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S I N T A K O T E ® S T E E L P I P E L I N E S
Handling & InstallationReference Manual
SINTAKOTE®
Steel pipelinesystems
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
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Section Page1. Transportation ........................................................................................12
2. Site Preparation ......................................................................................13
3. Unloading and Handling ........................................................................14
4. Stacking and Storage ............................................................................16
5. Stringing..................................................................................................19
6. Trenching ................................................................................................21
7. Bedding ..................................................................................................23
8. Laying and Jointing ................................................................................24
9. Backfilling................................................................................................40
10. Fittings ....................................................................................................43
11. Anchorage of Pipelines ..........................................................................44
12. Hydrostatic Field Test ............................................................................46
13. Commissioning Water Pipelines ............................................................48
AppendicesAPPENDIX A
Field Repair and Joint Reinstatement of SINTAKOTE ..................................49
APPENDIX B
Field Repair and Joint Reinstatement of Cement Mortar Lining ....................58
APPENDIX C
Field Application of Electrical Cables to CP Lugs ..........................................61
APPENDIX D
General Data ..................................................................................................63
Contents
DisclaimerThis manual has been prepared by Tyco Water to assist qualified Engineers
and Contractors in the use of the Company’s product, and is not intended
to be an exhaustive statement on pipeline design, installation or technical matters. Any conclusions, formulae and the
like contained in the manual represent best estimates only and may be based on assumptions which, while
reasonable, may not necessarily be correct for every installation.
Successful installation depends on numerous factors outside the Company’s control, including site preparation and
installation workmanship. Users of this manual must check technical developments from research and field
experience, and rely on their knowledge, skill and judgement, particularly with reference to the quality and suitability
of the products and conditions surrounding each specific installation.
When pipeline construction is being carried out for any water authority, as Principal, that water authority’s standards,
specifications or drawings, if at variance to any recommendation made in this manual, override the recommendations
made in the manual.
The Company disclaims all liability to any person who relies on the whole or any part of this manual and excludes all
liability imposed by any statute or by the general law in respect of this manual whether statements and representations
in this manual are made negligently or otherwise except to the extent it is prevented by law from so doing.
The manual is not an offer to trade and shall not form any part of the trading terms in any transaction. Tyco Water
trading terms contain specific provisions which limit the liability of Tyco Water to the cost of replacing or repairing
any defective product.
© Copyright Tyco Water Pty Ltd
This manual is a publication of TycoWater Pty Ltd, and must not becopied or reproduced in whole or partwithout the Company’s prior writtenconsent. This manual is and shallremain the Company’s property andshall be returned to the Company onits request. The Company reservesthe right to make changes to anymatter at any time without notice.Fifth edition published 2007
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S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
List of Figures & Tables Figure 1.1- Securing pipes for transport..........................................................................12
Figure 3.1- Twin slings or spreader bar ..........................................................................15
Figure 4.1 - Pipe support ................................................................................................16
Table 4.1 - Minimum pipe support area ..........................................................................16
Figure 4.2 - Pipe bearing area ........................................................................................17
Figure 4.3 - Stacking pipes using timber bolsters.............................................................17
Figure 5.1 - Single stringing of pipes................................................................................20
Figure 5.2 - Multiple stringing of pipes ............................................................................20
Figure 6.1 - Trench excavation machinery ........................................................................22
Figure 7.1 - Bedding layer minimum depth ........................................................................23
Figure 7.2 - Spreading bedding ......................................................................................23
Figure 8.1 - Jointing systems ..........................................................................................24
Figure 8.2 - Pulling SINTAJOINT pipes “home” to joint ......................................................25
Figure 8.3 - Fitting rubber rings into sockets ....................................................................27
Figure 8.4 - Alignment of pipes during jointing..................................................................28
Table 8.1 - Permissible misalignment and offsets during entry ........................................29
Figure 8.5 - Temporary construction and permanent SINTAJOINT deflection ....................30
Figure 8.6 - Axial offset measurement created by joint deflection ......................................31
Figure 8.7 - External inspection of assembled SINTAJOINT ..............................................32
Figure 8.8 - Welded ball and socket or slip-in joint field assembly ....................................33
Figure 8.9 - Raised face type flanges ..............................................................................34
Figure 8.10 - Matched o-ring type flanges ........................................................................34
Figure 8.11 - Star pattern tightening sequence ..................................................................34
Table 8.2 - Recommended gasket composition for transport of general domestic liquids including brine and sewage ..........................................................................35
Table 8.3 - Recommended Bolt Torques for Steel Flange Class 14 (AS4087 Fig B7) ......36
Table 8.4 - Recommended Bolt Torques for Steel Flange Class 21 (AS4087 Fig B8) ......37
Table 8.5 - Recommended Bolt Torques for Raised Face Steel Flange Class 35 (AS4087 Fig B9) ..........................................................................................38
Figure 9.1 - Zones of backfill and compaction..................................................................40
Figure 9.2 - Ring deflection limits ....................................................................................42
continued...
Contents (continued)
66 7
List of Figures & Tables (continued)
Figure 10.1 - Common fittings - welded pipelines ..............................................................43
Figure 10.2 - Common fittings - SINTAJOINT pipelines ......................................................43
Figure 11.1 - Anchor blocks for horizontal thrust restraint....................................................44
Figure 11.2 - Anchor blocks for vertical thrust restraint ......................................................45
Figure 11.3 - Pier support for above ground SINTAJOINT pipelines ....................................45
Figure 12.1 - Static head allowance for hydrostatic test with alternative pressure gauge locations..............................................................................46
Figure A.1 - Flow chart for determining appropriate SINTAKOTE repair method..................49
Figure A.2 - Joint region for Drader welding repair ..........................................................53
Figure A.3 - Drader gun assembly ..................................................................................54
Figure A.4 - Drader gun tip selection................................................................................55
Figure A.5 - Build up of material on cut end ....................................................................56
Figure A.6 - Care required when trimming ........................................................................56
Figure B.1 - Typical cement mortar lining crack greater than 2mm.....................................60
Figure B.2 - Enlarge crack to 4 - 6mm ............................................................................60
Figure B.3 - Completed repair ........................................................................................60
Table D.1 - SINTAKOTE Thicknesses..............................................................................63
Table D.2 - Cement Mortar Lining (CML) Thickness ........................................................63
Table D.3 - SINTAKOTE Steel Pipe Bores and Weights ..................................................63
Table D.4 - Manufacturing test pressure and rated pressure of MSCL pipes ....................67
Contents (continued)
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Risk & Safety Tyco Water is a strong advocate of Safety in the Workplace and believes that safety is paramount
All contracts and installers should commit to providing a work enviornment where everyone in the
The safe handling and installation of the SINTAKOTE Pipeline System in all applications relieson all personnel having a high level of safety awareness, reducing risk and improving site preparations
Steps to SafetyResponsibilities for Workplace safetyBe aware who has specific responsibilities
Plan to Work SafelyIdentify tasks and procedures, which control the risks arising from work activities
Involve EmployeesDisplay information in your workplace concerning health & safety. All employees should talk about ways to contribute to decisions that affect their safety in the workplace.
Develop ProceduresIdentify hazards in your workplace and assess any risks associated with them. (Mitigate these hazards through developing processes to eliminate or control).
Inform and Train EmployeesInform employees about hazards in their job
Monitor and ReviewAdjust, review and address any workplace or legislative changes. Processes change, staff changeand so may the risks.
Plant & EquipmentRegularley assess, inspect equipment and maintain records.Ensure appropriate Licenses are held for Plant in use
The above steps may be undertaken throughout and continued through the On-Site Inductions,Toolbox Meetings, or Site Assessments.
Remember you may have Principal Contractor's obligations whereby you may be responsible for:
Injury or accidents to members of the public; employees and other on site contractors, at or neara construction site or workplace.
in all that we do.
workplaced is safe at all times and recognise people as their greatest asset.
and planning.
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SINTAKOTE Training Program
The SINTAKOTE(R) Quality Pipeline Installation Program was introduced by Tyco in 1989 and, to date, over 4,000 Water Industry personnel have participated. This program assesses individuals
through compentency-based training and assessment, the application of an adherence to Quality, Safety, Environmental and Risk Systems.
In line with Tyco Water's commitment to continuous improvement, the program is accredited by theVocational Education and Training Board of NSW (VETAB NSW).
The program has been running for many years and is recognised as an Industry Leader. The Accreditation can be seen as a QA measure to ensure training for steel pipeline systems meets the most
appropriate specifications.
The basis for the Program and the Accreditation is the Tyco Water Handling and Installation Manual
and the Pipeline Installation Quality System, commonly known as the PIQS Manual.
Tyco Water Training & Auditing - Registered Training Organisation
Services -On-Site Auditing
Technical & Systems Support
Pre Qualification of Installers
On Site and Off Slite Training
Benefits
To Customer -Confidence in installers
Quality Installation
Reduce Unscheduled Maintenance
Traceability
Confidence in Asset Performance
Asset Longevity
Lower risk rating
To Installer -Certification of workersAbility to tender for more work
Lower risks
Increase efficiencies
Confidence in work
Less Re-work
Lower Injury Rates
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S I N T A K O T E ® S T E E L P I P E L I N E S
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Tyco Water embraces environmental protection and ensures its operations comply withrelevant environmental legislation.
Accordingly, Tyco Water as well as SINTAKOTE pipeline Installers and Contractors have a
You are expected to take all reasonable and practical measures to ensure that:-n Waste (spoil, concrete, off-cuts, etc) is minimised and disposed of in the correct manner
Environmental
n Water quality is not affected and contaminated run-off from site is prevented.
Risk Management.
n Soil erosion and sediment control is reduced
n Soil does not become contaminated (either from imported fill or excavation material.
and to assess the likelihood and severity of harm that may arise from such hazards. The
n Care is taken when handling and using hazardous substances
Australian Risk Management Standard AS 4360 contains greater details regarding the Risk
n The effect on air quality is minimised, through dust and pollution control measures.
Legislation in all states and territories requires an employer to identify all hazards in their workplace
n Mininimise disturbance to existing flora and fauna. Restore vegitation on completion of the works.
Management Process.
.
n Disruptions to surrounding services are to be minimised.
n Noise emissions are kept within required limits.
n Traffic and the movement of plant & equipment around the site does not impact the environment.
and doing something about it.
n Vibration to adjacent buildings and area should be minimised
Risk Management mean Looking at the Work and ProcessesYou Are About to Undertake
n Impact on heritage and archaeological sites should be minimised.
that could cause injury (entrapment), Making a Judgement on the Consequence and
n Report any environment incidents to environmental authorities or units.
Likelihood of what could happen as a result (death or injury to persons in an excavation),
Further details can be gained from state government, Environment Agencies, LocalCouncils and also from industry bodies..
responsibility to ensure your work activites do not harm the environment.
,
.
.
.
S I N T A K O T E ® S T E E L P I P E L I N E S
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This manual has been prepared by
Tyco Water Pty Ltd.
It is intended to provide guidance on the
field practices of handling and installation of
SINTAKOTE steel pipelines.
Adherence to these guidelines should
ensure that the SINTAKOTE steel pipeline
system will have the capacity to perform in
excess of one hundred years.
There may be aspects of handling and
installation not covered in this manual which
may become subject to revision. For this
reason and in the interests of continuous
improvement, feedback on the manual
is encouraged.
Inquiries or contributions should be directed
to the Manager Marketing,
Steel Pipeline Systems,
Tyco Water,
PO Box 141,
Fairfield NSW 1860
Australia.
Or email info@tycowater.com
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
1. Transportation S I N T A K O T E ® S T E E L P I P E L I N E S
12 | C H A P T E R 1
Secure the loadAll pipes must be secured by straps or other
suitable means to prevent movement during
transit and be in compliance with all local and
state regulations regarding load restraint.
Protect the pipe and coatingFactory installed toms are installed in some
pipes sizes and should be maintained in place
until after installation.
All supports, restraints and packing bearing on
pipe surfaces should be covered or wrapped
with material suitable to prevent chafing and
shock damage during transit.
In the case of rail transport, end protection
should be provided against shunting shocks.
Rubber mats, carpet etc. are suitable for this
purpose.
If bolsters are utilised only two per pipe length
should be used. Each should be placed 0.2
to 0.25 of the length from each pipe end
(outside quarter points). See Figure 1.1
The width of bolster must provide sufficient
area of support to protect the pipe coating.
A minimum bolster width of 150mm is required.
Double scalloped bolsters should be used to
separate layers of stacked pipe and pipes in the
same row spaced so that they do not touch.
Scallops must be cut to suit the outside
diameter of the pipe and have a minimum
saddle angle of 90 degrees.
The bottom bolsters should be securely
anchored to the floor or side of the road truck
or rail carriage. The load should be strapped
securely at a minimum of two locations, not
more than 500 mm from the bolsters and
using webbing straps with a minimum lashing
capacity of 2000kg. Multiple straps may be
necessary at each location. See Figure 1.1.
The strapping should be securely anchored
with approved ratchet type devices and
should be checked for tension at regular
intervals not exceeding 300 kilometres of
travel. Chains shall not be used to tie down
pipes or piles.
500mm
Bolster locations0.2 to 0.25 of the pipe length from each end
500mm
Figure 1.1 Securing pipes for transport
PPE is it on
This may be varied to suit vehicle loadrequirements.
P P E i s i t o n
C H A P T E R 2 | 13
Good site preparation maximises safety and
can save time and money
Site checksWhile preparing sites remember to check for :
Vehicle access� road conditions
� warning signs
� traffic control
� load limitations
� all weather access
Storage compounds� convenience of location
� security
� site dunnage availability
� protection from weather
Stacking areas� uneven surfaces that may require grading
� stability in bad weather
� clear of grass in case of fire
� overhead power lines
� other services
General � local traffic
� overhead powerlines
� location of other services
2. Site Preparation
Spreader bar
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
14 | C H A P T E R 3
R e m e m b e r p u b l i c s a f e t y a t y o u r s i t e , e v e n w h e n y o u a r e n o t t h e r e !
Personnel involved in unloading and handling
should wear personal protection equipment as
required by the Occupational Health and Safety
Act. Such as hardhat, safety shoes, safety
glasses, high visibility vest and other equipment.
Attention to the following items improves
efficiency of the operation, maximises safety
and minimises risk of damage.
Steel pipes are not susceptible to breakage but
poor handling can result in damaged coatings
and/or linings and damage to the pipe ends.
Damage to pipeline components will be
prevented by;
� adequate support and restraint during
transportation to site.
� proper use of handling equipment
� use of suitable handling equipment
� correct site storage
� unloading on even ground
� correct handling of load
When factory fitted cathodic protection (CP)
lugs are provided, extra care must be taken
to ensure that the lugs are not damaged and
that pipes are not bumped together as the
lugs may damage coating on adjacent pipes.
Before unloadingChoose a central storage site for general use,
storage of small components, gaskets, etc.
Choose and prepare suitable pipe storage
sites along the pipeline route.
If possible, select unloading and storage
areas which are clear of overhead powerlines.
Make sure the truck is on level ground before
releasing the straps.
Unloading(See also Section 5: Stringing)Immediately upon receipt, all items should be
visually examined for damage to;
� the pipe itself, particularly the ends
� cement mortar lining
� external coating
� rubber rings
� lubricant containers
All repair work should be carried out promptly.
Refer Appendices A: Field repair and joint
reinstatement of SINTAKOTE and B: Field
repair and joint reinstatement of cement
mortar linings.
Check that the correct quantities of materials
have been received.
Unload the truck evenly to keep it stable.
Lifting operationsAll lifting operations must meet legal and
occupation, health and safety requirements
applicable to the site.
Qualified personnel must be employed for
crane operation.
When unloading by mobile crane, a licensed
dogman must be present.
Lifting should be done smoothly without
sudden jerking motions. Pipe movement
should be controlled by use of guide ropes
and care taken not to bump other pipes or
equipment. See Figure 3.1.
Lifting and placing must be carried out so that
the stability of the pipe stack, crane or vehicle
is maintained.
