Exemption Operation and of Lifting Regulations 1998 (10). Equipment. (11). Note and Code Practice for Lifting Operation and Lifting operators should referequipment to the Health and Safety Executive Code of Practice L113, Lifting

Fig. 1.2.1 Fig.1.2.2 Fig. 1.2.1 Fig.1.2.2

Operation and Lifting equipment Regulations 1998 (11). (10). Ensure that the forklift is operating on hard, level and stable ground. The forklift must be capable lifting theisload (See Table 1.2.1). If not of liftingThe a complete Ensure thatof the forklift operating on hard, level andcapable stable ground. forklift must bundle refer to Section 1.2.2 and remove either one layer of pipes at a time, or be capable of lifting the load (See Table 1.2.1). If not capable of lifting a complete individually. bundle refer to Section 1.2.2 and remove either one layer of pipes at a time, or individually.

By Forklift By Forklift Ensure that the fork blades do not damage the pipe or external protection when feedingthat the forks under anddo back of thethe pipes (See 1.2.2),protection and that the pipes do Ensure the fork blades notout damage pipe or Fig. external when not move on the forks when lifting or manoeuvring. feeding the forks under and back out of the pipes (See Fig. 1.2.2), and that the pipes do not move on the forks when lifting or manoeuvring.

Stacking Bundled Pipes Stacking Bundled Pipes The forks of the forklift must be positioned under the protective bands around the bundle. pipes with applied wrapping by forklift truck, the metal The forksWhen of thelifting forklift must be factory positioned under the protective bands around the forks should belifting protected suitable type of paddingby toforklift preventtruck, damage to wrap. bundle. When pipesusing with afactory applied wrapping the metal The stacking area should provide firm foundation with a suitable approach for forks should be protected using a asuitable type of padding to prevent damageroad to wrap. vehicles. Stacks should be arranged to provide a safe vehicular and pedestrian access. The stacking area should provide a firm foundation with a suitable approach road for Bundles are provided base timbers and these can be laid directly onto a good, vehicles. Stacks shouldwith be arranged to provide a safe vehicular and pedestrian access. level, hard-standing surface. The bundles should be stacked one on top of the other Bundles are provided with base timbers and these can be laid directly onto a good, with the pipe axes parallel. level, hard-standing surface. The bundles should be stacked one on top of the other with the pipe axes parallel. Each pipe bundle is secured to two base timbers that can be laid directly onto a level hard-standing surface. Each pipe bundle is secured to two base timbers that can be laid directly onto a level hard-standing surface. The maximum stack height should not exceed five bundles. However, this may need to bemaximum reduced depending onshould site conditions andfive location. The stack height not exceed bundles. However, this may need to be reduced depending on site conditions and location.

13 13

Section 1: Pre Installation

Section 1: Pre Installation

Dismantling Bundles Dismantling Bundles If one side ofside the bundle is slightly higherhigher than the other, thecut straps from the If one of the bundle is slightly than the then other,cut then the straps from the highesthighest side. Do notDo usenot theuse pipes a lever break straps. side. theas pipes as atolever to the break the straps.

Fig. 1.2.3 Fig. 1.2.3

Straps Straps are applied under tension, thus extreme care should be taken are applied under tension, thus extreme care should be when taken cutting. when cutting. Use strap tools ortools suitable tin shears to cut the inner first, preferably at Usecutting strap cutting or suitable tin shears to cut thestraps inner straps first, preferably at the bottom of the bundle (See Fig. 1.2.3). The straps shouldshould be disposed of carefully. the bottom of the bundle (See Fig. 1.2.3). The straps be disposed of carefully.

Fig. 1.2.4 Fig. 1.2.4 600mm 600mm ➤ ➤➤ ➤

WhereWhere bundles need toneed be split off-load, pipes should be lifted bundles to betosplit to off-load, pipes should beusing liftedeither using chains either chains with padded hooks, hooks, slings or forklift (see Section 1.2.2). 1.2.2). Pipes should be taken with padded slings or forklift (see Section Pipes should be from takenthe from the outsideoutside first sofirst as not to not overtobalance the raggle boardsboards or baseortimbers with partially so as over balance the raggle base timbers with partially completed bundles. completed bundles. WhereWhere a forklift of sufficient capability is available, pipes may off-loaded a layeraatlayer a at a a forklift of sufficient capability is available, pipesbemay be off-loaded time taking care tocare avoid to the to pipes protection systemsystem with the time taking todamage avoid damage theexternal pipes external protection with the forkliftforklift blades.blades. Off-loaded pipes should be re-located onto timber battens, placedplaced about 600mm from the Off-loaded pipes should be re-located onto timber battens, about 600mm from pipe the pipe ends (See 1.2.4). the pipe ends (See Fig. 1.2.4). ends (See Fig.Fig. 1.2.4). When When only two pipes move them to the to centre of the timber and and only tworemain, pipes remain, movecarefully them carefully the centre of the timber chock them stability, then remove them one at one a time Fig. 1.2.5). chockboth themfor both for stability, then remove them at a(see time (see Fig. 1.2.5). Fig. 1.2.5 Fig. 1.2.5

Damage Repairs Damage Repairs If necessary, repair all damage to the to protection systemsystem that may If necessary, repair all damage the protection thathave mayoccurred. have occurred. Please Please refer torefer Section 1.4 for 1.4 details. to Section for details.

Single Single Pipes Pipes When When single pipes supplied or bundles are split Table dimensions and and singleare pipes are supplied or bundles aresee split see1.2.2 Tablefor 1.2.2 for dimensions weight.weight. Water Water pipes DN80-300 are fitted plasticplastic end caps both socket pipes DN80-300 are with fittedprotective with protective endoncaps onthe both the socket and spigot ends. These be removed if padded hooks are used lifting and and and spigot ends. should These should be removed if padded hooks arefor used for lifting replaced when off-loaded and forand storage. replaced when off-loaded for storage.

14

14

re Installation

highest side. Do not use the pipes as a lever to break the straps. Straps are applied under tension, thus extreme care should be taken when cutting. Use strap cutting tools or suitable tin shears to cut the inner straps first, preferably at the bottom of the bundle (See Fig. 1.2.3). The straps should be disposed of carefully.

Fig. 1.2.4

Where bundles need to be split to off-load, pipes should be lifted using either chains with padded hooks, slings or forklift (see Section 1.2.2). Pipes should be taken from the outside first so as not to over balance the raggle boards or base timbers with partially completed bundles. Single pipes should handled using either chains with padded slings or slings a Single pipesbeshould be handled using either chains withhooks, padded hooks, or a forklift. Whereforklift. a forklift of sufficient capability is available, pipes may be off-loaded a layer at a

Off-loading PipesPipes Off-loading 600mm ➤ ➤

time taking care to avoid damage to the pipes external protection system with the Never attempt to lift more than onethan pipe one at apipe timeat unless it is in a bundle. Never attempt to lift more a time unless it is in a bundle. forklift blades. Off-loaded pipes should re-located onto timber placed about 600mm from Off-loaded pipesbeshould be re-located ontobattens timber battens placed about 600mm from pipe Off-loaded pipes should be re-located onto timber battens, placed about 600mm from the the pipe ends (see Fig. 1.2.4). the pipe ends (see Fig. 1.2.4). the pipe ends (See Fig. 1.2.4).

Chains and Hooks Chains and Hooks When only two pipes remain, move them carefully to the centre of the timber and Fig. 1.2.6Fig. 1.2.6

chock them boththat for stability, then them oneand attoashape time (see Fig. 1.2.5). Use padded are of the correct and shape locate positively in the pipe Usehooks padded hooks that are ofremove thesize correct size to locate positively in the pipe ends (seeends Fig. 1.2.6) and workand from a stable area. (see Fig. 1.2.6) work from lifting a stable lifting area. Fig. 1.2.5 Always use padded forhooks protection of the coating and lining. Always usehooks padded for ofofthe coating and padded hooks forprotection protection the coating andlining. lining. Use chains and hooks that are able loadwith andload use aand spreader bar wherever Use chains and hooks that to arecope ablewith to cope use a spreader bar wherever possible (see Fig. 1.2.7). possible (see Fig. 1.2.7). Table 1.2.2: Dimensions and weight ofweight singleofof pipes Table 1.2.2: Dimensions andweights singlepipes pipes- Water 1.2.3: 1.2.3 Dimensions and single WATER SEWER Weight Pipe Length Pipe(m) Length (m)Average Pipe Average Pipe(kg) Weight (kg) Average Average Pipe Length Pipe Length 68Pipe Weight 6.0 Weight 60 60 Pipe class 6.0 68 DN Pipe (m) (m) (Kg/m) (Kg/m) 85/88 85/88 5.5/6.0 5.5/6.0 80 80 80 C40 12.0 5.5 or 6.0 13.0 6.0 102/109 102/109 5.5/6.0 5.5/6.0 100 100 C40to the protection 15.0 system that 5.5 or 6.0have occurred. 16.0 6.0 If necessary, 100 repair all damage may 137 1251.4 for details. 5.5/6.0 5.5/6.0 137 Please refer125 to Section 150 C40 22.0 5.5 or 6.0 23.5 6.0 5.5/6.0 150 153/164 200 150 C40 30.05.5/6.0 5.5 or 6.0 153/16431.0 6.0

Nominal Nominal Size DN Size DN

Fig. 1.2.7Fig. 1.2.7

Damage Repairs

Single Pipes

200 250

200

C40

5.5/6.0 42.05.5/6.0

204/222 5.5 or 6.0 204/22240.5

6.0

300 250 350 300

250

C40

55.55.5/6.0 5.5/6.0 69.05.5/6.0 5.5/6.0

5.5 or 6.0 262/29051.0 262/290 5.5 or 6.0 331/36466.5 331/364

6.0

900 700 1000 800

700

C30 6.0 300 C30or bundles are 79.5split see Table 5.5 or1.2.2 6.0 for dimensions 78.0 and 6.0 When single400 pipes are supplied 441/482 441/482 5.5/6.0 5.5/6.0 350 350 weight. 450 C30 94.0 5.5 or 6.0 92.5 6.0 524/573 524/573 5.5/6.0 5.5/6.0 400 400 500 C30 111.0 5.5 or 6.0 106.5 6.0 Water pipes DN80-300 are fitted with 5.5/6.0 protective plastic end caps on both the socket 616/676 450 450 5.5/6.0 616/676 600 C30 150.5 5.5 or 6.0 138.0 6.0 and spigot ends. These should be removed if padded hooks are used for lifting and 5.5/6.0 500 5.5/6.0 6.0/5.5 or 7.0713/781201.0 713/781 700 500 C25/C30 188.0/217.9 6.0 or 7.0 replaced when off-loaded and for storage. 5.5/6.0 600 5.5/6.0 930/1018 800 600 C25/C30 213.0/267.0 7.0 930/1018 243.5 7.0

14

C25/C30

800 C25/C30 1200 C25 900 900 1400 C25 1000 1000 1600 C25 1100 1800 1100 C25 1200 2000 1200 C25

260.0/279.0 5.5/7.0 5.5/7.0 311.5/334.0 5.5/7.0 5.5/7.0

7.0 7.0

461.5 7.0/8.0 7.0/8.0 634.5 7.0/8.0 7.0/8.0 807.5 8.0995.0 8.0

8.0

8.01210.08.0

291.5 1185/1517 1185/1517 343.0 1444/1862 1444/1862

7.0 7.0

8.0

507.5 2235/2511 2235/2511 679.0 2641/3091 2641/3091 851.5 3605 1036.5 3605

8.0

8.0

4269 1242.0 4269

8.0

8.0 8.0

1400

1400

8.0

8.0

5647

5647

1500

1500

8.0

8.0

6327

6327

1600

1600

8.0

8.0

7053

7053

1800

1800

8.0

8.0

8587

8587

2000

2000

8.0

8.0

10190

10190

8.0 8.0 8.0

Weights are provided for estimation purposes only and actual values may vary from those provided in this table

15

15

Section 1: Pre Installation

Slings

Fig. 1.2.8

Use two broad webbing slings made of Terylene, nylon or other synthetic material capable of withstanding the required loads (see Fig. 1.2.8). Never attempt to utilise chains or wire ropes as slings as these might allow the pipes to slip, or cause damage to the external protection system. Never attempt to lift multiple loose pipes..

Forklift Take care when lifting, using or removing slings from around the pipes, to avoid damage to the external protection system. Ensure the forklift is operating on hard, level and stable ground. With wrapped pipes, the forks of the forklift must be positioned under the protective bands. Where pipes have no protective band (as when breaking down bundles) extra care should be taken to avoid damage with the forklift blades.

Stacking Non-bundled Pipes Where individual pipes are to be stacked in a central stock ground for storage and held is pending further distribution, it is recommended that the parallel stacking method be used, using wooden battens between rows. The stacking area should provide a firm foundation with a suitable approach road for vehicles. Stacks should be arranged so as to provide safe vehicular and pedestrian access. During stacking and removal operations, safe access to the top of the stack is essential. In bad weather conditions, when pipe surfaces may become slippery, consideration should be given to the use of lightweight staging placed on top of the stacks. Pipes should be stacked on a base of raised wooden battens positioned approximately 600mm from each end of the pipe (see Fig. 1.2.9). The bottom layer of pipes should be securely anchored. Battens should also be placed across the pipes between each tier approximately 600mm from each end of the pipe. The sockets of pipes in each successive tier should be reversed and the battens should be of sufficient thickness to avoid metal-to-metal contact (see Fig. 1.2.10). Fig. 1.2.10

Fig. 1.2.9

600mm Approx

600mm Approx.

Chocks Intermediate Battens

ber

Baulks of Timber Under Layer Bottom Layer of Pipes

An adequate number of chocks should be wedged under the outer pipes of each tier and nailed to the timber bearers to ensure stability (see Fig. 1.2.10). Pipes may be rolled into position along the battens, thus facilitating stacking or removal from the end of the stack, however, care must be taken to ensure correct alignment to minimise any possible coating damage.

16

The maximum recommended number of layers in a stack is given in Table 1.2.3. However, this may need to be reduced depending on site conditions and location. If tape wrapped pipes are to be stacked then these stacks should not be more than 4 pipes high DN80-600 and as Table 1.2.3 for pipes DN700-2000. The maximum recommended number of layers in a stack is given in Table 1.2.4. 1.2.3. Table 1.2.3: Stacking of single pipes However, this may need to be reduced depending on site conditions and location.

Maximum recommended number Nominal SizetoDN If tape wrapped pipes are be stacked then these stacks should not be more than 4 of layers in stack pipes high DN80-600 1.2.3 for pipes DN700-2000. 80-800 and as Table 1.2.4. 900-2000. 60 24 Table 1.2.4. 1.2.3: Stacking 80 of single pipes

Damage Repairs

18

100 - 125 Nominal DN Nominal size DN 150Size

16 Maximum recommended number Maximum recommended 14 of layers in stack number of layers in stack

200 60 80-100 250 80 150 100300 - 125 200 350150 - 400 250-500 450200 - 500 600-800 600 250 900-1200 700 300 1400-2000 800 350--1400 400

12 24 12 10 18 15 8 16 10 7 14 68 12 46 10 2 3 8 2 71

1500 450 -- 2000 500

1 6

600

4

700

3

800 - 1400

2

If necessary, repair all-damage 1500 2000 to the protection system that may1have occurred. Please refer to Section 1.4 for details.

Damage Wrapped Repairs Pipes Handling If necessary, repair all damage to the protection system that may have occurred. Polyethylene sleeving is applied to prevent corrosive attack from the soil environment. Please refer to Section 1.4 for details. Penetration of groundwater through small perforations will not normally affect the performance of the protection but care must be taken to minimise damage. Tears or punctures must always be repaired as detailed in section 1.4.

Handling Wrapped Pipes

When receiving factory wrapped pipes (tape wrap), care must be taken to ensure that Polyethylene sleeving is applied to prevent corrosive attack from the soil environment. any major damage is avoided. Tape wrap is applied to isolate the pipe from its Penetration of groundwater through small perforations will not normally affect the surroundings. Penetration of groundwater must be prevented so all tears, holes or performance of the protection but care must be taken to minimise damage. Tears or punctures must always be repaired as detailed in section 1.4. punctures must always be repaired as detailed in section 1.4. When lifting wrapped pipes, do not permit the pipes to rub against each other or other When receiving factory wrapped pipes (tape wrap), care must be taken to ensure that objects. any major damage is avoided. Tape wrap is applied to isolate the pipe from its surroundings. Penetration of groundwater must be prevented so all tears, holes or Lifting can be carried out with crane hooks inside the ends of the pipe but they must punctures must always be repaired as detailed in section 1.4. be suitably protected to prevent damage to the coatings and internal linings (e.g. rubber coated). When lifting wrapped pipes, do not permit the pipes to rub against each other or other objects. Lifting can be carried out with crane hooks inside the ends of the pipe but they must be suitably protected to prevent damage to the coatings and internal linings (e.g. rubber coated).

17

17

1: Pre Installation Section 1: Pre Installation Section 1: Section Pre Installation

When lifting wrapped pipes with slings, the slings should be two broad webbing slings, each capable of lifting the load with a minimum length of 14m and made of Terylene, nylon or other suitable synthetic fibres with a recommended width greater than 80mm. If any other method is used, it is essential that some form of protection is used on the Whenoflifting wrapped pipes with slings,with the the slings should be two broad webbing area the pipe that will be in contact lifting tackle. slings, each capable of lifting the load with a minimum length of 14m and made of Terylene, nylon or are other synthetic fibres recommendedand width Ensure that pipes notsuitable rolled off or dropped offwith the atransportation thatgreater contact than 80mm. of pipe sockets to pipe bodies is kept to a minimum.

If any other method is used, it is essential that some form of protection is used on the area of the pipe that will be in contact with the lifting tackle.

Storage of Wrapped Pipes

The generally accepted methods of or stacking canoffbethe used but more care should be Ensure that pipes are not rolled off dropped transportation and that contact taken storing wrapped of pipewhen sockets to pipe bodiespipes. is kept to a minimum. It is essential that when releasing the bundle straps, the pipes are not used as a lever

break the straps.Pipes Storage oftoWrapped

When lifting wrapped pipes with slings, the slings should be two broad webbing The generally accepted methods of stacking be usedlength but more care should beof Adequate foundations be towith minimise movement ofof the stack onmade storage slings, each capable of must lifting theused load acan minimum 14m and taken when storing wrapped and when placed onpipes. thesynthetic ground to ensure that stones etc. arewidth not pressing Terylene, nylon orcorrectly other suitable fibres with a recommended greater against the pipe. than 80mm. It is essential that when releasing the bundle straps, the pipes are not used as a lever to break themethod straps. Whilst stacking, ensure that it the do not against other andisare noton the If any other is used, is pipes essential thatrub some formeach of protection used dropped onto the stack. area of the pipe that will be in contact with the lifting tackle. Adequate foundations must be used to minimise movement of the stack on storage and when correctly on the tomore ensure that stones etc.DN80-600 are not pressing Tape wrapped pipes not be stacked 4transportation pipes high and as Ensure thatplaced pipes areshould not rolled offground or dropped offthan the and that contact against thefor pipe. Table 1.2.3 pipes DN700-2000. of pipe sockets to pipe bodies is kept to a minimum.

Whilst stacking, ensure that the pipes do not rub against each other and are not stack. ofdropped pipesonto onthesite

Loading Off-loading Fittings of Wrapped Pipes Storage and Fig. 1.2.11

Caregenerally should beaccepted taken should when stacking and storing pipes on4 site tomore ensure thereand is The methods ofstacked stacking can be used but care should beno Tape wrapped pipes not be more than pipes high DN80-600 as Fittings are supplied either palleted or, for large diameter products, asthat singles. ingress1.2.3 of dirt, debris or groundwater taken when storing pipes. into the pipe ends. Table for pipes wrapped DN700-2000.