3. Unloading and Handling
Twin sling
Guide ropes
Guide ropes
Figure 3.1 Twin slings or spreader bar
C H A P T E R 3 | 15
When conditions are suitable, forklifts
may be used. The contact surfaces of
the tynes must be protected with thick
rubber with a minimum durometer hardness
(Shore D) of 45.
Choosing equipmentWhen choosing lifting equipment consider
� pipe weights
(Appendix D: General data; Table D.3)
� type of stacking
� outreach
� site conditions
AccessoriesSlingsPipes should be handled one at a time.
R e m e m b e r p u b l i c s a f e t y a t y o u r s i t e , e v e n w h e n y o u a r e n o t t h e r e !
Use twin slings, spreader bar or other
approved lifting devices. See Figure 3.1
Slings and lifting devices must comply
and be used in accordance with the
appropriate safety requirements.
The slings shall be of nylon or synthetic
material of sufficient width that shall not
damage the coated surface of the pipe or
pipe fitting.
Vacuum Lifting DevicesVacuum lifting devices are available to lift
pipes. These should be used in accordance
with the manufacturer’s specifications.
HooksHooks should not be used for lifting pipes
or fittings.
It is recommended that pipes be supported on
sawdust filled bags or sand mounds. The
supports should be positioned to ensure that
each pipe is stable. For long term storage, sand
mounds should be protected from erosion.
The entire pipe must be kept clear of the
ground to protect the coating from damage.
It is recommended that pipes be separated
from each other for ease of inspection and to
minimise the potential for damage during
handling.
Stacking heights forlong term storagePipes 610 mm OD and larger should be
stored in single layers only. Pipes less than
610 mm OD may be stacked. To prevent
damage to the SINTAKOTE and for safety and
handling reasons pipe stacks must not
exceed 2m in height.
Stacks should never be higher than they
are wide.
Timber bolsters of minimum cross section
dimensions: 150mm wide x 150mm clear
depth between scallops, should be used to
separate layers. The scallops shall have a
minimum saddle angle of 90 degrees.
In termite infested areas, timber bolsters may
not last unless the area is treated. Otherwise,
the bottom bolster should be made from
steel. Bottom bolsters must also be placed on
firm ground and must be level.
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
16 | C H A P T E R 4
R e m e m b e r p i p e s c a n e a s i l y b e r o l l e d a n d m o v e d . M a k e s u r e t h e y a r e s e c u r e ! R e m e m b e r p i p e s c a n e a s i l y b e r o l l e d a n d m o v e d . M a k e s u r e t h e y a r e s e c u r e !
Table 4.1- Minimum pipe support area
Minimum Support Bearing Area
Pipe Length
6m 9m 12 – 13.5m
mm2 mm2 mm2
≤ 813 10,000 10,000 10,000
>813 to ≤1403 10,000 15,000 20,000
>1403 to ≤1753 15,000 20,000 30,000
> 1753 20,000 30,000 40,000
CP Lugs ifprovided
Figure 4.1 - Pipe support Figure 4.2 - Pipe bearing area
Figure 4.3- Stacking pipes using timber bolsters.
4. Stacking and Storage
2 supports 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe
length from each end
Storage areaThe storage area should
� have a firm foundation for pipe stacks
and vehicle operation
� have suitable access for
road vehicles
� be free of overhead power lines
wherever possible
� be barricaded if necessary
Pipe supportCoated pipes should at all times be supported
clear of the ground. Beware of protruding
rocks and uneven ground.
If pipes are provided with factory fitted CP
lugs ensure that pipes are stored with lugs at
the top.
The pipe should be supported at two
locations 0.2 to 0.25 of the pipe length from
each end. See Figure 4.1.
Each support shall provide adequate bearing
area. The bearing area on the pipe should not
be less than that shown in Table 4.1. See
Figure 4.2.
Sawdust bags Soil mounds
Bolster locations 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe length from each end.
C H A P T E R 4 | 17
500mm 500mm
S I N T A K O T E ® S T E E L P I P E L I N E S
18 | C H A P T E R 4
R e m e m b e r p i p e s c a n e a s i l y b e r o l l e d a n d m o v e d . M a k e s u r e t h e y a r e s e c u r e ! T h e s a f e w a y i s t h e c o r r e c t w ay!
StorageSmall fittings, rubber rings and lubricant
should be stored in a secure convenient area.
Lubricant must not be stored for lengthy
periods in direct sunlight.
Rubber rings should be stored in bags,
out of the sun and away from petroleum
products. They should be stored in
a manner that prevents them from being
subject to high compressive or
tensile strains.
Rubber rings should be used within 12
months. If rubber rings are stored for longer
periods they should be discarded.
Storage of CementMortar Lined PipesCement mortar lining may crack and
possibly disbond when stored in hot, dry
conditions. The longer the storage period in
such conditions, the wider the cracks will
be and the greater the extent of any
disbondment (drumminess).
Cracks up to 2mm in width (as allowed in AS
1281, “Cement Mortar Lining of Steel Pipes
and Fittings”) are acceptable for pipes
conveying potable water as these cracks
close and heal on exposure to water.
When pipes greater than 800mm in diameter
are stored for more than a few weeks in hot,
dry conditions, cracks may develop in excess
of the 2mm allowable under AS 1281 and the
lining may disbond.
In such circumstances precautions should be
taken such as end capping (to reduce airflow
and thus rate of cracking) and adding water
to the pipes (to reduce the width of cracks).
Guidelines for repair when cracks or
disbondment exceeds 2mm are found in
Appendix B - Field repair and joint
reinstatement of cement mortar lining.
5. Stringing
Before pipe deliveryPlan stringing before arrival of the pipe
and consider:
� the construction programme
� the ground conditions, and
� the safety of workers and the
general public
Where to stringPipe should be located to minimise
handling during the laying operation.
Pipes should be properly supported.
Refer Section 4: Stacking and storage.
Large fittings and valves should be put
adjacent to where they will be needed.
Small fittings, gaskets, nuts and bolts
should be kept in a secure storage area
until they are needed.
What equipment to useCranes, forklifts or other appropriate
equipment approved by the relevant State
Occupational Health & Safety Authority may
be used.
Always use approved slings and accessories.
For large pipes, twin slings should be used,
Refer to Section 3: Unloading and handling;
Accessories.
Guide ropes should be used to control the
pipe. See Figure 3.1.
Method of stringing pipesKeep pipes close to the ground while they are
being moved.
Pipes should be near enough to the trench for
the laying crew, but far enough away so they
don’t interfere with equipment access, trench
digging or excavated spoil.
When single stringing, pipes should be in line
with the trench with sockets facing the
direction of laying such that when laying, a
spigot is inserted into an already laid socket.
This is the recommended technique for
jointing and allows the entry of the spigot into
the socket to be more easily seen and
controlled. It also minimises the risk of
scooping bedding material into the joint and
onto mating surfaces. See figure 5.1.
C H A P T E R 5 | 19
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
When laying pipe on steep slopes,
construction should start at the bottom and
proceed up hill. In this way the weight of the
pipes is used to advantage when jointing.
Pipes should thus be strung with sockets
facing uphill. See Figure 5.1.
When multiple stringing, groups of pipes
should be in line with the trench with their
sockets all facing the direction of laying.
Groups of pipes should be separated by the
distance covered by the number of pipes in
the group. See Figure 5.2.
Figure 5.1- Single stringing of pipes
Figure 5.2- Multiple stringing of pipes
Pipes strung with socketsfacing direction of laying
20 | C H A P T E R 5
T h e s a f e w a y i s t h e c o r r e c t w a y !
6. Trenching
Before excavationLocate and mark other underground utility
service lines. Check whether the water table
needs to be lowered with dewatering
equipment. Assess trench stability and
shoring requirements.
How wide should thetrench be?The trench width should be as narrow as
practicable, consistent with the need to
ensure;
� proper laying and jointing of the pipe, eg.
joint stations for welder in welded joint
pipelines,
� application of joint wrapping for welded
joint pipelines,
� where a change in direction is being made
at a joint, the trench should be wide enough
to allow the joint to be made with the pipes
aligned. The pipe should then be deflected
after jointing,
� proper haunch support and compaction of
the backfill in accordance with the design
specification,
� use of common size backhoe / excavation
bucket widths which are 300, 450, 600, 750,
900, 1100 and 1200 mm.
T r e n c h i n g . I f u n s u r e ? S h o r e !
How deep should thetrench be?The depth of the trench will depend on a
number of factors in addition to pipe diameter.
Other considerations include:
� location of other services, particularly in urban areas,
� future change in levels due to roadregrading or other civil works,
� required cover,
� valve pits etc.
The minimum depth of cover recommended
is 600 mm provided none of the other
considerations require a greater depth.
In rocky ground, the trench should be
excavated at least 50 mm deeper than
required and replaced with compacted
bedding as described in Section 9:
Backfilling.
Where the ground below the bedding is
unstable, additional excavation should be
made and backfilled as described in
Section 9: Backfilling.
CHAPTER 6 | 21
As a guide, the following trench minimum widthsare reasonable:
OD + 400mm for pipe diameters ≤450mmOD + 600mm for pipe diameters > 450mm , ≤900mmOD + 700mm for pipe diameters > 900mm , ≤1500mm0.25 x ODmm for pipe diameters >1500mm
S I N T A K O T E ® S T E E L P I P E L I N E S
Figure 7.1- Bedding layer minimum depth
7. Bedding
Figure 7.2- Spreading bedding
50mm min
Lift pipesuch thatbase of
pipe is attop of
bedding
Back hoe Excavator Trencher
Figure 6.1- Trench excavation machinery
How to excavateUsually an excavator or backhoe with bucket
attachment is used. Only authorised people
should operate this equipment. A trencher
may be used if conditions permit. This can be
a faster method. See Figure 6.1
SafetyIf working under power lines check with the
electricity supply authority and the government
safety authority. You may need to;
� arrange for overhead cables to be diverted
or protected with insulating covers,
� arrange for electricity to be cut off,
� put up goal post type barriers or,
� use luffing stops on the machine
Remember there is greater sag in power lines
on hot days.
Barricades should be used if there is a danger
of anybody falling into the trench.
Occupation, Health and Safety regulations
must be observed.
Shoring the trenchIt is generally necessary to shore the trench if
it is deeper than 1.5 metres. Refer to the
relevant authority on safe excavation practice.
It may still be necessary to use shoring in
trenches less than 1.5 metres deep if there is
a risk of trench wall collapse as a result of;
� poor soil strength,
� vibration from machinery,
� use of explosives,
� placement of spoil adjacent to the
trench / and/or materials, or
� water inflow.
22 | C H A P T E R 6
T r e n c h i n g , i f u n s u r e ? S h o r e ! F e n c e o f f w o r k a n d s t o r a g e a r e a s .
S I N T A K O T E ® S T E E L P I P E L I N E S
C H A P T E R 7 | 23
Why Bedding ?Bedding evenly supports the pipe and protects
the external coating.
Bedding should be spread evenly along the
trench with socket holes or welding stations
provided at each joint. The socket holes should
be deep enough to stop the socket of the pipe
bearing any weight. Welding stations should
also be big enough to allow welding and
wrapping at welded joints.
Bedding in wet orunstable groundIn wet or unstable ground, it may be necessary
to dig the trench deeper and backfill with gravel
to form a foundation layer. A barrier geotextile
material may then be placed over this and the
bedding material placed on top. The geotextile
material specified will prevent fine sand and soil
moving into the spaces between the gravel and
subsequent loss of support for the pipe.
Bedding in rockThe trench should be excavated to ensure that
there is space for a minimum of 50 mm
compacted bedding beneath the pipe and to
accommodate appropriate joint stations for
welding and reinstatement if required.
What to use for beddingBedding should be granular material such as
sand with no stones or sharp objects. The
maximum particle size should not exceed 13.2
mm. If the natural soil is not suitable, bedding
should be brought in.
The bedding layer under the pipe should be at least
50 mm thick when compacted See Figure 7.1.
How to put bedding into a trenchBedding is usually put into a trench with a front
end loader or backhoe. It should be evenly
spread along the trench. See Figure 7.2.
Bedding should be compacted to ensure a firm,
even base for pipe laying.
Allowance for slingwithdrawalConsideration should be given to making a
small depression in the bedding where slings
used to lift the pipe will come to rest after
lowering and jointing.
This will allow slings to be withdrawn from under
the pipe more easily.
S I N T A K O T E ® S T E E L P I P E L I N E S
After assembly
Figure 8.2- Pulling SINTAJOINT pipes“home” to joint
SINTAJOINT Common flange joint
Figure 8.1- Jointing systems
24 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
GeneralThe majority of water pipelines are laid below
ground. However there are also above ground
applications, such as at pumping stations,
treatment works, over creeks, along bridges or
where the cost of trenching is too expensive.
Work is often carried out in congested
conditions. Observe good housekeeping and
safe working practices to avoid injury. Inspect all
lifting and pulling equipment regularly for signs
of wear and deterioration.
All occupational health and safety requirements,
including confined space legislation, should be
complied with and take precedence over
working methods recommended herein.
Joint TypesA number of common jointing configurations
are available for steel pipe:
� Rubber ring joint, SINTAJOINT
� Expanded and collapsed or spherical
slip-in welded joint,
� Ball and socket welded joint,
� Butt welded joint
� Butt welded joint with band or collar
� Flanged joint
See Figure 8.1
SINTAKOTE pipes and fittings are factory
formed/assembled for site installation without
further site adjustment. Where, as a result of
site conditions or damage to pipe, pipes must
be cut to length on site, the following should
be noted:
Pipes with welded joints can be cut and joints
welded in accordance with this Section.
Pipe ends to be joined should be prepared in
accordance with site welding procedure and
joint areas reinstated in accordance with
Appendices A and B,
SINTAJOINT pipe, where cut, can only be
joined by welding in accordance with above.
Do not attempt to use a cut end in a rubber
ring joint.
SINTAPIPE pipe should not be cut for jointing.
Normally design is carried out to avoid the
need for cutting on site.
Where SINTAKOTE pipe with welded joint,
SINTAJOINT or SINTAPIPE is to be cut and
installed with a free end in a corrosive
situation, such as in sewer manholes, it is
recommended that a Tyco Water
representative is consulted.
8. Laying and Jointing
Spherical slip-on joint Ball and socket joint
Plain butt jointButt joint with collar
S I N T A K O T E ® S T E E L P I P E L I N E S
Jointing Equipment
Anchor slingReversed eye, synthetic webbing slings or
round slings (of endless fibre construction) are
recommended for use in the assembly of
SINTAJOINT pipes. Woven synthetic slings must
be sheathed to prevent penetration of the fabric
by grit, abrasion and deterioration. The slings are
fitted to the pipe using a “choker” hitch and in
this configuration the sling is rated to the SWL
limit marked on the webbing. See Figure 8.2.
Assembly forces will vary depending on the
relative dimensions of the ends being joined,
and to a lesser extent, the diameter and wall
thickness of the pipe.
It is expected that these forces would be
between 20 and 50 kN.
The length of the sling is generally pipe
circumference plus 400 mm.
PullerA winch block of 30-50kN pulling capacity
fitted with hooks on both ends is adequate.
Rubber matsTypically 500 x 500 x 6 – 12 mm thick pieces of
conveyor belt or similar should be placed
between equipment and pipe where the coating
is likely to be damaged during joint assembly.
RagsTo clean sockets and spigots immediately
before joint assembly.
Inspection of PipeBefore LayingGeneralAll pipes are factory inspected, however,
damage may occur in handling, transport or
site storage. Pipes must be reinspected on
site before laying. The inspection should
include pipe coating and lining and pay
particular attention to pipe ends on
SINTAJOINT pipes.
Pipe endsPipe ends must be inspected visually
for any damage that may have occurred
during transport, site storage or handling.
SINTAKOTE at pipe endsShould the coating or lining of the pipe ends
(socket or spigot end) be damaged, it must be
repaired in an approved manner
C H A P T E R 8 | 25
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
26 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
before the pipe is laid. See Appendix A for
methods of assessment of damage to
SINTAKOTE and methods of repair .