Pallets by Excavator/Crane

It is essential that when releasing the bundle straps, the pipes are not used as a lever

The excavator/crane must be capable of lifting the total weight of the pallet and able to break the straps. Loading and Off-loading Fittings to retain the load safely in case of power failure. Fig. 1.2.11

Adequate mustpalleted be usedor, tofor minimise movement of the as stack on storage Fittings arefoundations supplied either large diameter products, singles. Use two webbing slings through the pallet (see Fig. 1.2.11). Ensure that the load is and when placed correctly on the ground to ensure that stones etc. are not pressing lifted on the level. Never attempt to lift more than one pallet at a time. against theby pipe.Excavator/Crane Pallets The excavator/crane must be capable of lifting the total weight of the pallet and able Whilst stacking, ensure that the pipes do not rub against each other and are not to retain the load safely in case of power failure. By Forklift dropped onto the stack. Ensure that the forklift is operating on hard, level and stable ground. Use two webbing slings through the pallet (see Fig. 1.2.11). Ensure that the load is Tape wrapped pipes should not be stacked more than 4 pipes high DN80-600 and as lifted on the level. Never attempt to lift more than one pallet at a time. The must be capable of lifting the load. If not, the fitting should be off-loaded Tableforklift 1.2.3 for pipes DN700-2000. singularly (see opposite).

By Forklift

Loading and Off-loading Fittings

Ensure that the forklift is operating on hard, level and stable ground.

Fig. 1.2.11

18

Fittings are supplied either palleted or, for large diameter products, as singles. The forklift must be capable of lifting the load. If not, the fitting should be off-loaded individually. singularly (see Pallets by opposite). Excavator/Crane The excavator/crane must be capable of lifting the total weight of the pallet and able to retain the load safely in case of power failure. Use two webbing slings through the pallet (see Fig. 1.2.11). Ensure that the load is

Stacking Pallets It is recommended that pallets are stored with the shrink-wrap intact whenever possible. This is particularly important with epoxy coated fittings or valves as the coating may ‘chalk’ when exposed for prolonged periods in direct sunlight. The ability to stack pallets is dependent upon the shape and size of the fitting or valve. It is not possible to give specific guidelines but the overriding consideration must be for the safety of stock ground personnel.

Off-loading Singles By Excavator/Crane The excavator/crane must be capable of lifting the total weight of the item and able to retain the load safely in case of power failure. Use a webbing sling threaded through the bore of the item. Ensure that a safe balance is achieved before completing the lift. Avoid excess chafing between the sling and item as this may damage the coating.

Stacking Fittings should be stacked according to type and diameter. They must not be in contact with the ground but on timbers or planks. Provide adequate wedging between each fitting in the base layer and at the sides (see Figs. 1.2.12 and 1.2.13).

Fig. 1.2.12

Fig. 1.2.13

Rubber Gasket Rubber gaskets are supplied either pre-installed, with adequate protection, or in bags. Gaskets should be protected from sunlight, and contact with possible contaminants such as petrol, oil etc. must be avoided. Gaskets should be examined carefully for damage before use. Additional guidance on the storage and protection of gaskets is given in BS 3574 (11). 12

Bolts and Nuts Bolts and nuts are usually supplied ready packaged or may be factory fitted to specific items. Wherever possible these should be stored under cover in dry conditions.

19

Section 1: Pre Installation

1.3 Pipeline Protection Application of site applied polyethylene sleeving Certain precautions must be observed if the effectiveness of site applied loose polyethylene sleeving is not to be compromised by errors which may occur during installation. Damage to the polyethylene film must be avoided at all stages during the sleeving process, i.e. ● when opening the lay-flat tubular film ● while drawing the sleeve over the pipe or fitting ● during backfilling Note: - Pipes and fittings having additional polyethylene sleeving protection become very slippery in wet conditions. All joints at or near fittings utilising thrust blocks should have external wrapping to prevent concrete from the thrust block from entering the joint during placement and curing. Sleeved pipe should be lifted into the trench using padded slings or other lifting tackle that will not damage the sleeving. Any damage to the sleeving must be repaired before backfilling (see Section 1.4 for details). Care must also be taken during the placing of backfill materials to avoid sleeving damage. It is essential to ensure that soil clods and other foreign materials are removed from the pipe or fitting surface prior to sleeving. It has been found that intense corrosion can occur beneath soil clods attached to the pipe or fitting surface, which have been over-wrapped during sleeving. Loose polyethylene sleeving may fail to provide adequate protection if the pipe invert becomes exposed to flowing (ground) water, since this provides an effectively unlimited supply of fresh corrodent to sustain the corrosion reaction. This highlights the importance of sealing the ends of the sleeving and also the need to repair any sleeving damage incurred during installation. Close fitting of the sleeving around the pipe barrel is very important to ensure maximum performance of the sleeving system. In the event of the sleeving being damaged allowing moisture ingress, a snug fit helps promote thin film conditions which reduce the effect of any corrosion cells which might be established. Where fittings are incorporated in a pipeline and these are surrounded wholly or partially by concrete anchor blocks, it is important that the sleeving is continued under the concrete and no areas of metal are left exposed to the surrounding backfill. Note that joints on polyethylene sleeved iron mains should not be electrically overbonded (e.g. as for cathodic protection) since this can stimulate localised galvanic corrosion at areas of bare metal, such as ground spigot surfaces.

20

Application - Pipes Cut a piece of sleeving approximately 0.5m longer than the length of the pipe, e.g. 6m for 5.5m pipes. Slide the sleeving onto the spigot end and bunch up behind spigot timber (see Fig. 1.3.1). Fig. 1.3.1

Fig. 1.3.3 Reposition the spigot timber at the spigot end, place pipe with timbers at ends and pull the sleeving over the full length of the pipe (see Fig. 1.3.2). Fig. 1.3.2

As an alternative, small and intermediate diameter pipes may be supported using a specially fabricated padded ‘hairpin’ style lifting beam of appropriate design, inserted into one end of the pipe, allowing the sleeving to be pulled into position in one operation. Ensure that the sleeving is correctly positioned relative to the spigot end. Pull the sleeving tightly around the pipe barrel and fold the surplus over the crown of the pipe to form a triple thickness layer (see Fig. 1.3.3). Secure the fold in position using short strips of plastic adhesive tape as necessary along the length of the fold. At the spigot end of the pipe, leave enough of the spigot exposed to make the joint (see Fig. 1.3.4). Fig. 1.3.4

Then tape the end of the sleeving to the pipe body around the whole circumference ensuring that the tape overlaps the end of the sleeve onto the pipe. Where polyethylene sheets are used, both circumferential and longitudinal ends must be taped down. Pipes shorter than the standard length can be sleeved in a similar manner. The excess sleeve at the socket end may be left pulled back from the socket, or alternatively it may be temporarily folded into the mouth of the socket to keep out extraneous material while positioning the pipe in the trench.

21

Section 1: Pre Installation

Lay the pipe in the trench with the triple layer of sleeving on the crown to provide a cushioning effect during backfilling and make the joint in the recommended manner (see Section 2.2). If the sleeving has been folded into the socket, ensure that this is removed prior to jointing. If hydraulic jointing tackle is being used an extra piece of sleeving placed between the pipe and the tackle will help to protect the sleeving around the pipe from damage. After completion of the joint, any exposed portion of the spigot end between the sleeving and the face of the adjoining socket should be taped over using plastic adhesive tape. It should be ascertained that the sleeving or tape at the spigot end is not trapped under the gasket as this could impair the seal of the joint. Draw the excess sleeve over the joint, fold it neatly and tape around the circumference of the pipe at the back of the socket. Make a second pass with the tape around the circumference immediately in front of the socket. Finally, tape the end of the sleeve around the full circumference making sure that the tape overlaps onto the sleeve of the adjacent pipe to effect a seal (see Fig. 1.3.5). Fig. 1.3.5

Damage Repairs Should the polythene sleeving be damaged during pipe handling or installation it can easily be repaired on-site. Please refer to Section 1.4 for details.

22

Tape Wrapping Application The tape wrap is normally factory-applied to the pipe barrel leaving the socket and spigot area to be wrapped after jointing. Site application is not normally recommended but can be achieved by spirally winding a hand wrap tape round the pipe barrel, overlapping the edges by 25mm or 55% depending on the pipeline environment. The tape should be pulled tight and smoothed over with a gloved hand to ensure adhesion and eliminate any air bubbles or voids may be left between the pipe and the tape.

Joint Protection The metal area of the pipe and adjoining tape wrapping on the pipe barrel should be dry and clean. The clean, dry prepared surface should then be brush primed. The primer is classified as a hazardous substance and the manufacturers’ instructions should be followed. If in doubt refer to manufacturers COSHH sheets. Fig. 1.3.6

Once dry, press a mastic blanket or LD mastic firmly into position so that full contact is made with the primed metal and a smooth profile is built up to the socket face (see Fig. 1.3.6). Fig. 1.3.7

Using a hand grade tape, spirally wrap the joint area from the back of the socket to the spigot of the adjacent pipe, using sufficient tension to ensure conformability to the joint profile.

Joint wrapping should extend a minimum of 50mm onto the pipe barrel protection. End tape overlap between adjoining rolls should be a minimum of 150mm (see Fig. 1.3.7).

23

Section 1: Pre Installation

Mechanical Rapid Anchor Ve JointJoints (Mechanical) There are are two twomethods methodsrecommended recommendedfor forprotecting protecting Mechanical Anchor jointsinina a Rapid Ve joint (Mechanical) tape wrapped wrapped pipeline. pipeline.

Method 1: Petrolatum Tape All surfaces of the joint and adjacent area should be cleared. The clean, dry prepared surface should then be brush primed with a coat of petroleum primer. The primer is classified as a hazardous substance and the manufacturers’ instructions should be followed. If in doubt refer to manufacturers COSHH sheets. A petrolatum blanket, of appropriate size for the joint, should then be placed equidistant around the invert of the joint and pushed well home around its profile to eliminate voids. Further blankets, as required, should be similarly applied extending upwards to the crown of the pipe. All overlaps should be a minimum of 75mm, with the upper blanket always overlapping the one below (see Fig. 1.3.8). Fig. 1.3.8

Apply 150mm wide tape wrap in a spiral fashion over the joint area, commencing and finishing a minimum of 150mm onto the adjacent protective coating. Position the first 75mm of tape onto the pipe and smooth over with a gloved hand to secure adhesion. Wrap spirally over the joint employing sufficient tension to obtain conformability to the joint profile. Smooth over as before to ensure overall adhesion. The circumferential overlap should be 55% and end laps a minimum of 150mm.

Method 2: Shrink Sleeves An alternative method of providing protection at joints is by the use of heat shrink sleeves. All surfaces of the joint and adjacent area of the pipe should be thoroughly cleaned. Fit the appropriate size sleeve in accordance with the manufacturers’ instructions, taking care not to damage the protection system already in place when applying heat to the sleeve. Once the the sleeve sleeveisisshrunk shrunkaround aroundthe thejoint, joint, each end should sealed by overeach end should be be sealed by overwrapping from fromthe thesleeve sleeveonto ontothe thepipe pipebody, body,using using heavy duty to prevent prevent medium duty PVC tape, tape, to the ingress ingressof ofground groundwater. water.

24

1.4 Coating Repairs Pipes and Fittings The method of surface preparation required for repair of coating damage depends upon the severity and extent of that damage. Where the damage does not expose the iron substrate or where the damage exposes less than 25 cm2 of bare iron substrate AND the width of the damage is less than 5 mm, roughen the surface of the coating and any bare metal surfaces using a wire brush or abrasive paper. Remove all traces of rust and dust or other non-adherent material. The exposed area can be preheated to around 40°C (i.e. "hand-hot") to aid curing, using a gentle flame played over the area avoiding damage to adjacent coating. Repairs should not be attempted in temperatures less than 5°C. Apply the appropriate paint i.e. two-pack solvent based epoxy paint, mixed and prepared according to the manufacturers instructions supplied with the paint, or bitumen paint, by brush in criss-cross passes until it is up to the level of the original coat and overlapping the edges. Allow to dry. Where the damage exposes more than 25 cm2 of bare iron substrate, or the width of the damage is greater than 5 mm, shot blast the surface of the damaged area, overlapping slightly onto coating in good condition, or thoroughly wire brush the surface to remove all traces of rust, dust or other non-adherent material. The prepared surface should be uniformly grey with a slight metallic sheen. Again the exposed area can be preheated to around 40°C (i.e. "hand-hot") using a gentle flame played over the area avoiding damage to adjacent coating. Prime the exposed surface with two pack zinc rich epoxy primer (this should contain a minimum of 90% zinc solids by mass of dry film), mixed and prepared in accordance with the manufacturers instructions supplied with the paint to a minimum dry film thickness of 50 microns. Allow to dry in accordance with the manufacturers instructions. Apply the appropriate paint i.e. a two-pack solvent based epoxy paint, mixed and prepared according to the manufacturers instructions supplied with the paint, or bitumen paint, using a brush in criss-cross passes until it is up to the level of the original coat and overlapping the edges. Allow to dry. PAM Integral pipes DN80-2000 and PAM Natural pipes DN80-800 should be painted with a two-pack solvent based epoxy paint of the relevant colour. Water pipes DN8002000 should be painted with black bitumen paint. PAM Integral and PAM Natural fittings uti DN400 should be painted with a two-pack solvent free epoxy paint of the relevant colour. Fittings >DN400 should be painted with a two-pack solvent based epoxy paint of the relevant colour. NOTE: To build up the correct coating thickness on fittings it may be necessary to use a spatula rather than a brush. For outdoor repair in cold climates the bitumen paint may be thick and difficult to apply unless it is warmed. Warming the paint may be carried out by storing in a warm room or by lowering the paint can partially into a large container of hot water. On no account should heat be applied directly to the bitumen paint container. During repair the pipe must be kept dry, even to the extent of erecting a canopy. Zinc rich paint, epoxy paints and bitumen paints are classified as a hazardous substances and the safety instructions provided by the manufacturers of the material used for repair should be carefully followed. If in doubt refer to manufacturers COSHH sheets.

25

INSTALLATION INSTALLATION INSTALLATION REPAIRS DURING INSTALLATION INSTALLATION

REPAIRS DURING INSTALLATION REPAIRS DURING INSTALLATION REPAIRS DURING INSTALLATION Repairing TT PE external coating

Repairing TT PE external coating Repairing Repairing TT TT PE PE external external coating coating

Repairs to TT pipes

Rapid anchor joint

PE external coating PE external coating PE external coating  Equipment required PE external coating

1) PEC external coating (DN80-700)  Equipment required

Fig. 1.1.12

This system uses standard pipes and fittingsrequired with a modified gasket containing  Equipment cuter,  •Equipment required Equipment required moulded-in stainless steel inserts. For use with potable water and sewerage on both cuter, •• paint brushes, cuter, brushes, ••• paint • Cuter pipes and fittings UTI DN600 where self-restrained joints are required (see Fig. 1.1.12). putty knife, cuter, •• paint brushes, knife, • putty gas torch. • Paint brushes paint brushes, •• putty knife, gas torch. Repair kit**: patches and mastic. ••knife putty knife, Putty Please note that test and• working pressures are restricted when using anchor gaskets gaskit**: torch. Repair patches and mastic. • gas torch. • GasRepair torch kit**: patches and mastic. (see Table 2.3.1). Repair kit**: patches and mastic. Repair kit: patches and mastic. Procedure Mechanical anchor joints Procedure Procedure The mechanical anchor joint is used pipes the anddamaged fittings,PE. DN600-1200, where selfProcedure Cut andonremove  Procedure Cut and remove the damaged PE. Clean and dry the exposed area. restrained joints are required, and on pipes and fittings DN80-600 where pressure Cut and remove the damaged PE. PE. Cut and remove damaged Clean and dry 60 thethe exposed area. Heat to about °C. Cut and remove the damaged PE. ratings are greater than the maximum allowable for anchor Clean and dry the area. Clean dryexposed the°C. exposed area. gaskets. Heat toand about Clean dry 60 the°C. exposed area. Heat toand about 60 Heat to about 60 °C. Heat to about 60 °C. The joint utilises the same socket and gasket as the unanchored Rapid joint. Anchorage is provided by the addition of a weld bead on the pipe spigot, a locking ring (single piece uti DN700 and segmented for DN800-1200) which abuts the weld bead Apply the mastic, smooth with a putty knife. and a bolted gland which tightens the tape pipeoverlapping socket bolts retains Applyagainst the mastic, smooth with ausing putty knife.over the repair 50 hook mm theand edges of the cut area. ApplyApply the mastic, smooth with a putty knife. Apply the mastic, smooth with a putty knife.over the edges of the cut area. Apply the repair tape overlapping 50 mm the locking ring (see Fig. 1.1.13). Apply the mastic, smooth with a putty knife. the repair tape overlapping 50 mm edges area. ApplyApply the repair tape overlapping 50 mm overover the the edges of of thethe cutcutarea. Apply the repair tape overlapping 50 mm over the edges of the cut area. Fig. 1.1.13

the with tape the withgas the torch gas torch heat sensitive paintchanges changes colour. WarmWarm the tape untiluntil the the heat sensitive paint Warm the tape torch until the heat sensitive paint changes colour. Press down the with tape the withgas a suitable glove. Warmdown the tape torch until the heat sensitive paint changes colour. colour.Press the with tape the withgas a suitable glove. Warm the tape the gas torch until the heat sensitive paint changes colour. Press down the with tape with a suitable glove. Press down the tape with a suitable glove. Press down the tape with a suitable glove. REPAIRS DURING INSTALLATION REPAIRS DURING INSTALLATION REPAIRS DURING INSTALLATION

INSTALLATION INSTALLATION INSTALLATION

Repairing TT PUX external coating Repairing Repairing TT TT PUX PUX external external coating coating

2) PUX external

Polyurethane coating Polyurethane ** Available on ordercoating Polyurethane ** Available(DN800-2000) on ordercoating coating

 **Equipment Available onrequired order  **Equipment Available onrequired order  Equipment required Equipment required • brush, • Brush•• brush, paint brushes, • brush, paint brushes, spatula, • Paint •••brushes brushes, •• paint spatula, torch. •• gas spatula, • Spatula gas torch. • gas torch. • GasPaint torch ref.*: Paint ref.*: 4820 Ivory: Paint ref.*: EUROKOTE Paint ref.*: 4820 Ivory: EUROKOTE • 1 kg (Ref. • 50 ml158254) (Ref. 184727) • EUROKOTE 4820 158254) Ivory:Ivory: 1 kg (Ref. • 50 ml (Ref. 184727) EUROKOTE • 1 kg (Ref. 4820 158254) • 50 ml (Ref. 184727) • 1 kg (Ref. Water 158254) 50 ml (Ref. 184727) supply and•distribution - Edition 2010 Procedure  Procedure Water supply and distribution - Edition 2010  Procedure Water supply and distribution - Edition 2010 Brush,clean and dry surfaces to- be coated. Waterthe supply and distribution Edition 2010 Procedure Brush, clean and dry the surfaces to be coated. Brush, dry the surfaces to self-restrained be coated. The PAM Universal socket is used on clean pipes,and DN80-1200, where joints are Brush, clean and dry the surfaces to be coated. required. It is used with the Universal Rapid anchor and Universal Rapid locked joints

Fig. 1.1.14

PAM Universal socket and joints

and on directional drilling pipe joints (see Fig. 1.1.14).

Gasket Chamber

26

Chamber for Locking Ring

The joint utilises the same gasket as an unanchored joint, but has an elongated socket and does not have the collarette. Apply the epoxy paint with a paint brush or spatula, respecting the Apply the epoxy paint with indicated a paint brush or spatula, respecting the proportions o proportions of the components on the products. Apply the epoxy paint with athe paint brush or spatula, respecting the proportions o the components indicated on products. Apply the epoxyindicated paint with paint brush or spatula, respecting the proportions o the components on athe products. the components indicated on the products.

Paint Paint Paint

7 * Respect the recommendations for use on the safety data sheets available on www.pamline.com * Respect the recommendations for use on the safety data sheets available on www.pamline.com * Respect the recommendations for use on the safety data sheets available on www.pamline.com

Section 1: Pre Installation

Site Applied Polyethylene-wrapping Repairs If the polyethylene sleeving is damaged during pipe handling or installation it can easily be repaired on-site. Wipe clean and dry the damaged area. Any torn sleeving can be either smoothed down or cut off. Cut a sheet of polyethylene of sufficient size to cover the damaged area and pass around the circumference of the pipe. Plastic adhesive tape should be applied circumferentially to form a seal at both ends of the repair and also to the longitudinal seam.

Repairs to Spirally Tape Wrapped Pipes Where spiral tape wrapping is damaged, the following repair procedure should be followed: ● Remove punctured or disbonded tape using a sharp knife, forming a circular or oval cut shape (avoid angular cuts). Care should be taken to ensure that the edges are smoothly finished. ●

Ensure that the cleared area is free from debris or contaminants.

●

Apply primer to the cleared area, and allow to dry.

Note: The primer is classified as a hazardous substance and the manufacturers’ instructions should be followed. If in doubt refer to manufacturers COSHH sheets. ●

Apply hand-applied tape to the cleared and primed area, using sufficient tension to ensure good conformability.

1. Wrapping should be made in the same direction as the existing tape coating. 2. Wrapping should commence and finish on the opposite side of the pipe to where the damage has been sustained. 3. Wrapping should be made with a 55% overlap. 4. Wrapping should extend a minimum of 75mm either side of the damaged area. ●

Tape width should be appropriate to the diameter of the pipe.

1. Use 100mm width tape for pipes DN80-150. 2. Use 150mm width tape for pipes DN200-2000. Care should be taken at all stages to ensure that no air bubbles are entrapped underneath the tape wrapping.

26

27

Cement Mortar-lining Repairs Fig. 1.4.1

In the event that an area of cement mortar lining is damaged, repairs can be simply made by using the following procedure. UK’s recommended byby the DWI and is is Saint-Gobain PAM Pipelines recommendedrepair repairmortar mortarisisapproved approved the DWI and suitable for sewer If this is not available then,isfor pipes,then, an OPC suitable forwater waterand pipes andpipes. for PAM Integral pipes. If this notwater available for or Blast Furnace cement should be used be andused for sewer pipes anIntegral HAC cement used. water pipes, an OPC cement should and for PAM pipesshould an HACbecement should be used. Do not attempt a lining repair if the ambient temperature is ≤5°C.

Fig. 1.4.2

If possible position the pipe or fitting with the damaged area at invert level (see Fig. 1.4.1). Carefully chip out the damaged lining. Undercut the edges of the surrounding sound lining to form a ‘key’ for the repair (see Fig. 1.4.2). Clean away all loose debris (see Fig. 1.4.3). Thoroughly wet the exposed metal surface and the edges of the lining around the exposed area (see Fig. 1.4.4).

Fig. 1.4.3

Prepare the mortar for the repair. This should be stiff and consist of one part cement to approximately 1.5 parts dry washed coarse sand (by mass) and be mixed with fresh potable water. Place the mortar with a hand trowel (or float for large areas), and work it well into the edges of the existing lining (see Fig. 1.4.5). Build up the repair to a thickness just above that of the original lining and finally smooth down to the required thickness using a piece of wood against the pipe end, if appropriate, to produce a square end.

Fig. 1.4.4

Leave to cure for one day. On hot days cover with a wet sack, or similar, to prevent rapid evaporation until the mortar is sufficiently hardened. On completion of the repair, check that the cement mortar has been allowed to cure correctly, that it is firmly bonded to the pipe and is free from excessively wide cracks (see Table 1.9.1). Note: For System XL pipes, it is only necessary to repair damage to the cement. No attempt should be made to repair the seal coat itself.

Fig. 1.4.5

28

27

Section 1: Pre Installation

1.5 Cutting Ductile Iron Pipes It is essential that cutting of pipes be entrusted to persons who are fully trained in such operations and are fully aware of the danger of personal injury in all aspects of pipe cutting. Persons who use abrasive wheels should be aware of the statutory regulations in force in relation to their use.

Pipes Suitable for Cutting Fig. 1.5.1

80 Pipes DN60-300:

L

DN 60 to 300 Useable cutting length 2/3 L

80 All full length Saint-Gobain pipes DN60-300 are manufactured suitable for cutting onsite up to a maximum of 2/3 of the length of the pipe length measured from the spigot end (see Fig. 1.5.1).

Pipes DN350-2000: forfor cutting on-site must be specifically Pipes DN350-2000 DN350-2000required requiredtotobebesuitable suitable cutting on-site must be specifically requested on asas being suitable forfor cutting willwill be marked withwith requested on order. order.Pipes Pipessupplied supplied being suitable cutting be marked face and sometimes withare a tape around socketonthe initials initials‘SFCOS’ ‘SFCOS’on onthe thesocket socket face (see Fig 1.5.2).also These suitable forthe cutting marked SFC (see Fig 1.5.2). These forthe cutting to a maximum of 2/3 of site up to a maximum of 2/3 of are thesuitable length of pipeonsite lengthup measured from the the length spigot end.of the pipe length measured from the spigot end. Fig 1.5.2 Fig. 1.5.2

Successful jointjoint assembly cannot be guaranteed using cut DN>300 pipespipes that that are not N.B. Successful assembly cannot be guaranteed using cut DN>300 are marked as ‘sutiable for cutting’ . not marked as ‘suitable for cutting’.

Procedure Cutting Pipes All pipes: - Use a diameter tape or flat tape to check the external diameter of the pipe at the proposed point of the cut. Tip - Measure twice cut once. The dimension must comply with the limits specified in Table 1.5.1. Pipes DN350-2000: - After cutting the pipe check the cut end, where this is found to be oval, locate and mark the major axis. Measure the length of the major axis. Only where this exceeds the dimension specified in Table 1.5.1, will ovality correction be required prior to jointing (please refer to Section 1.6 for details).

28

29

Table 1.5.1: Average external diameter of pipe and maximum major axis of spigot ends

Nominal Size DN

30

Measured Circumferentially Measured Circumferentially with Standard Tape with Diameter Tape

Max. Major Axis of Spigot

Max. (mm)

Min. (mm)

Max. (mm)

Min. (mm)

60

245

236

78

75.3

78

80

311

302

99

96.2

99

100

373

364

119

116.1

119

125

455

446

145

142

145

150

537

527

171

167.9

171

200

700

690

223

219.7

223

250

863

853

275

271.5

274.5

300

1027

1015

327

323.3

326.6

350

1189

1179

378.5

375

378.5

400

1349

1338

429.5

426

429.5

450

1509

1498

480.5

477

480.5

500

1673

1661

532.5

528.5

532.5

600

1996

1982

635.5

631

635.5

700

2321

2307

739

734.5

739

800

2648

2632

843

838

843

900

2972

2955

946

940.5

946

1000

3295

3277

1049

1043

1049

1100

3619

3597

1152

1145.1

1152

1200

3944

3924

1255.5

1249

1255.5

1400

4594

4572

1462.5

1455.5

1462.5

1500

4920

4893

1566

1557.5

1566

1600

5242

5217

1668.5

1660.5

1668.5

1800

5892

5864

1875

1866.5

1875.5

2000

6544

6511

2083

2072.5

2083

29

Section 1: Pre Installation

Pipe Cutting Ductile iron pipes can be cut by a number of methods. Where flexible joints are to be made, the cut ends must be trimmed with a file or grinder to remove the burr formed during cutting and, unless the joint is to be made with couplings or adaptors, a chamfer must be provided (see Fig. 1.5.3 and Table 1.5.2).

Power driven abrasive disc These cutters should only be used by properly trained personnel. This is one of the most widely used methods for cutting ductile iron pipe. It has the advantage of being suitable for all sizes. There is no need for adjustment to suit pipe or attach machinery to the pipe. The abrasive discs are fitted to suitable hand held power tools usually driven by compressed air or small internal combustion engines. It is important when ordering disc cutting equipment to state that it is for use with ductile iron pipe and to ensure that the disc type and size and the spindle speed of the equipment are compatible.

Semi rotary wheel cutter A number of semi rotary wheel type cutters are available, ranging from the standard chain link cutters to more sophisticated tools employing a rigid hinged frame. With this type of equipment it is important to ensure that wheels specifically designed for use with ductile iron are employed. This type of cutter is normally used on pipes in the smaller diameter range.

Rotary and orbital pipe cutters Cutting tools of either the simple lathe or milling saw type respectively are available throughout the diameter range. Whichever type of cutter is employed the machine is attached to the pipe and the cutting tool is driven around the pipe by means of gears on a chain link track. The orbital type cutters have the advantage on the larger sizes of ductile iron pipe in that they are capable of accommodating the ovality which is sometimes present. These types of machinery are usually driven mechanically, e.g. by compressed air motor – although for pipes in the smaller diameters a hand-operated windlass may be employed. In machines using lathe type cutting tools, the cutter heads must have a 7° front rake.

Reciprocating power saws These may also be used for cutting ductile iron pipe. These tools are usually electrically driven and for this reason they are principally used in depots or workshops where a power supply is available.

30

31

End Preparation of Cut Pipe for Jointing Any burrs or sharp edges left after cutting must be trimmed off by filing or grinding. Where Rapid joints are to be used, the cut ends should be chamfered by filing or INSTALLATION grinding to give a radius of 3mm 3º and a chamfer profile ends and a chamfer profilesimilar similarto tothe theoriginal original spigot ends (see SSEMBLY Fig. 1.5.3 and Table 1.5.2).

Fig. 1.5.3 M

A

N

Cutting pipes

Table 1.5.2: Chamfer details

All dimensions in mm

Nominal Size DN

Minimum Radius 3mm

M

N

9 - 12

3

 Fettle or chamfer

60 - 600

•15For - 20EXPRESS mechanical 5joints, collar, fettle the cut •20For Vi, UNIVERSAL, et - 25STANDARD, STANDARD 7 chamfer with an angle grinder to avoid damaging the jo

700 - 1200 1400 - 1600 1800 - 2000

20 - 25

Cutting Pipes with Tape Wrap

8

DN

m (mm)

60 to 600

9

700 to 1200

15

Please note that the tape wrap is a medium heavy duty protection system and removal may duty protection system and removal may 20 1400 to 1600 prove verym difficult. It is recommended that at the time of ordering, you advise us of 23 1800 to 2000 the number and positions of cuts so that the pipes can be wrapped accordingly.

n r Marking insertion depths =3

The cut pipe end should be marked with the appropriate minimum and maximum insertion depths (see Fig. 2.2.6, Fig. 2.2.7 and Table 2.2.1).

Cross section of the chamfer

Repairing the coating

 Redo the coating

The cut pipe end should be recoated. For Natural coating: Recoat the edge exposed by the cut • EUROKOTE 448traditional (1Kg, Ref. 228604) For the black coating:

• ENDOLAC 245-30 (1 kg: For Integral coating: For NATURAL coating: • EUROKOTE 4820 (1Kg, Ref. 184653)

and the chamfer.

Ref. 518134; 5 kg: Ref 158

• EUROKOTE 438 (1 kg: Ref. 158255)

For Black coating: • ENDOLAC 245-30 (1Kg, Ref. 158134; 5Kg, Ref. 158131)

INSTALLATION

Respect the recommendations for use on the safety www.pamline.com

32

31

Section 1: Pre Installation

1.6 Ovality Correction Where pipes have been cut on site, the following procedures should be carried out in order to check and correct the ovality of the new spigot end.

Fig. 1.6.1

Major

Axis

●

Measure the length of the major axis. Only where this exceeds the dimension specified in Table 1.5.1 will ovality correction be required prior to jointing.

●

Spigots to be jointed into sockets must be chamfered to give a similar profile as the original spigot end (see Table 1.5.2).

Method A Fig. 1.6.2

The use of this method is recommended where it is possible to remove the tackle after ovality correction and subsequent jointing.

Major Axis

Position the timber strut and jack (approximately 5 tonnes capacity) 100mm – 200mm inside the spigot end and at 90° to the major axis. Rubber pads should be placed in position to prevent possible damage to the pipe lining (see Fig. 1.6.1). Extend the jack until the major axis has been reduced to the appropriate limit specified in Table 1.5.1. Complete the jointing operation with the major axis of the spigot vertical. After jointing, remove the tackle. Note: In some instances, e.g. jointing into couplings, it may be necessary to use two jacks in order to obtain a ‘round’ profile.

Method B: The use of this method is recommended where it is not possible to remove the tackle described in Method A, after ovality correction and subsequent jointing. Place the tackle around the spigot end of the pipe at a position approximately 450mm from the pipe end with major axis of the spigot vertical (see Fig. 1.6.2). Where pipes are sleeved or tape wrapped, rubber pads or similar should be placed between the re-rounding tackle and the protection system to prevent damage. Tighten the two nuts evenly until the major axis has been reduced to the appropriate limits specified in Table 1.5.1. Complete the jointing operation with the major axis of the spigot vertical. After jointing remove the tackle. Note: Where the pipes are to be concreted into a structure they should, if necessary, be re-rounded before this is done and left until the concrete has set before removing the rerounding tackle.

32

33

1.7 Moving Pipes & Fittings Onsite When transporting pipes and fittings on site, the load should be properly secured to the vehicle. Should it be necessary to travel for a short distance with a suspended load, this should be carried as near to the ground as practicable and steadied by ropes to prevent any pendulum motion. Pipes and fittings should not be placed in positions where they could be damaged by mechanical equipment or vehicles moving about the site or there is a risk of contamination by the ingress of soil, animals, fuel oils, chemicals etc. End caps may be used to help prevent accidental contamination.

Pipe Stringing When stringing pipes alongside the trench, dropping the pipes is to be avoided at all times, they should also be wedged or pinned to prevent accidental movement. Pipes should not be dragged or placed on stones or other objects that may damage the protective coating or sleeving and they should be supported evenly along their length. Where there is a risk of damaging the protective coating, especially factory applied polyethylene sleeving, timbers should be placed beneath the pipes to raise them clear of the ground. When stringing pipes in a road or on other hard surfaces the pipes should be completely supported on timbers clear of the surface.

Lowering Pipes and Fittings into Trench Pipes and fittings should be placed into the trench by crane, or excavator backhoe (see Fig. 1.7.1). Broad webbing slings should be used, which are made of Terylene, nylon or other synthetic material capable of withstanding the required loads. Never attempt to utilise chains or wire ropes as slings as these might allow the pipes to slip, or cause damage to the external protection system. Where a crane with single sling is used, the balance of the pipe should be checked with the pipe just clear of the ground. Smaller diameter pipes can be hung with a single sling from an excavator backhoe. Site safety rules should be observed at all times.

Fig. 1.7.1

34

33

Section Section 1:Pre Pre Installation Installation Section 1: 1:Pre Installation

1.8 Trenching 1.8 Trenching 1.8 Trenching

The following publications give recommendations regarding standards of good practice for trench excavation: The following publications give recommendations regarding standards of good ● BSfollowing EN for 805trench (12) practice excavation: The publications give recommendations regarding standards of good Civil Engineering Specification for the Water Industry (3) ● BS 8010 EN for 805trench (12) excavation: ● practice BS8010 (5) ● BS 6031 EN 805 (12) ● BS 8010 ● (13) Sewer for Adoption (6th Edition) (6) ● BS ● Report 6031 (13) ● R97, `Trenching Practice' published by CIRIA (14) BS8010 EN 805 (13) ● BS (13) ● Technical BS6031 6031 (14) Report R97, `Trenching Practice' published by CIRIA (14) published by CIRIA (15) ● Note TN95 `Proprietary trench support systems',

• • • • • • Specification ReportR97, R97, `Trenching Practice’ published by (15) ● Report `Trenching Practice' published byCIRIA CIRIA (14) published ● Technical Note `Proprietary trench support systems', by CIRIA (15) ● forTN95 the Reinstatement of Openings in Highways (the HAUC •●● specification) Technical Note TN95 `Proprietary trench support systems’, published by CIRIA (16) Technical Note TN95 `Proprietary trench support in systems', published by CIRIA (15) (16) for the Reinstatement of Openings Highways (the HAUC •● Specification Specification for the Reinstatement of Openings in Highways (the HAUC specification) specification) (16)

Specification for the Reinstatement of Openings in Highways (the HAUC (17) specification) (16) Trenching is a very hazardous operation. It requires specialised civil engineering skills and knowledge of the detailedoperation. statutory It regulations that govern this operation. skills These Trenching is a very hazardous requires specialised civil engineering instructions give to ensure thatIt the qualityspecialised of pipes and fittings is not skills and knowledge ofguidance the detailed statutory regulations that govern this operation. These Trenching is a very hazardous operation. requires civil engineering impaired during installation. contractor onand these instructions for instructions giveof guidance toThe ensure thatregulations theshould qualitynot of rely pipes fittings is not These and knowledge the detailed statutory that govern this operation. any other purpose than maintaining the quality of pipes and fittings installed for impaired during contractor onand these instructions instructions giveinstallation. guidance toThe ensure that theshould qualitynot of rely pipes fittings is not for underground use.installation. any otherduring purpose than maintaining the quality of pipes andonfittings installed for for impaired The contractor should not rely these instructions underground use. than maintaining the quality of pipes and fittings installed for any other purpose underground use.

Trench Widths Trench Widths The Contract will usually contain detailed requirements for trench widths and the Trench Widths

information is for guidance only. requirements for trench widths and the The Contractbelow will usually contain detailed information is for guidance only. requirements for trench widths and the The Contractbelow will usually contain detailed The width ofbelow trenchisshould be as narrow information for guidance only. as practiable, taking into consideration the type of native soil and backfill and the compaction equipment required. Where the The width of trench should be as narrow as practiable, taking into consideration mechanical is required for compaction sidefill, the trench should only beWhere wide enough type of native soil and backfill the equipment required. The width ofcompaction trench should be and as narrow as practiable, taking into consideration the to accommodate the equipment. mechanical compaction is required for sidefill, the trench should only be wide enough type of native soil and backfill and the compaction equipment required. Where

to accommodate the equipment. mechanical compaction is required for sidefill, the trench should only be wide enough Where mechanical compaction is not required, the width of trench should be 300mm to accommodate the equipment. greatermechanical than the pipe outside diameter, but maythe bewidth reduced where should narrowbe trenching Where compaction is not required, of trench 300mm techniques are employed. greatermechanical than the pipe outside diameter, but maythe bewidth reduced where should narrowbe trenching Where compaction is not required, of trench 300mm techniques greater thanare theemployed. pipe outside diameter, but may be reduced where narrow trenching Where utilising the lateral deflection available from flexible joints to make a change in techniques are employed. direction, the trench shoulddeflection be cut to available give sufficient room forjoints the joint to bea made Where utilising the lateral from flexible to make change in with the pipes in line, the pipe being deflected after the joint has been made (see in direction, the trench shoulddeflection be cut to available give sufficient room forjoints the joint to bea made Where utilising the lateral from flexible to make change Tablethe 2.2.2 andtrench Table 2.4.2). with pipes in line,should the pipe after room the joint been to made (see direction, the be being cut todeflected give sufficient for has the joint be made Tablethe 2.2.2 andin Table with pipes line,2.4.2). the pipe being deflected after the joint has been made (see Table 2.2.2 and Table 2.4.2). 2.7.2

34 34 34

35

1.9 Pre-installation Inspection Ductile iron pipes are not normally susceptible to handling and transport damage but mishandling can damage protective coatings, wrapping and linings or bruise and deform jointing surfaces and may create ovality. The following checks should be undertaken shortly before lowering the pipes and fittings into the trench: ● Deformation of the pipe ●

Loss of any mortar lining.

Note: mortar linings may contain small shrinkage cracks and areas of disbondment which should not affect the stability and effectiveness of the lining, permissible crack widths are shown in Table 1.9.1. ●

Cuts or tears to the wrapping

●

Loss of epoxy/bitumen coating

●

Spigot jointing surfaces for correct chamfer, protrusions in socket and paint build up in socket area

●

check that no foreign matter has entered pipes

Any defective pipes or fittings should be identified and stored away from the compliant pipes and fittings. For minor coating/lining repairs please refer to Section 1.4.