Testing of SINTAKOTEAll surfaces coated with SINTAKOTE are
factory tested for pin holes and other defects.
SINTAKOTE is a tough coating with a high
resistance to handling and transport damage.
However coating damage can occur through
poor handling or incorrect storage.
To ensure that the highest quality coating
system is placed in the ground, it is
recommended that field high voltage
holiday inspection be carried out on all
coated surfaces. SINTAKOTE can be
tested at high voltage without any
detrimental effect on coating properties.
The voltage for the testing should be set at
12,000V -14,000V and testing undertaken in accordance with AS3894.1 or AS4321“Fusion-bonded medium-density polyethylene
coating & lining for pipes and fittings”. Note
that the safety procedures detailed in the
Standard must be strictly followed.
With SINTAJOINT pipes, the earth should
be clamped to a metal plate, laid on the
cement mortar lining. The 12,000V-14,000V test voltage is specified for all coating and
lining thicknesses.
For SINTAPIPE pipes, ie. pipes that are
totally coated and lined with Sintakote, the
method specified in AS4321 shall be used.
Rubber ringsThe rings must be visually inspected for any
damage which may have occurred after
leaving the manufacturer. Damaged rings
must not be used.
LubricantInspect lubricant tins for damage and
replace if contaminated. Use only the
lubricant supplied by Tyco Water.
Laying and Jointing of PipeSINTAJOINT pipeThe laying of SINTAJOINT (RRJ) pipes is
simple and very high laying rates can be
achieved. The equipment is inexpensive,
light and easily handled.
To ensure high laying rates and watertight
joints, attention to detail and the
following recommended laying practices
are essential.
The guidelines below are additional to other
good practices which should be observed
when preparing a trench, storing and laying
steel pipes and backfilling.
The pipe is manufactured to close
tolerances assuring a consistent joint profile.
The rubber rings are also supplied to a strict
specification, for dimensions, hardness
and formulation.
These features produce joints with
assembly properties easily recognised
by the laying team. The ease of spigot
entry and the jointing force are so
consistent that the laying crew quickly
identifies any significant variation.
An additional check for correct joint
assembly can then be made.
C H A P T E R 8 | 27
The recommended method for joint
assembly is to pull the pipe being laid into
the socket of the previously laid pipe, using
anchor slings and winch blocks or pullers.
See Figure 8.2.
Another joint assembly method is easing the
pipe into the joint by slewing the excavator or
crane. This method is acceptable, provided it
does no damage to the pipe, including the
external coating or internal lining.
The slewing action must be controlled to ensure
alignment of the pipe. Care must be taken not
to drive the spigot past the witness mark as this
may damage the coating and/or lining.
If the pipe is to be cathodically protected,
it will be supplied with cathodic protection
lugs on both the socket and spigot. Ensure
the pipe is installed with these located at the
very top of the pipe, to enable connection
of joining cable across the joint.
PreparationStart with the free socket end of the previous
assembly which should be sitting over a
scooped out area of bedding.
Measure out the location where the next
socket end will fall in the trench, and scoop
out the bedding so that after laying there will
be sufficient clearance for the socket.
Fit the anchor sling behind the socket.
Rubber ringClean the inside of the socket with a clean
rag, then fit the rubber ring. Always inspectthe rubber ring for damage or tears prior to
inserting in the socket. The rubber ring is
first placed in the invert and then inserted into thegroove by progressively placing it and compressing
until the last part snaps in the groove. See Figure 8.3
The ring is slightly over length and this must be evenlydistributed by pre-compressing the rubber progressively
as it is fitted into the groove. A simple clamp can
A simple clamp can assist with holding the ring firmallowing two hands free to fit the balance of the ring.
The placement of rubber rings in pipes larger
then 1000mm OD may require two people.
LubricationLift the next pipe and fit an anchor sling over the
spigot positioning it about 2 metres from
the end.
Clean the spigot while it is suspended in theslings.
lubricant supplied by Tyco Water suitable for
use with SINTAKOTE pipe.
On the spigot, the lubricant should be sparingly applied to the area from the spigot end to the witness
mark, providing 100% cover.
Lubricate the internal socket lip, the rubber ring and the spigot end of the pipe to be inserted. Use only
Figure 8.3- Fitting rubber rings into sockets
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
�
�
Figure 8.4 - Alignment of pipes during jointing
Experience has shown that this is a criticalaspect of rubber ring joint field assemblyprocedures. Using an incorrect lubricant maycause failure of the rubber ring or SINTAKOTE.
The lubricant must cover every exposed partof the internal surface of the socket lip and
rubber ring. Unlubricated areas can cause the
rubber ring to be displaced from the groove.
Care should be taken to ensure lubricantdoes not get behind or under the rubber ring.
High temperatures may cause the lubricant tolose its consistency and become very fluid.Only lubricate the spigot end when operating
in high temperatures. High temperatures mayalso cause premature drying of the lubricantafter application. Lubricant should thereforebe applied immediately before jointing the pipes
In cold conditions it may be necessary to warm the lubricant to a brushable consistency by
standing the lubricant container in warm water.
Joint assembly with puller
Align the pipe with the previously laid pipe.
This alignment is necessary to ensure that the
rubber ring is not displaced from its seat
during joint assembly. See Figure 8.4.
Where field conditions prevent straight axial
entry the spigot can still be entered with a
maximum deflection shown in Table 8.1.
Jointing will be easier with smaller deflection.
Hook on the puller between the anchor slings,
and before applying the pulling force, place
protective mats under the puller and hooks to
prevent damage to the coating.
Carefully pull joint into full entry position.
The witness mark should be visible and inline
with the face of the socket.
28 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
C H A P T E R 8 | 29
When in line with the witness mark, hold in
position for a moment to allow the rubber ring
to go back to its original profile. Failure to do so
will result in the pipe ‘popping back’.
Do not over engage to compensate for this.
The final entry position for undeflected joints is
ideally at the line with a tolerance of ±5mm.
Insufficient entry that exposes the line by more
than 5mm after relaxation could result in a
leaking joint (Note that when the pipe is
deflected, the entry line may be exposed by up
to a maximum of 25mm). Entry greater than the
line will not lead to a leaking joint but may
prevent deflection of the joint. In addition,
if entered the full amount, this may result in
damage to the spigot end if the pipe “bottoms”.
With the puller load on, deflect the pipe
to the required grade and direction on the
sand bedding.
The maximum permanent deflections for
SINTAJOINT pipes are shown on Figure 8.5.
Please Note: If more precise figures are
required, please contact a Tyco Water Regional
Marketing Office.
The puller load must not be released until
sufficient backfill is placed around the pipe to
ensure that joint movement will not occur.
Care should be taken when withdrawing slings
from under bedded pipes to avoid damage to
the SINTAKOTE from sling eyes or hooks.
See Section 7: Bedding; Allowance for
sling withdrawal.
Important note for concavechanges in direction
To satisfy the requirement that rubber ring joints
be assembled with the pipes axially aligned, the
free end of a pipe just laid in a concave trench
must be raised, so increasing the deflection of
the previously assembled joint.
The joint design allows for this temporary
‘over deflection’ which, must not exceed
the limits shown on the joint drawing.
See also Figure 8.5.
Similar remarks apply when laying pipes on
changes in direction.
This temporary ‘over deflection’ in concave
changes in grade is achieved by lifting the
pipe end and placing a padded packer (a bag
filled with sand or sawdust) under it.
After completion of the next joint assembly the
packer is removed to allow the pipe to rest
back on the bedding.
The packer is then transferred to the free end
of the pipe just laid and the operation is
repeated.
Table 8.1 - Permissible misalignment of offsets during entry
Pipe size Max permissible Max permissibleOD misalignment offset (mm) pipe
(mm) (degrees) length (m)
6m 9m 12m 13.5m
less than 813 0.5 50 75 100 112
813 or larger 0.25 25 40 50 56
S I N T A K O T E ® S T E E L P I P E L I N E S
0 0.50 1.00 1.50 2.00 2.50 3.00
Deflection Angle (degrees)
6m 9m 12m 13.5m
800
700
600
500
400
300
200
100
0 ��
�
�
�
�
�
�
S I N T A K O T E ® S T E E L P I P E L I N E S
C H A P T E R 8 | 3 1
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
��
�
�
�
�
Figure 8.6 – Axial offest measurement created by joint deflection.
30 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
1700
1600
1500
1400
1300
1200
1100
1000
900
800
700
600
500
400
300
200
3.5° 3° 2.5° 2° 1.5° 1° 0.5°
Tem
pora
ry c
onst
ruct
ion
defle
ctio
n
Per
man
ent d
efle
ctio
n
D. O
utsi
de d
iam
eter
in m
illim
etre
s
θ Deflection angle in degrees Figure 8.5- Temporary construction and permanent SINTAJOINT deflection.
θ
� = % OD
Maximum deflectionsRRJ: 2%Welded joint: 3%Note: Vertical deflection shown left is greatlyexaggerated for clarity of termsBedding reaction
Pipe section after backfilland compaction loading
Pipe section before backfill and compaction
During this operation, to ensure that the
‘over deflected’ joint does not come apart,
it will be necessary to leave the puller load
on at the joint and use a second puller to
assemble the new joint.
After removal of the temporary ‘over-
deflection’, place a quantity of backfill over
the pipe before releasing the puller load.
Remove the pipe handling sling and if the
pipe is laid on a down grade, place a quantity
of backfill over the middle part of the pipe
and also compact backfill at the sides to stop
joint separation.
The placement of the backfill for pipes
negotiating concave changes in grade, or
changes in grade, or changes in direction,
must be delayed until the assembly as
described above is completed.
Remove pulling gear and prepare for jointing
the next pipe.
Inspection of assembled jointBy observing the required pulling force and
ease of spigot entry up to the witness mark,
laying teams quickly develop the skill to assess
correct joint assembly. These assessments are
generally very reliable, however correct
assembly should be verified by inspection.
The following inspection methods are
recommended to check that each joint is
correctly assembled.
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Figure 8.7- External inspection ofassembled SINTAJOINT
2. Lower onto bed to give correct entry and complete weld.
32 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
External check (see Figure 8.7)
Gap: Visual inspection of the gap between the
lip of the socket and the spigot end surface. It
should be uniform and in the range 0–1.5mm.
Entry: Entry witness marks applied by the
manufacturer and those applied during laying are
to confirm entry is correct and no disassembly
movement has occurred after laying.
Internal checkWhen regulations and pipe sizes allow entry
to the pipe, the assembled joint should be
inspected from inside the pipe.
This inspection gives the assurance that
the rubber ring remains properly seated
in its groove.
It must be ensured that no part of the
rubber ring protrudes past the spigot end
of the pipe.
On smaller pipe lengths, where access is not
practicable, inspection from the end of the
pipe using appropriate lighting, must be
performed on each joint.
Telescopic or video equipment may be used.
This procedure should detect most instances
of rubber ring displacement.
Joints indicating rubber ring displacement or
excessive gapping must be pulled apart,
cleaned of all lubricant and re-assembled
using a new rubber ring.
Summary of Important Pointsfor Laying and Jointing:
SINTAJOINT PipesUse recommended assembly equipment and
a method which allows the laying team to
develop a feel for correct joint assembly.
Use light gear which can be handled easily.
Use protection for the coating if there is any
possibility it could be damaged by equipment.
Inspect the pipe ends for damage before
assembly.
Inspect the joint and rubber ring. Ensure they
are clean and lubricate them correctly just
before the assembly.
Use the correct joint assembly procedures.
Inspect the assembled joint to confirm
successful and correct spigot entry.
If movement of the assembled joint is
possible, take appropriate precautions.
Only lubricants specifically recommended for
use with SINTAKOTE should come in contact
with the coating.
Be sure the laying crew have a current drawing
of the joint as supplied for the contract.
Figure 8.8- Welded ball and socket or slip-in joint field assembly
C H A P T E R 8 | 33
Welded jointsWhen welding, ensure adequate ventilation to
draw off welding fumes.
Clean the ends of the pipe with a wire brush
or power brush to remove surface rust etc.
Lay pipes with sockets facing the direction of
laying. It’s easier to locate a pipe spigot
correctly into a socket than a socket over a
spigot. There is also less chance of entrapping
soil in the joint as the spigot is pushed home.
Pick up the pipe, refer Section 3: Unloading
and handling.
Lower the pipe into the trench and insert
the spigot end into the socket. The pipe
should be inserted angled slightly down
toward the spigot. The top of the joint is then
tack welded and the pipe lowered onto the
bedding to give correct entry. See Figure 8.8.
The maximum allowable deflection for slip-in
joints is in the range 20 to 30. For ball and
socket welded joints, the maximum
allowable deflection is 30.
In general, only a single fillet weld is required
for sealing and structural purposes.
Pipe sizes 813 mm OD and larger may
require a seal weld internally to allow an air
leak tightness test of the weld.
The gap between cement mortar linings at
joints should be filled with cement mortar
for pipe sizes 813 mm OD and larger. Refer
Appendix B - Repair of cement mortar
linings and reinstatement of field joints.
For smaller sizes, design should ensure
joint configurations which permit cement
linings to abut.
Provide external coating at all joints using a
heat shrink sleeve (preferred) or tape field
joint coating systems. Refer Appendix A:
Field repair and joint reinstatement of
SINTAKOTE.
Where a SINTAKOTE pipe is cut for welding,
the pipe should be stripped back to the
steel for a minimum distance of 75 mm
each side of the weld.
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
14
10
62 15
3
134
8
1612
9
15
7
11
Figure 8.12 Star pattern tighteningsequence
Fig 8.10 Matched o-ring type flangesFig 8.9 Raised face type flanges
34 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
Flanged jointsFlanged joints are completely rigid and should
not be used for applications where movement
of the pipeline is expected, unless special
provision is made to accommodate it by, for
example, the inclusion of expansion joints.
Flanged joints are used mainly for above
ground applications, e.g. pumping stations,
water and sewage treatment plants and for
industrial pipework. They are also used to
facilitate the installation and removal of valves
in SINTAJOINT and welded pipelines and for
valve bypass arrangements.
For assembly of flanged joints no field welding
or other special equipment is required. Flange
dimensions are normally in accordance with
AS 4087 and are currently supplied in Class
14, Class 21 or Class 35.
For access covers and other blank flange
joints Tyco Water recommends the use of o-ring type gaskets because of their low
requirement for assembly stress and trouble
free operation. O-ring flanged joints have
these same advantages in other flanged joint
situations but it must be remembered that the
use of o-ring type flanges requires full
knowledge of all of the mating components to
avoid a joint situation with two o-ring groove
ends joining each other. The correct matching
is shown in Figure 8.10.
C H A P T E R 8 | 35
Where it is not possible or desirable to use
o-ring type flanges, Tyco Water recommends
the use of raised face steel flanges. See Figure
8.9. The use of flat-faced steel flanges is not
preferred except when the mating flange is cast
iron. This situation may occur at a pump
housing, but current practice is for most pipeline
components to be manufactured in steel or
ductile iron. Experience has shown that
flat-faced flanges are generally more susceptible
to sealing problems and successful sealing is
heavily dependent upon assembly technique.
Where the required flange sizes are larger than
DN 1200 or are outside the normal pressure
rating, special flanges must be designed. In this
situation o-ring type flanges are recommended
as being the best option for medium to high
pressure situations.
GasketsGaskets may be either elastomeric or
compressed fibre type. Elastomeric gaskets are
only recommended for the Class 16 flanges.
Compressed fibre gaskets are recommended
for Class 21 and Class 35 flanges.
Compressed fibre gaskets can also be used
with Class 16 flanges but will require the use of
high strength bolts because of the higher initial
compression necessary.
Table 8.2 details the recommended type of
gasket to be used for various classes of raised
face steel flanges. Generally full face gaskets
(that incorporate holes for the flange bolts) can
be used with raised face flanges as only the
raised face area inside the bolt holes is
clamped. The full face gasket enables better
location of the gasket compared to a ring type
gasket. (If rigid compressed fibre type gaskets
are used the use of ring type gaskets is normal)
For other liquids, temperatures or pressures
contact a Tyco Water Regional Marketing Office.