Table 1.9.1: Permissible crack widths and radial displacement

36

Maximum crack width & radial displacement (mm)

Nominal Size DN

Water pipes & fittings

PAM Integral pipes & fittings

60 - 300

0.4

0.6

350 - 600

0.5

0.7

700 - 1200

0.6

0.8

1400 - 2000

0.8

0.8

35

Section 2 Pipe Laying

37

Section 2: Pipe Laying

2.1 Pipe Laying When stringing pipes out along the line of the main, avoid dragging or dropping the pipes and check the ground for sharp objects which might cause damage to the coating or wrapping. Where possible a timber support under the spigot end is recommended. Before laying, check each pipe for any damage to the external protection system and carry out such repair work as necessary (see Section 1.4 for details). Working in trenches and lifting are hazardous operations. These instructions are designed to ensure that the quality of pipes and fittings is not impaired during installation. It is essential that these operations are entrusted to persons who are skilled in such work. The work must be properly supervised and appropriate regard paid to the relevant health and safety regulations. Pipes should only be lifted into the trench using webbing slings or padded hooks and care should be taken when removing these that the protection system is not damaged in the process. The pipes should not be rolled in from the side of the trench. To prevent damage to the pipes or coatings, contact with sharp objects should be avoided. Rolling the pipe along the ground should not be permitted. Pipes which have protective wrappings around them for transportation and handling purposes should be laid with these still in position. Joint holes should be formed in the bedding material or excavated final surface for each socket to ensure that each pipe is uniformly supported throughout the length of its barrel and to enable the joint to be made. Where pipes are required to be bedded directly on the trench bottom, the final surface should be trimmed and levelled to provide even bedding of the pipeline, and should be free from all extraneous matter that may damage the protective coating. Ensure adequate clearance is excavated under the joints to allow for the joint to be checked and if required, the joint protection to be properly applied. When entering the pipe spigot into the next socket, do so in a straight line. Excessive dragging of the pipe along the trench bottom should also be avoided to prevent damage to the protective coating. Do not lever against the side of the pipe to align pipes after jointing unless a suitable protective pad is used between the pipe and the lever. Backfill should be placed around the pipe in a reasonable manner and not dropped onto the crown of the pipe from an excessive height, to ensure that the protective coating remains undamaged. The trench bottom should be free of any object that is likely to cause damage to the protective coating, as should the pipe surround material in the immediate proximity of the pipes. Backfill should be carefully placed and care taken when compacting to avoid damage to the protective coating. All construction debris should be cleared from the inside of the pipe either before or just after a joint is made. This can be done by passing a pull-through along the pipe, or by hand, depending on the diameter of the pipe. When laying is not in progress, a temporary end-closure should be fitted securely to the open end of the pipeline. This may make the pipes buoyant in the event of the trench becoming flooded, in which case the pipes should be held down either by partial re-filling of the trench or by temporary strutting.

38

No protective cap, disc or other appliance on the end of a pipe or fitting should be removed permanently until the pipe or fitting which it protects is about to be jointed.

Thrust Blocks Any additional excavation required to accommodate thrust blocks should be carried out after the bend or branch is in position. The thrust face should be trimmed back to remove all loose or weathered material immediately prior to concreting. Thrust blocks should be allowed to develop adequate strength before any internal pressure is applied to the pipeline.

Pipe Bedding, Surround and Backfill Bedding for pipes should be laid by spreading and compacting suitable granular bedding material over the full width of the pipe trench. After the pipes have been laid, additional material should, if required, be placed and compacted equally on each side of the pipes under the pipe haunches, and where practicable, this should be done in sequence with the removal of the trench supports to prevent the formation of voids. Fill material should, where required, be placed and compacted over the full width of the trench in layers not exceeding 150mm before compaction to a finished thickness of 250mm above the crown of the pipes. The layers of backfill, up to 250mm above the crown of the pipe, should be placed and compacted with due care being taken not to damage the pipe or protective coatings. Special care should be taken to ensure that there are no large stones or other objects in the backfill that may damage the protective coating during compaction. Wherever possible, in order to minimise misalignment of the bed with resulting shear across the joint, backfill material should not be placed on a pipe until the succeeding pipe is laid and jointed. If joints are to be individually inspected during hydrostatic testing, it is not practicable to backfill the trench completely. It is important, however, to backfill over the barrel of each pipe and compact the backfill or take other such measures to prevent movement of pipes during the testing processes and, in some situations, to avoid flotation. On pipes greater than DN500, special attention should be given to the compaction of the backfill material under the haunch of the pipe. The bedding and surround will be specified in the contract, but the contractor should ensure that consideration has been given to protecting the pipe coatings and sleeving from being damaged during pipe laying. In particular the use of angular granular material 20mm or greater in size for bedding and sidefill should be avoided. For detailed information on bedding and surround, see Water Industry Specification (18) and 4-08-02, 15 (19) Information and Guidance Notes 4-08-01, 4 (17) (18). Where pipes are installed with concrete protection, to maintain flexibility, the concrete protection should be interrupted over its full cross-section at each flexible pipe joint by compressible filler. In highways the backfill should meet the requirement of the HAUC specification.

39

Section 2: Pipe Laying

2.2 Rapid Joint Basic conditions which should be ensured for all types of joint are: ● Make sure the socket and spigot to be jointed are in good condition. ● Appropriate chamfer and radius on spigot (see Fig. 1.5.3 and Table 1.5.2). ● Cleanliness of all parts. ● Correct location of components. ● Correct lubrication of joint components. ● Centralisation of spigot within socket. The inside of sockets and the outside of spigots should be clean for at least the insertion depth of each joint. Glands and gaskets should be wiped clean and inspected for damage. The spigot ends of all pipes should be checked for ovality. Where found to be oval, but within the limits set out in Table 1.5.1 the maximum axis should be buried vertically so the weight of the soil acts to re-round the pipe. If the ovality exceeds the limits set out in Table 1.5.1, please see Section 1.6. Where lifting gear has been used to place the pipe in the trench it should be used to support the pipe and assist in centralising the spigot in the socket. Where the pipeline is suspected to be subject to movement due to ground settlement or temperature variation, a suitable gap should be left between the end of the spigot and the bottom of the socket. If pipes are laid on a steep gradient where the soil/pipe friction is low, care should be taken to ensure that no excessive spigot entry or withdrawal occurs. As soon as the joint assembly has been made, the pipe should be held in place and the trench backfilled over the barrel of the pipe. Unless the gradient is 1:2 or steeper, anchorage is not normally necessary. However, for these very steep gradients, self-anchoring joints or anchor blocks at each socket are recommended. For pipelines laid above ground on steep gradients, self-anchoring joints should be used.

Jointing Instructions Fig. 2.2.1

General instructions for jointing are listed below, followed by the various methods for making the joint. Before assembly, the outside of the spigot and the inside of the socket of the two pipeline components to be joined must be thoroughly cleaned. Where there are no minimum and maximum insertion depths on the pipe, these should be marked according to Table 2.2.1. Insertion of the gasket may, if necessary, be facilitated by the prior application of a thin film of lubricant to the sealing chamber of the socket only (see Fig. 2.2.1). When using anchor gaskets do not apply any lubricant on the inside of the socket or the outside of the gasket. Note: Please follow the Health and Safety guidance specified on the lubricant packaging. If in doubt refer to manufacturers COSHH sheets.

40

The gasket should be inspected to ensure it is not deformed or damaged. The rubber gasket should be cleaned, flexed and then placed in the socket. Care must be taken to ensure that the gasket is correctly seated in the socket. Make sure the joint ring fits evenly around the whole circumference and smooth out any bulges which would prevent the proper entry of the spigot end (see Fig. 2.2.2).

Fig. 2.2.2

In the larger diameters this operation may be assisted by forming additional loops in the ring opposite the first, then pressing the loops flat one after the other (see Fig. 2.2.3). Apply a thin film of lubricant to the inside surface of the joint ring, where it will come into contact with the entering spigot. The spigot should also be covered with a thin film of lubricant for a distance of 75 mm from the end for pipes DN60-600 and 120mm for pipes DN700-2000 (see Fig. 2.2.4).

Fig. 2.2.3

The incoming spigot must be aligned and entered carefully into the socket until it makes contact with the joint ring. Final assembly of the joint is completed from this position. Do not ‘hook’ the spigot into the socket and lower the pipe into place as this may dislodge the gasket during jointing. The joint is then made by forcing the spigot of the entering pipe past the gasket of the receiving pipe, thus compressing the gasket, until the socket face is positioned between the recommended and the minimum insertion marks (see Fig. 2.2.5).

Fig. 2.2.4

Note: Insertion of the spigot past the recommended insertion mark can lead to damage to the cement lining and reduction in angular deflection and consequently may result in joint failure.

Lubricant

Lubricant

Fig. 2.2.5 2.2.5

Pipes DN700-1200 will be marked with three insertion marks. The first two marks from the spigot end should be used when jointing into fittings, the second two marks should be used when jointing into pipes. This is because on pipes the socket chamber is longer for greater joint deflection. Fig. 2.2.6

L=

Fig. 2.2.7

Minimum spigot insertion depths for pipes and fittings (except fittings DN700-1200)

L1 = Minimum spigot insertion depths for fittings DN700-1200 T=

Maximum spigot insertion depth (L+T) (L/L1+T)or (L1+T)

41

Section 2: Pipe Laying

Table 2.2.1: Minimum and maximum insertion depths

Drawing ID

A

B

A

Insertion Depth Rapid Pipes & Fittings

Nominal Size DN

L mm

60

67

10

80

70

10

100

72

10

125

75

10

150

78

10

200

84

10

250

84

10

300

84

10

350

88

10

400

90

10

450

93

10

500

95

10

600

105

10

700

159

120

15

800

160

130

15

900

160

135

15

1000

160

135

15

1100

178

153

15

1200

185

158

15

1400

194

20

1500

210

20

1600

209

20

1800

216

20

2000

235

20

L1 mm

T mm

Note: Insertion depths for anchor joints joints are are different different - see Section Section 2.4 2.4,for 2.7details. and 2.8 for details. Fig. 2.2.8

If this final assembly cannot be attained by the application of reasonable force, the spigot should be withdrawn and the position of the joint ring examined and replaced if necessary. Where necessary the spigot can be withdrawn from the bottom of the socket by moving the far end of the pipe upwards and sideways for a distance of about 150mm, and then returning to the straight position. Having successfully inserted the spigot, the joint should then be checked to see if the gasket is correctly seated. This is done by inserting a metal rule into the socket gap (see Fig. 2.2.8). The depth of penetration should be equal around the whole circumference. If a difference is found the gasket may have been displaced and the joint should be dismantled and re-made. Assembly of the joint is quick and simple, and may, according to size and local conditions, be carried out by any of the methods described in Section 2.9.

42

Joint Deflection Long radius curves may be negotiated by deflecting the joints (see Fig. 2.2.9). The pipes should be jointed straight and then pulled to the required deflection θ. This deflection should not exceed the recommended deflection for offsets as shown in Table 2.9.1. 2.2.2. The remaining flexibility is required for any subsequent pipeline settlement or ground movement. Fig. 2.2.9

Table 2.2.2 Allowable pipe deflections at flexible joints Table 2.2.2: Allowable pipe deflections at flexible joints Nominal size DN Nominal Size DN 80-300 60 350-1200

Rapid Vi (anchor) Rapid Recommended Deflection for Max. allowable Deflection Recommended Deflection Offsets Max. Allowable Deflection for Offsets mm per m mm per m Degree Degree length of pipe length of pipe θ Degree mm mm 5 87 3 52.5 5 522 3 314 4 70 2 35

1400-1600 80 - 100 1800 125 2000 150 - 300

35 2.5 5 2 5

52.5 480 43.5 522 35 480

1.5 3 1.25 3 1 3

28826 21.5 314 17.5 288

350 - 800

4

383

2

191

900 - 1200

4

558

2

279

1400 - 1600

3

418

1.5

209

1800

2.5

348

1.25

174

2000

2

279

1

139

43

Section 2: Pipe Laying

2.3 Anchor Gaskets Please note that the test and working pressures are restricted on anchor gaskets (see Table 2.3.1). Table 2.3.1: Working pressure (PFA) for anchor gaskets Table 2.3.1: Working and test pressures for use with anchor gaskets Rapid Vi (anchor) DN Class Water 40 Pipe Sewer Diameter 80 DN 100 150 60 200

C40 Working C40 Pressure C40 C4025

22

Test 16Pressure 16 16 35

Working 16 Pressure 16 40 16

250 80 300 100 350

C4023 C40 23 C30

16 32 16 32 16

12 12

125 400

C3022

16 31

12

450 150 500 200 600

C30 18 C30 C3016

13

11

11

26

10 24

16

12

9 8

K9 Test Pressure 53

32

43

32

43

28

39

25

35

20

29

250 16 24 20 29 Note.Allowable test pressure (PEA) operating for the 300 16 and allowable maximum 24 20pressure (PMA) 29 above pipes can easily be calculated by using the following formulas: PMA = PFA 350x 1.2 20 29 25 35 PEA = PMA + 5 bar 400 20 29 23 32 450

-

-

22

31

500

-

-

19

28

600

-

-

18

26

Joint Preparation Thoroughly clean the spigot, interior of socket and gasket. These gaskets should be inserted into the socket dry. Do not lubricate.

Fig. 2.3.1

Fold the gasket as shown in Fig. 2.3.1, taking care to position the inner loop between teeth and insert the gasket into the socket. Apply a thin film of lubricant to the surface of the gasket and to the outside surface of the spigot. Warning: Extra care should be taken as the anchor teeth are very sharp. Note: Please follow the Health and Safety guidance specified on the lubricant packaging. If in doubt refer to manufacturers COSHH sheets.

44

Lubricating Paste

Joint Assembly The jointing method for pipes and fittings using anchor gaskets is the same as for pipes and fittings using normal gaskets, and all forms of jointing tackle described in Section 2.2 can be used. However, with anchor gaskets extra care should be taken to make sure the joint is made ‘in line’. With anchor gaskets a certain amount of axial withdrawal occurs as anchorage is taken up. Care must be taken to ensure that the pipe layout is such that this movement does not cause excessive deflection at any other joints. On buried mains the anchored joint on fittings and pipes must be buried before pressure testing, in order to minimise movement. Where mains are not to be buried all of the necessary securing and strapping of the pipework appropriate to its final installation must be carried out before pressure testing, for the same reason.

Joint Dismantling The dismantling procedure for joints with anchor gaskets is described in Section 2.13.

45

2.4 PAM PAM Universal Universal Rapid 2.5 Rapid Vi Anchor Carefully clean the socket chambers. Pay particular attention to the gasket seat and the anchoring ring seat. Clean the spigot of the pipe to be jointed and the gasket and anchoring ring. If the pipe has been cut it is essential to remake the chamfer and mark 2.4.1 and Table 2.5.1). 2.4.1 Insert the gasket and anchoring ring the jointing depth (see Fig. 2.5.1 into their seats in the socket. Fig. 2.5.1 Fig.2.4.1

cm AA- -12cm

A

Table of A Table 2.4.1: 2.5.1:Dimension Dimensions of A DN DN A(mm) A (mm) DN

80350 112 184 350

100 400

A(mm)

184

176

140 400

176

150 450 148 190 450

200 500

500 250 166 200 600

190

20

209

155

600 300 180 209

Apply lubricant to the exposed surface of the gasket and the spigot end and chamfer. Centre the spigot in the socket and joint using one of the methods previously described. Note: Check the insertion depth on all pipes. The insertion depth is deeper when using the Universal socket due to the double chamber. The pipes should be jointed straight, any deflection can be made once the joint has been completed.

Joint Dismantling joint isjoint is The dismantling procedure for joints with PAM Universal Rapid Vi Anchor described in Section 2.13.

46

49

Section Section 2: PipePipe Laying Laying Section 2:2: Pipe Laying

Fig. 2.5.3 Fig. 2.5.3

2.5 PAM Universal 2.6 Rapid Locked 2.5 PAM PAM Universal Universal Rapid Rapid Ve 2.6 PAM Universal Rapid Ve Locked 2.6 PAM Universal Locked 2.6 PAM Universal Rapid Locked Equipment NeededRapid Equipment Needed Ve Jointjoint the following equipment will bewill be To joint the PAM Universal Rapid locked the following equipment

the following equipment will bewill be To joint the PAM Universal Rapid locked the following equipment Equipment Needed required:Equipment Needed Ve Jointjoint required:2.5.1 will be 1. locked Lockingjoint ringthe insertion toolequipment (Fig. 2.6.1) To joint the PAM Universal Rapid following To joint the PAM Universal Rapid locked joint the(Fig. following 2.5.1 equipment will be 1. Spacer Locking ring2.6.2) insertion tool 2.6.1) 2. (Fig. 2.5.2 required:- required:2. Spacer (Fig. 2.6.2) 2.5.2 1. Locking ring insertionring toolinsertion (Fig. 2.6.1) 1. Locking tool (Fig. 2.6.1) Fig. 2.5.2 Fig. 2.5.1 2. Spacer (Fig. 2.6.2) 2. Spacer (Fig. 2.6.2) Fig. 2.5.2 Fig. 2.5.1

Fig. 2.5.4 2.6.4 Fig. 2.5.4 2.6.4

Fig. 2.6.4

Fig. 2.6.4

Fig. 2.5.5 2.6.5 Fig. 2.5.5 2.6.5

Fig. 2.6.5

Fig. 2.6.6

Fig. 2.6.5

Fig. 2.6.6 Fig. 2.6.6 Fig. 2.5.6 Fig. 2.5.6 Fig. 2.6.6

Carefully clean the socket chambers. Pay particular attention to the gasket seat and Carefully cleanring the seat. socket chambers. Pay particular to the gasket seat and the anchoring Clean the spigot of the pipeattention to be jointed and the gasket and the anchoring ring seat. Clean the spigot of the pipe to be jointed and the gasket and locking ring. Carefully clean the socket particular attention to attention the gaskettoseat Carefully cleanchambers. the socketPay chambers. Pay particular theand gasket seat and locking ring. the anchoring ring seat. Clean the spigot of the pipe to be jointed and the gasket the anchoring ring seat. Clean the spigot of the pipe to be jointed andand the gasket and the gasket into the first chamber (innermost) of the socket as per normal ductile locking ring. Fit locking ring. Fit the gasket into the(see firstFig. chamber 2.5.3 (innermost) of the socket as per normal ductile iron pipe installation 2.6.3). 2.5.3 iron pipe installation (see Fig. 2.6.3). Fit the gasketFitinto firstinto chamber (innermost) the socketofasthe persocket normal thethe gasket the first chamber of (innermost) asductile per normal ductile Insert the(see prongs on the locking ring insertion tool into the holes on the locking ring iron pipe installation Fig. 2.6.3). iron pipe installation (see Fig. 2.6.3). Insert the prongs on the locking ring insertion tool into the holes on the locking ring (see Fig. 2.5.4 2.6.4). (see Fig. 2.5.4 2.6.4). Insert the prongs the locking toolinsertion into the tool holes on the the holes locking Inserton the prongs onring the insertion locking ring into onring the locking ring Rotate the insertion tool so the locking ring is compressed (see Fig. 2.6.5). 2.5.5 (see Fig. 2.6.4). (see Fig.the 2.6.4). Rotate insertion tool so the locking ring is compressed (see Fig. 2.6.5). 2.5.5 Fit the locking into thering second chamber (nearest socket face) of the socket (see Rotate the insertion toolinsertion soring the locking compressed (see Fig.to2.6.5). Rotate the toolthe so second the is locking ring is(nearest compressed (see face) Fig. 2.6.5). Fit the locking ring into chamber to socket of the socket (see 2.5.6 Fig. 2.6.6). 2.5.6 Fig. 2.6.6). Fit the locking thering second (nearest to socket face) the socket Fitring the into locking intochamber the second chamber (nearest to of socket face) of(see the socket (see spacer into the gap in the locking ring. This is to ease the insertion of the spigot Fig. 2.6.6). Fit Fig. 2.6.6). Fit spacer into the gap in Fig. the locking 2.5.7 ring. This is to ease the insertion of the spigot into the locking ring (see 2.6.7). 2.5.7 into the locking ring (see Fig. 2.6.7). Fit spacer into gap into in the locking This is to ease theisinsertion of the spigotof the spigot Fitthe spacer the gap inring. the locking ring. This to ease the insertion Centre the spigot into the socket and use one of the methods described in Section 2.9 into the locking ring (see Fig. 2.6.7). into the locking ring (see Fig. 2.6.7). Centre and useand oneremove of the the methods in Section 2.9 to enterthe thespigot spigotinto intothe thesocket locking ring spacerdescribed (see Fig. 2.6.8). 2.5.8 Push to enter the spigot into the locking ring and remove the spacer (see Fig. 2.6.8). Push 2.5.8 the spigot down to the bottom ofof the socket. The described weld beadinpushes the Centre the spigot into socket and use one the methods Sectionthrough 2.9in Section Centre thethe spigot into the socket and use one The of the methods described 2.9 the spigot down to the bottom of the socket. weld bead pushes through the 2.5.92.6.8). Push lockinginto ringthe andlocking holds the spigot in the socket (see (see Fig. 2.6.9). to enter the spigot ring and remove the spacer Fig. to enter the spigot into the locking ring and remove the spacer (see Fig. 2.6.8). Push 2.5.9 locking ring and holds the spigot in the socket (see Fig. 2.6.9). the spigot down to the down bottom the socket.ofThe bead through the through the the spigot toof the bottom theweld socket. Thepushes weld bead pushes locking ring and holds the spigot in the socket (see Fig. 2.6.9). locking ring and holds the spigot in the socket (see Fig. 2.6.9). Fig. 2.5.8 2.6.8 Fig. 2.5.9 2.6.9 Fig. Fig. 2.5.8 2.6.8 Fig. 2.5.9 2.6.9 Fig.

Fig. 2.6.8

Fig. 2.6.8

Fig. 2.6.9

Fig. 2.6.9

Fig. 2.6.7 Fig. 2.6.7

Fig. 2.6.7

50 50

50

Fig. 2.5.7 Fig. 2.6.7 Fig. 2.5.7

Note:- There are four types of looking rings available. The information contained in this Note:-relates There are four types ring of looking rings available. For information the installation page to the locking for DN250-350. For information on theon installation of the of the other three types (DN100-200, DN 400-700 & DN 8001200) please contact our other types (DN100-200, DN400-700 & DN800-1200) please contact our Technical Jointthree Dismantling Technical Department, Tel. 0700. 0115 930 0700. Joint Dismantling Department, Tel. 0115 930 The dismantling procedure for joints with PAM Universal Rapid locked joints is The dismantling procedure Joint Dismantling described in Section 2.13. for joints with PAM Universal Rapid locked joints is Joint Dismantling described in Section 2.13. The dismantling procedure for joints with Universal Rapid locked joints is joints The dismantling procedure for joints with PAM Universal Rapid Ve joints isjoints described The dismantling procedure forPAM joints with PAM Universal Rapid locked is in In Ve is described described in described Section 2.13. 2.13. in Section 2.13.

47

47

2.6 PAM PAM Directional Direxional 2.7 Fig. 2.6.1

Fig. 2.6.2

Equipment Needed equipment willwill be required:To joint the PAM Direxional Directionalpipes pipesthe thefollowing following equipment be required:1. Rubber protective protectivecollar collar(Fig. (Fig.2.6.1) 2.7.1) 2. Collar Collar (Fig (Fig 2.6.2) 2.7.2) 3. Pulling head head (Fig. (Fig.2.6.3) 2.7.3) 4. Locking ring insertion insertiontool tool(Fig. (Fig.2.6.4) 2.7.4) 5. Spacer (Fig. (Fig. 2.6.5) 2.7.5) 6. Dismantling DismantlingShims Shims(Fig. (Fig.2.6.6) 2.7.6)

Fig. 2.6.4 2.7.4

Fig.2.6.5 2.7.5 Fig.

Fig. 2.7.3

Fig. 2.6.3

Fig. 2.7.6

Method Ensure that the rubber protective collar is on the spigot end of pipe (Fig. 2.7.7) 2.6.7 to be jointed (pulled back slightly from the joint) and that the metal sheet is fitted via the spigot end of the jointing pipe and pulled adjacent to the socket (Fig. 2.7.8). 2.6.8 Fig. 2.6.7 Fig. 2.7.7

Fig. 2.6.8 Fig. 2.7.8

Carefully clean the socket chambers. Pay particular attention to the gasket seat and the anchoring ring seat. Clean the spigot of the pipe to be jointed and the gasket and locking ring. Fit the gasket into the first chamber (innermost) of the socket as per normal ductile iron pipe installation (see Fig. 2.7.9). 2.6.9 Fig. 2.6.9 Fig. 2.7.9

Fig. 2.6.10 Fig. 2.7.10

Fig. 2.6.6

48

51

Section 2: Pipe Laying Section 2: Pipe Laying

Fig. Fig.2.6.11 2.7.11

Insert the prongs on the locking ring insertion tool into the holes on the locking ring (see Fig. 2.7.10). 2.6.10

Fig. 2.7.11

Insert the prongs on the locking ring insertion tool into the holes on the locking ring 2.6.11 Rotate insertion tool so the locking ring is compressed (see Fig. 2.7.11). (see Fig.the 2.7.10). Fit the locking ring into chamber to socket of the socket (see Rotate the insertion toolthe so second the locking ring is(nearest compressed (see face) Fig. 2.7.11). Fig. 2.7.12). 2.6.12

Fit the locking ring into the second chamber (nearest to socket face) of the socket (see Fit into the gap in the locking ring. This is to ease the insertion of the spigot Fig.spacer 2.7.12). 2.6.13 into the locking ring (see Fig. 2.7.13). Fig.2.6.12 2.7.12 Fig.

Fig. 2.7.12

Fit spacer into the gap in the locking ring. This is to ease the insertion of the spigot Lubricate the gasket and the into the locking ring (see Fig. spigot 2.7.13).and push the spigot end of pipe into the socket (see Fig. 2.7.14). 2.6.14 Lubricate the gasket and the spigot and push the spigot end of pipe into the socket (see Fig. 2.7.14). Fig. Fig. 2.6.15 2.7.15 Fig. 2.7.14 2.6.14 Fig. Fig. 2.7.14

Fig. 2.7.15

Fig. 2.7.13 Fig. 2.6.13 Fig. 2.7.13

Cover the joint with the rubber protective collar. Position the metal sheet over the rubber protective collar and Hammer the metal sheet at edges to ensure it remains in place Fig. 2.7.15). 2.6.15 Cover (see the joint with the rubber protective collar. Position the metal sheet over the

rubber protective collar and Hammer the metal sheet at edges to ensure it remains in The ready to be pulled into drilling channel. placepipe (seeisFig. 2.7.15). Note.- There are four types of looking rings available. For information on the The pipe is ready be pulled drilling channel. installation of thetoother threeinto types please contact our Technical Department, Fitting the Pulling head Tel. 0115 930 0700. When fitting the pulling head some of the cement coating will have to be removed on Fitting Pulling the leadingthe pipe only. This is head so that the dismantling shims can be inserted to remove the pulling head when the pipes have installed. When fitting the pulling head some ofbeen the cement coating will have to be removed on the leading pipe only. This is so that the dismantling shims can be inserted to remove Firstly, use one ofwhen the shims (see Fig. to mark from the edge of the cement the pulling head the pipes have2.7.16) been installed. coating (see Fig. 2.7.17). Firstly, use one of the shims (see Fig. 2.7.16) 2.6.16 to mark from the edge of the cement coating (see Fig. 2.7.17). 2.6.17 Fig. 2.7.16 Fig. 2.7.17 Fig. Fig. 2.7.16 2.6.16

52

52

Fig. 2.6.17 2.7.17 Fig.

49

Fig. Fig. 2.7.18 2.6.18

Fig. 2.7.19

Use a hammer and chisel to remove the cement coating up to the score mark (see Fig. 2.7.18). 2.6.18

Fig. 2.6.19 Fit the the gasket gasketand andlocking lockingring ringand (seelubricate Fig. 2.7.19) and lubricate the(see gasket spigot (see the gasket and spigot Fig.and 2.6.19 and Fig. Fig. 2.7.20). 2.6.20). Place the pulling head onto spigot of pipe and use the digger bucket (or jointing 2.6.21 tackle) to push the locking ring over the welded bead (see Fig. 2.7.21).

Fig. 2.7.21 2.6.21 Fig.

Fig. 2.7.20

Fig. Fig.2.6.22 2.7.22

Fig. 2.6.20 To remove the pulling head use a hammer to knock the dismantling shims under the 2.6.22 The pulling head can now be locking ring up to the welded bead (see Fig. 2.7.22). removed.

Jointing to ‘normal’ mains Direxional pipes asas normal with PAM Natural andand PAMPAM Integral PAM Directional pipescan canbebejointed jointed normal with PAM Natural Integral pipes and fittings. Pipes

Dismantling To Dismantle, use the method described for removing the pulling head.

50

53

Section 2: Pipe Laying

2.7 Rapid Rapid Ve Joint (Mechanical) 2.4 Mechanical Anchor Preparation joint (Mechanical) is achieved Anchorage using the Rapid Ve mechanical anchoredDN80-1200 joint (DN80-1200) is by achieved by pushing a spigot into a socket, then holding it in position with an anchoring system 2.7.1 comprising a locking ring and bolted gland (see Fig. 2.4.1). Fig.2.7.1

If a pipe has been cut on site, the spigot will require the correct chamfer and radius (refer to Section 1.5) and the anchor bead will have to be welded on (refer to Section 2.10).

Fit the Locking Ring and Gland Carefully clean the locking ring and gland, particularly at the points indicated in Fig. 2.7.2. 2.4.2.

Fig.2.7.2 Fig. 2.4.2

Place the gland and ring on the spigot of the pipe to be jointed, behind the welded bead. The slope of the outer face of the locking ring needs to correspond to the slope of the inner face of the gland ring, i.e. thick end towards the welded bead (see Fig. 2.7.3). 2.4.3).

Clean Fig.2.7.3 Fig. 2.4.3

DN350-700 one-piece locking ring. The ring has to be opened by prizing with a wedge, crowbar or similar, inserted into the opening (see Fig. 2.4.4). 2.7.4). The spring of the locking ring is strong and care must be taken when prising the locking ring open not to trap fingers.

Fig. 2.4.4 Fig.2.7.4 450 180

4

40

60

4

Note: This UK. Note: This wedge wedgeisisnot notsupplied suppliedbybySaint-Gobain Saint-GobainPAM Pipelines.

46

51

DN800-1200 Segmented locking ring. For larger diameters the locking ring consists of several segments, joined together by rubber connecting pieces which are held in place 2.7.5 by two pins (see Fig. 2.4.5). Fig. 2.7.5

Fig. 2.7.6

Fig. 2.4.7

The slope of the rubber connecting pieces should face the same way as that of the locking ring segments (see Fig. 2.4.6). 2.7.6 Place a connecting piece in one end of the segment by inserting it into the notch in the plane face of the ring. Using a suitable drift, insert a pin, previously coated with jointing lubricant. Orientate the pin so that the sloping face corresponds with that in the elastomer lining then hammer it home (see Fig. 2.4.7). 2.7.7

Fig. 2.7.7

The remaining links are assembled in the same way to form a complete ring. The number of links required for each diameter are: ● 7 for DN800 ● 8 for DN900 ● 9 for DN1000 ● 11 for DN1200

Pipe Jointing Using a wedge, crowbar or similar, lever the locking ring onto the pipe spigot and position it behind the weld bead, ensuring a correct fit (see Fig. 2.4.8). 2.7.8

Fig. Fig.2.7.8 2.4.8

Mark the spigot insertion depth at a distance ‘a’ from the welded bead on the pipe spigot being laid (see Fig. 2.4.9). 2.7.9 The value of ‘a’ is indicated in Table 2.4.1. 2.7.1 Make sure the gasket and socket are clean and insert the gasket into the socket and lubricate the exposed surface of the gasket and the pipe spigot and chamfer, using jointing lubricant. Table 2.4.1: anchor joints 2.7.1 Spigot insertion mark for mechanical Rapid Ve joint. Fig. 2.4.9 Fig. 2.7.9 Jointing mark

52

a

DN

80 - 100

150 - 200

250 - 500

600 - 1000

1200

a (mm)

20

25

30

35

25

47

Section 2: Pipe Laying

Fig. 2.7.10 2.4.10

Jointing mark drawn on spigot

Using the methods described in Section 2.2, insert the spigot, checking the alignment of the assembled components until the jointing mark on the spigot is in line with the 2.7.10 socket face (see Fig. 2.4.10). Do not go beyond this point, to avoid the pipe making contact with the lining and to allow the possibility of joint deflection. Bring the locking ring into contact with the welded bead. Check that it fits snugly on the pipe spigot and against the weld bead (see Fig. 2.4.11). 2.7.11 Place the gland in contact with the ring and centre it.

Fig. 2.7.11 Fig. 2.4.11 Locking ring

Clean, lubricate and insert the bolts and screw on the nuts by hand until they contact the gland (see Fig. 2.7.12 2.4.12). Tighten the nuts until there is gland-socket face contact (this is when there is a rapid increase in tightening torque). The nuts must be tightened diametrically opposite one another to 50Nm. If lifting tackle is used it must not be removed until the joint is completely assembled.

Fig. 2.4.12 Fig. 2.7.12

The pipes must be jointed in a straight line. After assembly, the joint can be deflected if required, within the permissible limits (see Table 2.4.2). 2.7.2 Note: Anchor joints, aamount certain of amount of axial withdrawal as Note:With With Mechanical Rapid Ve joints, a certain axial withdrawal occurs asoccurs anchorage is anchorage is taken up. Care must be taken to ensure that the pipe layout is such that this taken up. Care must be taken to ensure that the pipe layout is such that this movement movement doesexcessive not cause deflection excessive deflection at anyjoints flexible joints or excessive does not cause at any flexible or excessive bendingbending moments moments at anyjoint. flanged joint. at any flanged Where self-anchored mains are buried, the required backfill and embedment must be in place before pressure testing in order to minimise any movement caused by the pipeline 'snaking'. Where mains are not to be buried, all the necessary securing and strapping of the pipework appropriate to its final installation must also be carried out before pressure testing. The bolts and joint area of this system will require extra protection. The minimum protection should be petrolatum tape/mastic blanket and PE sleeving, or, if necessary, a protection system equal to the protection system applied to the pipes. Table 2.7.2 Allowable pipe deflections Table 2.4.2: Allowable pipe deflections for mechanical anchor joints Nominal Size Nominal DNsize DN 80 - 150

Recommended Deflection Mechanical anchor joint Max. Allowable Deflection for Offsets Recommended Deflection for Max. allowable Deflection Offsets mm θ Degree mm

200 - 300 80-150 350 - 600 200-300

43

mm480 per m length of pipe 384 87 288 70

350-600 700 - 800

32

52.5 192

1.5 1

9626

700-800 900 - 1100 900-1200 1200

21.5 1.5 1.5

35 183 26 209

1 0.5 0.5 0.5

17.5 61 8.5 69

5 Degree 5

4

3 Degree 2.5 3 1.5 2.5

mm 288per m length of pipe 240 52.5 144 43.5

Joint Dismantling Once the Rapid Mechanical Anchor boltsremoved, have been the procedure dismantling procedure is asjoint, Ve bolts have been theremoved, dismantling is as for the Rapid for Rapid joint, see Section 2.13. see the Section 2.13.

48

53

Section 2: Pipe Laying

2.8 PAMLOCK PAMLOCK is the mechanical anchor system for water and sewer pipes DN1400-2000.

Equipment Needed To joint the PAMLOCK pipes the following equipment will be required:1. Conformator (Fig. 2.8.1) 2. Segmented locking ring (Fig 2.8.1) 3. Wire rope, clips & turnbuckle (Fig. 2.8.2) 4. Conformator gauge (Fig. 2.8.6) 5. Hydraulic jack (Fig. 2.8.7) 6. Conformator clamp (Fig. 2.8.8) 2.8.5) 7. Conformator wedge (Fig. (Fig. 2.8.6) 2.8.8) 8. Shot reservoir and shot (Fig. 2.8.9) 9. Pneumatic vibrator and compressor (Fig. 2.8.9) Carefully clean the socket chambers. Pay particular attention to the gasket seat and the anchoring chamber. Clean the spigot of the pipe to be jointed and the gasket and locking ring. Fit the gasket into the first chamber (innermost) of the socket as per normal ductile iron pipe installation.

Fig. 2.8.1

Fit the conformator on the spigot of the pipe to be jointed and position behind, but clear of the welded bead with the lip towards the next socket and the gap at the top (see Fig. 2.8.1). Next fit the segmented locking ring behind the welded bead. The locking ring consists of several segments, joined together by rubber connecting pieces which are held in place by two pins.

Fig. 2.8.1

Locking Ring

Conformator

Measure and mark the insertion point (see Table 2.8.1). Table 2.8.1 Pamlock insertion point

Locking Ring

Conformator

DN

1400

1600

1800

2000

Insertion Point (mm)

280

295

305

330

Fig. 2.8.2 Fit the turnbuckle and wire rope round the conformator and tighten the turnbuckle to pull the conformator close to the pipe spigot (see Fig. 2.8.2). Fig. 2.8.2

Fig. 2.8.3 2.8.3

Fig. Fig.2.8.4 2.8.4

Centre the spigot into the socket and push the spigot into the socket until the insertion point is reached (see Fig. 2.8.3). The conformator should be just outside the socket (see Fig. 2.8.4).

54

Fig. 2.8.5

Fig. 2.8.7 Fig. 2.8.7

Fig. 2.8.6

Fig. 2.8.6

Using a hammer, carefully position the conformator into the socket (see Fig. 2.8.5). Remove the wire rope and turnbuckle and use the gauge to check the correct depth of the conformator (see Fig. 2.8.6). Fit the conformator clamps and jack apart using the hydraulic jack (see Fig. 2.8.7). Use wedges to hold the conformator clamps in place (see Fig. 2.8.8) and lock using grub screw. Attach the shot reservoir to one of the conformator clamps and the pneumatic vibrator in the middle of the conformator clamps (see Fig. 2.8.9). The shot is used to fill the gap between the conformator lip and the inside of the socket face. Connect the vibrator to the compressor and fill the reservoir with shot. Switch the vibrator on and the shot will run down into the joint. The shot must be topped up when required.

Fig. 2.8.8 Fig. 2.8.8

When no more shot is being used remove the reservoir from the conformator clamp and position it in the other conformator clamp and repeat the process for the other side. Careful examination of the gap between the socket face and conformator ring will reveal small holes that can be used for inserting a wire gauge to assess the level of the shot inside the joint. The conformator clamps stay in place on the joint after assembly.

Fig. 2.8.9 Fig. 2.8.9

55

Section 2: Pipe Laying

2.9 Jointing Methods Trench excavator method - DN60-2000 80 This is by far the most widely used system. Where the trench is being prepared by using a backhoe type excavator, this machine may also be used to push the spigot home. A timber header should be placed between the pipe and the backhoe bucket to prevent damage to the pipe (see Fig. 2.9.1). The operation should be carried out with great care to avoid the over insertion of the spigot. Fig. 2.9.1

Fig. 2.9.2

80 Crowbar method - DN60-100 DN80 100 complete entry of of thethe spigot intointo the the socket maymay be be For joints DN 80and – DN100 complete entry spigot socket achieved by pushing with a crowbar or suitable lever against a timber held against the face of the socket of the entering pipe (see Fig. 2.9.2).

Fork tool method - DN80-200 For joints DN80 to DN200 a fork type tool may be used for assembly. Enter the spigot into the socket until contact with the gasket is made. Place the fork over and behind the socket of the last pipe laid and attach the eye of the wire rope to the hook on the fork tool. Thread the plain end of the rope through the rope grip on the socket hook and place the hook into the socket of the pipe to be jointed. Take up the slack in the rope and pull on the fork tool to complete the joint (see Fig. 2.9.3). Reasonable force only should be used.