Flange bolts and assembly torqueBolting used on flanges is usually galvanised
steel or stainless steel. Commercial grade bolts
are used with the Class 14 flanges and rubber
gaskets while high strength studs and nuts are
required for use with compressed fibre gaskets.
Poor assembly technique is by far the greatest
single cause of flange joint failure and use of the
correct technique and selection of the suitable
bolt torque is vital. Table 8.3, 8.4 or 8.5 may be
used as a guide for determining the final torque
setting for any flange within the specified range.
Table 8.2 - Recommended gasket composition for transport of general domesticliquids including brine and sewage
Maximum Maximum Gasket CompositionOperating Pressure TemperatureMPa °C
1.6 50 Solid EPDM Rubber 3mm thick
3.5 80 Composit Fibre 1.5mm thick
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
TABLE 8.3 Recommended Bolt Torques for Raised Face Steel Flanges Class 16 with Compressed Fibre Gaskets Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 80
C H A P T E R 8 | 3736 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s S a f a n i l i t y
36 | C H A P T E R 8
S a f e t y
1. 'Lightly oiled' refers to the application of a goodquality lubricating oil and is the usual as receivedcondition of fasteners.2. 'Well lubricated' refers to the application ofmolybdenum disulphide or Koprkote grease.3. The estimated torques provided in the table arebased on the friction factor (k) indicated. Where otherfactors apply, alternative torques should be calculated.4. Required bolt tensions and estimated torques havebeen assumed using established engineering principles.However, variation in installation procedures may result
in different requirements.5. Common pipe sizes not included are 559, 762,889, 914, 1086, 1124, & 1145For these sizes, raised face flanges with elastomericgaskets are not recommended due to eitheroverstressing of the gasket when tightening bolts toachieve gasket sealing or excessive flange deflectionunder pressure. If these pipe sizes are used theflanged joints may not be suitable for full test pressureO-ring grooved flanges are more suited to these pipesizes for Class 14 flanges.
Estimated Torque
Lightly Oiled Well Galvanised, or Lubricated Flange Pipe No. Bolt Bolt Well Lubricated Galvanised DN OD of Size Tension Stainless Steel Steel Bolts Studs or Bolts Studs or Bolts k = 0.22 k = 0.15 mm kN Nm Nm
100 114 4 M16 75 265 180
150 168 8 M16 75 265 180
200 178, 190, 219 8 M16 75 265 180
225 235, 240 8 M16 75 265 180
250 257, 273 8 M20 95 420 285
300 290, 305, 324, 337 12 M20 95 420 285
350 337, 356 12 M24 140 740 505
375 368 12 M24 140 740 505
400 406, 419 12 M24 140 740 505
450 457 12 M24 140 740 505
500 502, 508, 559 16 M24 140 740 505
600 610, 648, 660 16 M27 175 1040 710
700 700, 711, 762 20 M27 175 1040 710
750 800, 813 20 M30 210 1390 945
800 813, 889 20 M33 260 1890 1290
900 914, 959, 965, 972 24 M33 310 2255 1535
1000 1016, 1035, 1067, 1086 24 M33 260 1890 1290
1200 1200, 1219, 1283, 1290 32 M33 260 1890 1290 1. 'Lightly oiled' refers to the application of a good
quality lubricating oil and is the usual as received condition of fasteners.
2. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease
3. The estimated torques provided in the table are based on the friction factor (k) indicated.
. Where other factors apply, alternative torques should be calculated.
4. Required bolt tensions and estimated torques have been assumed using established engineering principles. However, variation in installation procedures may result in different requirements.
5. Common pipe sizes not included are 1124, 1145
For these sizes, raised face flanges with elastomeric gaskets are not recommended due to either overstressing of the gasket when tightening bolts to achieve gasket sealing or excessive flange deflection under pressure. If these pipe sizes are used the flanged joints may not be suitable for full test pressure O-ring grooved flanges are more suited to these pipe sizes for Class 16 flanges.
6. Full face flanges not recommended. If used, gasket should be ring type 3mm TEADIT NA1000 Compressed Fibre.
Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre for raised face flanges. - Ring type 1.5mm TEADIT NA1000 Compressed Fibre for flat face flanges. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70
Estimated Torque
Lightly Oiled Well
Galvanise Lubricated
Flange Pipe No. Bolt Bolt Well Lubricated Galvanised
DN OD o f Size Tension Stainless Stee l Steel
Bolts Studs or Bolts Stud s or Bolts
k = 0.22 k = 0.15
mm kN Nm Nm 100 114 8 M16 40 145 100
150 168, 178 12 M20 75 330 225
200 190, 219 12 M20 75 330 225
225 235, 240, 257 12 M24 80 425 290
250 257, 273, 290 12 M24 80 425 290
300 305, 324, 337 16 M24 80 425 290
350 356, 368 16 M27 115 685 470
375 406, 419 16 M27 115 685 470
400 419 20 M27 115 685 470
450 457, 502, 508 20 M30 115 760 520
500 559 24 M30 115 760 520
600 610, 648, 660 24 M33 190 1380 945
700 700, 711,762 24 M33 190 1380 945
750 800, 813 28 M33 190 1380 945
800 889 28 M33 190 1380 945
900 914, 959, 965, 972 32 M36 190 1505 1030
1000 1016, 1035, 1067, 1086 36 M36 190 1505 1030
1200 1124, 1145, 1200, 1219 40 M39 310 2660 1815
1200 1283, 1290 40 M39 310 2660 1815
1. 'Lightly oiled' refers to the application of a good quality
lubricating oil and is the usual as received condition of fasteners. 4. Required bolt tensions and estimated torques have been
assumed using established engineering principles.2. ' Well lubricated' refers to the application of molybdenum
disulphide or Koprkote grease. result in differenct requirements.However, variation in installation procedures may
3. The estimated torques provided in the table are based on the
friction factor (k) indicated. Where other factors apply, alternative torques should be calculated.
.
TABLE 8.4 Recommended Bolt Torques for Steel Flanges Class 21 with Compressed
Fibre Gaskets
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
TABLE 8.5 Recommended Bolt Torques for Raised Face Steel Flanges Class 35 with
Compressed Fibre Gaskets
Gasket - Full Face or Ring type 1.5mm TEADIT NA1000 Compressed Fibre Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70
Estimated Torque
Lightly Oiled Well Galvanised, or Lubricated
Flange Pipe No. Bolt Bolt Well Lubricated Galvanised DN OD of Sizes Tension Stainless Steel Steel
Bolts Studs or Bolts Studs or Bolts k = 0.22 k = 0.15 mm kN Nm Nm
100 114 8 M16 40 145 100
150 168, 178 12 M20 75 330 225
200 190, 219 12 M20 75 330 225
225 235, 240 12 M24 80 425 290
250 257, 273 12 M24 80 425 290
300 290, 305, 324 16 M24 80 425 290
350 337, 356 16 M27 115 685 470
375 368, 406 16 M27 115 685 470
400 406, 419 20 M27 115 685 470
450 457 20 M30 115 760 520
500 502, 508 24 M30 115 760 520
600 559, 610, 648 24 M33 190 1380 945
700 660, 700, 711 24 M33 190 1380 945
750 762, 800, 813 28 M33 190 1380 945
800 813 28 M33 190 1380 945
900 889, 914, 959 32 M36 210 1665 1135
1000 1016, 1035, 1067, 1086 36 M36 210 1665 1135
1200 1219, 1283, 1290 40 M39 300 2575 1755 1. 'Lightly oiled' refers to the application of a good quality
lubricating oil and is the usual as received condition of fasteners.
4. Required bolt tensions and estimated torques
have been assumed using established engineering principles.
2. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease.
However, variation in installation procedures may result in different requirements.
3. The estimated torques provided in the table are based on the friction factor (k) indicated. Where other factors apply, alternative torques should be calculated.
38 | C H A P T E R 8
R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .
C H A P T E R 8 | 39
Jointing instructions for flanged joints
1.Use a scraper or wire brush to thoroughly
clean the flange faces to be jointed, ensuring
there is no dirt, particles or foreign matter,
protrusions or coating build-up on the mating
surfaces.
2. Ensure that the mating threads of all nuts
and bolts are clean and in good condition.
3. Evenly apply a suitable lubricant (e.g.
molybdenum disulphide) to all mating threads,
including the nut load bearing face and washer.
4. Align the flanges to be joined and ensure
that the components are satisfactorily
supported to avoid bending stress on the
flanged joint during and after assembly.
5. Insert four bolts in locations 1 to 4 as
indicated in Figure 8.11 and position the
insertion gasket on the bolts, taking care not to
damage the gasket surface.
6. Offer the adjoining flange to the bolts, taking
care to maintain support and alignment of the
components.
7. Tighten nuts to finger tight and check
alignment of flange faces and gasket.
8. Insert the remaining bolts and tighten nuts to
finger tight.
9. Estimate the required bolt torque considering
bolt type and allowable tension, flange type and
rating, gasket material and max/min
compression, and the pipeline’s maximum
pressure (operating/test pressure). Refer to
tables 8.3, 8.4 or 8.5 for recommended torque
values.
10. Tighten nuts to 20% of estimated torque
using the star pattern; see Figure 8.11.
11. Tighten to 50% of estimated torque using
the same tightening sequence.
12. Tighten to 75% of estimated torque using
the same tightening sequence.
13. Tighten to 100% of estimated torque using
the same tightening sequence.
14. Repeat the tightening procedure on all nuts
until little or no movement can be achieved on
each nut. (particularly important on elastomeric
gaskets)
• Grade 8.8 galvanised steel or grade 316
property class 80 stainless steel stud bolts
are recommended for use with composite
fibre gaskets.
• Bolt tensions need to counter the force due
to expected internal pressure and to provide
an adequate sealing stress without exceeding
the maximum allowable gasket stress at the
time of installation.
• The application of excessive torque at the
time of installation may overstress the gasket
causing crushing or extrusion, which can lead
to leakage at operating pressures.
• The surface conditions of the threads as a
result of rust, plating, coating and lubrication are
the predominant factors influencing the torque /
tension relationship. However, there are many
others including thread fit, surface texture and
the speed and continuity of tightening.
• The flange faces are assumed to have a
surface roughness of Ra = 10 -12.5 µm.
• A torque wrench is most commonly utilised
to achieve the required bolt tension, however
in critical applications an hydraulic tensioner
should be used.
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
150 to300mm
50mm min under pipe barrel
600mm minZONE C
ZONE B
ZONE A
9. Backfilling
40 | C H A P T E R 9
F a t i g u e i t d o e s h a p p e n ? F a t i g u e i t d o e s h a p p e n ?
Figure 9.1- Zones of backfill and compaction
The materials used for backfilling the trench
and their compaction should be specified by
the designer. Proper support and protection of
the pipe should be considered together with
the future ground loading and activity.
For small diameter pipe laid in an area where
surface settlement is not a problem, minimum
backfill compaction is normally adequate.
However as the depth of cover increases or
where vehicle traffic occurs, and especially for
large diameter thin wall pipes, the degree of
compaction becomes critical to ensure the
long term performance of the pipeline.
Zones of backfill andcompactionThe soil surrounding the pipe can be
considered as three Zones shown in
Figure 9.1.
Zone A - Bedding
A minimum 50 mm thick compacted beddinglayer of sand, non cohesive native soil or
imported fill (100% less than 13.2mm) should
be provided under the pipe as bedding.
Bedding material may need to be imported or
may be present after excavation.
Bedding provides even support for the pipe
along its entire length and protects the
SINTAKOTE.
Zone B - Backfill for haunchsupport, side support and overlay
The haunch and side support areas provide
support for the pipeline and prevent sharp
objects imparting high loads onto the pipeline
coating. Backfill should consist of non-cohesive
native soil, free from stones and sharp objects
larger than 25 mm or imported fill, sand or
rounded gravel not greater than 20mm.
C H A P T E R 9 | 41
The degree of compaction required will
depend on the loading for which the pipeline
has been designed and the ring stiffness of
the pipe.
Ring stiffness depends on the pipe wall
thickness and diameter; a thick walled small
diameter pipe is stiffer than a thin walled large
diameter pipe. An indication of stiffness can
be taken from the diameter/steel wall
thickness ratio or D/t.
For steel pipes equal to or less than 914mm
OD, with a D/t less than 120, only moderate
compaction is required to achieve the
necessary support. Pipes with D/t values
greater than 120, or greater than 914 mm
OD, need more support from the side fill to
carry the soil and traffic loads and the level of
compaction specified should reflect this.
When high levels of compaction are specified
for these low stiffness pipes, it is essential
that backfill be well compacted between the
sides of the pipe and the trench. Particular
care should be taken in compacting the
material under the haunches of the pipe. The
backfill should be built up in 150 mm layers
evenly on both sides of the pipe.
Backfilling in layers should proceed until there
is an overlay of at least 150 mm above the
top of the pipe. This layer provides a zone of
material to prevent sharp objects imparting
high point loads on the coating.
When a pipeline is to be cathodically
protected, material should not be too high in
electrical resistivity as this will reduce the
effectiveness of the protection. Generally
sand or soil is suitable. Stone and gravel can
be too high in resistivity. Hence a well graded
mix of sand and gravel should be used on
cathodically protected lines where imported
backfill is required.
Zone C - Overburden trench fill
Material in this zone builds the trench up tothe original ground level and the materials
used and extent of compaction
depends on the allowable future surface
settlement. Under road pavements the
load bearing capacity of the ground surface is
important and backfill must be
compacted in layers all the way to the
surface.
Where the trench is across open land,
the compaction requirements of this zone
are not normally so important and the surface
can usually be built up to allow for some
future settlement.
The material used in Zone C, would normally
be the excavated trench material, but where
a high degree of compaction is needed in
bad natural ground, imported material may be
required.
S I N T A K O T E ® S T E E L P I P E L I N E S
Hockey Stick
1 metre shortMitred Bend
Reducer Tee Air valve or Scour Flanged Offtake
Eccentric Reducer Tee Angle Branch Y-Piece
Concentric Reducer Mitred Bend0° to 22.5°
Mitred Bend22.5° to 45°
Mitred Bend45° to 90°
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
� = % OD
Maximum deflectionsRRJ: 2%Welded joint: 3%Note: Vertical deflection shown left is greatlyexaggerated for clarity of termsBedding reaction
Pipe section after backfilland compaction loading
Pipe section before backfill and compaction
42 | C H A P T E R 9
F a t i g u e i t d o e s h a p p e n ? O b e y t h e s i t e r u l e s
Figure 9.2- Ring deflection limits
CompactionThe level of compaction to achieve in-situ
ground conditions, may require 65% Relative
Density for sand or 90% Standard Proctor
Density for clay type (cohesive) soils.
Soil density is usually specified as “Standard
Proctor Density” for clay type soils and
“Relative Density” for granular soils
(cohensionless).
Standard tests are available for determining
the density of compacted soils.
Ring deflection limitsTo ensure serviceability of the pipeline, ring
deflection must be limited as described below
and shown in Figure 9.2.
During construction these limits may need to
be lowered where service loads contribute
significantly to ring deflection.
Sintajoint (RRJ)
For SINTAJOINT pipe a safe service ringdeflection limit of 2% of the pipe OD is
recommended. This is to ensure that the
annular gap between spigot and socket is not
so distorted as to cause significant reductions
in gasket contact pressure.
Welded JointsFor pipes with welded joints and cement
mortar lining, a safe service ring deflection limit
of 3% of the pipe OD is recommended.
This is to avoid possible repetitive flexing of
the pipe and fraying of the lining.
S I N T A K O T E ® S T E E L P I P E L I N E S
Good planning at the design stage can result in
improved installation efficiency. This is particularly
true for pipelines requiring numerous fittings.
For fully welded lines, fittings should be
ordered to suit and can be fabricated from
SINTAKOTE pipe.