Fig. 2.9.3

56

Side link jointing tackle - DN80-400 Fig. 2.9.4

Fig. 2.9.5

Fig. 2.9.6

The side side link linkjointing jointingtackle tackleset setcomprises comprises:a socket frame, a spigot clamp and two levers/ socket frame; 1 spigot clamp; 2 lever/spanners (see Fig. 2.9.4) spanners.1See Fig 2.9.4 Fig. 2.9.7

Please note that each set of jointing tackle is size specific, e.g. a 250mm set will only joint a 250mm pipe.

Method Enter the spigot into the socket until contact with the gasket is made. Mount the socket frame immediately behind the socket of the installed pipe (see Fig. 2.9.5). Fig. 2.9.8 Secure with the chain (see Fig. 2.9.6). Place the spigot clamp loosely around the spigot with the lugs towards the socket face (see Fig. 2.9.7). Position the slots in the side links of the socket frame onto the lugs of the spigot clamp and tighten the clamp onto the pipe (see Fig. 2.9.8).

Fig. 2.9.9

Draw the spigot into the socket by turning the nuts on the lugs with the levers, taking care to exert an even pull on each side to prevent uneven entry (see Fig. 2.9.9). If jointing anchor gaskets, on completion of the joint, the levers should be pushed sharply in the opposite direction to check that anchorage is effective. On tape wrapped pipe it is often necessary to remove the wrapping at the spigot end in order to get the spigot clamp into position. Any damage to the coating or protection system must be repaired before reinstatement. Please refer to Section 1.4.

57

Section Laying Section 2: 2: PipePipe Laying

Rack and lever method - DN80-450

Rack and lever method - DN80-450 Fig. 2.9.10 Fig. 2.9.10

Fig. 2.9.11

Fig. 2.9.11

Fig. 2.9.12

Fig. 2.9.12

a rack with hook bolt, two long wire ropes, a short The rack rack and andlever leverjointing jointingset setcomprises comprises:wire rope,1arack extension tube and a socket hook. See Fig. 2.9.10wire rope; 1 extension tube; with hook bolt; 2 long wire ropes; 1 short The rack and leverhook jointing 1 socket (seeset Fig.comprises:2.9.10). 1 rack with hook bolt; 2 long wire ropes; 1 short wire rope; 1 extension tube; 1 socket hook (see Fig. 2.9.10).

Method - Pipes:

Fig. 2.9.13

Fig. 2.9.13

Enter the spigot into the socket until contact with the gasket is made. Place the rack Pipes: - Pipes: Method assembly on the socket of the installed pipe and fully extend the rack (see Fig. 2.9.11). Enter the spigot into the socket until contact with the gasket is made. Place the rack assembly thebolt socket of lowest the installed pipe and fully the extend thethe rack (seewire Fig. 2.9.11). Screw theon hook to its position and attach eye of short rope (see Fig. 2.9.12). Screw the hook bolt to its lowest position and attach the eye of the short wire rope (see Pass Fig. the 2.9.12). rope under the pipe making sure it is positioned behind the guide lugs and thread the plain end up through one side of the rope grip (see Fig. 2.9.13). Pass the rope under the pipe making sure it is positioned behind the guide lugs and thread plain end through thedown rope the gripother (see Fig. Pass thethe rope over theuptop of the one ropeside gripof and side2.9.13). (see Fig. 2.9.14). Pass the rope over the top of the rope grip and down the other side (see Fig. 2.9.14).

Fig. 2.9.14

Fig. 2.9.14

58

58

Fig. 2.9.15

Take up the slack and secure in the rope grip. Tighten the nut on the hook bolt until the rack assembly is secure (see Fig. 2.9.15). Attach the eye of one long wire rope to the socket hook and place the socket hook over the end of the pipe (see Fig. 2.9.16). Thread the plain end of the rope through the rope grip on the rack (see Fig. 2.9.17).

Fig. 2.9.16

Take up the slack in the rope and pass the rope round the rope grip and back through the taper to secure the rope grip (see Fig. 2.9.18). Fit the extension tube to the lever on the rack assembly and operate to complete the joint (see Fig. 2.9.19).

Fig. 2.9.17

Fig. 2.9.18

Fig. 2.9.19

59

Section 2: Pipe Laying

Fig. 2.9.20

Fittings:Attach the rack assembly as described. Form loops in the two long wire ropes by passing the plain ends through the eyes (see Fig. 2.9.20). Position the loops behind the socket of the fitting with the eyes diametrically opposite and on the horizontal centre line (see Fig. 2.9.21). Thread the plain ends of the ropes through the rope grips on the rack. Take up the slack ensuring that both ropes are equally taught (see Fig. 2.9.22). Operate extension tube to complete the joint.

Fig. 2.9.21 To dismantle the tackle, release tension on ropes by moving handle and ratchet back (see Fig. 2.9.23). To release the ropes strike the rope grip with hammer (see Fig. 2.9.24).

Fig. 2.9.22

Fig. 2.9.24

60

Fig. 2.9.23

Tirfor Method - DN60-2000 80

Tirfor Method - DN80-2000

Tirfor winching equipment is available with both mechanical and hydraulic winches. Manufacturers operating instructions should be followed.

Fig. 2.9.25

Pipes Enter the spigot into the socket until contact with the gasket is made. The wire rope should be looped and positioned behind the socket, the free end should then be attached to the Tirfor. The second wire rope can then be threaded through the winch and, using a hook, the joint is now made by operating the winch (see Fig. 2.9.25).

Fig. 2.9.26

Larger pipes and fittings will require the use of more than one Tirfor (see Fig. 2.9.26). Ensure that the joints are kept straight whilst jointing. DN60-300: One Tirfor 516 winch. 80 DN350-600: One Tirfor 532 winch. DN700-1200: Two Tirfor 532 winches, diametrically opposite. DN700-1200: 532winches, winches,120° 120°apart. apart. 1400-2000:Three Three Tirfor Tirfor 532

Fig. 2.9.27

Fittings The wire rope should be looped and positioned behind the socket, the free end should then be attached to the Tirfor. The second wire rope should be looped and positioned behind the socket of the fitting. The joint is now made by operating the winch (see Fig. 2.9.27).

61

Section 2: Pipe Laying

Jointing Tackle - DN450-600

Jointing Tackle - DN450 -600

Fig. 2.9.28

Fig. 2.9.29

This jointing tackle was designed for jointing pipes and fittings using anchor gaskets but may be used for ordinary gaskets aswell. The equipment supplied by Saint-Gobain Pipelines shown Fig. 2.9.28. DN there is a socket harness a spigot PAM UK isisshown in in Fig. 2.9.28. For For eacheach DN there is a socket harness and aand spigot clamp. The bolt sets are common for these three sizes. In addition to the tackle supplied the following is required: 150Nm torque wrench, 30mm extension socket and 30mm AF spanner. Joint assembly is most efficient with two people, each with a wrench and spanner.

Method Locate the spigot in the socket and make sure that the pipes are in line. When jointing fittings, always ensure the socket face is square with the pipe axis. Assemble the spigot clamp around the spigot, with the bolt lug adjacent to the two clamping bolts at the top of the pipe. This is easier if the female end of the clasp is fed under the pipe first (see Fig. 2.9.29).

Fig. 2.9.30

Locate the two spigot clamp bolts (220mm in length) and loosely fit the nuts with washers (see Fig. 2.9.30). Remove the locking pin from the socket harness and locate the harness behind the socket with the locking pin housing away from the socket face. Replace the locking pin (see Fig. 2.9.31). Push the socket harness up onto the socket and locate the three threaded bars. Adjust position of spigot clamp to give full thread engagement with the nuts. The nuts are domed at one end for location in the chamfered bolt-holes.

Fig. 2.9.31

Clamp spigot clamp to spigot with a torque of 150 Nm. Check that the threaded bar bolt-holes are in line by making sure that the top threaded bar is square to the socket clamp and the spigot harness. To make the joint, tighten the domed nuts equally until the correct insertion is achieved. Check that the socket face remains square during tightening (see Fig. 2.9.32).

Fig. 2.9.32

Remove the socket harness and threaded bars. If jointing anchor gaskets, locate the two 180mm bolts in the spigot clamp tubes and tighten the bolts to engage the anchor teeth. Remove spigot clamp and repair any coating damage. Please refer to Section 1.4. Note: If the pipes are tape wrapped the spigot clamp can be further restrained by tightening the grub screws positioned at each bolt lug, after tightening the two spigot clamp bolts. Do not over tighten the grub screws. On completing the joint repair any coating damage (please refer to Section 1.4). Before using the spigot clamp again, unscrew the grub screws so that they are flush with the inside of the clamp ring. Keep bolt sets clean and well lubricated.

62

Section 2: Pipe Laying

2.10 Anchor Bead Application When the mechanical anchoring system or Universal Rapid locked is used Ve jointjoint is used the the pipes are supplied with a factory applied welded bead. However, where the pipe is cut on site, the following procedure should be followed for on site bead welding.

Fig. 2.10.1

All site welding must be undertaken by a skilled welder. High nickel welding rods will be needed. The recommended welding rods are ‘Gricast 31’, Eutectic ‘Xuper 2240’ or equivalent. A copper guide ring will also be required which can be ordered through Saint-Gobain Pipelines. PAM UK. Carefully grind the area application overover a width of 25mm. The grinding must Carefully grind/linish the for areabead for bead application a width of 25mm. The grinding/linishing mustaffect not affect the pipe thickness 2.10.1). not the pipe thickness (see(see Fig. Fig. 2.10.1). Position and clamp the copper ring behind the weld position, paying attention to dimension ‘a’ ‘L’ in Table 2.10.1. The ring must fit the pipe snugly. Tap it lightly with a hammer if necessary to obtain a good fit (see Fig. 2.10.2).

Fig. 2.10.2 a c

b

Deposit the weld bead against the copper ring, to give a flat face vertical to the pipe surface. The bead must be applied in a single pass by an experienced welder using 3.2mm diameter electrodes. Work preferably between positions ‘A’ and ‘B’ (see Fig. 2.10.3). Keep to this working area by rotating the pipe. Table 2.10.1: Key dimensions of weld bead Fig. 2.10.3

5° B

Welding direction A

Start of weld

Tim ber

Fig. 2.10.4

b c aL Nominal Nominal Tolerance Nominal Tolerance Nominal Tolerance Size DN mm mm mm mm mm mm

No. of Passes

80

85

±3

7

±1

3

±1

1

100

90

±3

7

±1

3

±1

1

125

95

±3

7

±1

3

±1

1

150

95

±3

7

±1

3

±1

1

200

100

±3

7

±1

3

±1

1

250

110

±3

7

±1

3

±1

1

300

115

±3

7

±1

3

±1

1

350

114

±3

7

±1

3.5

±1

1

400

113

±3

8

±1

3.5

±1

1

450

120

±3

8

±1

3.5

±1

1

500

125

±3

8

±1

4

±1

1

600

135

±3

8

±1

4

±1

1

70 700

158

±3

8

±1

4

±1

1

800

150

±3

8

±1

4

±1

1

900

155

±3

9

±1

4

±1

1

1000

165

±3

9

±1

4

±1

1

1100

165

±3

9

±1

4

±1

1

1200

170

±3

9

±1

6

±1

1

Dimensions on contact our TechnicalSales SalesDepartment. Department, Tel: 0115 For Dimensions onDN1400-2000 DN1400-2000please please contact Technical 930 0700. Epoxy Peinture

It is important to keep to the ‘b’ and ‘c’ bead dimensions given in Table 2.10.1. Remove the copper ring and clean the weld bead using a wire brush. A brush can then be used to apply a solvent based epoxy (see Fig. 2.10.4) on the bead as well as on the chamfer (if pipe has been cut). For details of radius and chamfer see Section 1.5.3. It is essential that any protection system is repaired, see Section 1.4 for details.

64

63

2.11 Flanged Joints Fixed flanged joints

Fig. 2.11.1

8

The following tasks should be performed in sequence in order to bolt a flanged joint.

1

4

5

6

3

●

Ensure that the faces of the flanges are flat, clean and free from dirt or particles of foreign matter.

●

Use only undamaged rust free bolts, nuts and washers. Lubricate the bolt threads and all mating surfaces of nuts, washers and flanges using a suitable lubricant (when used on pipes intended for use with potable water, the lubricant should have WRc approval. For use on pipes intended for use with sewage and waste water, an automotive oil or grease will be satisfactory).

●

Location bolts may be inserted in the first four positions as shown in Fig. 2.11.1.

●

Use only 3mm thick, 80 IRHD hardness synthetic rubber gaskets to EN681-1 (20) and and with dimensions to suit the flange rating.

●

Position the gasket on the location bolts.

●

Offer the adjoining flange to bolts.

●

Lightly tighten the four location bolts in the order as shown in Fig. 2.11.1 to secure the adjoining flange.

●

Insert the remaining bolts and, using a torque wrench, tighten in the correct sequence (see Fig. 2.11.1). Where flanges have more bolts than shown follow the principle of tightening diametrically opposite bolts.

●

Tighten gradually and ensure that a sufficient number of circuits are undertaken to achieve the specified bolt torque (see Table 2.11.1).

●

Because of potential gasket creep, leave for one hour, check and, if necessary, retighten bolts. Repeat the checks until the bolts will not tighten any more.

7

2

8 Bolts 1

4 2

3

4 Bolts Fig. 2.11.2 3 2 1 3

1

2

Second First Quadrant Quadrant First Second Quadrant Quadrant

2

2 1

3 1

3

12 Bolts or more

For sizes having 12 bolts or more it is recommended that two jointers work simultaneously on diametrically opposite bolts. Each jointer tightens the first nut in the first quadrant, then the first nut in the second quadrant, returns to the second nut in the first quadrant and so on (see Fig. 2.11.2).

Bolting torque Table 2.11.1 2.5.1 indicates the approximate bolting torque required to seal flanged joints against internal pressure. Where the installation is such that high bending moments Technical Sales Department, Tel 0115 could be induced at these joints, please contact consult our Technical Sales Department. 930 0700. The relationship between applied torque and the actual load imparted by the bolts is not precisely predictable, therefore the values given in the charts are an approximate guide.

64

65

Section 2: Pipe Laying

Table 2.11.1: Approximate bolting torque for PN16, PN10 and PN25 fixed flanges Approximate Bolting Torque in Nm for Fixed Flanges Nominal Size DN

PN 16 Flanged Joints

PN 10 Flange Joints

PN 25 Flanged Joints

To Seal To Seal To Seal To Seal To Seal To Seal To Seal To Seal To Seal To Seal To Seal at 10 bar at 16 bar at 20 bar at 25 bar at 5 bar at 10 bar at 16 bar at 20 bar at 25 bar at 30 bar at 35 bar

80

70

70

75

75

70

70

70

80

85

85

85

100

75

80

80

80

70

75

80

120

125

130

130

150

115

120

125

135

110

115

120

180

185

195

210

200

110

115

120

130

120

130

140

170

180

190

205

250

155

165

175

180

110

120

130

230

250

275

305

300

165

180

190

210

120

130

145

220

235

265

295

350

160

175

185

200

115

125

135

290

330

375

415

400

200

220

235

270

155

170

185

380

435

495

555

450

195

215

230

260

150

165

180

355

410

470

525

500

240

270

295

345

155

170

195

415

485

555

625

600

305

365

425

505

200

225

275

595

700

800

905

700

350

465

540

635

200

230

295

675

795

915

1040

800

470

630

735

870

250

300

405

965

1150

1330

1510

900

475

645

760

900

250

300

415

990

1185

1375

1565

1000

605

835

985

1175

300

390

535

1355

1620

1885

2155

1100

610

850

1005

1205

300

395

550

1380

1655

1930

2205

1200

810

1140

1360

1630

360

495

695

1610

1940

2265

2595

1400

915

1300

1555

1875

420

590

840

1980

2395

2805

3215

1600

1180

1690

2035

2460

530

765

1095

2265

2745

3225

3705

Note: The need to seal a flanged joint at a pressure greater than the flange PN rating is only for site hydrostatic test purposes. Flanged joints should not be operated at these higher values. On flanged joints using elastomeric gaskets some relaxation of the gasket will be experienced and it should be ascertained that the bolting torque required to effect a seal at the appropriate pressure, as shown in the charts, are effective at the time of pressure testing. Bolt torques do not have to be restricted to those applicable for a specific test pressure and higher torque can be applied up to the maximum rated test pressure of the appropriate flange. On certain sizes of concentric tapers the bolt hole patterns differ at either end. In these cases there is a raised triangle between two bolt holes. This mark should be at the top of the taper when fitted. Technical Sales Department, Tel Please 0115 930 0700. Please that to when bolting to of valves, For other flange flangeratings ratingsplease pleasecontact contactour the Technical Sales Department. note that whennote bolting valves, some the some of the valve flanges are grey iron and will require longer bolts. valve flanges are grey iron and will require longer bolts. For details please contact the Technical Sales Department.

66

65

Adjustable flanges The following tasks should be performed in sequence in order to bolt a flanged joint with rotating flanges. ●

Ensure that the faces of the flanges are flat, clean and free from dirt or particles of foreign matter.

●

Location bolts may be inserted in the first four positions as shown in Fig. 2.11.1.

●

Position the gasket on the location bolts.

●

Align and offer the adjoining flange to bolts.

●

Lightly tighten the four location bolts in the order as shown in Fig. 2.11.1 to secure the adjoining flange.

●

Insert the remaining bolts and, using a torque wrench, tighten in the correct sequence (see Fig. 2.11.1). Where flanges have more bolts than shown follow the principle of tightening diametrically opposite bolts.

●

Tighten gradually and ensure that a sufficient number of circuits are undertaken to achieve the specified bolt torque (see Table 2.11.2).

Table 2.11.2: Approximate bolting torque for PN10, PN16, PN25 rotating flanges and fixed flanges using gaskets with metal inserts

DN 60 80 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1100 1200 1400 1600 1800 2000

Metal Reinforced Gaskets Approximate Bolting Torque in Nm for Rotating Flanges PN 10 PN 16 PN 25 40 40 40 40 40 40 40 40 40 40 40 60 60 60 80 60 60 80 60 80 80 60 80 120 60 80 120 80 120 150 80 120 180 80 150 180 120 180 300 120 180 400 150 300 500 150 300 500 180 400 600 180 400 600 300 500 600 400 500 700 500 600 700 500 600 800 500 700 800

Note: Adjustable flanges utilise different bolt lengths to fixed flanges, please please contact consultour Technical 930 0700. Technical Sales SalesDepartment, DepartmentTel for0115 information. The bolt torques given here are for lubricated bolt threads. Bolt tightening is only for gasket compression and should not exert any tractive force on the pipeline components.

66

For other flange ratings please contact the Technical Sales Department.

67

Section 2: Pipe Laying

2.12 Couplings and Adaptors These instructions are for couplings and adaptors supplied by Saint-Gobain PAM Pipelines, UK and should not be applied to any other manufacturers’ product range. Where other manufacturers product ranges are to be used the manufacturers’ instructions should be followed. Note – These couplings and adaptors are not designed to take thrust. Adequate restraint will be required to prevent end load of the fitting.

mLINK coupling DN50-300 PAM DN50-300 PAMuLINK uLINKcoupling NG couplings DN50-300 The following should be checked prior to the fitting of the unit:● The pipe ends should be clean and free from weld spatter, heavy score marks, dents and protrusions which would prevent an adequate seal to be made. ●

The pipe outside diameter is within the range of the coupling.

●

3° per pipe, 12° 6° inintotal. The deflection of the pipes is within the maximum of 6° total.

1. 1. Measure Measure the the length length of of the the coupling, coupling, loosen loosen the the gland gland nuts nuts and and push push the the coupling coupling onto one of the pipe sections. onto one of the pipe sections. 2. the pipe ends ensuring there is a general gapthe of seal 7mm to 16mm between 2. Offer Note –upFor DN80, DN100 & DN150 couplings ensure retaining lugs are the two ends. aligned in the end ring. 3. andpipe markends the ensuring pipe fromthere the joint, for halfgap theof length ofto the coupling – this 3. Measure Offer up the is a general 10mm 15mm between will aid centering the coupling over the pipe ends. the two ends. 4. the and coupling overfrom the joint and tighten progressively a 4. Place Measure markbody the pipe the joint, for halfthe thegland lengthnuts of the coupling – in this diametrically opposite sequence until torque of 53Nm to 61Nm (40 to 45 lbf.ft) is will aid centering the coupling over thea pipe ends. achieved. 5. Place the coupling body over the joint and tighten the gland nuts progressively in a diametrically opposite sequence until a torque of 53Nm to 61Nm (40 to 45 lbf.ft) is PAM uQUICK flange adaptor DN50-300 achieved.

PAM uQUICK NG flange adaptors DN50-300

The following should be checked prior to the fitting of the unit:● The pipe ends should be clean and free from weld spatter, heavy score marks, dents and protrusions which would prevent an adequate seal to be made. PAM mQUICK flange adaptor DN50-300 pipe outside diameter is within thethe range of the adaptor. TheThe following should be checked prior to fitting of the unit:● The deflection pipe ends should be clean and free weld spatter, of the pipes is within thefrom maximum of 6°. heavy score marks, dents and protrusions which would prevent an adequate seal to be made. ●

● 1.

The pipe outside is within rangeonto of the Loosen the gland diameter nuts and push the the adaptor theadaptor. pipe.

The deflection of end the pipes within flange the maximum 3°. is a general gap of 7mm Offer up the pipe to theismating ensuringofthere to16mm between the thetwo twounits. units. to 16mm between

● 2.

1. Ensure Loosen the gland bolts nuts and push thealigned adaptorwithin onto the 3. are correctly thepipe. recess of the flange face and offer up–the endDN100 to the& mating Insert the sealing between the two 2. Note Forpipe DN80, DN150flange. adaptors ensure the sealgasket retaining lugs are flanges and fit flange bolts. aligned in the end ring. 4. nutstoprogressively in a diametrically opposite sequence a 3. Tighten Offer upthe thegland pipe end the mating flange ensuring there is a general gapuntil of 10mm torque of 53Nm to 61Nm (40 to 45 lbf.ft) is achieved. to 15mm between the two units. 4. Ensure the gland bolts are correctly aligned within the recess of the flange face and offer up the pipe end to the mating flange. Insert the sealing gasket between the two flanges and fit flange bolts. 5. Tighten the gland nuts progressively in a diametrically opposite sequence until a torque of 53Nm to 61Nm (40 to 45 lbf.ft) is achieved.

68

67

Section 2: Pipe Laying

PAMDedicated DedicatedGSGS LINK coupling DN350-1200 PAM LINK coupling - DN350 -1400 The following should be checked prior to the fitting of the unit:● The pipe ends should be clean and free from weld spatter, heavy score marks, dents and protrusions which would prevent an adequate seal to be made. ●

The pipe outside diameter is within the range of the coupling.

1. Measure the length of the coupling then dismantle to ease fitting. 2. Present the 2 pipe ends to be joined, one to the other, to check concentricity is within acceptable limits. 3. Measure and mark the pipe from the joint, for half the length of the coupling – this will aid centering the coupling over the pipe ends. 4. Place one gland over each pipe clear of the working area. Lubricate and fit the gaskets. 5. Place the coupling body over one pipe. Offer up the pipe ends ensuring there is a general gap of 10mm to 12mm between the two ends. 6. Place the coupling body over the joint. Position gaskets and glands and fit bolts. 7. Tighten the gland nuts progressively in a diametrically opposite sequence until the correct torque is achieved. ●

53Nm to 61Nm (40 to 45 lbf.ft) for 12mm bolts

●

88Nm to 95Nm (65 to 70 lbf.ft) for 16mm bolts

PAMDedicated DedicatedGSGS QUICK flange adaptor DN350-1200 PAM QUICK flange adaptor DN350-1200 The following should be checked prior to the fitting of the unit:● The pipe ends should be clean and free from weld spatter, heavy score marks, dents and protrusions which would prevent an adequate seal to be made. ●

The pipe outside diameter is within the range of the adaptor.

1. Dismantle the adaptor to ease fitting. 2. Place the gland over the pipe clear of the working area. Lubricate and fit the gasket. 3. Offer up the pipe end to the mating flange ensuring there is a general gap of 15mm to20mm between the thetwo twounits. units. to 20mm between 4. Ensure the gland bolts are correctly aligned within the recess of the flange face and offer up the pipe end to the mating flange. Insert the sealing gasket between the two flanges and fit flange bolts. 5. Position gaskets and glands and fit bolts. 6. Tighten the gland nuts progressively in a diametrically opposite sequence until the correct torque is achieved.

68 70

●

53Nm to 61Nm (40 to 45 lbf.ft) for 12mm bolts

●

88Nm to 95Nm (65 to 70 lbf.ft) for 16mm bolts

Section 2: Pipe Laying

2.13 Dismantling Joints When dismantling a joint it is important to avoid dislodging other joints further along the pipeline. Joints in the middle of a pipeline will require cutting out and couplings will be required to make the pipeline complete. Joints that are at the end of pipelines can be dismantled as follows. Rapid joints can usually be separated by using lifting equipment appropriate to the size of the pipe. Secure a webbing sling, of suitable size and strength, around the pipe near the end furthest from the joint to be dismantled. This is then attached to the lifting equipment and the pipe is raised and lowered, within the specific limitations, whilst at the same time exerting a slight pulling force, so that the spigot is ‘walked’ out of the socket. If the pipes adjacent to the one being disjointed are in an uncovered situation (i.e. not backfilled), the next 2 joints along must be carefully checked to ensure that they are not disturbed unduly by the operation.

Dismantling joints with anchor gaskets and the Universal Rapid Vi Anchor joint joint If the joint has been pressurised, use the jointing tackle to pull the joint together, as previously described. This will help to partially release the anchor teeth from the pipe spigot. Insert an extractor shim in the carrying anvil and smear lubricant over the leading edge (see Table 2.13.1 for tackle requirements).

joint dismantling – tackle– tackle Table 2.13.1: Anchor gasket and Universal Rapid Vi Anchor joint dismantling requirements Nominal Size DN

72

Anchor Joint Dismantling - Tackle Requirements Anvil Type

No. of Shims

80

1

4

100

1

4

150

2

6

200

2

8

250

3

10

300

3

12

350

4

13

400

4

15

450

5

15

500

5

17

600

5

19

69

Fig. 2.13.1

Note: Safety glasses must be worn Commencing at the bottom of the joint, drive the shim under the gasket by striking the anvil (see Fig. 2.13.1). Prise the anvil off the shim (see Fig. 2.13.2). Continue driving shims under the gasket around the whole circumference of the joint keeping the gaps between the shims to a minimum. The final shim inserted will overlap the shims on either side.

DN80-400 - Side link jointing tackle Fig. 2.13.2 2.13.1

Attach the socket frame and spigot clamp, as described in jointing section 2.9, but with the lugs on the nut assemblies pointing away from the socket face. Draw the spigot out of the socket by turning the nut assemblies with the levers, taking care to exert an even pull on each side (see Fig. 2.13.3). After dismantling the joint, do not re-use the gasket. If the pipes are to be re-used and have been pressurised ensure the spigot is suitable for re-use. A thorough inspection should be made of the spigot jointing area and all sharp edges removed.

Dismantling joints with the Universal Rapid Ve locked jointjoint Fig. 2.13.3

Push the spigot into the bottom of the socket to free the locking ring. Open the locking ring by inserting 5 wedges between the pipe barrel and the ring (see Fig. 2.13.4). This enables the weld bead to slide under the locking ring. The spigot can then be pulled from the socket.

Fig. 2.13.4

70

73

Section 3 Post Installation

71 75

Section Post Installation Section 3: 3:Post Installation

3.1 Cleaning and Testing 3.1 Cleaning and Testing Cleaning Before a pipeline can be considered ready for service it should be cleaned internally as Cleaning thoroughly as possible to ensure that no foreign matter remains inside the pipe. Pigs Before a pipeline can be considered ready for service it should be cleaned internally as of suitable design, e.g. polyurethane swabs, may be used provided that the pipeline thoroughly as possible to ensure that no foreign matter remains inside the pipe. Pigs has been constructed to allow the passage of such pigs. Where the pipeline is to be of suitable design, e.g. polyurethane swabs, may be used provided that the pipeline tested with water, the filling and emptying of the pipeline may to some extent cleanse has been constructed to allow the passage of such pigs. Where the pipeline is to be the line. tested with water, the filling and emptying of the pipeline may to some extent cleanse the line.

Testing The following guidance is intended to complement current Codes of Practice and Safe Testing Working Systems for testing ductile iron pipes and should not be taken to represent a The following guidance is intended to complement current Codes of Practice and Safe detailed explanation of testing methods. Site safety regulations should be followed at Working Systems for testing ductile iron pipes and should not be taken to represent a all times. It is recommended that anyone involved with the testing of pipelines should detailed explanation of testing methods. Site safety regulations should be followed at familiarise themselves with relevant accepted procedures and safety regulations. all times. It is recommended that anyone involved with the testing of pipelines should familiarise themselves with relevant accepted procedures and safety regulations. All pipelines should be tested before being bought into service to check for:

All pipelines should be tested before being bought into service to check for: Leak tightness

●

● ●

Soundness of any construction work, particularly anchorage. Leak tightness

Soundness of any construction work, particularly anchorage. The type of test will depend upon the fluid which the pipeline will eventually convey and may be a hydrostatic test or a low pressure (100mm water gauge) pneumatic test, The type of test will depend upon the fluid which the pipeline will eventually convey or both. The hydrostatic test is safer to carry out and can be made more stringent as and may be a hydrostatic test or a low pressure (100mm water gauge) pneumatic test, regards the strength of a completed pipeline. With the exception of testing nonor both. The hydrostatic test is safer to carry out and can be made more stringent as pressure pipelines at very low pressures (100mm water gauge), pneumatic testing is to regards the strength of a completed pipeline. With the exception of testing nonbe avoided, if possible, because of the hazards inherent in containing large volumes of pressure pipelines at very low pressures (100mm water gauge), pneumatic testing is to compressed air. However, there may be occasions when hydrostatic testing is not be avoided, if possible, because of the hazards inherent in containing large volumes of possible and air is the only medium available for applying a test pressure. It is compressed air. However, there may be occasions when hydrostatic testing is not recommended that testing is carried out in accordance with BS 8010. possible and air is the only medium available for applying a test pressure. It is The contractor and personnel carrying out these tests must satisfy themselves that it recommended that testing is carried out in accordance with BS 8010. The specific contract usually contain requirements for pressure testing is safe to do so prior towill commencement of detailed test. and the information provided below is for guidance only. The specific contract will usually contain detailed requirements for pressure testing and the information provided below is for guidance only. ●

Hydrostatic test It is recommendedtest that testing be carried out in accordance with BS 8010. Hydrostatic It is recommended that testing be carried out in accordance with BS 8010.or BS EN 805. This Standard specifies that the site test pressure for ductile iron pipes, fittings and flanged joints should not be less than: This Standard specifies test pressure ductile pipes, fittings and BS8010 specifies that thethat site the test site pressure for ductilefor iron pipes,iron fittings and flanged joints flanged joints should not be less than: should not be less than: ● Working pressure + 5 bar; Maximum pressure Working pressure + 5under bar; surge conditions; but should not exceed the test pressure rating (PEA) of the pipeline components. ● Maximum pressure under surge conditions; but should not exceed the test pressure rating (PEA) of the pipeline components. Note. Anchor gaskets and some types of fitting have a restricted test pressure rating. Please refer to the relevant product catalogue or to the Technical Sales Department for Note. Anchor gaskets and some types of fitting have a restricted test pressure rating. details. Please refer to the relevant product catalogue or to the Technical Sales Department for details. ● ●

72 76

76

Fig. 3.1.1

Before carrying out a hydrostatic test the following should be checked: All anchorage is in position and the section of the pipeline to be tested is properly blanked off, for example by one of the methods illustrated in Fig. 3.1.1.

●

●

All concrete should have developed adequate strength before testing begins.

●

All air is released from the pipeline.

●

Where joints are left uncovered during the test, ensure that sufficient backfill has been placed over the barrels of the pipes to prevent movement at exposed joints.

●

Where unrestrained closure pieces are used, adequate temporary restraint should be put in place to prevent movement at exposed joints.

Flange Spigot and Blank Flange

Flange Socket and Blank Flange

NOTE. It may often be economical to provide a concrete anchor block which has subsequently to be demolished, rather than risk movement of temporary stop ends during testing. Hydraulic jacks may be inserted between temporary anchors and stop ends to take up any horizontal movement of the temporary anchors. If self-anchored joints are to be used, it is essential that the correct length of anchorage is calculated to determine the required number of anchored joints. ●

Where restrained closure pieces are used (i.e. with self anchored joints) care must be taken to ensure that all personnel are kept a safe distance away from the section under test.

●

Sufficient time is allowed, after the pipeline has been filled, for absorption of water into cement mortar linings. At least 24 hours should be allowed.

Test Procedure The completed pipeline may be tested either in one length or in sections. Fill the pipeline with clean water (semi treated water can be used for sewage pipelines), ensuring that all air is removed, pressurise to working pressure and leave until stable conditions are achieved. Steadily increase pressure until the test pressure is reached at the lowest point of the section being tested. If pressure measurements are not made at the lowest point of the section, an allowance should be made for the static head between the lowest point and the point of measurement to ensure that the maximum permissible pressure is not exceeded at the lowest point. Maintain pressure for one hour, by pumping if necessary. Disconnect pump for one hour. Note the pressure and restore to the test pressure by pumping. Stop pumping on reaching the test pressure and draw off water until the pressure equals the noted value. If using anchor gaskets with closure pieces to test a section of pipeline, after dismantling following testing, ensure that the gasket is disposed of and not reused.

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Section 3: Post Installation Section 3: Post Installation

Test Results The generally accepted standard of loss to absorption in ductile iron pipelines is:-

Test Results

● litres/mm of nominal boreofper 24 hoursinper bar pressure. The0.02 generally accepted standard losskm toper absorption ductile iron pipelines

●

is:-

0.02 litres/mm of nominal bore per km per 24 hours per bar pressure.

Fault Finding In the event of an unsatisfactory test and where joint leakage is suspected various Fault Finding methods may be used to detect the leak:

In the event of an unsatisfactory test and where joint leakage is suspected various each joint, if not covered by the backfill;

● Visual inspection of to pipeline, methods may be used detect especially the leak: ●

● ● ● ● ● ●

●

Aural inspection, using a stethoscope or listening stick in contact with the pipeline; Visual inspection of pipeline, especially each joint, if not covered by the backfill; Use of electronic listening devices including leak noise correlators which detect and Aural inspection, a stethoscope or listening stick inbetween contact the withprobe the pipeline; amplify the soundusing of any escaping fluid; actual contact and the pipe may or may not be essential; Use of electronic listening devices including leak noise correlators which detect and

amplify escaping fluid; actual contact probe and the Use of a the bar sound probe of to any detect signs of water in the vicinitybetween of joints,the if backfilled; pipe may or may not be essential; Introduction of a gas compound into the test water, using a gas detection device to Use of a barpresence probe toofdetect signs water in thethrough vicinity the of joints, detect the any gas thatofhas escaped leak. if backfilled;

Introduction of a gas compound into the test water, using a gas detection device to detect the is presence ofinany gas that has escaped through leak. Where there difficulty locating a fault, the section underthe test should be

●

subdivided and each part tested separately.

Where there is difficulty in locating a fault, the section under test should be Once the cause thepart apparent has been identified and rectified the test should subdivided and of each testedloss separately. be repeated. Once the cause of the apparent loss has been identified and rectified the test should NOTE. It is important to ensure that proper arrangements are made for the disposal of be repeated. water from the pipeline after completion of hydrostatic testing and that all consents which may be required land owners occupiers and river, andof NOTE. It is important tofrom ensure that properand arrangements arefrom made for drainage the disposal water authorities have been obtained. water from the pipeline after completion of hydrostatic testing and that all consents which may be required from land owners and occupiers and from river, drainage and water authorities have been obtained.

Pneumatic Test

Pneumatic testing should generally be avoided except for testing non-pressure Pneumatic Test pipelines using very low test pressures (100mm water gauge). A low pressure air test may be carried out at regular intervals toexcept help narrow any search areas should a Pneumatic testing should generally be (daily) avoided for testing non-pressure problem pipelinesarise. using very low test pressures (100mm water gauge). A low pressure air test

may be carried out at regular intervals (daily) to help narrow any search areas should a Air is 20,000 times more compressible than water and this means that a pipeline problem arise. under high air pressure contains considerable potential energy which could be released explosively the event the failure ofthan a pipeline component. Air is 20,000intimes moreof compressible water and this means that a pipeline under high air pressure contains considerable potential energy which could be released The contractor and personnel carrying out pneumatic tests must satisfy themselves that it is safe If a pneumatic testevent is to of bethe carried outofplease refer component. to: explosively in the failure a pipeline to do so prior to commencement of test. ● If ●

IGE/TD/3 BS 8010 (5)

●

IGE/TD/3 (21)

●

74 78

78

8010 aBS pneumatic test is to be carried out please refer to:

3.2 Commissioning Individual water utilities will have their own procedures for commissioning water mains. There are no special procedures for sewers other than pressure testing. Disinfected water used for disinfection of the pipeline should receive treatment to neutralise or dilute the disinfectant to an acceptable level before discharge to sewer or watercourse.

3.3 Service Connections Recommended types of service connections Table 3.3.1 identifies the recommended type of connections that should be used for given mains pipe sizes.

Table 3.3.1 : Recommended service connections Connection Inlet Size Connection Inlet(in) size (in)

80

100

150 200 Nominal size DN

1/2 3/4

250

Class 30 (EN545:2010) 300+

300

350

Nominal Size DN Class 40 (EN545:2010)

80

100

150

200

250

400+

0.5 1 0.75 111/4 1/2 11.25

1.5 2 2 Conventional or external seal type Conventional or

External seal typeExternal only seal

external seal type

type

Use saddles, tees etc Use saddles,

tees, etc only

Drilling and tapping machines Fitting service connections to ductile iron pipes is carried out using purpose-designed drilling and tapping machines. There are two basic types of machine; those for making connections to dead (non-pressurised) mains and those for making connections to live (pressurised) mains. It is good practice to protect the pipe coatings and sleeving from being damaged.

Service connections Service connections in common use on ductile iron water mains are of two types; the `Conventional' type which depends on the screw thread on the inlet for sealing and anchorage onto the pipe and the `External-seal' type which incorporates separate sealing components, the screw thread being used primarily for anchorage.

75 79

Section 3: Post Installation

Fig. 3.3.1

Conventional type connections

Fig. 1.1.17

The inlets of ‘Conventional’ type connections have taper screw threads. The angle of taper and type of screw threads may vary on the connections of different manufacturers. When fully tightened, the threaded inlet of the connection provides both the anchorage and a leak-tight seal (see Fig. 3.3.1). This type of connection is obtainable in a number of materials in the form of tees or swivel balance ferrules and the outlet may have screwed compression or flexible joints. Fig. 3.3.1 Fig. 3.3.2

External seal type connections The thread on the inlet of `External-seal' type connections is used primarily for anchoring and both parallel and taper screw threads are used. The pressure seal is achieved by compressing a gasket of elastomeric material onto the pipe body and the inlet stem of the connection (see Fig. 3.3.2). The required compressive load is applied by tightening a backing nut onto a suitable shaped saddle. In common with the `Conventional' type, `External' type connections are available in a number of materials in the form of tees or swivel balance ferrules and the outlet may have screwed, compression or flexible joints.

Service connections to pipes with factory-applied wrapping The following tasks should be performed to make the service connections to pipes with factory applied wrapping:

76 80

●

Prior to making the service connection, place the saddle of the tapping machine on the pipe in the correct position. Mark around the saddle.

●

Remove the saddle and carefully cut away the wrap in the area marked.

●

Proceed with the tapping in the normal way.