For rubber ring joint pipelines, consideration
needs to be given to anchorage at change in
direction, dead ends, tapers or tees. See
Section 11: Anchorage of pipelines.
For rubber ring pipe joints under maximum
allowable deflection (see Figure 8.6)
thorough compaction of the embedment
zone on the outside of the joint is
required.
For directional changes greater than that
achieved by deflection of a pipe joint, fittings
are required.
For common use fittings see Figures 10.1 and
10.2.
10. Fittings
Figure 10.1- Common Fittings - welded pipelinesNote that Tees, Angle Branches and Y-Pieces may require reinforcing as indicated.
Figure 10.2- Common Fittings - SINTAJOINT pipelinesNote that reducers may require a thrust flange.
C H A P T E R 1 0 | 43
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Anchor block for horizontal bend
Anchor block for horizontal taperAnchor block for horizontal tee
11. Anchorage of Pipelines
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
C H A P T E R 1 1 | 45
Figure 11.3 - Pier support for above ground SINTAJOINT pipelines
Hold down over bearing material
Bearing material toaccommodate
expansion movementwhere necessary
Anchor block for vertical slope Anchor block for vertical bend
Figure 11.1- Anchor blocks for horizontal thrust restraint
Static thrustsAll pressure pipelines having unanchored
flexible joints, require anchorage at changes of
direction, changes in diameter, tees, valves
and at blank ends to resist the thrusts
developed by internal pressure.
Additional dynamic thrusts are created by
moving water but are usually negligible unless
the flow velocity is extremely high.
Anchorage of buriedmainsAnchorage to resist thrusts must be designed
for the maximum pressure expected in the
main in service or during test. Anchorage can
be provided in several ways:
� Anchor blocks,
� Ties to concrete blocks, or
� Pipe surface friction
The most common method is the use of
concrete anchor blocks. These should be
poured immediately after excavation for the
block to ensure that the soil bearing strength
does not deteriorate. Where possible
concrete anchor blocks should be of such a
shape as to allow sufficient space for the
joints to be pulled apart, pipe or fittings
replaced and reassembled.
Anchor blocks forhorizontal thrust-buriedmainsThe horizontal thrust developed in buried
mains must be transferred to the undisturbed
soil of the trench wall by anchor blocks poured
against the soil face. The thrust is distributed
over the total bearing area of the block to
ensure that the safe bearing pressure of the
trench wall is not exceeded. See Figure 11.1
Anchor blocks forvertical thrust restraint.Downward vertical thrusts are transferred to
the undisturbed ground by anchor blocks in
the same manner as horizontal thrusts.
44 | C H A P T E R 1 1
B e a w a r e o f y o u r s u r r o u n d s B e a w a r e o f y o u r s u r r o u n d s
Upward vertical thrusts are counteracted by
the weight of the concrete anchor block.
If the water table in the area is likely to reach
the level of the anchor block, the submerged
weight of the block must be sufficient to
counteract the thrust. If the natural ground is
of sufficient strength ie., rock, special anchor
blocks can be cast into the rock to resist
upward thrust forces. See Figure 11.2
Ties to concrete blocksTies are rarely used except where there is
limited space or lack of bearing area behind
the pipe fitting.
Pipe surface frictionThrust resistance can be achieved by utilising the
skin friction between the pipe and soil surround.
This requires the welding or harnessing of several
pipe lengths, the length of which must be
determined by the pipeline design engineer.
Above ground pipesFor above ground applications all steel pipes
must be supported and anchored. Where
relative movement of the pipe support and
anchorage is likely, the bearing materials should
be chosen to allow for this. See Figure 11.3
Figure 11.2- Anchor blocks for vertical thrust restraint
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Location A Location BTest pressure 200m Test pressure 175m
200m test pressure required at Location AGauge at A should read 200mGauge at B should read 175m
25m static head
Pipeline section under test
12. Hydrostatic field test
Figure 12.1- Static head allowance for hydrostatic test with alternative pressure gauge locations
A pipeline is subjected to a field pressure test
primarily to check that all joints are watertight.
At the same time the test checks the integrity
of all fittings and appurtenances, as well as
construction work such as anchorages.
It is recommended that a hydrostatic test iscarried out on the first 200m of pipe laid to
confirm that laying practices are effective.
Where concrete anchor blocks are installed,a reasonable time must be allowed for the
concrete to cure before testing commences.Cement mortar lined pipe should becompletely filled with water of approved
quality and allowed to stand for at least 24
hours. This permits maximum absorption of
water by the lining and release of any air.
Additional water should be added to replace
the quantity absorbed.
The pipeline should be filled slowly to
prevent water hammer and to minimise
entrapment of air. If the pipeline section to
be tested is not provided with isolation
valves then the ends must be fitted with
bulkheads. Pipes or bulkheads must be
fitted with the necessary outlets forincoming water and outgoing air.
The hydrostatic test usually commences
after the 24 hour standing period.
The water pressure should be raised to the
specified field test pressure, such
pressure being measured at the lowest
point of the section under test.
Alternatively a static head allowance may
be made between the lowest point and the
point of the section under test.
See Figure 12.1.
46 | C H A P T E R 1 2
T a k e t h e c o r r e c t a t t i t u d e t o s i t e T a k e t h e c o r r e c t a t t i t u d e t o s i t e
C H A P T E R 1 2 | 47
Field hydrostatic test pressures are specified
by the design Engineer after consideration of
the working pressure of the pipeline.
The test pressure should be maintained for at
least 2 hours.
If the pressure has dropped at the end of the
test, the volume of water needed to restore
the original pressure should be measured.
The test should be repeated a number of
times with any make-up volume being
measured. This make-up volume may result
from pipe movement and compression of
small quantities of entrapped air. Some
leakage may be permitted to accommodate
field constructed mechanical joints, and seals
on fittings and appurtenances.
Allowable make-upvolumeAny allowable make-up volume should be
specified by the designer.
A generally accepted make-up volume rate is;
Allowable make-up rate (L/hr) =
1.4 x 10-7x D x L x H
Where D = Pipe OD (mm),
L = Pipeline length (m),
H = Average test head(m)
If the specified allowable make-up volume is
exceeded the following procedure should be
followed.
Ensure that all air has been expelled and the
24 hour standing period has elapsed.
Check all valves for full closure and sealing.
Check all mechanical joints, gibaults and
flanges. Bolts should be uniformly tight and full
sealing achieved.
If subsequent testing still results in
unacceptable make-up volume, the ground
above the line should be inspected for signs
of obvious leakage. If none are apparent the
line should be tested in halves with the failing
section being subsequently halved and tested
until the leak is located.
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Choose either heat shrinksleeve (preferred) or tape
wrap field joint coating
Use either adhesivepatch, heat shrink
sleeve or tape wrapcoating method
Repair is atSINTAJOINT ends,use Drader welding
repair method
Isrepair
a welded field
joint?
Isrepair
away fromSINTAJOINT
ends?
Isrepair area
>10,000mm2?(100 x 100mm)
Prior to commissioning ensure the removal of
any solid material from the inside of the
pipeline including rubbish, dirt, welding stubs
and other foreign matter.
This may be achieved by placing a swab or
“pig” through the line or in the case of larger
diameter pipes, by operators travelling through
the line. Only soft foam swabs (with no
scouring pad attachments) should be used on
seal coated pipelines.
A pipeline which will carry potable water
should be sterilised with chlorinated water in
accordance with the water authority’s
requirements.
13. Commissioning water pipelines
48 | C H A P T E R 1 3
D e f i n e r e s p o n s i b i l i t i e s
A P P E N D I X A | 49
Mild steel cement mortar lined pipe is
supplied with SINTAKOTE, a fusion bonded
medium density polyethylene coating for
welded or rubber ring jointing. Fittings may be
fabricated from SINTAKOTE pipe, but are also
available as SINTALINK fittings, entirely coated
with SINTAKOTE.
In order to determine whether or not a
damaged area requires repair the following
assessment should be made:-
Continuity test at 12kV. If a holiday is
detected then repair.
Determine the coating thickness. If less than
1.0 mm then repair.
Figure A.1 has been devised to determine the
best method for field repair of SINTAKOTE for
buried service at ambient temperature. Heat
shrink sleeves are the preferred method of
protection of field welds.
Enclosed are the procedures for heat shrink
sleeve coating (A1), tape wrap coating (A2),
adhesive patch repair (A3), Drader gun welding
repair (A4) and SINTAPIPE end repairs (A5).
The use of petrolatum tape protection
systems is not recommended for the repair or
field joint coating of SINTAKOTE. This is
primarily due to their very poor resistance to
soil stresses.
The techniques detailed in this Appendix do
not apply to pipelines operating at
temperatures above 30 0C, nor do they apply
to piles/pipelines used in above ground
situations. For repair/joint coating of these
pipes contact Tyco Water.
Figure A.1 - Flow chart for determiningappropriate SINTAKOTE repair method
APPENDIX A - Field repair and Joint
Reinstatement of SINTAKOTE®
Choose either heat shrinksleeve (preferred) or tape
wrap field joint coating
YES
YESYES
NO NO
NO
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
The application of heat shrink sleeves will give
the optimum field protection. However,
personnel applying sleeves need to be fully
trained and experienced.
Recommended SleevesThe recommended sleeves are:
1. Raychem WPCB available from Petro Coating Systems Pty. Ltd. The primer is Petrocote primer.
2. CANUSA KLS available from Denso PtyLtd. The primer is Denso Primer.D.
Application procedure
1. Bevel the edges of the SINTAKOTE so that
there is a tapered transition of at least 5 mm
between the full coating thickness and the
exposed steel.
2. Remove any corrosion products on the
steel and abrade the steel surface
(if necessary) to produce a clean, non-
corroded, roughened surface. Suitable
abrasives are emery paper or a steel file.
3. Prepare the area to be repaired (to be
free from dirt, dust and other contaminates)
in accordance with the recommendations
of the shrink sleeve manufacturer.
4. Using 120 grit emery or sandpaper slightly
roughen the SINTAKOTE around the repair
for a minimum distance of 100 mm from
the edge of the repair. Solvent wipe the
SINTAKOTE with a clean cloth (isopropanol
is a suitable solvent for cleaning).
5. Apply the shrink sleeve in accordance with
the application procedures of the manufacture.
If preheating cannot be achieved, brush apply
a thin film of primer to any steel not coated with
SINTAKOTE and onto the SINTAKOTE for a
distance of 100 mm. Do not apply the primer
prior to preheating. Ensure that the sleeve
overlaps the SINTAKOTE for a minimum width
of 100 mm. Note that the specified preheat
and postheat is necessary to ensure
satisfactory bonding of the sleeve. A roller
should be used to eliminate voids from under
the sleeve.
6. The repair should be visually inspected to
ensure that it is in intimate contact with the
pipe and that a bead of mastic has exuded
from each end of the sleeve for the full pipe
circumference. (If this is not in evidence
additional heating is required).
Procedure A1 - Heat Shrink Sleeve Coating Method
50 | A P P E N D I X A
A P P E N D I X A | 51
Procedure A2 - Tape Wrap Coating Method
This tape system provides a thick coating repair
or field joint coating with similar impact resistance
to that of SINTAKOTE. Thinner coating systems
may not provide the same degree of protection.
The outerwrap of a thin PVC tape is provided to
reduce soil stresses as far as is possible with a
tape wrap system. A heat shrink sleeve
repair/joint protection is recommended for
optimum resistance to soil stresses.
Recommended tape wrapThe following tape system or equivalent is
recommended:-
Primer - Denso Densolen HT primer or
Denso Primer D.
Primary tape - Denso Ultraflex 1500 tape with
a minimum 55% overlap.
Secondary tape - Denso MP/HD tape with a
minimum 10% overlap.
These products are available from Denso
(Aust.) Ltd.
Application procedureThe method of application should be in
accordance with the tape manufacturer’s
recommended procedures with the following
additions:-
PreparationUse a knife to remove all burrs/stubs from the
parent coating. For coating repair, slightly
roughen the SINTAKOTE for 100 mm from the
edge of the repair using 120 grit emery.
The steel and coating area should be clean
and dry before application of the primer.
Procedure1. Cut out a piece of tape (Ultraflex 1500)
to fit into the bare steel area. (This is used
for repair, it is not necessary for field
joint coating).
2. Using a brush, apply a thin even coat of
primer onto the steel and onto the
SINTAKOTE by 100 mm.
3. Allow the primer to tack dry (approx.
10mins). Insert into the repair the cut piece
of tape.
4. Spirally apply the tape (Ultraflex 1500)
to the repair area ensuring a 100 mm
overlap onto the SINTAKOTE. The overlap
of tape layers should not be less than
55% of tape width.
5. Spirally apply the outerwrap (Denso
MP/HD) to completely cover the first layer
of tape coating. The overlap of layers
should not be less than 10% of the
overwrap width.
6. Some tension should be applied
when applying the tapes to ensure
that air voids, wrinkles etc. are not
present after wrapping.
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Jointing Region200mm
Jointing Region
This method is recommended for repair areas
up to 10,000 mm2 (ie 100 x 100 mm). It is
only recommended for field use. The method
uses a mastic filler, a heat fused repair patch
and an overwrap tape. The tape overwrap is
provided to reduce the effect of soil stresses
on the patch coating. A heat shrink sleeve
coating is recommended for optimum
resistance to soil stresses (see A1). Note that
rolls of Perp material should not be left in the
sun as the product can heat up and cause
the layers in a roll to fuse together.
Recommended MaterialsThe following system or equivalent is
recommended:
� Filler - Raycem Perpfiller
� Patch - Raychem Perp
� Overwrap - PCS PVC250 overwrap
Products available from Petro Coating Systems.
Application ProcedureRecommended adhesive repair patches
1. Clean and dry the area to be repaired (free
from dirt, dust and other contaminates). At all
the coating interfaces with bare steel, the
coating must be bevelled to an angle of ≤300
to the steel.
2. Cut a patch from the Perp roll big enough
to extend 80mm beyond the damaged area on
all sides. The corners of the Perp patch should
be rounded to at least a 30mm diameter.
3. Slightly roughen the SINTAKOTE around
the repair for a minimum distance of 80 mm
from the edge of the coating damage, using
120 grit emery. Solvent wipe the SINTAKOTE
with a clean cloth (acetone and isopropanol
are a suitable solvents for cleaning).
4. Preheat the entire region to be covered by
the patch (including the exposed bare metal), to
a minimum temperature of 600C, with a yellow
flame from a propane/air gas torch. The
temperature can be measured with a melt stick.
5. Place a pre-cut piece of Perpfiller to cover
the area of exposed steel. Heat the mastic
and smooth it with a flame heated paint
scraper type blade to cover all bare metal and
to exclude all air. Do not smear the mastic
over the SINTAKOTE. Any excess mastic
should be removed so that the mastic just fills
the damaged region.
6. Apply a yellow flame to the SINTAKOTE to
warm the surface.
7. Apply a yellow flame to the adhesive side
of the Perp until it appears glossy.
8. Immediately apply the patch to the
damaged area centering the Perp with respect
to the damage.
9. Heat, using the gas torch, from the centre
of the Perp, and use rubber coated or Teflon
roller to eliminate any entrapped air. Continue
heating and rolling until adhesive is observed
exuding from all areas of the Perp.
10.Ensure the area to be tape wrapped is
clean and free from any dirt/contamination.
If in doubt, solvent wipe.
11.Spirally apply the Denso MP/HD tape
around the full circumference of the pipe, with
tension applied, to completely cover the patch
repair and overlap it by at least 80mm on all
sides. The tape overlap should not be less
than 10% of the tape width.
52 | A P P E N D I X A
Procedure A3 - Adhesive patch repair method Procedure A4 - Drader welding repair method (for field repair at SINTAJOINT pipe ends only)
For use only where damaged SINTAKOTE
surfaces occur in the jointing region shown
in Figure A2. The Shrink Sleeve method or
Adhesive Patch method should be used
where damage occurs away from the joint
region.