●

Once the connection is made, complete the protection by the application of waterproof tape over all exposed metal surfaces, including the ferrule.

3.4 References 3.4 3.4 References References 3.4 References 1.

1. 1. 2. 1. 2. 2. 3. 2. 3. 3. 4. 3. 4. 4. 5. 4.

5. 5. 6. 5. 6. 7. 6. 7. 6. 8. 7. 8. 7. 9. 8. 9. 8. 10. 9. 10. 10. 9. 10. 11. 10. 11. 11. 10. 11. 12. 11. 12. 12. 11. 12. 12. 13. 13. 12. 13. 13. 14. 13. 14. 14. 13. 14. 15. 14. 15. 15. 14. 15. 16. 15. 16. 16. 15. 16. 16. 17. 17. 16. 17. 17. 18. 17. 18. 18. 17. 18. 19. 18. 19. 19. 18. 19. 20. 19. 20. 20. 19. 20. 21. 20. 21. 21. 20. 21. 22. 21. 22. 21. 22. 22. 22. 23.

BS EN 545: 2002. 2010 Ductile iron pipes, fittings accessories and their joints for water pipelines. methods. BS EN 545:Requirements 2002. irontest pipes, fittings accessories and their joints for water 2010 Ductileand BS EN 545:Requirements 2002. Ductileand irontest pipes, fittings accessories and their joints for water pipelines. methods. BS EN 598: 1995: Ductile iron pipes, fittings,accessories accessoriesand andtheir theirjoints jointsfor forwater 2007. pipelines. methods. BS EN 545:Requirements 2002. Ductileand irontest pipes, fittings sewerage applications. Requirements and test methods. BS EN 598:Requirements 1995: irontest pipes, fittings, accessories and their joints for 2007. Ductileand pipelines. methods. BS EN 598:applications. 1995: Ductile iron pipes, fittings, accessories sewerage Requirements and test methods. and their joints for Civil Engineering Specification for the Water Industry (CESWI). 4th Edition. 7 joints sewerage applications. Requirements and test methods. BS EN 598: 1995: Ductile iron pipes, fittings, accessories and their forWRc Publications. Civil Engineering Specification for the Water Industry (CESWI). 4th Edition. WRc 7 sewerage applications. Requirements and test methods. Civil Engineering Specification for the Water Industry (CESWI). 4th Edition. WRc Publications. Standard Specification for Water Schemes (applicable in Scotland Publications. Civil Engineering Specification forand theSewerage Water Industry (CESWI). 4th Edition. WRc and Northern Ireland. Standard Specification for Water and Sewerage Schemes (applicable in Scotland Publications. Standard Specification and Northern Ireland. for Water and Sewerage Schemes (applicable in Scotland BS 8010 PtSpecification 2 –Ireland. Codes offor Practice onSchemes land: design construction and and Northern Standard Waterfor and‘Pipelines Sewerage (applicable in Scotland installation. Ductile Iron’. BS Pt 2 Section –Ireland. Codes2.1 of Practice for ‘Pipelines on land: design construction and and8010 Northern BS 8010 Pt 2 Section – Codes2.1 of Practice for ‘Pipelines on land: design construction and installation. Ductile Iron’. Regulation 31. Water supply regulations for England and Wales. Sewers installation. 2.1 Ductile Iron’. BS 8010for PtAdoption 2 Section – Codes6th of edition Practice for ‘Pipelines on land: design construction and Regulation 31. Water6th supply regulations for England and Wales. Sewers for Adoption edition installation. Section 2.1 Ductile Iron’. The Water Supply (Scotland) Regulationsfor 1990. Regulation 31. Water supply regulations England and Wales. The Water Supply (Scotland) Regulations 1990. Regulation 31. Water supply regulations for England and Wales. Health andSupply safety (Scotland) guidance note PM42. Excavators used as cranes. The Water Regulations 1990. Health andSupply safety (Scotland) guidance note PM42. Excavators used as cranes. The Water Regulations 1990. Exemption number CON(LO)1981/2 Excavators, Health and certificate safety guidance note PM42. Excavators used asLoaders cranes. and Combined Excavator/Loaders. Exemption number CON(LO)1981/2 Excavators, Health and certificate safety guidance note PM42. Excavators used asLoaders cranes. and Combined Exemption certificate number CON(LO)1981/2 Excavators, Loaders and Combined Excavator/Loaders. Health and certificate Safety Executive Code of Practice L113. Safe useLoaders of lifting equipment. Excavator/Loaders. Exemption number CON(LO)1981/2 Excavators, and Combined Lifting Operations and LiftingCode Equipment Regulations 1998. Health and Safety Executive of Practice L113. Safe use of lifting equipment. Excavator/Loaders. Health Operations and Safety Executive of Practice L113. Safe use of lifting equipment. Lifting and LiftingCode Equipment Regulations 1998. BS 3574: 1989 (1996) Specification for the controlled storage packaging of Lifting Operations and Lifting Equipment Regulations 1998. Health and Safety Executive Code of Practice L113. Safe use ofand lifting equipment. vulcanised rubber and rubber products. BS 3574: 1989 (1996) for theRegulations controlled storage Lifting Operations andSpecification Lifting Equipment 1998. and packaging of BS 3574: 1989 (1996) for the controlled storage and packaging of vulcanised rubber andSpecification rubber products. BS 805: 2000 Water supplyproducts. - Requirements for systems andand components vulcanised rubber andSpecification rubber BS EN 3574: 1989 (1996) for the controlled storage packaging of outside buildings BS EN 805: 2000 Water supply Requirements for systems and components vulcanised rubber and rubber products. BS EN 805: 2000 Water supply - Requirements for systems and components outside buildings BS 1981 Code of Practice Earthworks.for systems and components outside buildings BS 6031: EN 805: 2000 Water supply -for Requirements BS 6031: 1981 Code of Practice for Earthworks. outside buildings Report R97: Trenching by CIRIA. BS 6031: 1981 Code ofPractice. Practice Published for Earthworks. Report R97: Trenching by CIRIA. BS 6031: 1981 Code ofPractice. Practice Published for Earthworks. Technical Note TN95: Proprietary trench support systems. published by CIRIA Report R97: Trenching Practice. Published by CIRIA. Technical Note TN95: Proprietary trench support systems. published by CIRIA Report R97: Trenching Practice. Published by CIRIA. Specification forTN95: the Reinstatement of Openings Highways. June 1992 (the Technical Note Proprietary trench support in systems. published by CIRIA HAUC specification). Specification for the Reinstatement of Openings in Highways. June 1992 (the Technical Note TN95: Proprietary trench support systems. published by CIRIA Specification for the Reinstatement of Openings in Highways. June 1992 (the HAUC specification). IGN No. 4-08-01 Importedof Granular andinselected As-Dug and HAUC specification). Specification for (4), the 1994. Reinstatement Openings Highways. June Bedding 1992 (the Sidefill Material for Buried Pipelines. WRc Publications. IGN No. 4-08-01 (4), 1994. Imported Granular and selected As-Dug Bedding and HAUC specification). IGN No.Material 4-08-01 for (4),Buried 1994. Imported and selected As-Dug Bedding and Sidefill Pipelines. Granular WRc Publications. IGN 4-08-02 (15), 1994.Imported Bedding Granular and Material BuriedBedding Pipelines. WRc Sidefill Pipelines. WRcSidefill Publications. IGN No. No.Material 4-08-01 for (4),Buried 1994. and selectedfor As-Dug and Publications. IGN No.Material 4-08-02 for (15), 1994.Pipelines. Bedding and Material for Buried Pipelines. WRc Sidefill Buried WRcSidefill Publications. IGN No. 4-08-02 (15), 1994. Bedding and Sidefill Material for Buried Pipelines. WRc Publications. BS 681-1: 1996: Elastomeric sealsand – Material for pipe joint seals Publications. IGNEN No. 4-08-02 (15), 1994. Bedding Sidefill requirements Material for Buried Pipelines. WRc used in water and drainage applications. BS EN 681-1: 1996: Elastomeric seals – Material requirements for pipe joint seals Publications. BS ENin681-1: Elastomeric seals – Material requirements for pipe joint seals used water1996: and drainage applications. IGE/TD/3. Institution of Gas Engineers. Recommendations on Transmission used in water and drainage applications. BS EN 681-1: 1996: Elastomeric seals – Material requirements for pipe joint and seals Distribution Practice. Second Edition 1983. IGE/TD/3. Institution of Gas Engineers. Recommendations on Transmission and used in water and drainage applications. IGE/TD/3. Institution of Gas Engineers. Recommendations on Transmission and Distribution Practice. Second Edition 1983. COSHH sheets can beSecond obtained from 1983. theRecommendations product manufacturer. If any problems Distribution Practice. Edition IGE/TD/3. Institution of Gas Engineers. on Transmission and are experienced in obtaining this data please contact Saint-Gobain Pipelines COSHH sheets can be obtained from the product manufacturer. If any problems Distribution Practice. Second Edition 1983. COSHH sheets be obtained from product manufacturer. If any problems Technical Salescan Department. are experienced in obtaining this datathe please contact Saint-Gobain Pipelines our Technical Sales Department. are experienced in obtaining this data please contact Saint-Gobain Pipelines COSHH sheets can be obtained from the product manufacturer. If any problems Technical Sales Department. BS EN 1514-1: Non-metallic flat please gasketscontact with orSaint-Gobain without inserts. Technical Sales1997: Department. our Technical Sales Department. are experienced in obtaining this data Pipelines BS EN 1514-1: Non-metallic flat gaskets with or without inserts. Technical Sales1997: Department. BS EN 1514-1: 1997: Non-metallic flat gaskets with or without inserts.

22. 23. BS EN 1514-1: 1997: Non-metallic flat gaskets with or without inserts.

81 77 81 81 81

3: Post Installation nion Section Section 3: 3: PostPost Installation Section Installation

3.5 Contacts 3.5 Contacts

Tel: 930 Tel: +44(0)115 +44(0)115Pipelines 930 0799 0799 Saint-Gobain Fax: 0115 930 0731 Fax: 0115 930 0731 Mob: +44(0)771 2880143 Mob: +44(0)771 2880143 Tel: +44(0)115 930 0799 Email: [email protected] Email: [email protected] Fax: 0115 930 0731 Fax: 0115 930 0731 Mob: +44(0)771 2880143 Email: [email protected] [email protected] Email: Fax: 0115 930site 0731 Tape Tape wrap wrap on on site Email: [email protected] Barrier Ltd. Barrier Ltd. site Tape wrap Tape wrap on on site Contact: John Contact: John Jones Jones Barrier Ltd. Barrier Ltd. Tape wrap on Pipelines site815134 Saint-Gobain PAM UK Tel: +44 (0)1244 Tel: +44 (0)1244 815134 Contact: John Jones Contact: John Technical SalesJones Department Barrier Ltd. Fax: +44 (0)1244 815134 Saint-Gobain Pipelines PAM UK Fax:+44 +44(0)1244 (0)1244 815134 Tel: 815134 Tel: +44 (0)1244 815134 +44(0)115 930 0700/0650 Contact: John Jones Technical Sales Department Fax: +44 (0)1244 815134 Fax: +44 (0)1244930 815134 Tel: +44 (0)1244 815134 Fax: +44(0)115 0731 etc. [email protected] Pipe supports Tel: 930straps 0700/0650 Pipe+44(0)115 supports and and straps etc. Fax: +44 (0)1244 815134 Carpenter and Patterson Fax: +44(0)115 930 0731 etc. [email protected] Pipe supports Pipe supports and and straps straps etc. Bob Lemons Tel: +44(0)1938 552061 Carpenter and Patterson Tel: +44(0)1938 552061 Carpenter andPipelines Patterson Pipe supports and straps etc. Saint-Gobain Tel: 552061 Bob+44(0)1938 Lemons Tel: +44(0)1938 552061 Tel: 552061 +44(0)115 930 0799 Carpenter and Patterson Tel: +44(0)1938 Fax: +44(0)1938 555306 Saint-Gobain Pipelines Fax: +44(0)1938 555306 or or 552818 552818 [email protected] Tel: +44(0)1938 552061 Tel: +44(0)1938 Mob: +44(0)771552061 2880143 www.cp-ltd.co.uk Tel: +44(0)115 930 0799 or 552818 www.cp-ltd.co.uk Fax: +44(0)1938 555306 Fax: +44(0)1938 555306 or 552818 [email protected] Tel: +44(0)1938 552061 Fax: 0115 930 0731 Mob: +44(0)771 2880143 www.cp-ltd.co.uk www.cp-ltd.co.uk Email: [email protected] Fax: +44(0)1938 555306 or 552818 Lifting hooks Fax: 0115 930 0731 Lifting hooks www.cp-ltd.co.uk Parsons Chain Email: [email protected] Chain Company Company Lifting hooks Lifting hooks Tape wrap on site Tel: +44 (0)1299 827700 Tel: +44 Chain (0)1299 827700 Parsons Chain Company Parsons Company Lifting hooks Barrier Ltd. Fax: +44 (0)1299 827659 Tape wrap on site Tel: +44 (0)1384 563700 Fax: +44 (0)1299 827659 Tel: +44 (0)1299 827700 Tel: +44 Chain (0)1299 827700 Contact: John Jones Parsons Company www.parsonschain.co.uk www.parsonchain.co.uk Barrier Ltd. www.parsonschain.co.uk Fax: +44 (0)1299 827659 Fax: +44(0)1384 (0)1299563700 827659 Tel: +44 Tel: (0)1299 827700 (0)1244 815134 Contact: John Jones www.parsonschain.co.uk www.parsonchain.co.uk www.parsonschain.co.uk Fax: +44 (0)1299 827659 (0)1244 815134 Pipework & Services Tel: +44 (0)1244 815134 Pipework & Welding Welding Services Ltd Ltd www.parsonschain.co.uk Tel: +44 (0)1488 674138 Contact: Fred Boardman Fax: +44 (0)1244 815134 Contact: Fred Boardman Pipework & Services Ltd Pipework & Welding Welding Services www.pipeworkwelding.co.uk Pipe supports and straps etc. Ltd Phil Boardman Phil Boardman Contact: Fred Tel: +44 (0)1488 674138 Contact: Fred Boardman Pipework &and Welding Services Ltd Carpenter Patterson Tel: +44 (0)1488 681336 Pipe supports and straps etc. www.pipeworkwelding.co.uk Tel: +44 (0)1488 681336 Phil Boardman Phil Boardman Tel: +44(0)1938 552061 Contact: Fred Boardman Fax: +44 (0)1488 681433 Carpenter and Patterson Fax:+44 +44(0)1488 (0)1488 681433 Tel: 681336 Tel: +44 (0)1488 681336 +44(0)1938 552061 Phil Boardman Tel: Tel: +44(0)1938 Fax: +44 (0)1488 (0)1488552061 681433 Fax: +44 681433 Tel: (0)1488 681336 Fax:+44 +44(0)1938 555306 or 552818 Tel: +44(0)1938 552061 www.cp-ltd.co.uk Fax: +44 (0)1488 681433 Fax: +44(0)1938 555306 or 552818 www.cp-ltd.co.uk Lifting hooks

82 82 82 82 82

Parsons Chain Company Lifting hooks Tel: +44 (0)1299 827700 Parsons Chain Company Fax: +44 (0)1299 827659 Tel: +44 (0)1299 827700 www.parsonschain.co.uk Fax: +44 (0)1299 827659 www.parsonschain.co.uk Pipework & Welding Services Ltd Contact: Fred Boardman Pipework & Welding Services Ltd Phil Boardman Contact: Fred Boardman Tel: +44 (0)1488 681336 Phil Boardman Fax: +44 (0)1488 681433 Tel: +44 (0)1488 681336 Fax: +44 (0)1488 681433

78 82 78 82

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A comprehensive range ofiron ductile iron access covers and in compliance with WRAS requirements where applicable, Fax:+44(0)115 932 9513 A new of cast push-fit fittings and couplings an a y n a a on BS 437, favoured for under building drainage, and unstable saint-gobain.com ridge drainage applications, providing lifetime service for and manu ac u ed n acco dance w h SO 900materia innovative Ductan lining to prevent the risk of corrosion. • Gate valves, resilient and metal faced DN50 to DN300 ground conditions due to its superior strength performance. ast iron rainwater and gutter systems to BS 460 BBA Tel:+44(0)115 Email:technical.covers.uk.pam@ Cast iron below ground system BSI Kitemark approved advan age o eof aance co o +44 on e0 an ex e opedoduc coa andto pipe ed o o and wa e a 930 nwa5000 e u pended bu ed and BS 437 avou o ng unde buhed ng dincreasing a nage and un ab e Fax 664 8 2060 requirements BS EN 598. 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Te +44 0 5black 930068 of external protection, fully compliant with the Cast iron rainwater and gutter systems to BS 460 from wide tolerance fittings to dedicated products. •• A va veKitemark new ange onsystem purange h ng and coup ng to ce Seven gu eBBA o knowledge, e inand c • cu a and ectime angu a Fire hydrants Standards and ISO 9001 requirements. A Butterfly valves DN50PAM to DN2000 p ma e avaisw na acco dance w hof Bedgutters h Eu opean A comprehe The information given in literature is, to the ofprange our correct at the of going to soil print. However, Saint-Gobain UK is and manufactured in accordance with ISO 9001. 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Any orders placed will be subject to our Standard Conditions of Sale, available on request. or immediate installation. available in a factory applied semi-gloss black finished coat • Con o va ve www.saint-gobain-pam.co.uk Designed to meet the requirements and expectations of BShydrants 416on part 2, used for soil waste refurbishment, and diameter water pipeline DN900 to oand downpipes systems supplied a black S 437 o unde bu d ng d a nage and un ab e an a y avou n a ed a on •Large Gate valves, resilient andto metal faced DN50 toanda DN300 CinDN300 aproducts ca P primer uavailable a coat. d services ange gu eCa and downp pe Non return valves DN80 above g ound y and em BS K prior emanotice, k appany oved •• therefore Fire constantly at ways of their products and reserve theDN50 right to without of theo Butterfly valves tochange, DN2000 for immediate installation. 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However, Saint-Gobain PAM UK is data contained in this publication. Any orders placed will be subject to our Standard Conditions of Sale, available on request. SI Kitemark approved to BS EN 877. syphonic roof outlets cast iron to BS EN 877 lassical Plus is a standard range of gutters and downpipes and manufactured in accordance with ISO 9001. www.saint-gobain-pam.co.uk BBA certified. Ilkeston, Derbyshire, DE7 4QU with plastic pipe made from ductile iron. It has added in compliance with WRAS requirements where applicable, peace of mind and confidence to water utilities and ast iron above and below ground drainage system A complete syphonic rainwater system, consisting of steel supplied inand a an black primer coat. its optimum condition. small diameter, push fit water pipe system compatible Sownpipes 437, for under building drainage, and unstable BA Lows Lane S on by Da e syphonic roof outlets and cast iron pipework to BS EN 877 o wa e and ewe age app ca on A va ve a e upp ed An installation accreditation scheme, designed to give contractors in the knowledge that the ductile iron pip g ound cond on due o upe o eng h pe o mance • A va ve that they have purchased will be installed effectively and in constantly looking at ways of improving their products and services and therefore reserve the right to change, without prior notice, any of the exast edfavoured Seven gu e p o e c cu a and ec angu a Fire hydrants ecertified. na o systems ack o ad ona appea ance peace of mind and confidence to water utilities and iron below ground system BSI Kitemark approved to Your local stockist is: A comp e e yphon c a nwa e y em con ng o ee con ac o n he know edge ha he duc e on p pe ne • Butterfly valves DN50 to DN2000 Head Office: An n Systems a a on BS accEN edISO a 14001:2004 on cheme de ••gned g ve Ga eoretu va v Quality Assurance Environmental Standard © 2011 Saint-Gobain PAM UK cast Saint-Gobain PAM UK Non BBA certified. vailable in aand factory applied semi-gloss black finished coat Tel: +44 (0)115 930 5000 Tidal flap Quality Management Systems BS EN ISO 9001:2000 Environmental Management data contained in publication. 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