This method is the only approved method for
repairing the spigot end and socket end of
SINTAJOINT pipe or fittings.
When properly executed, this method will
ensure good fusion between the filler material
and existing SINTAKOTE.
QualificationsEach operator who is to make repair welds
upon coatings should be suitably practised
and should be able to achieve adequate
fusion in practice welds. Such welds can be
evaluated by removing full thickness
sections perpendicular to the weld.
These sections can then be bent one way
and then the other, through an angle of
approximately 300, to place the internal
and external surfaces of the coating in
tension. Any lack of fusion indicate an
unsatisfactory weld.
Welding equipment1. Drader extrusion welder and suitable
welding tips. Refer Figure A.3 & A.4.
2. 240 V extension lead and power supply
3. Air supply 550 to 700 kPa (80 to 100 psi)
4. Thick leather gloves
5. Wraparound tip
Figure A.2 - Joint Region for Materials Drader welding repair 1. A 4 mm nominal diameter extruded
medium density polyethylene filler rod supplied
by Tyco Water. (SINTAKOTE filler rod).
2. Clean cotton rags and isopropanol cleaning
solution.
General Instructions1. The Drader Injectiweld can produce sound
weld deposits of various shapes that are
effectively bonded to the original surface
provided the correct technique is used.
2. Temperature setting – The welder unit
should be preset to 270ºC initially and no
further adjustment is necessary.
3. Select the correct tip and fit to the gun as
follows:
Remove the retaining nut with the tool
provided. This will require the gun to be
switched on and heated up for a few minutes.
Remove the previous tip being careful to
locate the aluminium washer that is fitted
between the tip and the body of the gun.
4. Figure A.3 shows the gun with tip removed.
Always replace the washer: Failure to replace the
washer before fitting the new tip will allow
extruded material to be forced down these holes
and possibly damage the heater and/or sensor.
A P P E N D I X A | 53
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54 | A P P E N D I X A
Barrel
GunHandle
SensorIndexing Pin
Heater
AluminiumWasher
Figure A.3 – Drader gun assembly
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
5. Apply a small amount of the ‘Heat transfer’
paste to the top of the washer and the
threads of the body to enable them to be
easily removed later. Place the gun on a
horizontal surface so that it is pointed up and
place the tip over the end so that it fits snugly
over the washer and pin. Occasionally the tip
may not engage correctly because the
locating holes are filled of plastic. In this case
wait until the tip heats up and melts the plastic
in the holes. Ensure that the tip sits firmly on
the washer and place the retaining nut over
the tip and push it down until it engages the
thread (use thick gloves and/or cotton rags to
prevent burning hands – all of these
components will get hot).
6. Never place the tip into the retaining nut
first and screw it onto the gun. This could
break off the locating pin making it very
difficult to repair.
7. Screw the retaining nut up tight with the tool
provided. This process may need to be repeated
a few times as the components heat up and the
retaining nut expands. (It may also be necessary
to heat up the gun to replace a tip later).
8. Fit the Ø4 mm plastic wire into the hole at
the base of the gun and rotate the feed nut to
engage the wire. The wire should not be able
to be pulled out from the gun when correctly
engaged. Never operate the feed trigger
without plastic wire being engaged. This could
result in damage to the feed mechanism.
Various concave tips for wraparound end repairThese specially developed tips are designed
to repair the Sintajoint wraparound ends in a
single pass. They produce a finished end that
generally only needs one side trimmed,
(outside of the spigot or inside of the socket)
The technique used for the repair of end
damage requires a determination of the
extent of the damage. Small damage such as
punctures or dents might be repaired with a
number of tips including the Cone tip, Ball
end tip, the 3/16’ Fillet weld tip or one of the
butt weld tips.
Large damage which involve more than 25
mm long repairs to the end will be best
repaired with the concave tip that suits the
particular plate thickness.
These tips are identified as W06 for 6 mm
pipe wall thickness, W08 for 8 mm pipe wall
thickness etc. The following procedure
describes the use of these concave tips.
If there is a split in the coating away from the
end of the pipe this should be first repaired with
a butt weld tip before attempting this repair.
Operators who attempt this repair technique
should have attended a Sintakote repair
training course and be certified as being
competent in the use of the equipment.
1. Clean the affected area to ensure that all
the dust and foreign matter is removed from
the repair area. Use a file or knife to remove
any coating that may be sticking out.
2. The transition area from full thickness at the
start and finish of the defect should be tapered
over about 40 mm to enable the tip to travel
smoothly without catching on any step. This is
best done with a sharp knife or rasp.
3. Fit the Concave tip that suits the pipe wall
thickness to the gun. Experience has shown
that it is better to fit the tip so that the groove
is horizontal when the gun is held out with the
handle vertical. This means that the gun
travels sideways and gives the operator a
better view of the repair area both in front of
and behind the weld.
4. Ensure that the heating tip has reached the
correct temperature and that the LED is flashing.
5. Test the feed rate by pressing the trigger
for several seconds until a quantity of plastic
extrudes out of the end of the tip. Adjust the
feed rate to give a moderate flow (no more
than 2 pulses per second has been found to
give good results). Remove the extrudate with
a knife or suitable tool.
Figure A.4 - Drader gun tip selection 6. Determine the line of weld that the repair
should be laid along and place the welding
tip about one tip length before the transition
to the defect. This ensures that any lack of
bond on start up is outside the original
defect area. The gun should be held so that
it remains straight out from the pipe end but
angled sideways (about 150) in the direction
of the weld as determined by the angle of
the tip, keeping the full face of the tip in
contact with the end of the pipe at all times.
Make certain that the surface beneath
the tip begins to melt before commencing
the weld.
7. Hold down the trigger and start moving the
welder the required direction at a constant
speed to ensure smooth feeding of the
weld pool.
8. Use a travel speed that will give good build
up of material and good coverage of the
coating on both sides (see Figure A.5). Failure
to get good fusion on either or both sides will
result in further more complicated repairs.
(Generally good fusion will result when the
build up on either side of the end is about the
same). If there is still poor fusion then the
travel speed is too fast.
9. It is important to complete the line of weldwithout stopping until the tip is beyond thedefect area otherwise a new transition willhave to be prepared before restarting repairs.
A P P E N D I X A | 55
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Welding tip
Plastic depositOutside
Trim excessive material
Figure A.6 – Care required when trimmingFigure A.5 – Build up of material on cut end
Procedure A5 - Wraparound reinstatement of SINTAPIPEafter field cutting
EquipmentRefer to Procedure A.4
MaterialsRefer to Procedure A.4
General InstructionsRefer to Procedure A.4
Various concave tips for wraparound end reinstatement
1. Identification Marks W05, W06, W08, W10,
W11 etc. for 5,6,8,10 and 11 mm wall
thickness pipes.
2. These specially developed tips are designed
to reinstate the Sintakote around the end in a
single pass. It will produce a sound repair that
is bonded to the external and internal coating.
10. When the run is completed angle the
gun so that it is perpendicular to the end of
the pipe and continue to extrude material as
the tip is withdrawn from the surface. This
will reduce any plasticised defects caused
by the tip.
11. When the weld has solidified the excess
material can be removed using a suitable
tool, being careful not to cut below the
original surface level (see Figure A.6).
12. Remove material from the end in the start
and finish zone where double thickness has
been applied.
13. Do not remove any material from the end
in the defect zone. (Wood rasps and planer
can be used for this purpose). It is only
necessary to remove excess material from
the outside of the spigot. It is better to
remove the excess from both the inside
(necessary) and outside of the socket to give
a better appearance.
14. Visually examine the finished area for
defects and repair if necessary using a
suitable tip.
15. Check the repair using a High Voltage
Holiday Detector. Repair any defects and retest.
56 | A P P E N D I X A
It is assumed that the pipe has been cut
with a suitable machine and is presented
with the coating and lining flush with the
end of the pipe.
Operators who attempt this repair technique
should have attended a Sintakote repair
training course and be certified as being
competent in the use of the equipment.
1. Clean the affected area with isopropanol to
ensure that all the dust and foreign matter is
removed. Use a file or knife to remove any
coating that may be sticking out.
2. Fit the Concave tip that suits the pipe wall
thickness to the gun. Experience has shown
that it is better to fit the tip so that the groove
is horizontal when the gun is held out with the
handle vertical. This means that the gun
travels sideways and gives the operator a
better view of the repair area both in front of
and behind the weld.
3. Ensure that the heating tip has reached the
correct temperature (i.e. the LED is flashing.)
4. Test the feed rate by pressing the trigger for
several seconds until a quantity of plastic
extrudes out of the end of the tip. Adjust the
feed rate to give a moderate flow (no more
than 2 pulses per second has been found to
give good results). Remove the extrudate with
a knife or suitable tool.
5. The gun should be held so that it remains
straight out from the pipe end but angled
sideways (about 15º) in the direction of the
weld as determined by the angle of the tip.
Keep the full face of the tip in contact with the
end of the pipe at all times. Make certain that
the surface beneath the tip begins to melt
before commencing the weld.
6. Hold down the trigger and start moving
the welder the required direction at a
constant speed to ensure smooth feeding of
the weld pool.
7. Use a travel speed that will give good build
up of material and good coverage of the
coating on both sides (see Figure A.5). Failure
to get good fusion on either or both sides will
result in further more complicated repairs.
(Generally good fusion will result when the
build up on either side of the end is about the
same). If there is still poor fusion then the travel
speed is too fast.
8. It is recommended to complete as much
welding as possible without stopping as a
new transition will have to be prepared for
each start. The start area must be feathered
back to the surface to remove any unbonded
areas and to provide a smooth area for
finishing the weld.
9. To complete the run make sure that the
bead finishes past the initial start area to
ensure a complete seal.
10. When the weld has solidified the excess
material can be removed using a suitable tool
being careful not to cut below the original
surface level (see Figure A.6).
11. Visually examine the finished area for defects
and repair if necessary using a suitable tip.
12. Check the repair using a High Voltage
Holiday Detector. Repair any defects and retest.
The finished end should now be suitable for
the attachment of a pipe coupling.
A P P E N D I X A | 57
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58 | A P P E N D I X B
APPENDIX B
Field Repair and Joint Reinstatement of Cement Mortar LiningThe cement mortar lining of steel pipes in
factory production is carried out in
accordance with Australian Standard
AS 1281- Cement mortar lining of steel pipes
and fittings using a centrifugal process. This
method ensures a dense, low water cement
ratio mortar in close contact with the steel. In
the factory all pipes are end capped and held
for several days to enable the mortar to cure.
Pipe fittings are lined in the factory either using
a centrifugal mortar applicator, by hand lining
or by a combination of centrifugally lined pipe
with the joints reinstated by hand. Lined
fittings are end capped and allowed to cure
before delivery.
In order to determine whether or not the
mortar requires repair the following procedure
should be followed:-
1. Use a 2.0 mm feeler gauge and see if it
can be inserted to a depth greater than half
the thickness of the lining. If it can, the mortar
should be repaired as described in B2.
2. Use the feeler gauge to determine if the
mortar has disbonded to give a gap in excess
of 2 mm between the mortar and the steel
pipe. This can be measured by attempting to
insert the feeler gauge into the gap (at the
ends of pipe) or to check if the step between
adjacent sections of the lining (at a crack) is
greater than 2 mm. If the disbondment is
greater than 2 mm break out the disbonded
lining and repair as described in B1.
Disbonded (drummy) linings are acceptable
provided the above criteria are not exceeded
or if potable water is placed inside the pipe
and water absorption leads to total loss of the
drumminess.
Cement mortar lining repairs and pipe joint
reinstatement are usually done by hand
application of the cement mortar.
The procedures detailed herein aresummarised as follows:-
1. Lining repair using premixed materials.
2. Epoxy repair of cement mortar lining cracks.
A P P E N D I X B | 59
Procedure B1 - Cement mortar lining repair method
Using EZILINE Premixed Materials (for field repair/joint reinstatement)
The EZILINE Mortar Mix is a high performanceproduct specifically designed for compatability
and use in reinstating the field joints and repairof Tyco Water cement mortar lined steel pipes
Materials
Available from Tyco Water in kit form.
Dry Mix - Part AType SR blended cement in compliance
with AS 3972 and sand in full compliance
with AS 2758.1.
Liquid - Part B
The liquid is a high performance acrylic
modifier.
Primer - Liquid Part B is used undiluted asthe primer.
For safe use of the product, refer to the
MSDS.
7. The mortar should be protected fromexcessive heat, water and sub-zero temperaturesduring the first 24 hours from placement. It
least 7 days prior to service.
Application Instructions1. Ensure all surfaces are free of grease
oil, paint and loose or flaking materials.
and fittings. 2. Wet the adjacent mortar, leaving
the surface damp, but with no excess/pooledwater
3. Brush apply a primer coat of Part B (liquid)
to cover the steel and adjacent mortar.
Note do not dilute. The mortar can be applied when this coat is wet or dry, but must be
applied the same day, otherwise apply another
prime coat.
4. Thoroughly manually mix Part A (do not usea cement mixer) and as much of Part B required to form a stiff workable mixture.Do not add water. Ensure there is no dry mixture present. Note the working time reduces with temperature,and is apporx. 20 minutes at 300C.
5. Apply the mortar, compacting it into placeto the level of the adjacent mortar.
6. Finish with a metal trowel to provide a smootheven finish.
should be allowed to fully dry/cure for at
8. Open bags of mortar not used within 24 hoursshould be discarded thoughtfully.
9. Dispose of packaging and waste materialappropriately after use.
Epoxy grout
4 – 6mm
Steel pipe
Crack
Cementmortar lining
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
This method is applicable to repair of cracks
in cement mortar lined (CML) pipes. It is used
to repair cracks that are greater than the
2.0mm width allowed in AS 1281.
MaterialsThe following materials are suitable:-
Epirez construction products - Epirez 633
solventless epoxy paste. Epirez advises that this
product meets the requirements of AS/NZS 4020
for contact with drinking water, or Hilti (Aust) Pty.
Ltd. CA 273 solventless epoxy paste.
PreparationThe CML should be dry at the time of
undertaking the repair.
Enlarge the crack to a width of 4 to 6mm
using a 100 mm angle grinder (or equivalent)
fitted with a diamond tipped cutting blade
nominally 3.2mm in width. The depth of the
groove should be set at 2mm less than the
lining thickness. The depth should be
checked with a ruler.
Application1. Mix the resin and hardener components of
the epoxy paste thoroughly in the specified
ratio. Mix a reasonable quantity of product to
ensure that the mix ratio is achieved. Only
mix an amount that can be placed within 20
minutes. Discard all product that is not used
within 20 minutes. The minimum application
temperature is 5ºC. For large repairs the
easiest method of application is to fill
an empty caulking gun container and apply
with a caulking gun. This method pushes the
epoxy into the groove to completely fill the
space and exclude air.
2. With a spatula or knife applicator press theepoxy into the groove to exclude all air.Slightly overfill as shown in the diagram.
Allow to cure for at least 24 hours prior to
exposure of the epoxy to water.
Figure B.3 - Completed repair
Figure B.1 - Typical cement mortarlining crack greater than 2mm.
Figure B.2 - Enlarge crack to 4 – 6mm
Procedure B2 - Epoxy repair of cement mortar lining cracks
S I N T A K O T E ® S T E E L P I P E L I N E S
60 | A P P E N D I X B
to CP LugsField Application of Electrical Cables
A P P E N D I X C | 61
APPENDIX C
M a t er ia ls
• Cable cutter suitable for 25 mm2 copper cable (ALM type ME 11-65, Wattmaster ME 60 or equivalent.)
• Hand crimping tool (Wattmaster MK 80, Utilux No 20 or equivalent. (See picture below.)
Note: Hydraulic type crimpers are not suitable for crimping this style of lug.
• Cable (19/1.35 (25 mm2) single core double insulated P.V.C.
• Shrink tube 100 long (Raychem WCSM 28/9 / 1200)
• Knife or stripping tool (For cable and 9.5 mm dia lug)
• Battery operated hand drill and 6.5 mm bit (17/64”)
• Solvent (Methylated Spirits, isopropanol or acetone) and clean rags
• Propane/Butane heating torch with primus 2956 burner or equivalent
P r o c e d u r e
1. When making the joint make sure that both lugs are aligned as close as possible (Fig 1), preferably, at the top of the pipe.
Fig. 1
2. Strip the Sintakote for a distance of 25 mm from the end of the lug by cutting around the full circumference of the lug and twisting the loosened Sintakote cap. (See Fig 2)
Fig. 2 Using the battery drill on low speed insert the 6.5 mm drill bit into the hole in the end of the lug to remove any residual Sintakote and clean the inside copper surface.
62 | APPENDIX C
3. Cut the length of cable to the required length (distance between the lugs including room to bend the cable) using the cable cutters. Bare both ends of the cable for a distance of 20 mm taking care to avoid damaging the ends of the copper cable. See Fig 3
Fig. 34. Slide two lengths of shrink
tube over the cable and insert the ends into the hole on the lugs of each pipe.
5. Adjust the screw on the crimp tool for 25 mm2 cable and while holding the cable firmly into the lug make a crimp close to the end of the lug. The crimp must be made from the top with the tool at 90º to the pipe surface Repeat this operation adjacent to the first crimp. (see Fig. 4)
Fig 4(In the diagram above the crimp appears on the top of the lug for illustration purposes – in practice it will be on the sides of the lug).
6. Clean the surface of the lug and at least 50 mm of cable next to the lug using methylated spirits and a clean rag.
7. Slide the shrink tube down to the surface of the pipe and using a low flame heat the sleeve around the location of the crimp join as shown in Fig 5. Move the flame outwards towards the cable end of the tube whilst heating the tube all around. When this is completed a small amount of adhesive/sealant will squeeze from the end of the tube.
Fig. 5 Repeat this operation
towards the pipe end until sealant squeezes out from that end. See Fig 6
Fig. 6 8. Repeat procedure 6 and 7
on the other lug and cable end to complete the joining operation.
S I N T A K O T E ® S T E E L P I P E L I N E S
S I N T A K O T E ® S T E E L P I P E L I N E S
S I N T A K O T E ® S T E E L P I P E L I N E S
A P P E N D I X D | 63
114 4.8 1.6 9 86.4 19.9 19.4 0.1 na na na
114 4.8 1.6 9 86.4 19.9 19.4 0.1 na na na168 5 1.6 9 140 31.0 30.2 0.2 0.3 na na190 5 1.6 9 162 35.3 34.4 0.2 0.3 na na
219 5 1.6 9 191 41.0 40.0 0.2 0.4 na na240 5 1.6 9 212 45.1 44.0 0.3 0.4 na na257 5 1.6 9 229 48.5 47.2 0.3 0.4 na na273 5 1.6 9 245 51.6 50.3 0.3 0.5 na na290 5 1.8 12 256 61.0 59.4 0.4 0.5 na na
305 5 1.8 12 271 64.3 62.6 0.4 0.6 na na324 4 1.8 12 292 60.8 59.1 0.4 0.5 na na324 4.5 1.8 12 291 64.6 62.9 0.4 0.6 na na324 5 1.8 12 290 68.4 66.7 0.4 0.6 na na324 6 1.8 12 288 76.0 74.2 0.5 0.7 na na337 4 1.8 12 305 63.4 61.6 0.4 0.6 na na337 4.5 1.8 12 304 67.3 65.5 0.4 0.6 na na337 5 1.8 12 303 71.3 69.5 0.4 0.6 na na337 6 1.8 12 301 79.1 77.3 0.5 0.7 na na344 4 1.8 12 312 64.7 62.9 0.4 0.6 na na344 4.5 1.8 12 311 68.8 66.9 0.4 0.6 na na344 5 1.8 12 310 72.8 71.0 0.4 0.7 na na344 6 1.8 12 308 80.8 79.0 0.5 0.7 na na356 4 1.8 12 324 67.1 65.2 0.4 0.6 na na356 4.5 1.8 12 323 71.3 69.4 0.4 0.6 na na356 5 1.8 12 322 75.4 73.5 0.5 0.7 na na356 6 1.8 12 320 83.8 81.9 0.5 0.8 na na
406 4 1.8 12 374 76.8 74.6 0.5 0.7 0.9 1.0406 4.5 1.8 12 373 81.6 79.4 0.5 0.7 1.0 1.1406 5 1.8 12 372 86.4 84.2 0.5 0.8 1.0 1.2406 6 1.8 12 370 96.0 93.8 0.6 0.9 1.2 1.3406 8 1.8 12 366 114.9 112.8 0.7 1.0 1.4 1.6419 4 1.8 12 387 79.3 77.1 0.5 0.7 1.0 1.1419 4.5 1.8 12 386 84.3 82.1 0.5 0.8 1.0 1.1
Stee
l out
side
di
amet
er (m
m)
Stee
l wal
l th
ickn
ess
(mm
)
SIN
TAKO
TE
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
bore
(mm
)
Mas
s pe
r met
re
SKC
L (k
g/m
)
Mas
s pe
r met
reU
CC
L (k
g/m
)
6.0
9.0
12.0
13.5
APPENDIX D
General Data
Pipe OD SINTAKOTE Thickness(mm) (mm)
≤273 1.6
>273 to 508 1.8
>508 to 762 2.0
>762 2.3
Pipe OD CML Thickness(mm) (mm)
≤273 9 ± 3
>273 to 762 12 ± 4
>762 to 1219 16 ± 4
> 1219 to 1829 19 ± 4
Table D.1 – SINTAKOTE Thicknesses
Table D.3 – SINTAKOTE Steel Pipe Bores and Weights
Table D.2 – Cement Mortar Lining (CML) Thickness
SKCL PIPE Weight (tonnes)Pipe Length (m)
S I N T A K O T E ® S T E E L P I P E L I N E S
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
64 | A P P E N D I X D
419 5 1.8 12 385 89.2 87.0 0.5 0.8 1.1 1.2419 6 1.8 12 383 99.1 96.9 0.6 0.9 1.2 1.3419 8 1.8 12 379 118.7 116.5 0.7 1.1 1.4 1.6457 4.5 1.8 12 424 92.2 89.7 0.6 0.8 1.1 1.2457 5 1.8 12 423 97.6 95.1 0.6 0.9 1.2 1.3457 6 1.8 12 421 108.4 106.0 0.7 1.0 1.3 1.5457 8 1.8 12 417 129.9 127.4 0.8 1.2 1.6 1.8
502 4.5 1.8 12 469 101.5 98.8 0.6 0.9 1.2 1.4502 5 1.8 12 468 107.4 104.8 0.6 1.0 1.3 1.5502 6 1.8 12 466 119.4 116.7 0.7 1.1 1.4 1.6502 8 1.8 12 462 143.1 140.4 0.9 1.3 1.7 1.9508 4.5 1.8 12 475 102.7 100.0 0.6 0.9 1.2 1.4508 5 1.8 12 474 108.8 106.1 0.7 1.0 1.3 1.5508 6 1.8 12 472 120.8 118.1 0.7 1.1 1.4 1.6508 8 1.8 12 468 144.8 142.1 0.9 1.3 1.7 2.0559 4.5 2 12 526 113.6 110.3 0.7 1.0 1.4 1.5559 5 2 12 525 120.3 117.0 0.7 1.1 1.4 1.6559 6 2 12 523 133.6 130.3 0.8 1.2 1.6 1.8559 8 2 12 519 160.1 156.8 1.0 1.4 1.9 2.2
610 4.5 2 12 577 124.2 120.6 0.7 1.1 1.5 1.7610 5 2 12 576 131.5 127.9 0.8 1.2 1.6 1.8610 6 2 12 574 146.1 142.5 0.9 1.3 1.8 2.0610 8 2 12 570 175.1 171.5 1.1 1.6 2.1 2.4610 9.5 2 12 567 196.7 193.1 1.2 1.8 2.4 2.7648 4.5 2 12 615 132.1 128.2 0.8 1.2 1.6 1.8648 5 2 12 614 139.8 136.0 0.8 1.3 1.7 1.9648 6 2 12 612 155.4 151.5 0.9 1.4 1.9 2.1648 8 2 12 608 186.3 182.4 1.1 1.7 2.2 2.5648 9.5 2 12 605 209.3 205.5 1.3 1.9 2.5 2.8660 4.5 2 12 627 134.5 130.6 0.8 1.2 1.6 1.8660 5 2 12 626 142.5 138.6 0.9 1.3 1.7 1.9660 6 2 12 624 158.3 154.4 0.9 1.4 1.9 2.1660 8 2 12 620 189.8 185.9 1.1 1.7 2.3 2.6660 9.5 2 12 617 213.3 209.4 1.3 1.9 2.6 2.9660 12 2 12 612 252.2 248.3 1.5 2.3 3.0 3.4
700 4.5 2 12 667 142.8 138.7 0.9 1.3 1.7 1.9700 5 2 12 666 151.3 147.1 0.9 1.4 1.8 2.0700 6 2 12 664 168.1 163.9 1.0 1.5 2.0 2.3700 8 2 12 660 201.5 197.4 1.2 1.8 2.4 2.7700 9.5 2 12 657 226.5 222.4 1.4 2.0 2.7 3.1700 12 2 12 652 267.9 263.8 1.6 2.4 3.2 3.6711 4.5 2 12 678 145.1 140.9 0.9 1.3 1.7 2.0711 5 2 12 677 153.7 149.5 0.9 1.4 1.8 2.1711 6 2 12 675 170.8 166.6 1.0 1.5 2.0 2.3711 8 2 12 671 204.8 200.6 1.2 1.8 2.5 2.8711 9.5 2 12 668 230.2 225.9 1.4 2.1 2.8 3.1711 12 2 12 663 272.2 268.0 1.6 2.4 3.3 3.7762 4.5 2 12 729 155.7 151.2 0.9 1.4 1.9 2.1762 5 2 12 728 164.9 160.4 1.0 1.5 2.0 2.2762 6 2 12 726 183.2 178.7 1.1 1.6 2.2 2.5762 8 2 12 722 219.8 215.2 1.3 2.0 2.6 3.0
Stee
l out
side
di
amet
er (m
m)
Stee
l wal
l th
ickn
ess
(mm
)
SIN
TAKO
TE
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
bore
(mm
)
Mas
s pe
r met
re
SKC
L (k
g/m
)
Mas
s pe
r met
reU
CC
L (k
g/m
)
6.0
9.0
12.0
13.5
SKCL PIPE Weight (tonnes)Pipe Length (m)
S I N T A K O T E ® S T E E L P I P E L I N E S
A P P E N D I X D | 65
762 9.5 2 12 719 247.0 242.5 1.5 2.2 3.0 3.3762 12 2 12 714 292.2 287.7 1.8 2.6 3.5 3.9
800 4.5 2.3 16 759 187.3 181.9 1.1 1.7 2.2 2.5800 5 2.3 16 758 197.0 191.5 1.2 1.8 2.4 2.7800 6 2.3 16 756 216.2 210.7 1.3 1.9 2.6 2.9800 8 2.3 16 752 254.5 249.0 1.5 2.3 3.1 3.4800 9.5 2.3 16 749 283.0 277.6 1.7 2.5 3.4 3.8800 12 2.3 16 744 330.4 325.0 2.0 3.0 4.0 4.5813 4.5 2.3 16 772 190.4 184.9 1.1 1.7 2.3 2.6813 5 2.3 16 771 200.2 194.7 1.2 1.8 2.4 2.7813 6 2.3 16 769 219.8 214.2 1.3 2.0 2.6 3.0813 8 2.3 16 765 258.7 253.2 1.6 2.3 3.1 3.5813 9.5 2.3 16 762 287.8 282.2 1.7 2.6 3.5 3.9813 12 2.3 16 757 335.9 330.4 2.0 3.0 4.0 4.5
914 6 2.3 16 870 247.6 241.4 1.5 2.2 3.0 3.3914 8 2.3 16 866 291.5 285.3 1.7 2.6 3.5 3.9914 10 2.3 16 862 335.2 329.0 2.0 3.0 4.0 4.5914 12 2.3 16 858 378.7 372.5 2.3 3.4 4.5 5.1914 16 2.3 16 850 465.2 458.9 2.8 4.2 5.6 6.3960 6 2.3 16 916 260.3 253.7 1.6 2.3 3.1 3.5960 8 2.3 16 912 306.4 299.9 1.8 2.8 3.7 4.1960 10 2.3 16 908 352.4 345.9 2.1 3.2 4.2 4.8960 12 2.3 16 904 398.2 391.7 2.4 3.6 4.8 5.4960 16 2.3 16 896 489.2 482.6 2.9 4.4 5.9 6.6965 6 2.3 16 921 261.7 255.1 1.6 2.4 3.1 3.5965 8 2.3 16 917 308.1 301.5 1.8 2.8 3.7 4.2965 10 2.3 16 913 354.3 347.7 2.1 3.2 4.3 4.8965 12 2.3 16 909 400.3 393.8 2.4 3.6 4.8 5.4965 16 2.3 16 901 491.8 485.2 3.0 4.4 5.9 6.6
1,016 8 2.3 16 968 324.6 317.7 1.9 2.9 3.9 4.41,016 10 2.3 16 964 373.4 366.5 2.2 3.4 4.5 5.01,016 12 2.3 16 960 421.9 415.0 2.5 3.8 5.1 5.71,016 16 2.3 16 952 518.4 511.5 3.1 4.7 6.2 7.01,067 8 2.3 16 1019 341.2 333.9 2.0 3.1 4.1 4.61,067 10 2.3 16 1015 392.5 385.2 2.4 3.5 4.7 5.31,067 12 2.3 16 1011 443.5 436.3 2.7 4.0 5.3 6.01,067 16 2.3 16 1003 545.0 537.8 3.3 4.9 6.5 7.41,086 8 2.3 16 1038 347.4 340.0 2.1 3.1 4.2 4.71,086 10 2.3 16 1034 399.6 392.2 2.4 3.6 4.8 5.41,086 12 2.3 16 1030 451.6 444.2 2.7 4.1 5.4 6.11,086 16 2.3 16 1022 555.0 547.6 3.3 5.0 6.7 7.51,124 8 2.3 16 1076 359.7 352.1 2.2 3.2 4.3 4.91,124 10 2.3 16 1072 413.8 406.1 2.5 3.7 5.0 5.61,124 12 2.3 16 1068 467.7 460.0 2.8 4.2 5.6 6.31,124 16 2.3 16 1060 574.8 567.2 3.4 5.2 6.9 7.8
1,200 8 2.3 16 1152 384.4 376.3 2.3 3.5 4.6 5.21,200 10 2.3 16 1148 442.2 434.1 2.7 4.0 5.3 6.01,200 12 2.3 16 1144 499.9 491.7 3.0 4.5 6.0 6.71,200 16 2.3 16 1136 614.5 606.3 3.7 5.5 7.4 8.3
Stee
l out
side
di
amet
er (m
m)
Stee
l wal
l th
ickn
ess
(mm
)
SIN
TAKO
TE
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
bore
(mm
)
Mas
s pe
r met
re
SKC
L (k
g/m
)
Mas
s pe
r met
reU
CC
L (k
g/m
)
6.0
9.0
12.0
13.5
SKCL PIPE Weight (tonnes)Pipe Length (m)
S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S
Notes: Pipe masses may vary +/- 10 % due to material tolerancesCalculations based on:Steel shell 0.02466(D-t)tCement lining 0.00755T(D-2t-T)SINTAKOTE 0.00296Dts
where D = outside diameter of pipe (mm) t = steel wall thickness (mm)T = cement lining thickness (mm) ts= SINTAKOTE thickness (mm)
Total mass may carry minor round-off error
S I N T A K O T E ® S T E E L P I P E L I N E S
66 | A P P E N D I X D
1,219 8 2.3 16 1171 390.6 382.3 2.3 3.5 4.7 5.31,219 10 2.3 16 1167 449.3 441.0 2.7 4.0 5.4 6.11,219 12 2.3 16 1163 507.9 499.6 3.0 4.6 6.1 6.91,219 16 2.3 16 1155 624.4 616.1 3.7 5.6 7.5 8.4
1,283 8 2.3 19 1229 439.3 430.6 2.6 4.0 5.3 5.91,283 10 2.3 19 1225 501.1 492.4 3.0 4.5 6.0 6.81,283 12 2.3 19 1221 562.7 554.0 3.4 5.1 6.8 7.61,283 16 2.3 19 1213 685.4 676.6 4.1 6.2 8.2 9.31,290 8 2.3 19 1236 441.7 432.9 2.7 4.0 5.3 6.01,290 10 2.3 19 1232 503.9 495.1 3.0 4.5 6.0 6.81,290 12 2.3 19 1228 565.9 557.1 3.4 5.1 6.8 7.61,290 16 2.3 19 1220 689.2 680.4 4.1 6.2 8.3 9.3
1,404 8 2.3 19 1350 481.3 471.8 2.9 4.3 5.8 6.51,404 10 2.3 19 1346 549.1 539.6 3.3 4.9 6.6 7.41,404 12 2.3 19 1342 616.7 607.2 3.7 5.6 7.4 8.31,404 16 2.3 19 1334 751.3 741.7 4.5 6.8 9.0 10.11,422 8 2.3 19 1368 487.6 477.9 2.9 4.4 5.9 6.61,422 10 2.3 19 1364 556.3 546.6 3.3 5.0 6.7 7.51,422 12 2.3 19 1360 624.7 615.1 3.7 5.6 7.5 8.41,422 16 2.3 19 1352 761.1 751.4 4.6 6.8 9.1 10.31,440 8 2.3 19 1386 493.9 484.1 3.0 4.4 5.9 6.71,440 10 2.3 19 1382 563.4 553.6 3.4 5.1 6.8 7.61,440 12 2.3 19 1378 632.8 623.0 3.8 5.7 7.6 8.51,440 16 2.3 19 1370 770.9 761.1 4.6 6.9 9.3 10.41,575 8 2.3 19 1521 540.8 530.1 3.2 4.9 6.5 7.31,575 10 2.3 19 1517 617.0 606.3 3.7 5.6 7.4 8.31,575 12 2.3 19 1513 693.0 682.3 4.2 6.2 8.3 9.41,575 16 2.3 19 1505 844.5 833.7 5.1 7.6 10.1 11.4
1,750 10 2.3 19 1692 686.4 674.5 4.1 6.2 8.2 9.31,750 12 2.3 19 1688 771.1 759.2 4.6 6.9 9.3 10.41,750 16 2.3 19 1680 939.8 927.9 5.6 8.5 11.3 12.7
2,159 10 2.3 na na na na na na na na2,159 12 2.3 na na na na na na na na2,159 16 2.3 na na na na na na na na
Stee
l out
side
di
amet
er (m
m)
Stee
l wal
l th
ickn
ess
(mm
)
SIN
TAKO
TE
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
thic
knes
s (m
m)
Cem
ent m
orta
r lin
ing
bore
(mm
)
Mas
s pe
r met
re
SKC
L (k
g/m
)
Mas
s pe
r met
reU
CC
L (k
g/m
)
6.0
9.0
12.0
13.5
SKCL PIPE Weight (tonnes)Pipe Length (m)
A P P E N D I X D | 67
559 5 4.8 492 3.9 394559 6 5.8 591 4.6 473559 8 7.7 788 6.2 630
610 4.5 4.0 406 3.2 325610 5 4.4 451 3.5 361610 6 5.3 541 4.2 433610 8 7.1 722 5.7 577610 9.5 7.0 714 5.6 571648 4.5 3.8 382 3.0 306648 5 4.2 425 3.3 340648 6 5.0 510 4.0 408648 8 6.7 679 5.3 544648 9.5 6.6 672 5.3 538660 4.5 3.7 375 2.9 300660 5 4.1 417 3.3 334660 6 4.9 500 3.9 400660 8 6.5 667 5.2 534660 9.5 6.5 660 5.2 528660 12 8.2 834 6.5 667
700 4.5 3.5 354 2.8 283700 5 3.9 393 3.1 314700 6 4.6 472 3.7 377700 8 6.2 629 4.9 503700 9.5 6.1 622 4.9 498700 12 7.7 786 6.2 629711 4.5 3.4 348 2.7 279711 5 3.8 387 3.0 310711 6 4.6 464 3.6 372711 8 6.1 619 4.9 495711 9.5 6.0 613 4.8 490711 12 7.6 774 6.1 619762 4.5 3.2 325 2.6 260762 5 3.5 361 2.8 289762 6 4.3 433 3.4 347762 8 5.7 578 4.5 462762 9.5 5.6 572 4.5 457762 12 7.1 722 5.7 578
800 4.5 3.0 310 2.4 248800 5 3.4 344 2.7 275800 6 4.1 413 3.2 330800 8 5.4 550 4.3 440800 9.5 5.3 545 4.3 436800 12 6.8 688 5.4 550813 4.5 3.0 305 2.4 244813 5 3.3 338 2.7 271813 6 4.0 406 3.2 325813 8 5.3 542 4.3 433813 9.5 5.3 536 4.2 429813 12 6.6 677 5.3 542
114 4.8 8.5 866 6.8 693168 5 8.5 866 6.8 693190 5 8.5 866 6.8 693
219 5 8.5 866 6.8 693240 5 8.5 866 6.8 693257 5 8.5 866 6.8 693273 5 8.5 866 6.8 693290 5 8.5 866 6.8 693
305 5 8.5 866 6.8 693324 4 6.7 679 5.3 544324 4.5 7.5 764 6.0 612324 5 8.3 849 6.7 679324 6 8.5 866 6.8 693337 4 6.4 653 5.1 523337 4.5 7.2 735 5.8 588337 5 8.0 817 6.4 653337 6 8.5 866 6.8 693344 4 6.3 640 5.0 512344 4.5 7.1 720 5.7 576344 5 7.8 800 6.3 640344 6 8.5 866 6.8 693356 4 6.1 618 4.9 495356 4.5 6.8 696 5.5 557356 5 7.6 773 6.1 618356 6 8.5 866 6.8 693
406 4 5.3 542 4.3 434406 4.5 6.0 610 4.8 488406 5 6.7 678 5.3 542406 6 8.0 813 6.4 651406 8 8.5 866 6.8 693419 4 5.2 525 4.1 420419 4.5 5.8 591 4.6 473419 5 6.4 657 5.2 525419 6 7.7 788 6.2 630419 8 8.5 866 6.8 693457 4.5 5.3 542 4.3 434457 5 5.9 602 4.7 482457 6 7.1 723 5.7 578457 8 8.5 866 6.8 693
502 4.5 4.8 493 3.9 395502 5 5.4 548 4.3 439502 6 6.5 658 5.2 526502 8 8.5 866 6.8 693508 4.5 4.8 488 3.8 390508 5 5.3 542 4.3 433508 6 6.4 650 5.1 520508 8 8.5 866 6.8 693559 4.5 4.3 443 3.5 354
Table D.4- Manufacturing Test Pressure and Rated Pressure for MSCL Pipes
Out
side
Dia
met
er (m
m)
Wal
lTh
ickn
ess
(mm
)
Test
Pre
ssur
e(M
Pa)
Test
Pre
ssur
e(m
)
Rate
d Pr
essu
re(M
Pa)
Rate
d Pr
essu
re(m
)
Out
side
Dia
met
er (m
m)
Wal
lTh
ickn
ess
(mm
)
Test
Pre
ssur
e(M
Pa)
Test
Pre
ssur
e(m
)
Rate
d Pr
essu
re(M
Pa)
Rate
d Pr
essu
re(m
)
559 5 4.8 492 3.9 394559 6 5.8 591 4.6 473559 8 7.7 788 6.2 630
610 4.5 4.0 406 3.2 325610 5 4.4 451 3.5 361610 6 5.3 541 4.2 433610 8 7.1 722 5.7 577610 9.5 7.0 714 5.6 571648 4.5 3.8 382 3.0 306648 5 4.2 425 3.3 340648 6 5.0 510 4.0 408648 8 6.7 679 5.3 544648 9.5 6.6 672 5.3 538660 4.5 3.7 375 2.9 300660 5 4.1 417 3.3 334660 6 4.9 500 3.9 400660 8 6.5 667 5.2 534660 9.5 6.5 660 5.2 528660 12 8.2 834 6.5 667
700 4.5 3.5 354 2.8 283700 5 3.9 393 3.1 314700 6 4.6 472 3.7 377700 8 6.2 629 4.9 503700 9.5 6.1 622 4.9 498700 12 7.7 786 6.2 629711 4.5 3.4 348 2.7 279711 5 3.8 387 3.0 310711 6 4.6 464 3.6 372711 8 6.1 619 4.9 495711 9.5 6.0 613 4.8 490711 12 7.6 774 6.1 619762 4.5 3.2 325 2.6 260762 5 3.5 361 2.8 289762 6 4.3 433 3.4 347762 8 5.7 578 4.5 462762 9.5 5.6 572 4.5 457762 12 7.1 722 5.7 578
800 4.5 3.0 310 2.4 248
800 6 4.1 413 3.2 330800 8 5.4 550 4.3 440800 9.5 5.3 545 4.3 436
813 4.5 3.0 305 2.4 244813 5 3.3 338 2.7 271813 6 4.0 406 3.2 325813 8 5.3 542 4.3 433813 9.5 5.3 536 4.2 429813 12 6.6 677 5.3 542
114 4.8 8.5 866 6.8 693168 5 8.5 866 6.8 693190 5 8.5 866 6.8 693
219 5 8.5 866 6.8 693240 5 8.5 866 6.8 693257 5 8.5 866 6.8 693273 5 8.5 866 6.8 693290 5 8.5 866 6.8 693
305 5 8.5 866 6.8 693324 4 6.7 679 5.3 544324 4.5 7.5 764 6.0 612324 5 8.3 849 6.7 679324 6 8.5 866 6.8 693337 4 6.4 653 5.1 523337 4.5 7.2 735 5.8 588337 5 8.0 817 6.4 653337 6 8.5 866 6.8 693344 4 6.3 640 5.0 512344 4.5 7.1 720 5.7 576344 5 7.8 800 6.3 640344 6 8.5 866 6.8 693356 4 6.1 618 4.9 495356 4.5 6.8 696 5.5 557356 5 7.6 773 6.1 618356 6 8.5 866 6.8 693
406 4 5.3 542 4.3 434406 4.5 6.0 610 4.8 488406 5 6.7 678 5.3 542406 6 8.0 813 6.4 651406 8 8.5 866 6.8 693419 4 5.2 525 4.1 420419 4.5 5.8 591 4.6 473419 5 6.4 657 5.2 525419 6 7.7 788 6.2 630419 8 8.5 866 6.8 693457 4.5 5.3 542 4.3 434457 5 5.9 602 4.7 482457 6 7.1 723 5.7 578457 8 8.5 866 6.8 693
502 4.5 4.8 493 3.9 395502 5 5.4 548 4.3 439502 6 6.5 658 5.2 526502 8 8.5 866 6.8 693508 4.5 4.8 488 3.8 390508 5 5.3 542 4.3 433508 6 6.4 650 5.1 520508 8 8.5 866 6.8 693559 4.5 4.3 443 3.5 354
Table D.4- Manufacturing Test Pressure and Rated Pressure for MSCL Pipes
Out
side
Dia
met
er (m
m)
Wal
lTh
ickn
ess
(mm
)
Test
Pre
ssur
e(M
Pa)
Test
Pre
ssur
e(m
)
Rate
d Pr
essu
re(M
Pa)
Rate
d Pr
essu
re(m
)
Out
side
Dia
met
er (m
m)
Wal
lTh
ickn
ess
(mm
)
Test
Pre
ssur
e(M
Pa)
Test
Pre
ssur
e(m
)
Rate
d Pr
essu
re(M
Pa)
Rate
d Pr
essu
re(m
)
S I N T A K O T E ® S T E E L P I P E L I N E S
1,404 8 3.1 314 2.5 2511,404 10 3.2 327 2.6 2611,404 12 3.9 392 3.1 3141,404 16 5.1 523 4.1 4181,422 8 3.0 310 2.4 2481,422 10 3.2 323 2.5 2581,422 12 3.8 387 3.0 3101,422 16 5.1 516 4.1 4131,440 8 3.0 306 2.4 245
1,440 10 3.1 319 2.5 2551,440 12 3.8 382 3.0 3061,440 16 5.0 510 4.0 408
1,575 8 2.7 280 2.2 2241,575 10 2.9 291 2.3 2331,575 12 3.4 349 2.7 2801,575 16 4.6 466 3.7 373
1,750 10 2.6 262 2.1 2101,750 12 3.1 314 2.5 2521,750 16 4.1 419 3.3 335
2,159 10 2.1 212 1.7 1702,159 12 2.5 255 2.0 2042,159 16 3.3 340 2.7 272
Out
side
Dia
met
er (m
m)
Wal
lTh
ickn
ess
(mm
)
Test
Pre
ssur
e(M
Pa)
Test
Pre
ssur
e(m
)
Rate
d Pr
essu
re(M
Pa)
Rate
d Pr
essu
re(m
)
914 6 3.5 361 2.8 289914 8 4.7 482 3.8 385914 10 4.9 502 3.9 401914 12 5.9 602 4.7 482914 16 7.9 803 6.3 642960 6 3.4 344 2.7 275
960 8 4.5 459 3.6 367960 10 4.7 478 3.8 382960 12 5.6 573 4.5 459960 16 7.5 764 6.0 611965 6 3.4 342 2.7 274965 8 4.5 456 3.6 365965 10 4.7 475 3.7 380965 12 5.6 570 4.5 456965 16 7.5 760 6.0 608
1,016 8 4.3 433 3.4 3471,016 10 4.4 451 3.5 3611,016 12 5.3 542 4.2 4331,016 16 7.1 722 5.7 5781,067 8 4.0 413 3.2 3301,067 10 4.2 430 3.4 3441,067 12 5.1 516 4.1 4131,067 16 6.8 688 5.4 5501,086 8 4.0 405 3.2 3241,086 10 4.1 422 3.3 3381,086 12 5.0 507 4.0 4051,086 16 6.6 676 5.3 5411,124 8 3.8 392 3.1 3131,124 10 4.0 408 3.2 3261,124 12 4.8 490 3.8 3921,124 16 6.4 653 5.1 522
1,200 8 3.6 367 2.9 2941,200 10 3.8 382 3.0 3061,200 12 4.5 459 3.6 3671,200 16 6.0 611 4.8 489
1,219 8 3.5 361 2.8 2891,219 10 3.7 376 3.0 3011,219 12 4.4 451 3.5 3611,219 16 5.9 602 4.7 482
1,283 8 3.4 343 2.7 2751,283 10 3.5 357 2.8 2861,283 12 4.2 429 3.4 3431,283 16 5.6 572 4.5 4581,290 8 3.3 341 2.7 2731,290 10 3.5 356 2.8 2841,290 12 4.2 427 3.4 3411,290 16 5.6 569 4.5 455
Out
side
Dia
met
er (m
m)
Wal
lTh
ickn
ess
(mm
)
Test
Pre
ssur
e(M
Pa)
Test
Pre
ssur
e(m
)
Rate
d Pr
essu
re(M
Pa)
Rate
d Pr
essu
re(m
)
Maximum test pressure =90% of yield stress of
steel, but not greater than 8.5 MPa.
Rated pressure =72% of yield stress of steel,
but not greater than 6.8 MPa.
Yield stress of steel = 300MPa for t<=8.0mm,
250MPa for t>8.0mm.
where t is steel wall thickness (mm).
Working pressure is determined by the designer
after consideration of the Rated Pressure of the
pipe and fittings and taking into account the various
factors such as external loads and transient
hydrostatic conditions.
68 | A P P E N D I X D
S I N T A K O T E ® S T E E L P I P E L I N E S